Assembly line production and assembly of an aircraft wing

Abstract

The present disclosure relates to assembly line fabrication and assembly of aircraft wings. Systems and methods for assembling a wing are provided. The method includes suspending an upper wing panel of an aircraft below a shuttle, translating a rib into position, and placing the rib in contact with the upper wing panel, and then securing the rib to the upper wing panel while the upper wing panel is suspended. Some methods include installing a rib and spar to the upper wing panel while the upper wing panel is suspended, and joining a lower wing panel to the rib and spar. Some methods involve joining a rib to a spar (e.g., in whole or in part) to create a support structure, and then securing the support structure to the upper wing panel. The system includes a shuttle to suspend the upper wing panel, and a cart including a support to hold the rib, a chassis to translate the rib into position below the upper wing panel, and a lifting device to lift the rib into contact with the upper wing panel.

Description

Technical Field

[0001] This disclosure relates to the field of aircraft, and in particular to the manufacture and assembly of aircraft wings. Background Technology

[0002] The airframe defines the mechanical structure of an aircraft. The airframe consists of multiple components that provide desired structural characteristics. For example, a portion of the airframe for an aircraft wing may include components mechanically joined together (e.g., by co-bonding, co-curing, or fasteners) according to design parameters. Specifically, a wing assembly typically includes an upper wing panel and a lower wing panel, each wing panel comprising a wing skin stabilized by a series of longitudinal spars. These spars together clamp a support structure consisting of a front spars and a rear spars extending along the span of the wing panel and are connected by a series of parallel ribs, each extending chordally across the wing panel. In current practice, airframe components are fabricated and assembled in predetermined units in a factory workshop. For example, components may be laid, cured, or otherwise fabricated at one unit and then transported as a whole to a new unit for work.

[0003] While the fabrication process discussed above is reliable, delays occur when work on specific parts of components takes longer than expected. For example, if a particular section of a wing requires more time to lay or fasten than anticipated, the entire wing assembly will remain at the unit until all delayed work is completed. Furthermore, significant time is spent cataloging the configuration of components after they have been moved. This time is not value-added. In addition, frequent moves between units add substantial amounts of non-value-added time. That is, every move of a component between units (and therefore every unit used in the fabrication process) requires setup time, and this setup time should be minimized for efficiency. Current designs utilize automated optical inspection techniques and / or probes to inspect part positions along their six degrees of freedom, but these are particularly time-consuming and costly.

[0004] Therefore, it is desirable to have a method and apparatus that takes into account at least some of the problems discussed above, as well as other possible problems.

[0005] The abstract of EP3604141A1 states: "An aircraft structure manufacturing apparatus includes: a fixture for supporting aircraft structural components; a plurality of elevators; and a control unit for controlling the position of supports of the elevators. The control unit includes: an input unit for inputting position information of a destination point for movement toward a reference point set for the component; a storage unit for pre-storing master data relating to the position information of the supports of each elevator to the position information of the destination point; a unit position information acquisition unit for acquiring the position information of the supports of each elevator based on the position information of the destination point and the master data; and a movement command unit for simultaneously moving the supports of the plurality of elevators."

[0006] The abstract of EP2939931A1 states: "A method and apparatus for manufacturing an aircraft structure. A drivable support member can be driven from a first position to a second position, such that the drivable support member is combined with at least one other drivable support member to form a drivable support system. The drivable support system can be used to hold the structure in a desired position." Summary of the Invention

[0007] The embodiments described herein provide reinforcement systems and techniques that facilitate the fabrication and assembly of aircraft wings via an assembly line. According to these embodiments, large components, such as wing panels, are transported in a pulsed or continuous manner. Discrete workstations arranged along the assembly line perform various work tasks on the components (e.g., during pauses between pulses or while the components are moving continuously). As discussed in more detail below, the embodiments herein focus on assembling wing assemblies by following the path of the wing panel, to which other components (e.g., ribs and spars, then another wing panel) are progressively attached via the assembly line. In some embodiments, shifting features for shifting components (e.g., wing panels) to one or more workstations are formed in the component. In embodiments where the component is a wing panel, shifting features are formed in a manufacturing allowance area of ​​the wing panel, which is eventually trimmed away as part of the wing panel formation. The wing panel can be shifted to the workstation by means of these shifting features. In some embodiments, the workstations are arranged close enough to each other that the wing panel, due to its size, can encounter multiple workstations simultaneously. For example, an assembly line might include a series of stations arranged along the machining direction, such that as a wing panel moves along the machining direction, the forward portion of the wing panel first encounters an inspection station (e.g., a non-destructive testing or NDI station), then a cutting station, and then a rib mounting station. These stations can be positioned close enough to each other that, for example, when the forward portion encounters the rib mounting station, the middle portion of the wing panel encounters the cutting station, and the rear portion encounters the NDI station, such that, for example, two or more stations, or all three stations, can perform work tasks on the same portion of the wing panel within the respective station's field of vision, either simultaneously or overlapping in time. This assembly technology offers technical advantages by integrating the transport process into the assembly process and by reducing the amount of work performed on a large component each time it is moved.

[0008] Some embodiments are methods of assembling an aircraft wing, wherein the method includes: suspending an upper wing panel of the aircraft below a shuttle, translating a rib to a position below the upper wing panel, positioning the rib to contact the upper wing panel, and securing the rib to the upper wing panel while the upper wing panel remains suspended. Some methods also include: orienting the rib vertically and / or vertically raising the rib to the upper wing panel. Alternatively or additionally, in some methods, the upper wing panel is lowered to the rib. In some methods, placing the rib includes engaging complementary alignment features on the rib and the upper wing panel. Some methods also include applying a profile to the rib before securing it. Some methods also include securing a spars to the upper wing panel. Some methods also include attaching a lower wing panel to the rib and / or spars secured to the upper wing panel. In some methods, the rib and spars are secured to each other to create a support structure, and then the support structure is secured to the upper wing panel. In some methods, translation, placement, and attachment are performed simultaneously with the upper wing panel suspended below the shuttle.

[0009] Some embodiments are methods of assembling an aircraft wing, wherein the method includes: suspending an upper wing panel of the aircraft below a shuttle, attaching ribs and spars to the upper wing panel, and joining a lower wing panel to the ribs and spars, wherein the installation and joining are performed simultaneously with the suspension of the upper wing panel. In some methods, one or more or all of the ribs are installed before any spars are installed. In some methods, the spars are fastened to the ribs to create a support structure (which is then attached to the upper wing panel) before any of the spars and ribs are installed.

[0010] Some embodiments are methods of assembling an aircraft wing, wherein the method includes (in the following order): joining ribs for the wing assembly with spars for the wing assembly to create a support structure, joining the upper wing panel of the aircraft to the support structure, and joining the lower wing panel of the aircraft to the support structure. In some methods, the upper wing panel is suspended below the shuttle prior to joining.

[0011] Some embodiments are methods for assembling an aircraft wing, wherein the method includes: suspending an upper wing panel of the aircraft below a shuttle; while the upper wing panel remains suspended, simultaneously attaching at least one rib and at least one spars to the upper wing panel via corresponding stations located at the upper wing panel; and pulsating the upper wing panel through the stations in the processing direction. Some methods also include simultaneously performing work on the upper wing panel via multiple stations during pauses between pulsations.

[0012] Some implementations are non-transitory computer-readable media that implement instructions that, when executed by a processor, are operable to perform the methods briefly mentioned above.

[0013] Some implementations are wing assembly systems, which include: a shuttle configured to suspend the upper wing panel of the aircraft below the shuttle; and a trolley further including supports configured to vertically hold ribs for the wing assembly, a chassis configured to translate the ribs onto the upper wing panel at a location directly below where the ribs will be fixed, and a lifting device configured to vertically lift the ribs to contact the upper wing panel. In some systems, the shuttle includes a carrier configured, for example, to be connected to the upper surface of the upper wing panel via a vacuum coupling.

[0014] Some implementations are wing assembly systems, which include: a positioning plate configured to suspend an upper wing panel below it via a spring of adjustable length, the spring being configured to engage with the upper wing panel; and a trolley further including a support configured to vertically hold the rib. In such systems, the positioning plate is configured to lower the upper wing panel to contact the rib by adjusting the length of the spring. In some systems, the trolley is an AGV and / or configured to translate the rib to a position on the upper wing panel directly below where the rib will be secured.

[0015] Other exemplary embodiments (e.g., methods, computer-readable media, systems, etc. related to the foregoing embodiments) may be described below. The features, functions, and advantages already discussed may be implemented independently in various embodiments or may be combined in other embodiments, as can be seen in further details with reference to the following description and accompanying drawings. Attached Figure Description

[0016] Some embodiments of this disclosure will now be described by way of example only and with reference to the accompanying drawings. Throughout the drawings, the same reference numerals denote the same elements or elements of the same type.

[0017] Figure 1 This is a block diagram illustrating, in an exemplary embodiment, the application of an indexing feature to a system for laying manufacturing allowances in a preform that will be hardened into a composite part.

[0018] Figure 2A An example of a laying mandrel awaiting laying is shown in an exemplary embodiment.

[0019] Figure 2B An exemplary embodiment is shown of a laying mandrel covered by composite parts.

[0020] Figure 3 This is a flowchart illustrating an exemplary embodiment of a method for applying an indexing feature to a manufacturing allowance in a preform to be hardened into a composite part.

[0021] Figure 4The production cycle timing of a feed line for composite parts in an exemplary embodiment is depicted.

[0022] Figures 5A to 5F This is a diagram of the wing assembly line in an exemplary embodiment.

[0023] Figure 5G This is a diagram of an alternative configuration of the assembly line for the wing in an exemplary embodiment.

