Patent Description:
In many automated, robotic manufacturing facilities that manufacture large structural components, for example an airplane component assembly, one or more automated motion platforms or positioning machines are employed in the manufacturing of the structural component. The motion platforms are controlled by a control system to manipulate end effectors on the motion platforms around the structural component being manufactured. The end effectors are operable to perform such tasks as drilling fastener holes at predetermined locations in the structural component, retrieving or vacuuming shavings of the material of the structural component produced by drilling the holes, inserting fasteners into the drilled holes and manipulating the fasteners in order to complete assembly process(es). The end effectors and the motion platforms are controlled by the control system to not only perform the manufacturing steps such as drilling holes, but are also controlled by the control system to move about a work cell area in which the structural component is located to perform tasks such as moving to a tool location to deposit a tool at the tool location that had been used by the end effector and replace that tool with a different tool, to move the end effector to a fastener location to obtain a fastener that is then moved by the motion platform and the end effector to a location of a fastener hole in the structural component where the fastener is inserted, to move the motion platform and the end effector to another location to obtain another tool to be used by the end effector to manipulate the fastener in order to complete the assembly process using the tool obtained, etc..

The movements of the motion platforms and the end effectors on the motion platforms in the work cell area during the manufacturing process of the structural component are controlled by the control system. The control system operates autonomously according to a computer program without input from personnel overseeing the manufacturer of the structural component by the automated motion platforms and their end effectors. The work cell area occupied by the structural component and the motion platforms and end effectors manufacturing the structural component is surrounded by a safety barrier that is there to prevent personnel from entering the work cell area while the control system is controlling the movements of the motion platforms and their end effectors in manufacturing the structural component. Should it be necessary for an operator or other personnel to enter the work cell area through the safety barrier for the purpose of replacing tools in a tool location area in the work cell area, removing shavings accumulated from drilling holes in the material of the structural component, replenishing fasteners that are being used in the manufacture of the structural component or for any other reason related to the manufacture of the structural component by the automated motion platforms and their end effectors, it is necessary that the entire manufacturing process being conducted by the motion platforms and their end effectors inside the barrier surrounding the work cell area be shut down for the safety of the operator passing through the barrier and entering the work cell area.

Any routine maintenance or repair needed for any of the automated motion platforms and their end effectors, and/or other automated equipment in the work cell area that requires an operator to access the work cell area through the safety barrier requires a complete shut down of all of the automated machinery in the work cell area to ensure the safety of the operator entering the work cell area. The operator must enter the work cell area through a safety lockout gated entry system of the safety barrier surrounding the work cell area. The operator must then perform the maintenance or repair activity needed to the automated machines in the work cell area while all of the automated machines in the work cell area remain shut down, whether an automated machine requires maintenance and repair or not. At the completion of the maintenance or repair activity performed by the operator, it is then necessary to conduct a full work cell area surveillance to ensure that the operator or any other personnel have exited the work cell area through the lockout gate of the barrier surrounding the work cell area to ensure safe operation integrity prior to the control system resuming production activity with the control system controlling the automated motion platforms and their end effectors and other automated equipment in the work cell area in the manufacturing of the structural component in the work cell area.

The above described need to shut down the operation of all of the automated motion platforms and other automated machines in the work cell area required for an operator or other personnel to enter the work cell area to perform routine maintenance or to repair a machine in the work cell area detracts significantly from the efficiency of the manufacturing operations taking place in the work cell area and significantly increases the time required for the manufacturing of the structural component in the work cell area.

<CIT>, in accordance with its abstract, states: A robot system includes one or more robots which are provided to a first area where an entry by a person is restricted, and configured to perform a first work which includes one or more steps in the first area, a controller configured to control an operation of the one or more robots, and a visitor detector configured to detect a visitor to the first area. The controller includes a first work control portion configured to control the one or more robots so that the one or more robots perform the first work in the first area, and a first suspension control portion configured to control a predetermined at least a first robot of the one or more of the robots when one or more of the robots are performing one of the steps in the first area based on control by the first work control portion and the visitor (V) is detected by the visitor detector (B), so that the first robot performs a predetermined act of suspension after performing the first work up to any predetermined stage, including an intermediate stage of the one step, a successful completion stage of the one step, and a successful completion stage of another step after the one step.

According to the present disclosure, a safety architecture and a method as defined in the independent claims are provided. Further embodiments of the invention are defined in the dependent claims. Although the invention is only defined by the claims, the below embodiments, examples, and aspects are present for aiding in understanding the background and advantages of the invention.

The safety architecture of this disclosure provides a barrier separating a robotic work cell area containing a multiple of automated, motion platforms or positioning machines from an operator or personnel area for personnel that maintain the motion platforms or positioning machines in the work cell area. The safety architecture enables an operator in the personnel area to conduct routine interactions with a nonfunctioning motion platform or positioning machine located in the work cell area through openings in the barrier, while other motion platforms or positioning machines in the work cell area continue to function. When personnel are accessing a nonfunctioning motion platform or positioning machine, access is granted such that a barrier is maintained at all times protecting personnel from the automation that continues to function on the work piece.

