Method for autonomously scanning, processing, and creating a digital twin of a workpiece

A method comprising:

• accessing a set of images captured by an optical sensor arranged on an end effector traversing a scan path over a workpiece during a scan cycle;
• compiling the set of images into a virtual model of the workpiece;
• generating a first toolpath for a first workpiece region of the workpiece based on the virtual model, the first toolpath comprising:
• a first keypoint located on the virtual model;
• and
• a second keypoint located on the virtual model;
• assigning a first target force to the first workpiece region;
• during a processing cycle:
• accessing a first sequence of force values output by a force sensor coupled to a sanding head arranged on the end effector;
• via a set of actuators coupled to the end effector:
• navigating the sanding head across the first workpiece region according to the first toolpath;
• and
• based on the first sequence of force values, deviating the sanding head from the first toolpath to maintain forces of the sanding head on the first workpiece region proximal the first target force;
• interpreting a first position of a reference point, on the sanding head, in contact with the workpiece when the sanding head occupies the first keypoint;
• interpreting a second position of the reference point in contact with the workpiece when the sanding head occupies the second keypoint;
• transforming the virtual model to align:
• the first keypoint on the virtual model to the first position of the reference point;
• and
• the second keypoint on the virtual model to the second position of the reference point;
• and
• storing the virtual model, transformed according to the first position and the second position, as a digital three-dimensional record of the workpiece.

A method comprising:

• accessing a set of images captured by an optical sensor arranged on an end effector traversing a scan path over a workpiece during a scan cycle;
• compiling the set of images into a virtual model of the workpiece;
• generating a toolpath for the workpiece based on a geometry of the workpiece represented in the virtual model;
• assigning a target force to the workpiece;
• 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;
• via a set of actuators coupled to the end effector:
• navigating the sanding head across the workpiece according to the toolpath;
• and
• based on the sequence of force values, deviating the sanding head from the toolpath to maintain forces of the sanding head on the workpiece proximal the target force;
• tracking a sequence of positions of a reference point on the sanding head, traversing the workpiece, in contact with the workpiece;
• transforming the virtual model into alignment with the sequence of positions of the reference point;
• and
• storing the virtual model, transformed according to the sequence of positions, as a digital three-dimensional record of the workpiece.