[0024] Figure 6 This is a flowchart illustrating a method for applying contours to a wing panel in an exemplary embodiment.

[0025] Figure 7 and Figure 8 This is a flowchart illustrating a non-destructive inspection method for wing panels in an exemplary embodiment.

[0026] Figure 9 This is a flowchart illustrating a method for mounting ribs and spars to wing panels in an exemplary embodiment.

[0027] Figure 10 This is a flowchart illustrating another method for applying contours to a wing panel in an exemplary implementation.

[0028] Figures 11A to 11D The installation of the rib on the upper wing panel is shown in an exemplary embodiment.

[0029] Figure 12 This is a flowchart illustrating a method for fixing a rib to an upper wing panel in an exemplary embodiment.

[0030] Figures 13 to 15 This is a flowchart illustrating a method for mounting ribs and spars to the upper wing panel in an exemplary embodiment.

[0031] Figures 16A to 16C This is a diagram illustrating the automatic installation of a gasket between the rib and the wing panel in an exemplary embodiment.

[0032] Figures 17A to 17C Further views are shown of a robotic arm that performs automated inspection and shim installation between the rib and the wing panel in an exemplary embodiment.

[0033] Figure 18 This is a flowchart illustrating a method for installing a pad using a robotic arm in an exemplary embodiment.

[0034] Figure 19 This is a perspective view of an aircraft including a fully assembled wing in an exemplary embodiment.

[0035] Figure 20 These are block diagrams of the various components and systems discussed herein in exemplary embodiments.

[0036] Figure 21 The control components of a production system that performs ultrasonic inspection in an exemplary embodiment are shown in general.

[0037] Figure 22 An assembly line in an exemplary embodiment is depicted.

[0038] Figure 23 This is a flowchart of an exemplary embodiment of an aircraft production and service method.

[0039] Figure 24 This is a block diagram of an aircraft in an exemplary embodiment. Detailed Implementation

[0040] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. It will therefore be understood that those skilled in the art will be able to design various arrangements, although not expressly described or shown herein, that implement the principles of this disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and should be construed as not being limited to these specifically referenced examples and conditions. Therefore, this disclosure is not limited to the specific embodiments or examples described below, but is limited by the claims.

[0041] For convenience, the description is presented as a series of operations that may occur during the production of an aircraft wing, as it is assembled from component parts on an assembly line. Specifically, the description begins with the formation of a wing panel from prefabricated parts and continues through various operations performed on the wing panel, including adding structural components such as ribs and spars to the wing panel (which may be an upper wing panel) and combining it with another wing panel (such as a lower wing panel) to form a wing assembly. The term "wing assembly" generally refers herein to a wing panel to which one or more major structural components (e.g., ribs and spars) have been fixed or mounted, and thus may include a complete wing. However, since the description primarily refers to the formation of wing panels and the addition of major structural components thereto, it need not include the cabling and mechanical and electrical systems that are typically also incorporated into the complete wing. Not all operations, processes, steps, and other actions described herein must occur in all embodiments described herein (e.g., embodiments of wing assemblies, embodiments of their structural components, embodiments of methods associated with their assembly, etc.) or in other embodiments consistent with this disclosure. Furthermore, the described operations or certain actions contained therein may occur in a different order than those discussed, may occur simultaneously with other actions or overlap in time, may represent operations of different wing panels (e.g., upper wing panel instead of lower wing panel, etc.), and so on.

[0042] The wings and wing assemblies described herein may include metallic parts and / or composite parts. Composite parts (such as carbon fiber reinforced polymer (CFRP) parts) are initially laid out in multiple layers, which together are called preforms. Individual fibers within each layer of the preform are aligned parallel to each other, but different layers exhibit different fiber orientations to increase the strength of the resulting composite part along different dimensions. The preform includes a viscous resin that solidifies to harden the preform into a composite part (e.g., for use in aircraft). Carbon fibers impregnated with uncured thermosetting or thermoplastic resins are called “prepregs.” Other types of carbon fibers include “dry fibers” that are not impregnated with thermosetting resins but may include tackifiers or binders. Dry fibers are injected with resin before curing. For thermosetting resins, curing is a one-way process called curing, while for thermoplastic resins, the resin reaches a viscous form if reheated.

[0043] Figure 1 This is a schematic diagram of an exemplary layup system 100 that applies indexing features to the manufacturing allowance of a preform to be hardened into a composite part, in an exemplary embodiment. In previous systems, the manufacturing allowance of the composite part, i.e., the material exceeding the expected final size or boundary (e.g., final perimeter) of the composite part, is trimmed immediately after demolding. For example, this might involve placing a wing panel into a dedicated cell, scanning the wing panel to characterize it, and then trimming the wing panel along the perimeter of the part (e.g., using a tool) until the final perimeter size is achieved. A similar process is applied when trimming manufacturing allowances for fuselages. As will be described in more detail herein, the layup system 100 is unique in that it utilizes material that is conventionally trimmed from the composite part immediately after demolding. In particular, various indexing features are formed in the manufacturing allowance of the preform, which can then be used to index (e.g., position, orient, mark, etc.) the hardened composite part for further operations, such as at one or more stations on an assembly line or other manufacturing processes. The laying system 100 includes any system, device, or component operable to apply an indexing feature to a preform to be hardened into a composite part. In this embodiment, the laying system 100 includes a laying mandrel 110 (e.g., a rigid metal mandrel) that defines a profile 112 (e.g., a curved, flat, or other shaped profile) for a preform to be hardened into a composite part (e.g., an airfoil panel). The preform 200 is shown as being disposed on the laying mandrel.

[0044] refer to Figure 2A and Figure 2BIt can also be seen that an isometric view of a simplified version of the laying mandrel 110 is shown, the mandrel having surface features 114, such as indentations, protrusions, ridges, grooves, notches, through holes, blind holes, dams, etc. Just as profile 112 (which gives the preform a corresponding profile), surface features 114 can be used to directly place the corresponding indexing feature shown at 210 onto the preform. Other adaptations include trimming manufacturing allowances at the laying mandrel 110, or drilling holes in the hardened composite part at the laying mandrel 110. In other words, surface features 114 locally modify the shape of the preform 200 to place the indexing feature 210 into the preform and / or the hardened composite part, and the various types of surface features 114 provide different ways to form the indexing feature into the composite part. One approach is to lay a preform on a surface feature (e.g., forming a protrusion in the preform corresponding to the indentation, which becomes part of the composite part after hardening); another approach is to machine (e.g., by drilling) a displacement feature (e.g., a through hole) into the hardened composite part. For example, in Figure 1 In this context, surface feature 114 is shown as including a recess 118 filled with a potting compound and finished to a surface profile complementary to profile 112, such that indexing features, such as through holes, can be drilled into the hardened composite part from preform 200 before demolding the part from mandrel 110, with some of the potting compound removed by over-brushing during the drilling operation without damaging the surface of the laying mandrel. Surface feature 114 is used to shape or apply indexing features to (and / or onto) the preform 200 laid on the laying mandrel 110.

[0045] Over-bursting during processing (e.g., drilling or trimming) at the hardened laying mandrel 110 requires rework of the potted surface before the next use of the laying mandrel 110. The preform 200 is laid on the laying mandrel 110, covering the contour 112 and surface features 114.

[0046] like Figure 1 As shown and in Figure 2A As can also be seen, it shows a laying mandrel 110 awaiting laying, the laying mandrel including a laying area 120 for the preform 200, which includes a contour 112 and is surrounded by a manufacturing allowance area 122, within which surface features 114 are provided. Accordingly, as Figure 1As shown, the preform 200 extends beyond the final trimming boundary or final perimeter 202 of the resulting composite part. The area where the preform extends beyond the final perimeter 202 is a manufacturing allowance, denoted by 204, which is defined by the manufacturing allowance edge 206. Therefore, surface feature 114 is positioned to complementaryly form an indexing feature 210 in the preform 200. More specifically, for example, surface feature 114 disposed in the manufacturing allowance region 122 forms an indexing feature 210 in the manufacturing allowance 204 of the preform 200 before hardening, which, as described above, can be used for indexing after the preform 200 is hardened into the composite part 250. Although the curve of the profile 112, shown as a shallow concave surface, is shown as extending beyond the final perimeter 202 of the resulting composite part on the laying mandrel 110, this is not necessary in all embodiments, as profile 112 is only required for a portion of the resulting composite part within the final perimeter 202. Furthermore, although a concave laying mandrel 110 is shown, laying mandrels of any suitable shape can be used. For example, convex laying mandrels and laying mandrels defining complex curvatures are also possible. Additionally, although an external mold line laying mandrel 110 is shown, an internal mold line laying mandrel can be used in another embodiment.

[0047] Although Figure 2A The laying mandrel 110, awaiting installation, is shown. Figure 2B The composite part, indicated by 250, has been hardened from the preform 200 and is awaiting demolding from the laying mandrel 110. The indexing feature 210 of the preform 200 has become the indexing feature 210 of the composite part 250.

[0048] In some embodiments, surface features 114 are spaced apart from adjacent surface features by a predetermined distance (e.g., several millimeters, centimeters, or meters), for example, to create uniformly spaced indexable features 210 at / on / in the preform 200 and the resulting composite part 250. In another embodiment, surface features 114 are spaced apart from each other non-uniformly. The positions and / or predefined distances between indexable features may depend in part on factors such as the arrangement of workstations on an assembly line.