The barrier has several openings through the barrier. The openings provide the personnel in the personnel area with access to a nonfunctioning motion platform or positioning machine in the work cell area through the openings while other motion platforms or positioning machines in the work cell area are functioning. The access to the work cell area from the personnel area provided by the openings enable the operator to remain in the personnel area external to the work cell area while conducting manual and automated tool changes, loading and removing tool test coupons, recharging lubricant of an end effector on a nonfunctioning motion platform or positioning machine in the work cell area, completing an entire change out or a replacement of an end effector on a nonfunctioning motion platform or positioning machine in the work cell area, etc. through the openings provided in the barrier separating the personnel area from the work cell area while other motion platforms or positioning machines in the work cell area continue to function. Again, when personnel are accessing a nonfunctioning motion platform or positioning machine, access is granted such that a barrier is maintained at all times protecting personnel from the automation that continues to function on the work piece.

Panels are positioned over the openings in the barrier. The panels are movable between closed positions of the panels where the panels cover over the openings and opened positions of the panels where the panels are displaced from the openings.

A control system communicates with motion platforms or each positioning machine in the work cell area and with each of the panels. The control system is operable to lock a panel in the closed position in response to the control system sensing a functioning motion platform or positioning machine adjacent the opening covered by the panel. The control system is also operable to unlock the panel and enable the panel to be moved to the opened position of the panel in response to the control system moving a motion platform or positioning machine adjacent the opening covered by the panel and the control system controlling the motion platform or positioning machine to be nonfunctioning.

The safety architecture includes a first cart. The first cart is manually moveable over a floor surface of the work cell area and personnel area. A first cart panel of the panels is secured to the first cart. The first cart panel extends vertically upward from the first cart. The first cart has a surface that is configured for receiving and supporting an end effector received on the surface of the first cart from a motion platform or positioning machine in the work cell area. The first cart is manually moveable from the personnel area through a first opening of the openings through the barrier and into the work cell area to a position in the work cell area where an end effector can be positioned on the surface of the first cart by a motion platform or positioning machine. As the first cart is moved through the first opening, the first cart panel is moved to a closed position of the first cart panel over the first opening in response to the first cart being moved from the personnel area through the first opening and into the work cell area. With the first cart positioned in the work cell area, a motion platform or positioning machine can position an end effector needing replacement on the surface of the first cart and then disconnect from the end effector. With the end effector supported on the surface of the first cart having been disconnected from the motion platform or positioning machine, the first cart is moveable from the work cell area through the first opening through the barrier and into the personnel area to remove the end effector from the work cell area. As the first cart is moved from the work cell area through the first opening through the barrier and into the personnel area, the first cart panel is moved to an opened position of the first cart panel where the first cart panel is displaced from the first opening.

The safety architecture also includes a second cart. The second cart is also manually moveable. A second cart panel of the panels is secured to the second cart. The second cart panel extends vertically upward from the second cart. The second cart has a surface that is configured for receiving and supporting an end effector received by the second cart. The end effector could be a replacement end effector to replace a disconnected end effector removed from the work cell area such as that discussed above. The second cart is moveable from the personnel area through the first opening of the openings through the barrier and into the work cell area. As the second cart is moved from the personnel area through the first opening through the barrier and into the work cell area, the second cart panel is moved over the first opening to a closed position of the second cart panel where the second cart panel covers over the first opening. The second cart is also moveable from the work cell area through the first opening through the barrier and into the personnel area. As the second cart is moved from the work cell area through the first opening through the barrier and into the personnel area, the second cart panel is moved to an opened position of the second cart panel where the second cart panel is displaced from the first opening.

The control system is operable to communicate with the motion platforms or positioning machines in the work cell area and with the first cart panel on the first cart. The control system is operable to lock the first cart panel in the closed position of the first cart panel in the first opening through the barrier in response to the control system sensing a functioning motion platform or positioning machine adjacent the first opening through the barrier. The control system is operable to unlock the first cart panel enabling the first cart panel to be moved to the open position of the first cart panel in response to the control system controlling the motion platform or positioning machine moved adjacent the first opening to be nonfunctioning. The control system is operable to lock and unlock the second cart panel in the same manner as the first cart panel.

The first opening through the barrier has an upper portion and a lower portion. The first cart panel is a lower panel that is configured to cover over the lower portion of the first opening when the first cart panel is moved to the closed position of the first cart panel over the first opening. There is a first upper panel positioned over the upper portion of the first opening. The first upper panel is moveable between a closed position of the first upper panel where the first upper panel covers over the upper portion of the first opening, and an opened position of the first upper panel where the first upper panel is displaced from the upper portion of the first opening.

