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

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 is defined as identifying a 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
• a parameter modifier configured to identify 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;
• wherein the modeler is configured to determine whether the riveted structure that would be produced by the riveting operation meets the set of criteria based on test data, wherein the test data is digital 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 a 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.