[0049] The position of surface feature 114 in the lay-up mandrel 110 is precisely tolerated (e.g., to one-thousandth of a millimeter), so the position of the corresponding indexing feature 210 at the preform 200 is also known with precise tolerance, even after the preform 200 has hardened into the composite part 250 and been demolded from the lay-up mandrel 110. Thereafter, the indexing feature 210 can be used by a station on the assembly line to orient and position the resulting composite part in a desired manner so that work can be performed on the composite part. Furthermore, because the lay-up mandrel 110 is reusable, there is no need for a separate process of applying the indexing feature to the preform. Performing this process on a lay-up mandrel within the tolerance range results in the indexing feature also being within the tolerance range. The recess 118 (also known as the potting area) is filled with potting compound and positioned to accommodate machining overpasses from machining operations (e.g., drilling operations) to install indexing features (e.g., through holes) after the composite part 250 has been hardened, as described above, and to be refilled and / or re-laid as needed after machining and demolding in preparation for the next preform.

[0050] Some implementations include installing a readable identification device in the prefabricated component (in... Figure 1 (Often shown as 126), such as a radio frequency identification (RFID) chip. In such embodiments, one or more RFID chips are coupled, attached, or embedded in the manufacturing allowance 204 of the preform 200. A readable identification device such as an RFID chip can facilitate the transfer process by reporting information characterizing aspects of the resulting composite part coupled thereto. For example, an RFID chip can provide instructions to a workstation regarding structural portions within a particular workstation's preview. One or more RFID chips can provide instructions to one or more workstations, and a one-to-one relationship between an RFID chip and a workstation is not required. In another example, an RFID chip reports to a workstation the type of structure / wing, including right or left, top or bottom, or even model number.

[0051] Furthermore, although not shown in the figures, as part of the forming process, in addition to or in lieu of an RFID chip, one or more other readable identification devices 126 may be provided to the preform 200 or the composite part 250 formed therefrom. For example, barcodes or other markings that can be scanned or read by a suitable reader at one or more stations on the assembly line may be engraved or applied to the preform or the resulting composite part prior to demolding. For the purposes of this disclosure, all references herein to specific types of readable identification devices 126 (e.g., RFID chips or barcodes) (and their descriptions in the figures) are intended to cover any such readable identification device in a general sense.

[0052] Figure 1The illustrated laying system also includes a cutter 130 having blades 132 (e.g., reciprocating or circular blades) and an actuator 134, the actuator 134 driving the blades 132 to cut off a portion of the composite part near the guide 116, the guide 116 being shown in the form of an adjacent groove in the laying mandrel 110 covering a manufacturing allowance region 122. That is, the guide 116 positions the cutter 130 and / or defines the path of the cutter 130. Furthermore, as Figure 1 As shown, guide 116 can be filled with potting compound to accommodate the blades of the cutter (and refilled after use, similar to recessed area 118). As Figure 2B As shown, for clarity, the groove that together forms the guide 116 is shown as a rectangular perimeter, the composite part 250 is shown as a portion 252 included within the laying area 120, and a portion 254 in the manufacturing allowance area 122 that conforms to the surface feature 114. Figure 2B The diagram shows excess material flash 256 extending beyond the manufacturing allowance area 122. A cutting operation performed before demolding the composite part 250 from the laying mandrel 110 removes the flash 256 to define the manufacturing allowance edge 206 and leaves sufficient manufacturing allowance 204 to include the indexing feature 210 for use at stations in the assembly line. The coarse cut provides a consistent edge for the part, the manufacturing allowance edge 206, during the manufacturing process before trimming the edge to the final perimeter (i.e., the final perimeter 202). This is desirable compared to working on parts without a fixed, consistent perimeter in terms of manufacturing allowance. The operation of the cutter 130 is managed by a controller 140. The controller 140 can be implemented as, for example, custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

[0053] Illustrative details of the operation of the laying system 100 will be about Figure 3 The discussion and method 300 shown therein. For this embodiment, it is assumed that after the composite part has been demolded from the laying mandrel 110, the laying mandrel 110 has been cleaned and returned to the starting point of the assembly line. Therefore, the laying mandrel 110 awaits the laying of a preform (e.g., preform 200) for the next composite part 250.

[0054] Figure 3 This is a flowchart illustrating a method 300 in an exemplary embodiment for applying an indexing feature to a manufacturing allowance 204 of a preform 200 to be hardened into a composite part 250. The steps of method 300 are referenced below. Figure 1 , Figure 2A and Figure 2BThe components of the laying system 100 shown are described, but those skilled in the art will understand that method 300 can be performed in other systems. As with all methods historically and described in this disclosure, the steps shown in the flowcharts described herein are neither all-inclusive nor exclusive. Furthermore, the flowcharts herein (e.g.) Figure 3 While only specific embodiments of a particular method (e.g., method 300) have been described in this disclosure, it should be understood that other embodiments of the method consistent with and covered by this disclosure include fewer or more steps than shown, steps performed in a different order than shown, and / or include other (e.g., additional, fewer, and / or alternative) actions besides those depicted. Furthermore, it will become clear from this disclosure that because the various methods shown and discussed herein involve several different operations and sequences that can be performed during the formation and assembly of wing panels into wing assemblies, the methods according to this disclosure may combine or otherwise include two or more of the various steps and operations of the various methods shown. Moreover, although the reference numerals for the aforementioned components are used in the description of method 300, it should be understood that this method (and other methods described herein) is applicable to components that may have different configurations than those shown and described above.

[0055] In method 300, in step 302, preform 200 is laid on lay mandrel 110, for example, on lay area 120, and on portions of lay mandrel 110 that extend beyond the final trimming boundary (i.e., final perimeter 202) of composite part 250, such as manufacturing allowance region 122. Manufacturing allowance region 122 of lay mandrel 110 includes surface feature 114 configured to complementaryly form indexing feature 210 in preform 200. Lay mandrel 110 defines the outline 112 of composite part at least in the lay area, and preform 200 includes manufacturing allowance 204 extending beyond the final perimeter of composite part. Laying can be performed as lay mandrel 110 itself is pulsed or continuously moved through the assembly line, and can include simultaneous (at once) synchronous operation of multiple laminators (e.g., during continuous movement of the lay mandrel, during pauses between movements of the lay mandrel, etc.). During the layup process, unidirectional fiber reinforcements of multiple layers are sequentially applied to construct a preform 200 with desired dimensions and strength. The layup process extends the preform 200 beyond the final trimmed (e.g., component size) boundary (e.g., beyond the final perimeter 202), meaning that a portion of the preform 200 extends above surface feature 114. In this embodiment, the preform 200 is a preform of a wing panel 550 having multiple layers / multiple sheets.

[0056] In step 304, the preform 200 conforms to surface feature 114 at the layup mandrel 110, which is located beyond the final trimming boundary of the composite part 250, and complementaryly forms / applies a feature to the preform 200, which will be hardened into an indexing feature 210. In one embodiment, this includes consolidating the preform 200 by vacuum bagging and applying consolidation pressure. In a further embodiment, the fiber reinforcement tow applied during layup in step 302 is compressed by rollers or other equipment to conform the preform 200 to surface feature 114.

[0057] In the exemplary method, steps 302 and 304 are typically performed in a cleanroom environment to minimize the possibility of foreign debris and other contaminants (e.g., during laying) coming into contact with the preform 200. The laying mandrel 110 is then moved to an autoclave, where the preform 200 is hardened into a composite part 250 by heating and / or pressurizing. In step 306, the preform 200 is hardened into a composite part 250 including a displacement feature 210 complementaryly formed therein, since the displacement feature 210 is complementary to and disposed at the surface feature 114. During hardening, the preform 200 may be heated to the curing temperature of the thermosetting resin within the preform 200, or the preform 200 may be heated to the melting temperature of the thermoplastic resin and then cooled until the thermoplastic resin is solidified. This results in the composite part 250 having the displacement feature 210 disposed at the surface feature 114 on the laying mandrel 110.

[0058] In a further embodiment, additional indexing features 210 are added by milling or drilling the manufacturing allowance (e.g., by removing material from the manufacturing allowance through mounting holes, notches, channels, and / or grooves). In an even further embodiment, the additional indexing features 210 are used and / or mounted, such as pins, clamps, rings, etc.

[0059] Some implementations include mounting a readable identification device 126 (e.g., an RFID chip, barcode, etc.) into a manufacturing allowance 204 of the preform 200 or composite part 250. In other words, the RFID chip and / or other readable identification device 126 is placed into the manufacturing allowance 204 before or after the preform is hardened into the composite part 250.

[0060] In step 308, material is removed (e.g., cut off or otherwise separated) from the composite part 250, while retaining a manufacturing allowance 204 including the indexing feature 210. The cutting operation in step 308 creates a consistent perimeter / boundary of the manufacturing allowance 122. In one embodiment, this includes operating the cutter 130 along the guide 116 to cut off resin flash (or flash 256) or other boundaries of the composite part 250, thereby creating the manufacturing allowance edge 206. In one embodiment, the flash 256 of the composite part 250 is trimmed off before demolding the resulting composite part 250 from the laying mandrel 110. The composite part 250 retains a manufacturing allowance 204 having an indexing feature 210 that will be used to index the composite part as it is processed at a station in the assembly line. Composite part 250 may also include indexing features 210 in areas to be trimmed to accommodate other portions, such as wing access doors or wing panels, and / or in manufacturing allowances extending beyond the final perimeter of the wing panel. The final perimeter 202 can then be obtained by trimming away the remaining manufacturing allowance later in the process. That is, one or more indexing features may be removed to accommodate one or more additional components during assembly. For example, a workstation may be designed to trim away manufacturing allowances or portions thereof, install components such as ribs or spars, join components such as wing panels together, etc. In a further embodiment, additional indexing features 210 (e.g., holes, notches, channels, grooves, etc.) are installed onto / formed at composite part 250 via drilling, milling, or other operations. In another embodiment, material removal from composite part 250 includes installing such additional indexing features 210.