The control system is operable to communicate with the motion platforms or positioning machines in the work cell area and with the first upper panel. The control system is operable to lock the first upper panel in the closed position of the first upper panel over the upper portion of the first opening in response to the control system sensing a functioning motion platform or positioning machine having been moved adjacent to the upper portion of the first opening. The control system is operable to unlock the first upper panel in the closed position of the first upper panel over the upper portion of the first opening in response to the control system sensing the motion platform or positioning machine having been displaced from adjacent the upper portion of the first opening.

There is also a second opening through the barrier, for example a tooling opening. The tooling opening provides personnel in the personnel area access to a tool changing location in the work cell area through the tooling opening.

A second panel, for example a tooling panel is positioned over the tooling opening. The tooling panel is moveable between a closed position of the tooling panel where the tooling panel covers over the tooling opening and an opened position of the tooling panel where the tooling panel is displaced from the tooling opening.

The control system communicates with the motion platform or positioning machines in the work cell area and with the tooling panel. The control system is operable to lock the tooling panel in the closed position over the tooling opening in response to the control system sensing a functioning motion platform or positioning machine adjacent the tooling opening. The control system is also operable to unlock the tooling panel and enable the tooling panel to be moved to the opened position of the tooling panel in response to the control system sensing a nonfunctioning motion platform or positioning machine adjacent the tooling opening.

There is also a third opening through the barrier, for example a test opening. The test opening provides personnel in the personnel area access to a test coupon location in the work cell area through the test opening.

A third panel, for example is a test panel is positioned over the test opening. The test panel is moveable between a closed position of the test panel where the test panel covers over the test opening and an opened position of the test panel where the test panel is displaced from the test opening.

The control system communicates with the motion platforms or positioning machines in the work cell area and with the test panel. The control system is operable to lock the test panel in the closed position over the test opening in response to the control system sensing a functioning motion platform or positioning machine adjacent the test opening. The control system is also operable to unlock the test panel and enable the test panel to be moved to the opened position of the test panel in response to the control system sensing a nonfunctioning motion platform or positioning machine adjacent the test opening.

The features, functions and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.

Further features of the safety architecture for an automated work cell and its method of operation are set forth in the following detailed description of the safety architecture and in the following drawing figures.

The safety architecture for an automated work cell of this disclosure eliminates the requirement for an automation cell operator or other personnel to enter an automated, work cell through a monitored gate in a safety barrier surrounding the work cell to conduct routine operations in the maintenance of motion platforms or positioning machines and their end effectors and other automated machines in the work cell. The operator remains in a personnel area external to the work cell area while conducting manual and automated tool changes, loading and removing tool test coupons, recharging lubricant of an end effector on a motion platform or positioning machine in the work cell area, completing an entire changeout or a replacement of an end effector on a nonfunctioning motion platform or positioning machine in the work cell area, etc. through openings provided in a barrier separating the personnel area from the work cell area while other motion platforms or positioning machines and other automated positioning machines in the work cell area continue to function. This results in the benefits of increased automation operator or personnel safety by reducing exposure of the personnel to functioning automated motion platforms or positioning machines and other automated machines in the work cell area, and reducing critical path machine down time by being able to stage and conduct routine maintenance activities in a more rapid fashion on an automated motion platform or positioning machine or other automated machine while the machine is nonfunctional and while other motion platforms or positioning machines and other automated machines in the work cell area continue to function.

Referring to <FIG>, a floor surface <NUM> of a production facility is represented. There are a number of automated, machines positioned on the floor surface <NUM>. The machines include a pair of automated, motion platforms or positioning machines <NUM>, <NUM>. The motion platforms or positioning machines <NUM>, <NUM> have end effectors <NUM>, <NUM>(EE) at the ends of arms of the motion platforms or positioning machines <NUM>, <NUM>. The structure of the end effectors <NUM>, <NUM> and the programming of the end effectors is determined to best suit the motion platforms or positioning machines <NUM>, <NUM> to manufacture a structural component, for example an aircraft component assembly in response to command signals received by the motion platforms or positioning machines <NUM>, <NUM> from a control system <NUM> that includes a human/machine interface (HMI). Although only two motion platforms or positioning machines <NUM>, <NUM> and their respective end effectors <NUM>, <NUM> are represented in <FIG> and <FIG>, the safety architecture of this disclosure could also be employed in controlling and maintaining the safety of more than two motion platforms or positioning machines and their associated end effectors. The end effectors <NUM>, <NUM> could be provided with a variety of different types of tools that would be needed in the manufacture of a structural component, for example drills, cutting tools, grippers, sanders, screwdrivers, spray guns, welders, vacuum tips, etc. All of the automated motion platforms or positioning machines <NUM>, <NUM> represented in <FIG> are described generally as positioning machines herein.

