Systems and methods for identifying mis-aligned holes in structural components

A method comprising:

• receiving, by a control unit, one or more force signals from one or more force sensors coupled to one or both of a tool or an end effector coupled to the tool, wherein the one or more force signals are indicative of one or more forces exerted in relation to the tool or the end effector as the tool operates on one or more components to form an expanded hole;
• comparing, by the control unit, the one or more forces in relation to force data associated with a reference expanded hole that is aligned with an alignment hole of the one or more components;
• and
• determining, by the control unit, that the expanded hole caused a deformation when the one or more forces differ from the force data.

A system comprising:

• a tool configured to form an expanded hole in a component;
• an end effector coupled to the tool;
• one or more force sensors coupled to one or both of the tool or the end effector;
• a control unit configured to:
• receive one or more force signals from the one or more force sensors, wherein the one or more force signals are indicative of one or more forces exerted in relation to the tool or the end effector as the tool operates on the component to form an expanded hole,
• compare the one or more forces in relation to force data associated with a reference expanded hole that is aligned with an alignment hole of the one or more components, and
• determine that the expanded hole caused a deformation when the one or more forces differ from the force data;
• and
• a user interface having a display, wherein the control unit is further configured to show information regarding the expanded hole on the display.