[0061] In step 310, after material is removed from composite part 250 (e.g., separating flash 256 and / or placing one or more indexing features 210), the composite part is demolded from layup mandrel 110. Composite part 250 then continues (not shown) to assembly line for further fabrication and assembly, while layup mandrel 110 returns to be cleaned and receive another preform for the composite part. In one embodiment, layup mandrel 110 is also reworked (e.g., after drilling or cutting over-punches into filler area 118, refilled with filler compound as needed to restore layup profile 112 before demolding, repair, etc.) and transported to the initial layup location (e.g., on a wing panel layup line).

[0062] The method can then continue. For example, and as described in more detail herein, the resulting composite part 250 can be indexed to a station in the assembly line via indexing feature 210, and work can be performed on the composite part at that station while it is indexed. In some embodiments, the composite part 250 is suspended or otherwise conveyed through the assembly line via a shuttle (e.g., a positioning plate). The composite part 250 can be indexed to the shuttle (e.g., via a corresponding indexing unit on the positioning plate). The positioning plate can then be indexed to the station, in which case it can be said that the composite part is indexed to the station via the positioning plate. In any case, indexing characterizes at least a portion of the composite part 250 (and / or the positioning plate) within the field of view of the station. In further embodiments, multiple indexing features interact with multiple stations and / or with the positioning plate. Shifting can occur at one or more workstations until the manufacturing allowance 204 is finally trimmed from the composite part 250 (e.g., after the shifting features located in the manufacturing allowance are no longer used for assembly). After trimming, the composite part 250 has its final perimeter 202, and the shifting features 210 in the manufacturing allowance have been removed. The composite part 250 is then integrated into the wing assembly of the aircraft.

[0063] Method 300 offers significant advantages over the prior art because it enables the indexing feature 210 to be mounted into the composite part 250 during layup via a surface feature 114 on a reference mandrel 110 that has already been precisely tolerant. This eliminates the need for precise measurements of the preform 200 for mounting the indexing feature 210, as the indexing feature has already been positioned precisely known by means of the placement of the surface feature and its placement relative to the layup mandrel 110. Therefore, the precision of the layup mandrel 110 and the layup process avoids the need for contour scanning and indexing in downstream processes. Thus, the precision of the layup mandrel 110 is extended / utilized not only during the layup process but also in post-hardening processes (e.g., trimming, milling, or drilling) to add the indexing feature prior to demolding of the composite part 250. Therefore, the precise relationship between the multiple surface features 114 and the corresponding indexing features 210 (placed in the composite part 250 by using the laying mandrel 110) is carried as the composite part is advanced, which allows the manufacturing process steps to occur simultaneously on the same part.

[0064] Figure 4 An example diagram is shown illustrating how different feed lines and assembly or laying lines are coordinated in an assembly line for assembling, for example, wing components. Figure 4This is a flowchart illustrating an example of a mode in an exemplary implementation, shown as mode 480 for feed line 490 and assembly / layout line 491. Mode 480 provides a detailed example flowchart of wing fabrication in relation to feed lines and production cycle times. For a particular implementation, all feed lines are depicted, showing the integration of the wing into the fuselage section from the layout material feed line through a joining operation. Furthermore, each step, indicated by the arrows, is performed based on a desired production cycle time according to the production cycle time of the component it feeds.

[0065] In this embodiment, each feed line is designated by a different reference numeral 490 (e.g., 490-1, 490-2, etc.), and each assembly or laying line is designated by a different reference numeral 491 (e.g., 491-1, 491-2, etc.). More specifically, feed line 490-1 supplies laying material to wing panel laying line 491-1. Feed line 490-2 supplies laying material to spars laying line 491-5. Feed line 490-3 supplies laying material to rib laying line 491-3, and feed line 490-4 supplies laying material to longitudinal spars laying line 491-2. The laying lines also feed into other laying lines. Rib laying line 491-3 is fed to the rib rear fabrication line 491-7, wing panel laying line 491-1 is fed to the wing longitudinal spars placement line 491-4, and spars laying line 491-5 is fed to the spars rear fabrication line 491-6.

[0066] Each feeder line displays a production takt time, which facilitates the production of the components it manufactures. The production takt times between the feeder lines and the assembly lines they feed to are synchronized to provide just-in-time (“JIT”) delivery of parts to one or more stations 520 that use these parts (e.g., as consumables, as input to a product being manufactured, etc.). The resulting parts move along the assembly line 500 with the stations 520 and also advance within the production takt time. The production takt times for each of the feeder lines 490-1 to 490-9 and / or lines 491-1 to 491-9 may be the same, some may be the same, or all may be different. Each feeder line 490-1 to 490-9 travels at the common production takt time of that particular line.

[0067] The production cycle time of each feeder line can depend on the expected productivity of the assembly line fed by the feeder line. For example, if ribs are attached at a rate of one per hour and are attached by 200 fasteners, then the feeder line should supply 200 fasteners to the rib mounting station per hour, resulting in a fastener production cycle time of 3 minutes and one-third of the fasteners per minute.

[0068] For example, in this embodiment, the rib laying line 491-3 travels at a production cycle time of 7 and is fed into the rib rear fabrication line 491-7. The wing panel laying line 491-1 travels at a production cycle time of 3 and is fed into the wing spars placement line 491-4. The spars laying line 491-5 travels at a production cycle time of 5 and is fed into the spars rear fabrication line 491-6.

[0069] The rib fabrication line 491-7 travels at a production cycle time of 6, the wing spars placement line 491-4 travels at a production cycle time of 2, and the spar fabrication line 491-6 travels at a production cycle time of 4. All materials are fed into the wing assembly line 491-8, which travels at a production cycle time of 1. Hatch covers are also received from the hatch cover feed line 490-5, miscellaneous materials from the scrap feed line 490-6, fasteners from the fastener feed line 490-7, and sealant from the sealant feed line 490-8. The wing panel 550 is hardened in an autoclave in line 490-10. The composite part 250 is then trimmed and (in some embodiments) has an indexing feature 210 added before separation from the mandrel 110 (e.g., in a demolding station in line 490-11). The excess material from the finishing process is removed from the wing assembly line 491-8 via the drop chute 490-9. After the wing is completed, line 491-9 moves the wing toward the fuselage for assembly. Each of the various lines discussed above can supply material and / or components to its feed lines on time at any rate that may be desired. The production cycle time of a downstream line may or may not be equal to that of one or more lines feeding it. Each line may have a unique production cycle time.

[0070] Any assembly line (including feed lines) can operate as a micro-pulsating, full-pulsating, and / or continuous line, with the manufacturing process proceeding from left to right (relative to mode 480), and various production takt times synchronized to deliver parts and / or materials on time at the next downstream line. As used herein, “pulsating” refers to a part advancing through the assembly line in the machining direction and then pausing. A part can be “micro-pulsating” (the term herein refers to a part advancing a distance less than its length in the machining direction) or it can be “full-pulsating” (a part advancing a distance equal to or greater than its length). As part of pulsed production, parts in the assembly line are pulsed synchronously, and multiple stations can perform work on different portions of the part during the same pause between pulses or during the pulse itself. In other words, each station simultaneously performs work on a portion of the wing panel, such that each station performs work on a different portion during the pause in the wing panel’s advancement along the track.

[0071] This parallel processing significantly increases the workload density within the factory. The production cycle time for each micro-pulsating or full-pulsating component can be the same or different, or it can be a defined fraction of the production cycle time of another assembly line receiving the component. For example, the production cycle time at feed line 490-2 for wing spars layup material may differ from the production cycle time at feed line 490-1 for wing panel layup material, and the production cycle time for sealant supplied via sealant feed line 490-8 may also differ. In one embodiment, the production cycle time is constant for each exemplified segment.

[0072] As described above, the various feed lines discussed herein can be either pulsating or continuous. Pulsating lines can achieve micro-pulsation, where the manufactured components are advanced less than their length during pauses before receiving work from the workstation; or they can be fully pulsating, where components are advanced by an amount equal to their length. Furthermore, various components (e.g., wing assemblies, wing panels, ribs, spars, etc.) can be manufactured as composite parts or using additive or subtractive manufacturing techniques for metals. For example, in one embodiment, ribs are manufactured via subtractive manufacturing of metal components at fabrication lines 491-7 behind the ribs, while wing panels are manufactured as composite parts (e.g., preforms) at wing panel laying lines 491-1.

[0073] Figure 4 The various aspects of the patterns shown and described above can be implemented in any manufacturing environment (e.g., in a factory shop and / or on an assembly line for an aircraft wing), such as coordinating the timing of assembly, movement (e.g., pulsed and / or continuous) and / or delivery of parts and supplies and / or other operations on a JIT basis or otherwise. Accordingly, the assembly line (e.g., in a JIT-based or otherwise coordinated manner) can be implemented in any manufacturing environment (e.g., on an aircraft wing assembly line). Figures 5A to 5F The exemplary embodiment of assembly line 500 described below corresponds to assembly lines 491-8. However, even if not specifically mentioned in the description of the embodiment, other assembly lines and manufacturing processes consistent with this disclosure may implement such a mode or any aspect thereof.