The safety architecture comprises a barrier <NUM> on the floor surface <NUM>. The barrier <NUM> extends completely around the positioning machines <NUM>, <NUM> on the floor surface <NUM>. The barrier <NUM> is a metal mesh or wire screen type barrier that has a height dimension of approximately <NUM> feet. Other equivalent types of barriers could be employed. The barrier <NUM> extending around the positioning machines <NUM>, <NUM> on the floor surface <NUM> separates a work cell area <NUM> of the floor surface <NUM> within the barrier <NUM> from an operator or personnel area <NUM> outside the barrier <NUM>. The personnel area <NUM> is for personnel or operators that maintain the positioning machines <NUM>, <NUM> in the work cell area <NUM>.

The barrier <NUM> has several openings through a front section of the barrier. The openings provide the personnel in the personnel area <NUM> with access to an immobile, nonfunctioning positioning machine in the work cell area <NUM> through the openings, while other positioning machines in the work cell area are functioning. The access to the work cell area <NUM> from the personnel area <NUM> provided by the openings enable an operator or personnel to remain in the personnel area <NUM> external to the work cell area <NUM> while conducting manual and automated tool changes, loading and removing tool test coupons, recharging lubricant of an end effector on a nonfunctioning positioning machine in the work cell area <NUM>, completing an entire change out or a replacement of an end effector on a nonfunctioning positioning machine in the work cell area <NUM>, etc. This maintenance and/or repair is conducted through the openings provided in the barrier separating the personnel area <NUM> from the work cell area <NUM> while other positioning machines in the work cell area continue to function. When personnel are accessing a nonfunctioning positioning machine <NUM>, <NUM>, access is granted such that a barrier is maintained at all times protecting personnel from the automation that continues to function on the work piece.

The openings through the barrier <NUM> include a cart and end effector opening or a first opening <NUM> represented by dashed lines in <FIG>. The first opening <NUM> is actually a lower portion <NUM> of the first opening, which also includes an upper portion <NUM> of the first opening. The lower portion of the first opening <NUM> has a rectangular configuration through the barrier <NUM>. The lower portion of the first opening <NUM> extends to the bottom of the barrier <NUM> with the floor surface <NUM> defining the bottom of the lower portion of the first opening <NUM>. The upper portion of the first opening <NUM> through the barrier <NUM> is represented by dashed lines <NUM> in <FIG>.

The safety architecture includes a first cart <NUM>. As represented in <FIG>, the first cart has a base with a general rectangular configuration. There are multidirectional roller devices, for example castors or other equivalent types of roller devices mounted to the bottom of the first cart <NUM>. The roller devices enable the first cart <NUM> to be manually moveable over the floor surface <NUM> in multiple directions. The first cart <NUM> also has a top surface <NUM> having means for receiving and supporting an end effector. For example means for receiving and supporting an end effector <NUM> needing replacement on the top surface that has been positioned by a positioning machine on the top surface <NUM> and disconnected from the positioning machine. As represented in <FIG>, a first cart panel <NUM> is secured to the forward edge of the first cart <NUM>. The first cart panel <NUM> extend vertically upward from the first cart <NUM>.

The first cart <NUM> is manually moveable from the personnel area <NUM> through the lower portion of the first opening <NUM> in the barrier <NUM> and into the work cell area <NUM> to a position of the first cart <NUM> in the work cell area <NUM>. With the first cart <NUM> positioned in the work cell area <NUM>, an end effector can be positioned on the top surface <NUM> of the first cart <NUM> by a positioning machine or robot <NUM>, <NUM>. As the first cart <NUM> is moved through the lower portion of the first opening <NUM>, the first cart panel <NUM> is moved to a closed position of the first cart panel <NUM> over the lower portion of the first opening <NUM>. With the first cart <NUM> positioned in the work cell area <NUM>, a positioning machine <NUM> can position an end effector <NUM> needing replacement on the top surface <NUM> of the first cart <NUM>, and then disconnect from the end effector <NUM>. With the end effector <NUM> supported on the top surface <NUM> of the first cart <NUM> having been disconnected from the positioning machine <NUM>, the first cart is manually moveable from the work cell area <NUM> through the lower portion of the first opening <NUM> in the barrier <NUM> and into the personnel area <NUM> to remove the end effector <NUM> from the work cell area <NUM>. As the first cart <NUM> is manually moved from the work cell area <NUM> through the lower portion of the first opening <NUM> in the barrier <NUM> and into the personnel area <NUM>, the first cart panel <NUM> is moved to an opened position of the first cart panel <NUM> where the first cart panel <NUM> is displaced from the lower portion of the first opening <NUM>. This leaves the lower portion of the first opening open and accessible.

