Systems and methods for machining to nominal geometry using local features

A method for returning an object to a nominal geometry comprising:

• scanning a surface of the object with a first imaging device;
• comparing data from the first imaging device to a predetermined dataset;
• determining a location of one or more structural features introduced onto the surface of the object, wherein the location of the one or more structural features is based on the predetermined dataset;
• determining a location of one or reference areas on the surface of the object that are free from defects greater than 0.005″, wherein the location of the one or more reference areas is based on the location of the one or more structural features;
• determining a location of one or more surface defects on the surface based on the location of the one or more reference areas;
• determining a nominal geometry for the surface based on the one or more reference areas;
• establishing a local coordinate system based on the location of the one or more reference areas;
• positioning a machining device based on the local coordinate system;
• calculating a tool path to machine the surface to the nominal geometry;
• machining, with the machining device, the surface to the nominal geometry;
• rescanning the surface with the first imaging device;
• and
• determining if the surface conforms to the nominal geometry.

A system for machining a surface of an object to a nominal geometry comprising:

• a robotic arm comprising:
• one or more arm motors configured to position the robotic arm;
• one or more tool motors configured to position a tool holder on the robotic arm;
• and
• one or more machining devices configured to machine the surface of the object to bring the surface to the nominal geometry;
• and
• a first imaging device configured to identify:
• one or more structural features introduced onto the surface of the object, wherein a location of the one or more structural features is based on a predetermined dataset;
• one or more reference areas on the surface of the object that are free from defects greater than 0.005″, wherein the location of the one or more reference areas is based on the location of the one or more structural features;
• and
• one or more surface defects on the surface to be machined based on a location of the one or more reference areas;
• and
• a controller configured to:
• determine a position of the system relative to the surface based on the reference areas;
• and
• position the one or more machining devices relative to the surface based on the position of the system relative to the surface, thereby to machine the one or more surface defects on the surface of the object to bring the surface to the nominal geometry.