[0074] Figures 5A to 5F The illustration depicts various aspects of an example assembly line 500 for an aircraft wing, which is an exemplary embodiment. Assembly line 500 can be used to assemble an aircraft wing via the above... Figures 1 to 4 Work is performed on wing panels (e.g., wing panel 550) produced using the technologies and systems provided in the document. Figures 5A to 5FThe description and the structures, components, and operations shown therein are provided relative to the wing panel, but are applicable to any composite part. The wing panel 550 is described somewhat generally and can be an upper wing panel or a lower wing panel, or a right wing panel or a left wing panel. In describing the operation or characteristics specific to a particular type of wing panel 550 (e.g., an upper wing panel), the wing panel will be represented as follows. Assembly line 500 (its top view is shown in...) Figure 5A (Illustrated schematically) includes a track 510, along which a shuttle (shown as a set of three positioning plates 540) travels in a processing direction 541 (e.g., from station to station in a pulsating or continuous manner). The track 510 includes one or more guide rails, rollers, or other elements that facilitate the movement of the shuttle along the track 510 (e.g., rolling or sliding). The track 510 can be mounted to a floor, suspended from above, etc., depending on the specific environment in which it is used. In the exemplary embodiment, the track 510 is positioned above the respective stations, and the shuttle (positioning plates 540) carries the wing panel 550 in the processing direction. Specifically, from... Figure 5D As can be seen, the positioning plate 540 is shown to include an adapter 543, which engages with and is movable via the track 510. For example, the adapter 543 may drive the positioning plate 540 along the track 510, or the track 510 may be able to drive the positioning plate 540. In either case, this configuration is intended to encompass, in general, any suitable structural means designed for conveying the wing panel 550 in the processing direction 541. In a further embodiment, the track 510 may include a chain drive, a motorized trolley, or other power system (not shown) capable of moving the positioning plate 540 in the processing direction 541.

[0075] One or more positioning plates 540 advance the wing panel 550 through various stations, typically indicated by 520, where work is performed on the wing panel 550. Figure 5A In this configuration, three positioning plates 540 cooperate to support a single wing panel 550. However, more or fewer positioning plates 540 may be used, if appropriate. For convenience, the term "positioning plate" generally refers herein to a single structure configured to extend over a lateral section (e.g., a chordal section) of the wing panel 550; however, for convenience, the term may be used herein to refer generally to a shuttle comprising multiple such structures. When two or more positioning plates 540 cooperate to support a component such as a wing panel 550, they may be coupled to each other (not shown) in a manner that maintains their constant relative position, such that only one positioning plate 540 is driven along track 510. In this way, wing panels 550 of varying lengths may be carried via assembly line 500, for example, by coupling a suitable number of positioning plates 540 together to support the entire length of the wing panel 550.

[0076] In some embodiments, the indexing features of the wing panel 550 (e.g., within manufacturing allowances) can be used to index the wing panel 550 using a positioning plate 540 supporting the wing panel 550. Figure 5B ( Figure 5B Corresponding to Figure 5A In the view indicated by arrow "5B" in the diagram, the positioning plate 540 is shown to include a shifting unit 542 configured to mate with a corresponding shifting feature in the manufacturing allowance 554 of the wing panel 550 (which may correspond to the manufacturing allowance 204 of the preform 200 hardened into the wing panel 550 according to the aforementioned manufacturing process). In the illustrated embodiment, the shifting unit 542 is physically connected to the shifting feature, wherein the shifting unit 542 is shown to include a head 549 received within the shifting feature 210-1, which is shown as a through-hole. Although Figure 5B Only one indexing unit 542 is shown, but each positioning plate 540 may include any suitable number of indexing units. Each indexing unit may be configured to engage with the indexing feature 210 of the wing panel 550, for example, to initially align the positioning plate with the wing panel and / or maintain the alignment of the positioning plate with the wing panel. Like the indexing feature 210, the indexing unit 542 may adopt any suitable construction and may include engagement devices other than those achieving mechanical connection, such as magnets. The indexing unit may be configured to engage with a variety of different indexing features 210, or with indexing features whose position can change from one wing panel 550 to another, for example, to enable the positioning plate 540 to engage with different wing panels as needed.

[0077] exist Figure 5A In the diagram, assembly line 500 is shown with stations 520 including a non-destructive testing (NDI) station 524, a cutting station 526, a rib mounting station 528, and a spar mounting station 530. These stations and the operations performed at each station, as well as other exemplary stations, will be discussed in more detail below. Other embodiments may include stations different from those shown, stations arranged in a different order, multiple stations of one or more types, etc. For example, in some embodiments, a fastener sealing station is used to seal the wing, and stations are also included for installing electrical components, electrical equipment, and / or fuel tank-related systems.

[0078] like Figure 5A As shown and more clearly in Figure 5BAs shown, during operation at various stations 520 such as NDI station 524, the wing panel 550 is held suspended below the positioning plate 540 by a carrier 545 (e.g., an independently adjustable component, such as a telescopic carrier, also referred to herein as a spring (pogo)) including a vacuum connector 548, which applies a removable vacuum connection to the wing panel to secure it to the wing panel below the positioning plate 540. Figure 5B The view shows four carriers 545, three of which are shown positioned with their vacuum connectors 548 abutting against the upper surface 574 of the wing panel 550, and one of which is shown in a shortened configuration such that its vacuum connectors 548 are spaced apart from the upper surface of the wing panel 550. Brief reference. Figure 5A The diagram illustrates different numbers of carriers 545 used to collectively support each of three positioning plates 540 of the wing panel 550, with the carriers arranged in a straight line along the width of the wing panel. However, any number and / or configuration of carriers 545 can be used. The carriers 545 are aligned to contact the wing panel 550 at predetermined positions and heights. Once set to the desired length, each carrier is rigid. Thus, the carriers 545 (or more specifically, the alignment of the carriers 545 relative to each other and their length relative to the wing panel 550) can be arranged to impart forces transmitted through the wing panel 550 and apply a desired profile 544 to the wing panel 550. Thus, the positioning plates 540 suspend the wing panel 550 below it while applying the profile 544 to the wing panel. This profile 544 can be the profile of the wing panel given by the laying mandrel 110 (e.g., as shown in the diagram). Figure 1 The outline 544 shown is 112, or a different outline desired for a specific application. Therefore, as the positioning plate 540 advances along the track 510 in the processing direction 541, the outline 544 is applied by holding each carrier 545 at the desired height, which forces the geometry at the wing panel 550 to correspond to the outline 544.

[0079] As in Figure 5BAs can be seen in the attachment mechanism shown in the exemplary embodiment, the carrier 545 engages with the upper surface 574 of the wing panel 550 to form a vacuum clamp between the vacuum connector 548 of the carrier and the wing panel 550. The length of the carrier 545 is controlled by an actuator 546 (e.g., a hydraulic or pneumatic actuator, or a linear actuator). For example, one of the carriers 545 is shown being shortened, as indicated by arrow 1000. The length of the carrier 545 may be adjusted, for example, before the vacuum attachment is formed (e.g., to facilitate the initial alignment of the vacuum connector 548) and / or after the vacuum attachment is formed (in order to bend the wing panel 550 into a desired shape and / or apply a desired profile to the wing panel). In some embodiments, the actuator 546 is controlled via a controller 620.

[0080] Although the shape of the wing panel 550 (including its profile and curvature) is determined during layup and curing, it may be desirable to apply and adjust the profile after the wing panel has been demolded. Profile application ensures that the wing panel 550 maintains the desired shape and does not exhibit an undesirable profile, such as sagging under its own weight. In some embodiments, the profile applied by the positioning plate 540 and the carrier 545 facilitates the mounting of ribs and spars to the wing panel, for example by ensuring proper alignment between the component and the portion of the wing panel to which it will be mounted. Specifically, the carrier 545 applies both the chordal and spanwise profiles to the desired tolerance level. In one embodiment (not shown), the carrier 545 is movable relative to the positioning plate to a predefined position to apply profiles for various wing shapes. Furthermore, depending on which orientation is preferred for contour application (and / or other operations as the wing panel 550 travels through the assembly line 500), the "upper surface" 574 to which the carrier 545 is attached can be the outer surface of the wing panel 550 oriented "right-side up" relative to the positioning plate 540, or it can be the inner surface of an inverted wing panel.

[0081] During the discussion of assembly line 500 and the operations performed by the various workstations 520, reference will be made intermittently to the accompanying drawings (e.g., Figures 6 to 10 The various flowcharts presented in the document illustrate the process according to... Figures 5A to 5G The components and methods of operation are shown. Figure 6This is a flowchart illustrating a method 800 for carrying a wing panel 550 in an exemplary embodiment. According to method 800, step 802 includes aligning a positioning plate 540 over the wing panel 550. In some embodiments, this includes driving the positioning plate 540 along a track 510 until it is positioned over a desired and / or predetermined lateral portion (e.g., a chordal portion) of the wing panel 550. In some embodiments, this includes driving multiple positioning plates 540 until they are each positioned over different desired and / or predetermined lateral (e.g., chordal) portions of the wing panel 550. In one example, a positioning plate 540 may be moved along the track 510 until it is positioned on a different portion of the wing panel 550 from another positioning plate 540 that remains stationary. In some embodiments, aligning the positioning plates 540 is performed by or includes transposing the positioning plates 540 onto the wing panel 550. In some such embodiments, the shifting is accomplished by connecting the positioning plate 540 to one or more shifting features of the wing panel 550, for example by physically connecting the shifting unit 542 of the positioning plate 540 to the corresponding shifting feature 210 of the wing panel 550. In this way, shifting the positioning plate 540 using the wing panel 550 can (e.g., throughout the subsequent actions of the method) maintain the correct alignment of the positioning plate with the wing panel.