The safety architecture also includes a second cart <NUM>. The second cart <NUM> is basically a duplicate of the first cart <NUM>. The second cart <NUM> is also manually moveable. A second cart panel <NUM> is secured to a forward edge of the second cart <NUM>. The second cart panel <NUM> extends vertically upward from the forward edge of the second cart <NUM> and has a configuration that will close over the lower portion of the first opening <NUM> when positioned over the lower portion of the first opening. The second cart <NUM> also has a top surface <NUM> having means for receiving and supporting an end effector <NUM> received by the second cart <NUM>. The end effector <NUM> could be a replacement end effector to replace a disconnected end effector <NUM> needing replacement removed from the work cell area <NUM> such as that discussed above. The second cart <NUM> is manually moveable from the personnel area <NUM> with the replacement end effector through the lower portion of the first opening <NUM> in the barrier <NUM> and into the work cell area <NUM> to a position where the positioning machine or robot <NUM> can connect to the replacement end effector. As the second cart <NUM> is moved from the personnel area <NUM> through the lower portion of the first opening <NUM> and into the work cell area <NUM>, the second cart panel <NUM> is moved over the lower portion of the first opening <NUM> to a closed position of the second cart panel <NUM> where the second cart panel <NUM> covers over the lower portion of the first opening <NUM>. The second cart <NUM> is also manually moveable without the replacement end effector from the work cell area <NUM> through the lower portion of the first opening <NUM> in the barrier <NUM> and into the personnel area <NUM>. As the second cart <NUM> is moved from the work cell area <NUM> through the lower portion of the first opening <NUM> in the barrier <NUM> and into the personnel area <NUM>, the second cart panel <NUM> is moved to an opened position of the second cart panel <NUM> where the second cart panel <NUM> is displaced from the lower portion of the first opening <NUM>.

The control system <NUM> is operable to communicate with the positioning machines or motion platforms <NUM>, <NUM> in the work cell area <NUM> and with the first cart panel <NUM> on the first cart <NUM> and the second cart panel <NUM> on the second cart <NUM>. The control system <NUM> is operable to lock the first cart panel <NUM> in the closed position of the first cart panel <NUM> in the lower portion of the first opening <NUM> in the barrier <NUM> in response to the control system <NUM> sensing a mobile, functioning positioning machine or robot <NUM>, <NUM> adjacent the lower portion of the first opening <NUM> in the barrier <NUM>. The control system <NUM> is operable to unlock the first cart panel <NUM> enabling the first cart panel <NUM> to be moved to the opened position of the first cart panel <NUM> in response to the control system <NUM> controlling a positioning machine or robot <NUM>, <NUM> to move to a position adjacent the lower portion of the first opening <NUM>. With the positioning machine <NUM>, <NUM> having been moved to a position adjacent the lower portion of the first opening <NUM>, the control system then controls the positioning machine <NUM>, <NUM> to be immobile and nonfunctioning. The control system <NUM> is operable to lock and unlock the second cart panel <NUM> in the same manner as the first cart panel <NUM>.

There is a first upper panel <NUM>, or a manual tool change panel (MTC) positioned over the upper portion of the first opening <NUM>. The first upper panel <NUM> is moveable between a closed position of the first upper panel <NUM> where the first upper panel <NUM> covers over the upper portion of the first opening <NUM>, and an opened position of the first upper panel <NUM> where the first upper panel <NUM> is displaced from the upper portion of the first opening <NUM>. With the upper portion of the first opening <NUM> positioned directly above the lower portion of the first opening <NUM>, there is sufficient area behind the lower portion of the first opening <NUM> and the upper portion of the first opening <NUM> to maneuver a positioning machine or robot <NUM>, <NUM> supporting an end effector to the area behind the lower portion of the first opening <NUM> and the upper portion of the first opening <NUM>, and position the end effector directly behind the first upper panel <NUM>. With the control system <NUM> positioning the positioning machine or robot <NUM> and the attached end effector <NUM> behind the first upper panel <NUM>, the control system <NUM> can control the positioning machine or robot <NUM> and end effector <NUM> to be immobile and nonfunctioning. The immobile and nonfunctioning end effector <NUM> then can be accessed by personnel from the personnel area <NUM> for servicing of the end effector <NUM>.

The control system <NUM> is operable to communicate with the positioning machines <NUM>, <NUM> in the work cell area <NUM> and with the first upper panel <NUM>. The control system <NUM> is operable to lock the first upper panel <NUM> in the closed position of the first upper panel <NUM> over the upper portion of the first opening <NUM> in response to the control system <NUM> sensing a mobile, functioning positioning machine <NUM>, <NUM> having been moved adjacent to the upper portion of the first opening <NUM>. The control system <NUM> is operable to unlock the first upper panel <NUM> in the closed position of the first upper panel <NUM> over the upper portion of the first opening <NUM> in response to the control system <NUM> sensing the positioning machine <NUM>, <NUM> adjacent the upper portion of the first opening <NUM> having been controlled by the control system <NUM> to be immobile and nonfunctioning.

There is also a second opening through the barrier <NUM>. The second opening <NUM> is represented by dashed lines in <FIG>. The second opening <NUM> is, for example, a tooling opening that enables personnel in the personnel area <NUM> to access a tool changing location behind the second opening <NUM> in the barrier <NUM> to position tools in the tool changing location in the work cell area <NUM> or replace tools from the tool changing location.

