Systems and methods for forming tapered holes in workpieces

A robotic forming method for forming a tapered hole in a workpiece, the robotic forming method comprising:

• providing an end effector including a housing and a nose extending from the housing, wherein the housing defines an internal chamber;
• fluidly coupling a vacuum gate with an internal cavity of the nose;
• providing a seal within the nose;
• providing a first spindle comprising a first operative head, the first spindle retained within the internal chamber;
• providing a second spindle comprising a second operative head, the second spindle retained within the internal chamber;
• moving the first spindle between a first stowed position within the housing and a first operating position in which the first operative head extends into the nose;
• forming, by the first operative head of the first spindle in the first operating position, an initial hole within the workpiece;
• moving the second spindle between a second stowed position within the housing and a second operating position in which the second operative head extends into the nose;
• and
• modifying, by the second operative head of the second spindle in the second operating position, the initial hole to form the tapered hole.

A robotic forming system for forming a tapered hole in a workpiece, the robotic forming system comprising an end effector including:

• a housing and a nose extending from the housing, wherein the housing defines an internal chamber;
• a first spindle comprising a first operative head, the first spindle retained within the internal chamber, wherein the first spindle is configured to be moved between a first stowed position within the housing and a first operating position in which the first operative head extends into the nose, wherein the first operative head is configured to form an initial hole within the workpiece;
• a second spindle comprising a second operative head, the second spindle retained within the internal chamber, wherein the second spindle is configured to be moved between a second stowed position within the housing and a second operating position in which the second operative head extends into the nose, wherein the second operative head is configured to modify the initial hole to form the tapered hole;
• a third spindle comprising a third operative head, the third spindle retained within the internal chamber, wherein the third spindle is configured to be moved between a third stowed position within the housing and a third operating position in which the third operative head extends into the nose, wherein the third operative head is configured to form a countersink or a counterbore in the tapered hole;
• a vacuum gate in fluid communication with an internal cavity of the nose;
• a vacuum generator coupled to the vacuum gate;
• a valve disposed within the vacuum gate, wherein the valve is configured to be selectively moved between an open position that allows for fluid communication with the vacuum generator, and a closed position that prevents fluid communication with the vacuum generator;
• a lubricant dispenser within the nose, wherein the lubricant dispenser is configured to dispense lubricant onto one or more of the first operative head in the first operating position, the second operative head in the second operating position, the third operative head in the third operating position, the initial hole, or the tapered hole;
• and
• a seal within the nose, wherein the seal is configured to sealingly engage the first spindle in the first operative position, the second spindle in the second operative position, and the third spindle in the third operative position.

A robotic forming system for forming a tapered hole in a workpiece, the robotic forming system comprising an end effector including:

• a housing and a nose extending from the housing, wherein the housing defines an internal chamber;
• a vacuum gate in fluid communication with an internal cavity of the nose;
• a seal within the nose;
• a first spindle comprising a first operative head, the first spindle retained within the internal chamber;
• and
• a second spindle comprising a second operative head, the second spindle retained within the internal chamber, wherein the second operative head is configured to modify an initial hole to form the tapered hole.

A robotic forming method for forming a tapered hole in a workpiece, the robotic forming method comprising:

• providing an end effector including a housing and a nose extending from the housing, wherein the housing defines an internal chamber;
• fluidly coupling a vacuum gate with an internal cavity of the nose;
• providing a seal within the nose;
• providing a first spindle comprising a first operative head, the first spindle retained within the internal chamber;
• providing a second spindle comprising a second operative head, the second spindle retained within the internal chamber;
• and
• modifying, by the second operative head of the second spindle, an initial hole to form the tapered hole.