[0082] Step 804 includes forming a vacuum attachment between the upper surface 574 of the wing panel 550 and the vacuum connector 548 of the spring member 545 extending below the positioning plate 540, thereby attaching the spring member 545 to the upper surface 574 of the wing panel 550. In one embodiment, this includes extending each spring member 545 until the vacuum connector 548 of the spring member physically contacts the upper surface 574 of the wing panel 550. In another embodiment, the spring members are systematically attached from the middle of the wing panel 550 (e.g., chordally or spanwise) and then moved outward, systematically attached starting from the spring member at the outermost position on the wing panel, or attached all at once, etc.

[0083] As described in more detail below, the position of the spring 545 along the surface of the wing panel 550 can be determined by a variety of factors, one of which is the way the spring and the stress and / or the resulting strain can cooperate in different possible configurations to impose a predetermined profile on the wing panel. However, other competing factors exist. As an example, as detailed below, inspection of the wing panel 550 (e.g., via non-destructive testing (NDI) scanning) may require the NDI inspection head to be positioned at one or more specific locations on the wing panel, or to move over one or more specific locations on the wing panel 550. Because the spring can be selectively retracted, this can be done by temporarily retracting the spring 545 to allow NDI inspection of the location on the wing panel 550 to which the vacuum connector 548 is attached, or by initially attaching the spring only to a location on the wing panel that does not interfere with the NDI inspection. As another example, the attachment of ribs and spars to the lower surface 576 (e.g., the inner surface) of the wing panel 550 may involve a fastening operation (e.g., drilling) occurring at a corresponding location on the upper surface 574 of the wing panel. Thus, the position of the spring member 545 can be positioned so as not to interfere with such operation. Therefore, the position of the spring member 545 can optimize some or all of these (and / or other) considerations.

[0084] The applied connection is the result of evacuating a vacuum between the vacuum connector 548 and the wing panel 550 (more specifically, its surface, such as the upper surface 574). The amount of vacuum force applied over a portion of the wing panel 550 is sufficient to clamp and hold the wing panel, and also sufficient to bend the wing panel and hold it according to the desired profile 544. Specifically, the volume between the carrier 545 and the wing panel 550 is evacuated to a pressure that allows the atmospheric pressure around the vacuum connector 548 to removably adhere the carrier 545 to the wing panel 550. During transport, including during pulsations and pauses, the applied vacuum is maintained via the carrier 545.

[0085] Step 806 includes adjusting the length of the springs 545 to apply a predetermined profile to the wing panel 550. That is, after vacuum attachment is formed, the length of the springs 545 is adjusted (e.g., via pressure, actuators, etc.) to conform the wing panel 550 to a desired profile 544. In the illustrated embodiment, the springs 545 are independently adjustable. That is, the springs are adjusted to the desired length depending on the position of each spring 545 along the length and width of the wing panel 550 (e.g., determined by manual or laser-assisted processing) and depending on the desired profile. If the wing panel 550 already conforms to the desired profile, the length of one or more springs 545 may not be adjusted or only slightly adjusted. Alternatively, if the wing panel 550 does not conform to the desired profile (e.g., outside the tolerance range), the length of the springs 545 is adjusted to bend or shape the wing panel (e.g., by applying a desired strain and strain direction) to maintain the wing panel in the desired shape.

[0086] In some implementations, a scan is performed to determine an initial wing panel profile. If the wing panel 550 is already initially in a desired (e.g., predetermined) profile (spanning the entire wing panel or one or more sections thereof), a profile change may not be necessary. In some such implementations, adjusting the length of each spring 545 relative to the positioning plate 540 (i.e., making it longer or shorter) will push and / or pull the wing panel 550 into the desired profile. The adjustment of the length of each spring 545 is based at least in part on the determination of the degree to which the wing panel 550 is misaligned with the desired profile. That is, the lengths of some springs 545 may need to be adjusted, while the lengths of others may not (e.g., if only some sections of the wing panel 550 are misaligned with the predetermined profile). The vacuum coupling 548 of the springs 545 is precisely positioned relative to the upper surface 574 of the wing panel 550 to ensure that the profile applied by the springs corresponds to the expected profile when the springs are at the desired length.

[0087] The length of the spring 545 can be dynamically adjusted (e.g., by adjusting the pneumatic logic applied to the pneumatic actuator controlling the length, adjusting the hydraulic actuator controlling the length, etc.) to align the spring to establish a vacuum attachment in a first stage (e.g., step 804) and then apply the profile in a second stage (e.g., step 806). This is beneficial for length adjustment during the initial attachment because if the spring 545 is rigidly set to a specific length based on the intended shape of the wing panel 550, the vacuum connector 548 may not be able to form a vacuum attachment if the wing panel does not have that profile (i.e., because the spring is too long or too short).

[0088] In some implementations, a scan is performed to determine whether the wing panel 550 is within a predetermined profile. This can be done while adjusting the length of the spring member 545, or after all spring members have been adjusted.

[0089] The method can then continue, for example, by advancing the wing panel 550 while applying a contour, for example by moving the positioning plate 540 along the track 510 in the processing direction 541, and / or, for example, performing work on the wing panel at various work stations 520 while applying the contour. In embodiments that perform scanning, the method may include contour scanning during or after the work operation, for example, to ensure that the wing panel 550 remains in the desired contour, or in other words, that the wing panel does not become misaligned with the predetermined contour due to the work operation.

[0090] Back Figure 5A Workstations 520, set along track 510, perform work on wing panel 550 and can operate simultaneously (or overlapping in time) with each other, or synchronized with one or more other workstations, to perform different tasks in different sections of wing panel 550 (e.g., in wing root section 577, mid-length section 578, wingtip section 579, etc.). In this embodiment, NDI station 524 inspects wing panel 550 for out-of-tolerance conditions (e.g., internal voids, foreign object debris or FOD, edge delamination or inconsistencies, etc.), cutting station 526 cuts hatches into wing panel 550 (e.g., in manufacturing allowance 549), rib mounting station 528 mounts ribs to wing panel 550, and spars mounting station 530 mounts spars to wing panel 550.

[0091] In this embodiment, as will be explained in more detail below, ribs are attached to the wing panel 550 during micro-pulsation propulsion. This may include multiple stations operating simultaneously on each rib, or multiple stations where each station operates on a different rib during the same time period. A sparsity is then attached while the wing panel 550 is held at a full-pulsation station 520. However, depending on the embodiment, the sparsity may be attached before the ribs, or may be installed using a full-pulsation or micro-pulsation process. Ribs are attached to the wing panel 550 and spars using micro-pulsation or full-pulsation assemblies. Alternatively, the wing panel 550 is lowered above the subsequently attached ribs, and the sparsity is pulsed to the wing panel 550.

[0092] In one implementation, the ribs and spars are installed via parallel feed lines (e.g., by means of feed lines respectively with...) Figure 4The continuous rib feed line 491-7 and the continuous spar feed line 491-5 shown in pattern 480 are similar feed lines that are implemented by supplying rib and spar segments in a JIT manner. The feed lines are individually shown with different reference numerals 570 (e.g., 570-1, 570-2, etc.). Figure 5A These feed lines may be the same as, similar to, or different from the various feed lines 490 shown in pattern 480 in terms of the materials or components provided, the production cycle time on which the feed lines provide the materials or components, etc. In one embodiment, several spar segments may be joined (e.g., end-to-end) to form a spar. In a further embodiment, there are several rib mounting stations, as well as one or more fastener sealing stations and multiple spar mounting stations. Another embodiment makes each spar include three segments spliced ​​together at the ends of the ribs.

[0093] Workstations 520 are arranged along track 510 and may be spaced apart by a length less than or even a portion of the length of wing panel 550. In one embodiment, this arrangement allows multiple workstations (e.g., NDI workstation 524, cutting workstation 526, and rib mounting workstation 528) to perform work on wing panel 550 simultaneously or overlappingly in time. In a further embodiment, the workstations are spaced apart and / or otherwise configured such that only one workstation performs work on wing panel 550 at a time.

[0094] As discussed in further detail in this article, during the journey Figure 5A After station 520, as shown, the wing panel 550 (which can be the upper wing panel, to which ribs and spars can be installed) enters the panel assembly stage, as... Figure 5F The plate joining station 599 shown attaches another wing panel (which may be a lower wing panel) to form a complete section of the fuselage (e.g., a wing assembly) to form the wing. After the wing panel 550 stops at the wing panel joining station 599 for fastening, the wing panel joining phase operates independently (e.g., on its own across the entire wing, without other stations operating). In one embodiment, the pause of the wing panel 550 at the plate joining station 599 continues while other wing panels pulse through the station until the other wing panels have advanced at least their entire length.

[0095] In the illustrated embodiment, feed lines 570-1 to 570-6 at least partially correspond to feed lines 491-7, 491-4, and 491-5. Feed lines 570-1 to 570-6 supply resources and components to the various workstations 520 on a Just-In-Time (JIT) basis, and their operation is controlled and / or synchronized by controller 560 (or an additional controller 560) according to the desired production cycle time. In one embodiment, feed line 570-1 at least partially corresponds to hatch cover feed line 490-5 and supplies newly manufactured hatch covers to cut-out workstation 526. Feed line 570-2 supplies fasteners to cut-out workstation 526. Feed line 570-3 supplies fasteners to spar installation workstation 530. Feed line 570-4 supplies sealant to spar installation workstation 530. Feed line 570-5 provides fasteners to rib mounting station 528, and feed line 570-6 provides sealant to rib mounting station 528. In a further embodiment, additional / other feed lines provide newly manufactured ribs, fasteners and sealant, spars, lower plates, etc., to various stations.