A second panel <NUM>, for example, a tooling panel is positioned over the tooling opening <NUM>. The tooling panel <NUM> is moveable between a closed position of the tooling panel where the tooling panel <NUM> covers over the tooling opening <NUM>, and an opened position of the tooling panel <NUM> where the tooling panel is displaced from the tooling opening <NUM>.

The control system <NUM> communicates with the positioning machines or motion platforms <NUM>, <NUM> in the work cell area <NUM> and with the tooling panel <NUM>. The control system <NUM> is operable to lock the tooling panel <NUM> in the closed position over the tooling opening <NUM> in response to the control system <NUM> sensing a mobile, functioning positioning machine <NUM>, <NUM> adjacent the tooling opening <NUM>. The control system <NUM> is also operable to unlock the tooling panel <NUM> and enable the tooling panel to be moved to the opened position of the tooling panel where the tooling panel <NUM> is displaced from the tooling opening <NUM> in response to the control system <NUM> sensing an immobile, nonfunctioning positioning machine adjacent the tooling opening <NUM>.

A third opening <NUM>, for example, a test coupon opening is provided in the barrier <NUM>. As represented in <FIG>, the third opening <NUM> is shown in dashed lines and is positioned just above the second, tooling opening <NUM>. The third opening <NUM> or test coupon opening enables personnel in the personnel area <NUM> to access a test coupon holder positioned in the work cell area <NUM> just behind the test coupon opening <NUM> to supply material test coupons to the test coupon holder or remove used test coupons from the test coupon holder.

A third panel, for example, a test panel <NUM> is positioned over the test coupon opening <NUM>. The test panel <NUM> is moveable between a closed position of the test panel where the test panel <NUM> covers over the test coupon opening <NUM>, and an opened position of the test panel <NUM> where the test panel is displaced from the test coupon opening <NUM>.

The control system <NUM> communicates with the positioning machines or motion platforms <NUM>, <NUM> in the work cell area <NUM> and with the test panel <NUM>. The control system <NUM> is operable to lock the test panel <NUM> in the closed position over the test coupon opening <NUM> in response to the control system <NUM> sensing a mobile, functioning positioning machine adjacent the test coupon opening <NUM>. The control system <NUM> is also operable to unlock the test panel <NUM> and enable the test panel <NUM> to be moved to the opened position of the test panel <NUM> displaced from the test coupon opening <NUM> in response to the control system <NUM> sensing an immobile, nonfunctioning positioning machine adjacent the test opening <NUM>.

There is a fastener feed cabinet <NUM> positioned in the personnel area <NUM> and separated from the work cell area <NUM> by the barrier <NUM>. The fastener feed cabinet <NUM> communicates with the work cell area <NUM> by a fastener feed conveyor <NUM> that extends from the fastener feed cabinet <NUM> across the barrier <NUM> to the work cell area <NUM>. The fastener feed cabinet <NUM> is controlled by the control system <NUM> to provide needed fasteners to the end effectors <NUM>, <NUM> in the work cell area <NUM>.

A vacuum system with a collection canister <NUM> is positioned in the personnel area <NUM> and is separated from the work cell area <NUM> by the barrier <NUM>. The vacuum system and collection canister <NUM> communicate with the end effectors <NUM>, <NUM> in the work cell area <NUM>. The vacuum system and collection canister <NUM> are controlled by the control system <NUM> to vacuum material shavings produced by drilling holes in the structural component in the work cell area and collect the shavings in the vacuum system and collection canister <NUM>. Positioning the vacuum system and collection canister <NUM> in the personnel area <NUM> and separated by the barrier <NUM> from the work cell area <NUM> provides personnel access to the canister to dispose of shavings without personnel entering the work cell area <NUM>.

<FIG> is a flow chart representing the operation of the control system <NUM> when a first end effector <NUM> (EE) is replaced by a second end effector <NUM> (EE). Step <NUM> represents a command input to the control system <NUM> by an operator to replace the first end effector <NUM> with the second end effector <NUM>. At <NUM> a first robot <NUM> is controlled by the control system <NUM> to move to a swap position adjacent the lower portion of the first opening <NUM>. At <NUM> the first robot <NUM> is controlled by the control system <NUM> to shut down the operation of the first end effector <NUM>(EE) and prepare the first end effector <NUM> for disconnection from the first robot <NUM>. At step <NUM>, the control system <NUM> checks the position of the first cart <NUM> to determine if the first cart is positioned properly adjacent the lower portion of the first opening <NUM>. At step <NUM>, if the first cart <NUM> is not properly positioned, the control system <NUM> controls the first robot <NUM> to cease operation and wait for the proper positioning of the first cart <NUM>. At step <NUM>, the control system <NUM> checks to see if the first upper panel <NUM> (MTC) is closed. If the first upper panel <NUM> is not closed, the control system <NUM> controls the operation of the robot <NUM> to stop until the first upper panel <NUM> is closed.

