System and method for autonomously scanning and processing a compliant workpiece

A method comprising:

• accessing a set of images captured by an optical sensor arranged on an end effector while traversing a scan path over a workpiece;
• compiling the set of images into a virtual model defining unloaded surfaces of the workpiece;
• prompting an operator to annotate the virtual model with compliance characteristics of the workpiece;
• defining a first workpiece region characterized by compliance characteristics within a first compliance range based on the virtual model and compliance characteristics supplied by the operator;
• assigning a first target force to the first workpiece region based on the first compliance range;
• defining a second workpiece region, adjacent the first workpiece region, characterized by compliance characteristics within a second compliance range greater than the first compliance range based on the virtual model and compliance characteristics supplied by the operator;
• assigning a second target force, less than the first force, to the second workpiece region based on the second compliance range;
• and
• during a processing cycle:
• accessing a sequence of force values output by a force sensor coupled to a sanding head arranged on the end effector;
• and
• via a set of actuators coupled to the end effector:
• navigating the sanding head across the first workpiece region of the workpiece;
• selectively driving the sanding head below a first unloaded surface of the workpiece stored in the virtual model to maintain forces, of the sanding head on the first workpiece region of the workpiece, within to approximate the first target force, based on the sequence of force values;
• navigating the sanding head across the second workpiece region of the workpiece;
• and
• selectively driving the sanding head below a second unloaded surface of the workpiece stored in the virtual model to maintain forces, of the sanding head on the second workpiece region of the workpiece, to approximate the second target force, based on the sequence of force values.

A method comprising:

• during a scan cycle:
• navigating an end effector over a first section of a workpiece;
• accessing a first set of images captured by an optical sensor arranged on the end effector while traversing the first section of the workpiece;
• compiling the first set of images into a virtual model defining unloaded surfaces of the workpiece;
• calculating a first vector normal to a first location in the first section of the workpiece based on the virtual model;
• accessing a first sequence of force values from a force sensor arranged on the end effector while driving the end effector along the first vector toward the first location on the workpiece;
• characterizing a first compliance of the workpiece at the first location based on the first sequence of force values and a first sequence of positions of the end effector following contact between the end effector and the workpiece;
• navigating the end effector over a second section of the workpiece;
• accessing a second set of images captured by the optical sensor while traversing the second section of the workpiece;
• expanding the virtual model based on the second set of images;
• calculating a second vector normal to a second location in the second section of the workpiece;
• accessing a second sequence of force values from the force sensor while driving the end effector along the second vector toward the second location on the workpiece;
• characterizing a second compliance of the workpiece at the second location based on the second sequence of force values and a second sequence of positions of the end effector following contact between the end effector and the workpiece;
• defining a first workpiece region characterized by compliance characteristics within a first compliance range based on the virtual model and the first compliance;
• assigning a first target force to the first workpiece region based on the first compliance;
• defining a second workpiece region characterized by compliance characteristics within a second compliance range greater than the first compliance range based on the virtual model and the second compliance;
• and
• assigning a second target force, less than the first force, to the second workpiece region based on the second compliance range;
• and
• during a processing cycle:
• accessing a third sequence of force values output by the force sensor;
• and
• via the set of actuators:
• navigating the sanding head across the first workpiece region of the workpiece;
• selectively driving the sanding head below a first unloaded surface of the workpiece stored in the virtual model to maintain forces, of the sanding head on the first workpiece region of the workpiece, to approximate the first target force, based on the third sequence of force values;
• navigating the sanding head across the second workpiece region of the workpiece;
• and
• selectively driving the sanding head below a second unloaded surface of the workpiece stored in the virtual model to maintain forces, of the sanding head on the second workpiece region of the workpiece, to approximate the second target force, based on the third sequence of force values.