[0096] In one implementation, the upper wing panel travels through... Figure 5A Workstation 520 is shown, followed by the lower wing panel. As briefly described above, the lower wing panel does not receive ribs or spars (i.e., because these components are already mounted to the upper wing panel). It will become clear that the cutting workstations (e.g., cutting workstation 526) perform most of the work on the lower wing panel, while most of the work on the upper wing panel involves installing ribs and spars.

[0097] Each station 520 in assembly line 500 is designed to physically connect, image, and / or otherwise interact with the indexing feature 210 in wing panel 550, or with a positioning plate 540 which is itself physically connected to the indexing feature 210. The indexing feature 210 is placed at a desired location along wing panel 550. In some embodiments, the indexing features are aligned along wing panel 550. In some embodiments, the indexing features are not aligned. In some embodiments, the indexing features are equidistant, and in some embodiments, the indexing features are not equidistant. In some embodiments, the number of indexing features is equal to the number of stations in the assembly line. In some embodiments, there may be more or fewer indexing features 210 than there are stations on the assembly line. The indexing feature 210 is provided in a manufacturing allowance 554 in wing panel 550, which is trimmed off before the wing is assembled into the fuselage.

[0098] In this embodiment, each station 520 in assembly line 500 inserts, grips, engages, or aligns the shift feature 210. In addition to (or instead of) physical (e.g., mechanical) connections, in some embodiments, shifting can be facilitated or accompanied by reading an RFID chip and / or other readable identification device 126 (e.g., a barcode, etc.) on the wing panel. An illustrative example of a physical connection is... Figure 5B The diagram shows a section of the wing panel 550 within the NDI station 524. Among the various structural components of the NDI station 524 is the upper NDI unit 602, which includes an upper frame 614. The upper frame 614 is shown to include a shifting unit 622. Similar to the shifting unit 542 described above for the positioning plate 540, the shifting unit 622 of the NDI station 524 is physically connected to the shifting features of the wing panel 550, specifically by means of a head 624 accommodated in a shifting feature 210-2 located in the manufacturing allowance 554, wherein the shifting feature 210-2 is shown as a through-hole. Similarly, although... Figure 5B Only one indexing unit 622 is shown, but each station 520 may include any suitable number of indexing units 622. Each indexing unit 622 may be configured to engage with an indexing feature of the wing panel 550, for example, to initially align the wing panel with the station and / or maintain the alignment of the wing panel with the station. Like the indexing features, the indexing units 622 may employ any suitable construction and may include connection devices other than those used to achieve mechanical connections, such as magnets. The indexing units may be configured to engage with a variety of different indexing features, or with indexing features whose position can change from one wing panel to another, for example, to enable the station to engage with different wing panels as needed.

[0099] In the illustrated embodiment, the indexing feature 210-1 of the wing panel 550 is shown as an indexing unit 542 connected to the positioning plate 540, while the indexing feature 210-2 is shown as an indexing unit 622 connected to the NDI station 524. This is intended to illustrate the example indexing configuration for ease of explanation, and not to suggest that all embodiments require indexing of the wing panel by means of a physical connection with both the positioning plate and the station. In some embodiments, one or more stations use the positioning plate supporting the wing panel for indexing, rather than using the wing panel directly. In some embodiments, one or more stations use the wing panel 550 for indexing instead of the positioning plate 540. In some embodiments, the station uses both the wing panel and the positioning plate for indexing. In any of these embodiments, the positioning plate may also be indexed using the wing panel.

[0100] When using an RFID chip (or other readable identification device), for example, in addition to or in place of another type of indexing feature, an RFID scanner (or suitable reader) can be coupled to provide indexing during communication at the workstation. In a further embodiment, the positioning plate 540 itself is physically coupled to the indexing feature 210, the RFID chip, and / or a hard stop or other feature to index the positioning plate 540 to the workstation. During assembly, the positioning plate 540 is coupled / mounted to the track 510 for movement along the track 510 and is pulsed (e.g., micro-pulsed less than the length of the wing panel 550 depending on whether it can or cannot be shared with other assembly lines). In one embodiment, the limiting factor of the production cycle is the amount of time a portion of the wing panel 550 spends within the field of view of a particular workstation plus the pulsation time. This time can be adjusted by changing the working field of view of the particular workstation, or by adding additional workstations to perform the same work (e.g., multiple rib mounting workstations 528 instead of just one), etc. The pulsation discussed herein can be implemented as a distance at least equal to the shortest distance between the transposition features 210 (e.g., the spacing between ribs, or "rib spacing," or a multiple or fraction of the rib spacing, etc.), or the entire length or a portion of the length of the wing panel 550. In embodiments where the spacing between ribs and / or the rib spacing is used for the pulsation length, it can be used to establish a micro-pulsation length. The wing panel 550 can move continuously and be transpositioned to station 520. Once transpositioned, the work is performed by station 520. Whenever the transposition feature 210 (and / or the RFID chip) and the positioning plate 540 mate or otherwise communicate, the positioning plate 540 is transpositioned to one or more stations 520, and the position of the wing panel 550 is transpositioned to a position in a coordinate space shared by the track 510 and known to the station. In a further embodiment, the transposition also includes conveying 3D features of a structure (e.g., profile 544) within the field of view of the station. For example, an RFID chip or other identification device 126 (e.g., a barcode) can transmit information indicating the geometry of the composite part on which work is being performed.

[0101] In one embodiment, at least the wing panel 550 is indexed based on a positioning plate 540 that moves along a track 510, which includes a guide rail system located above a workstation 520. The guide rail system may be connected to a rack or structure above the workstation (e.g., a ceiling), or to a floor (e.g., embedded in the floor, bolted to the floor, etc.), or to another part of the factory. The wing panel 550 has been fabricated on a laying mandrel 110 according to the precise dimensions described above. Because the laying mandrel 110 has surface features with precise tolerances, and because the prefabricated part 120 of the wing panel 550 is laid over and conforms to those surface features, the wing panel 550 includes indexing features 210 precisely positioned within a manufacturing allowance 554. Therefore, once the wing panel 550 is rotated, suspended below the positioning plate 540, and advanced to station 520, the 3D position and rotation (including profile 544) of the wing panel 550 are transmitted through rotation and precisely known at station 520. Thus, rotation eliminates the need for, for example, full scanning at each station 520 via probes or robust optics. This information is provided to station 520 as needed, as part of the rotation process, for example, via an RFID chip. This allows a line to work sequentially on different parts of the aircraft (e.g., left wing panel, right wing panel, upper wing panel, lower wing panel, and even different parts (e.g., wing panels) on different aircraft models). Therefore, the characteristics of the wing panel 550 within the field of view of station 520 are transmitted to the station as part of each pulse or micro-pulse. Because wing panels have more variation between pulsating positions compared to fuselage panels, manufacturing allowances at the wing panels may include a large number of surface features to facilitate rotation.

[0102] Due to the precise indexing performed, the position of the tool relative to the wing panel 550 at each station 520 is precisely known when indexed to the workstation. In some embodiments, the wing panel 550 is locked in place at the workstation 520. The 3D position and orientation of the wing panel are then established or indexed to any CNC programming or manual or automatic system used at that workstation. Therefore, it may not be necessary to set a time or scan after each movement of the wing panel (e.g., pulsation and / or micro-pulsation). Furthermore, structures added to or removed from the wing panel 550 in an existing workstation 520 can be added to any wing panel model or representation within the system without scanning the wing panel for modification.

[0103] The operation of workstation 520 is managed by a controller, generally in Figure 5AThis is referred to as controller 560. In one embodiment, controller 560 determines the movement of positioning plate 540 along track 510 (e.g., based on input from a technician) and uses this input to manage the operation of the workstation according to instructions stored in an NC program. Controller 560 can be implemented as, for example, custom circuitry, a hardware processor that executes programmed instructions, or some combination thereof.

[0104] The following paragraphs discuss Figure 5A The operations of various workstations 520 are shown. For example... Figure 5A As shown, in assembly line 500, three stations 520 (specifically, NDI station 524, cutting station 526, and rib mounting station 528) are arranged close enough along track 510 that the wing panel 550 can encounter all three stations as it travels in the processing direction 541. More specifically, considering the spanwise length 590 of the wing panel 550 from its leading edge to its trailing edge (e.g., from wingtip to wing root, oriented as shown in the illustrated embodiment), different portions of the wing panel can simultaneously travel through two or more different stations 520. For example, the wing panel 550 is shown positioned such that the rear portion (shown as root segment 577) encounters NDI station 524, while the front portion (shown as wingtip segment 579) encounters rib mounting station 528, and the middle portion (shown as middle length segment 578) encounters cutting station 526. Therefore, one, two, or all three of these stations 520 can perform operations on corresponding portions of the wing panel 550 simultaneously or in overlapping time. In some embodiments, not all of these operations need to be performed simultaneously, even if multiple portions of the wing panel 550 are positioned in each station 520. In one embodiment, NDI is performed at NDI station 524 as multiple portions of the wing panel 550 pulsate through the stations. Therefore, NDI within NDI station 524 occurs only on that portion of the wing panel 550 within that station at any given time.

[0105] Figure 5B This is a front view of the NDI station 524 in the exemplary embodiment (and, as described above, corresponding to...). Figure 5A The view arrow “5B” in the diagram shows the process of inspecting wing panel 550, which is shown in cross-section. Figure 5B The illustration shows inspection techniques and systems that can be implemented, for example, before the ribs and spars are installed onto the wing panels. Figure 5B A positioning plate 540 is depicted below which the wing panel 550 is suspended. An NDI station 524 is set at the track 510 and inspects the wing panel 550 while it is suspended below the positioning plate 540.