At step <NUM>, the control system <NUM> issues a message to a human/machine interface (HMI) of the control system <NUM> notifying the operator that the first cart <NUM> is not property positioned adjacent the lower portion of the first opening <NUM>. At step <NUM>, the control system <NUM> issues a (HMI) message to the operator indicating that the first upper panel <NUM> (MTC) is not in the closed position. At step <NUM>, the operator then manually, properly positions the first cart <NUM> relative to the lower portion of the first opening <NUM>, and/or closes the first upper panel <NUM>. At step <NUM>, the operator then issues a command to the control system <NUM> to restart the end effector swap process. At step <NUM>, the robot <NUM> is moved relative to the lower portion of the first opening <NUM> where the first robot <NUM> is ready to swap the first end effector <NUM> for the second end effector <NUM>.

At step <NUM>, the first end effector <NUM> (EE) is checked to ensure that it is shut down. At step <NUM>, if the first end effector <NUM> is not shut down and ready to be swapped for the second end effector <NUM>, the operator resolves the problem preventing the swap. At step <NUM>, if the first end effector <NUM> is shut down and is ready to be swapped with the second end effector <NUM>, the first robot <NUM> is controlled by the control system <NUM> to position the first end effector on the first cart <NUM>.

At step <NUM>, the control system <NUM> checks to see if the first end effector <NUM> is properly positioned on the first cart <NUM>. If the first end effector <NUM> is not property positioned on the first cart <NUM>, the operator resolves the problem at step <NUM>. If the first end effector <NUM> is properly positioned on the first cart <NUM>, the control system <NUM> controls the first robot <NUM> to release the first end effector <NUM> (EE) onto the top surface <NUM> of the first cart <NUM> at step <NUM>. At step <NUM>, the first robot <NUM> moves away from the lower portion of the first opening <NUM>. At step <NUM>, the control system <NUM> unlocks the first cart <NUM> from the lower portion of the first opening <NUM>, and at step <NUM> the first cart <NUM> with the removed first end effector <NUM> (EE) supported on the top surface <NUM> of the first cart is manually moved out of the lower portion of the first opening <NUM>. With the first cart <NUM> removed from the lower portion of the first opening <NUM>, the second end effector <NUM> positioned on the top surface <NUM> of the second cart <NUM> can be moved into the now open lower portion of the first opening <NUM> where the first robot <NUM> can be operated by the control system <NUM> to connect to the second end effector <NUM>.

<FIG> is a flowchart representing the operation of the control system <NUM> controlling the first robot <NUM>, the first end effector <NUM> and the first upper panel <NUM> during a manual tool change on the first end effector <NUM>. At step <NUM> a command signal is sent by the control system <NUM> to the robot <NUM> that a manual tool change of the end effector <NUM> is to take place. At step <NUM>, the first robot <NUM> begins to move to a position adjacent the upper portion of the first opening <NUM>. At step <NUM> the control system <NUM> checks to ensure that the first upper panel <NUM> (MTC) over the upper portion of the first opening <NUM> is closed. At step <NUM>, if the control system <NUM> determines that the first upper panel <NUM> is not closed, the control system <NUM> controls the first robot <NUM> to stop at a wait position. At step <NUM>, the control system <NUM> provides a (HMI) signal to the operator indicating that the first upper panel <NUM> is open and that the first robot <NUM> cannot proceed with the manual tool change. At step <NUM>, the operator closes the first upper panel <NUM> and at step <NUM> the operator controls the control system <NUM> to restart the movement of the first robot <NUM>. Again, at step <NUM> the robot <NUM> begins to move to a position adjacent the upper portion of the first opening <NUM> and at step <NUM>, the control system <NUM> again checks to ensure that the first upper panel <NUM> is closed. With the control system <NUM> determining that the first upper panel <NUM> is closed, the first robot <NUM> moves to a park position with the first end effector <NUM> positioned adjacent the first upper panel <NUM>. At step <NUM>, the control system <NUM> places the first robot <NUM> in a safe stop, and at step <NUM>, the control system <NUM> unlocks the first upper panel <NUM> to allow the operator access to the first end effector <NUM>. At step <NUM>, the operator performs the work needed on the first end effector <NUM> and at step <NUM> the operator closes the first upper panel <NUM>. At step <NUM>, the operator controls the control system <NUM> to restart the first robot <NUM> and at step <NUM>, the control system <NUM> checks the first upper panel <NUM> to ensure it is closed. If the control system <NUM> determines that the first upper panel <NUM> is not closed, at step <NUM>, the control system <NUM> issues a (HMI) message notifying the operator that the first upper panel <NUM> is open and the first robot <NUM> cannot proceed. If at step <NUM>, the control system <NUM> determines that the first upper panel <NUM> is closed, at step <NUM> the control system <NUM> locks the first upper panel <NUM>. At step <NUM>, the control system <NUM> then takes the first robot <NUM> out of its safe stop and powers up the robot <NUM>. At step <NUM>, the first robot <NUM> moves from the park position adjacent the upper portion of the first opening <NUM> and back to the work cell area <NUM>. At step <NUM>, the first robot <NUM> is controlled by the control system <NUM> to return to the work cell area <NUM>.

