Intelligent fixture system

The flexible fixture system comprising:

• a fixture configuration station including a station controller;
• an input conveyor leading into the fixture configuration station;
• an output conveyor leading out of the fixture configuration station;
• a pallet assembly at the fixture configuration station, the pallet assembly comprising a pallet which supports a micro-positioner and a fixture having a plurality of clamps supported by the micro-positioner;
• a first part sensing system mounted along the input conveyor and a second part sensing system mounted at the fixture configuration station;
• means for adjusting the pitch and yaw of a part clamped in the fixture;
• and, means for recording on the pallet assembly X, Y, and Z position errors and roll orientation errors of the part clamped in the fixture.

The method of machining a family of parts comprising:

• providing a fixture configuration station including a robot and a station controller;
• sensing a part as it enters the fixture configuration station using a first part sensing system;
• providing a pallet assembly at the fixture configuration station;
• sensing the position and orientation of a part which is clamped into the pallet assembly using a second part sensing system;
• developing X, Y, and Z axis offsets to compensate for X, Y, and Z axis position errors of the clamped part as sensed by the second part sensing system;
• developing roll, pitch, and yaw orientation errors of the clamped part as sensed by the second part sensing system;
• and,
• adjusting the pitch and yaw of the clamped part to correct the pitch and yaw errors as sensed by the second part sensing system.