<FIG> is a flowchart representing the operation of the control system <NUM> controlling a tool changer of the safety architecture in installing or removing changeable tooling of the safety architecture. At step <NUM>, the operator observes the automatic tool changer and determines whether there is a need to install or remove changeable tooling that is controlled by the automatic tool changer. At step <NUM>, the operator presses a button to open the automatic tool changer (ATC) if the operator determines that there is a need to install or remove changeable tooling controlled by the automatic tool changer. At step <NUM>, the control system <NUM> determines if a command has been received from the robot <NUM> for a tool change on the robot, and checks the automatic tool changer (ATC) to determine if the automatic tool changer is operating to make a tool change. At step <NUM>, the control system <NUM> places the automatic tool changer (ATC) in a safe stop. At step <NUM>, the control system <NUM> unlocks the automatic tool changer (ATC) access door, or the tooling panel <NUM> covering the second opening <NUM>. At step <NUM>, the operator opens the tooling panel <NUM> (ATC) and at step <NUM> the operator performs the needed work on the automatic tool changer, either installing or removing changeable tooling on the automatic tool changer. At step <NUM>, the operator closes the tooling panel <NUM> (ATC). At step <NUM>, the control system <NUM> locks the tooling panel <NUM> (ATC) in its closed position. At step <NUM>, the automatic tool changer (ATC) runs an autoscan to determine the changes made to the changeable tooling operated by the automated tool changer. At step <NUM>, the automatic tool changer communicates to the control system <NUM> that the tooling change is complete.

<FIG> is a flow chart representing the operation of the control system <NUM> in supplying and removing test coupons of the safety architecture. At step <NUM>, the control system <NUM> controls the robot <NUM> to produce a material test coupon for the aircraft component being constructed in the work cell area <NUM>. At step <NUM>, the control system <NUM> controls the robot <NUM> to bring the material test coupon to a position adjacent the third opening <NUM>. As the robot <NUM> moves toward the third opening <NUM>, the control system <NUM> determines if the third panel <NUM> is closed at step <NUM>. If the third panel <NUM> is determined by the control system <NUM> to not be closed, the control system <NUM> controls the robot <NUM> to stop at a wait position at step <NUM>. At step <NUM>, the control system <NUM> (HMI) notifies the operator that the third panel <NUM> is open and that the robot <NUM> has been commanded to stop and not move toward the third opening <NUM>. At step <NUM>, the operator closes the third panel <NUM> and at step <NUM>, the operator commands the control system <NUM> to restart the movement of the robot <NUM>. At step <NUM>, the robot <NUM> again moves toward the third opening <NUM> and at step <NUM>, the control system <NUM> again checks to ensure that the third panel <NUM> is closed. With the control system <NUM> determining that the third panel <NUM> is closed, at step <NUM> the control system <NUM> locks the third panel <NUM>. At step <NUM>, the robot <NUM> moves to a position adjacent the third panel <NUM> and deposits the material test coupon on a coupon holder adjacent the third panel <NUM>. At step <NUM>, with the material test coupon positioned on the coupon holder, the control system <NUM> then controls the robot <NUM> to move to a park position, or to move out to the work cell area <NUM>. At step <NUM>, the control system <NUM> moves the robot <NUM> to the park location, or to the work cell area <NUM> to continue the manufacturing operation of the robot <NUM>. At step <NUM>, the control system <NUM> unlocks the third panel <NUM>. At step <NUM>, the operator opens the third panel <NUM> and retrieves the material test coupon deposited adjacent the third panel <NUM>. At step <NUM>, the operator communicates to the control system <NUM> that the material test coupon action has been completed.

Claim 1:
Safety architecture for a machine work cell comprising:
a barrier (<NUM>) separating a work cell area (<NUM>) for positioning machines (<NUM>, <NUM>) that are automated manufacturing positioning machines from a personnel area (<NUM>) for personnel that maintain the positioning machines in the work cell area;
a control system (<NUM>) communicating with the positioning machines (<NUM>, <NUM>) and controlling movements and functioning of the positioning machines; characterized in that it further comprises
an opening (<NUM>) through the barrier, the opening providing personnel in the personnel area (<NUM>) access through the opening to a positioning machine (<NUM>) in the work cell area (<NUM>) that has been controlled to move to a position adjacent the opening and then controlled to be immobile and nonfunctioning while other positioning machines in the work cell area are mobile and functioning, and the opening (<NUM>) being a cart and end effector opening through the barrier (<NUM>); and
a tooling opening (<NUM>) through the barrier (<NUM>), the tooling opening providing personnel in the personnel area (<NUM>) access to a tool changing location in the work cell area (<NUM>) through the tooling opening, or a test coupon opening (<NUM>) through the barrier (<NUM>), the test coupon opening providing personnel in the personnel area (<NUM>) access to a test coupon location in the work cell area (<NUM>) through the test coupon opening.