[0106] Figure 5BThe NDI station 524 shown includes an upper NDI unit 602 and a lower NDI unit 604. The upper NDI unit 602 includes a support 614 and a frame 612 that carries one or more NDI inspection heads 606 (shown as upper NDI inspection head 608), which are configured to move relative to the wing panel 550 and inspect the upper surface 574 of the wing panel 550. The lower NDI unit 604 of the NDI station 524 is also shown including a frame 614 and a support 616 that carries additional NDI inspection heads 606 (shown as lower NDI inspection head 610), allowing the inspection heads to inspect the lower surface 576 of the wing panel 550 in this way. For simplicity, the NDI inspection head 606 is also referred to as an "inspection head" or simply "head". The inspection heads 606 may be movable, meaning they can be configured to move relative to the upper NDI unit 602, the lower NDI unit 604, and / or the wing panel 550, or they may be stationary or fixed. For example, in the illustrated embodiment, the upper inspection head 608 is shown by directional arrow 1002 in the process of moving relative to the upper surface 574 of the wing panel 550, such as by means of rails and / or drives or any suitable mechanism (not shown) of the upper NDI unit 602. Some or all of the lower inspection heads 610 may also be movable, in which case they may be independently movable, configured to move uniformly as an array, etc., or they may be stationary. Further embodiments may include, in addition to Figure 5BAny number or configuration of inspection heads other than those shown. Moving inspection heads can be used to perform surface inspections during pauses between advances or other movements of the wing panel 550 relative to the NDI station 524, for example, by individually traversing different areas of the surface of the wing panel 550. Fixed inspection heads can be used for surface inspections when the wing panel 550 pulsates or otherwise moves relative to the NDI station 524. For efficiency, the arrangement of the inspection head 606 relative to the NDI station 524 and / or relative to the wing panel 550 as the wing panel 550 advances past the station 520 can be such that the inspection head is positioned at locations of interest, such as where out-of-tolerance conditions are more likely to be found, such as those locations where previous wing panel inspections and / or analysis of previous wing panel inspections indicate that inspection is necessary or expected, and not placed in locations where inspection is less necessary. Other arrangements of inspection heads may be used depending on the expectations or needs of a particular application. Some embodiments may include upper and lower inspection heads arranged in pairs on either side of the wing panel 550, for example, to perform through-hole inspection techniques. In some embodiments, inspection head 606 is configured to inspect the entire surface or multiple surfaces of wing panel 550. For example, in another embodiment, a fixed NDI inspection head is positioned such that the inspection occurs during pulsation, and the inspection head is configured to cover the entire surface without movement. This configuration can be used for both the upper and lower surfaces and can be implemented with less complexity than a system utilizing a moving head. The inspection head 606 discussed herein may include an ultrasonic transducer that transmits ultrasonic energy through wing panel 550 to characterize the internal features of the wing panel. The operation of inspection head 606 (e.g., both upper inspection head 608 and lower inspection head 610) is managed by a controller (shown as 620) that operates an NC program to coordinate the movement of the inspection head to facilitate scanning of wing panel 550 in pulsating echo or transmissive modes. Controller 620 may interface with and be different from controller 560. In some embodiments, controller 560 may provide the aforementioned functions of controller 620.

[0107] As described above, in the illustrated embodiment, the NDI station 524 is shown as physically shifting to the wing panel 550 by means of the shifting unit 622 of the NDI station, the head 624 of the shifting unit 622 being housed within the shifting feature 210-2 of the wing panel 550.

[0108] The positioning plate 540 includes a telescopic or adjustable-length carrier or spring member 545, which includes a vacuum connector 548 configured to be removably attached to the upper surface 574 of the wing panel 550 – thereby creating a vacuum clamp between the vacuum connector 548 and the wing panel 550. As described above, the length of the carrier member 545 (e.g., imparting or applying a profile to the wing panel 550) is controlled by an actuator 546 (e.g., a hydraulic or pneumatic actuator, or a linear actuator). A controller 620 can coordinate the control of the actuator 546. In some embodiments, the controller 620 coordinates the control of the actuator 546 with the operation of the NDI station 524, for example, to allow inspection of the wing panel 550 in a manner that allows for the avoidance or containment of the vacuum connector 548 attached to the wing surface. In one such implementation, the controller 620 guides the positioning plate 540 to selectively retract one or more vacuum connectors 548 by shortening the corresponding carrier 545, allowing the inspection head 608 of the NDI station 524 to inspect the portion of the upper surface 574 of the wing panel 550 (e.g., portion 582) that has been attached to the vacuum connector 630. This is in Figure 5B As shown, one of the carriers 545 retracts from portion 582 into its vacuum connector 548, as indicated by directional arrow 1000, while the upper inspection head 608 moves toward portion 582, as indicated by directional arrow 1002. For example, after the NDI inspection of portion 582 is completed, the corresponding carrier 545 is extended such that its vacuum connector 548 is vacuum-connected again to the upper surface 574 of the wing panel 550. In a similar manner, other portions of the upper surface 574 of the wing panel 550 that are obscured by the vacuum connector 548 can be systematically inspected. Of course, not all embodiments require such a configuration. For example, in another embodiment, the inspection head 606 routes around the carrier 545 and vacuum connector 548 that are not retracted during the NDI inspection. In a further embodiment, the profile of the wing panel 550 varies depending on the type of wing panel or different models of wing panels, and therefore, depending on the profile of the wing panel, the carrier 545 extends to different positions / extensions.

[0109] In other embodiments using the positioning plate 540, a position check is performed on the wing panel 550 that contacts the positioning plate (e.g., by means of spring 545 and vacuum connector 548) via NDI before the wing panel is suspended below the positioning plate.

[0110] Figure 7 This is a flowchart illustrating an embodiment of a method for inspecting a wing panel, designated as method 820. Method 820 is performed in a series of steps, including referencing... Figure 5B And in Figures 1 to 4 and Figure 5AThe components and structures shown describe the actions. Method 820 is shown beginning with step 822, which includes suspending the wing panel 550 below the shuttle (e.g., positioning plate 540). In one embodiment as described above, suction is applied via a retractable vacuum connector 548 to hold the wing panel 550 in place and apply a desired profile 544 to the wing panel 550. Specifically, the vacuum connection of the vacuum connector 548, the inflexibility of the positioning plate 540, and the extendability of the spring member 545 allow profile application to be performed on the wing panel 550. The spring member 545 is removably coupled to the wing panel 550 to maneuver the wing panel 550 into the desired profile.

[0111] Step 824 includes advancing the wing panel 550 in the processing direction via a shuttle through the NDI station 524. In an embodiment where the shuttle is a positioning plate 540, this includes driving the positioning plate 540 along a track 510, as described above for the earlier method, and can be performed via a pulsed or continuous motion technique. In an embodiment where the shuttle takes the form of a trolley, automated guided vehicle (AGV), etc., this step includes driving the shuttle along a guide rail or a suitable path.

[0112] Step 826 includes inspecting the wing panel 550 via NDI station 524 while the wing panel 550 is suspended below positioning plate 540. In one embodiment, this includes performing pulse echo technology (e.g., via one or more individual inspection heads 606) or by transmission technology (e.g., via pairs of inspection heads 606 arranged on either surface of the wing panel 550). These arrangements detect timing differences from expected values ​​as ultrasonic energy travels through the thickness of the wing panel 550. This may include simultaneously operating an array of inspection heads 606 at NDI station 524. The detected timing differences are analyzed by controller 620 to determine if there are out-of-tolerance conditions requiring rework of the wing panel 550. Rework can be performed at a dedicated station downstream of NDI station 524. That is, controller 620 detects out-of-tolerance conditions at the wing panel 550 based on input from NDI station 524 and reports out-of-tolerance conditions for rework (e.g., via notification provided to technicians). In another embodiment, controller 620 controls NDI station 524 and the advance of wing panel 550 in the machining direction, and correlates the input from NDI station with the position on wing panel 550.

[0113] As described above, in some embodiments, when one or more inspection heads 606 inspect the surface of the wing panel, the inspection involves (e.g., via positioning plate 540) selectively retracting one or more vacuum connectors 548, for example, to allow inspection of corresponding portions of the surface that would otherwise be obscured by the vacuum connectors. In further embodiments, the inspection is performed by: arranging carriers 545 and / or otherwise positioning vacuum connectors 548 at locations on the surface of the wing panel 550 where NDI inspection is not required; inspecting the locations on the wing panel that contact the positioning plate 540 via NDI before suspending the wing panel under the positioning plate, such as the portions to which the vacuum connectors 548 are connected; and / or performing the entire inspection to be performed by manipulating an array of inspection heads 606 without moving individual inspection heads, etc.

[0114] As described above, NDI station 524 may include a movable, fixed, or combination thereof NDI inspection head 606. In some embodiments, the method includes positioning at least some inspection heads at locations of interest, such as those locations where previous inspections and / or analyses have indicated that inspection is necessary or desired. In some embodiments, the inspection heads are positioned to enable inspection of the entire desired portion of the wing panel 550 (e.g., one or more entire portions of the wing panel 550, or the entire wing panel). In some embodiments where the NDI inspection head is fixed, propelling the wing panel 550 includes propelling the wing panel past the fixed inspection head as the fixed inspection head inspects a portion of the wing panel. In such embodiments, steps 824 and 826 may occur simultaneously or overlapping in time. In some embodiments where the NDI inspection head is movable, propelling the wing panel 550 includes propelling the wing panel past the movable inspection head. In some such embodiments, such as those where propelling the wing panel 550 includes pulsating the wing panel in the processing direction, inspection is performed during pauses between pulsations and / or during the pulsation itself. In some embodiments that include an inspection head array, the method includes moving the inspection head relative to the wing panel 550 while operating the array. In any of these embodiments, as the wing panel 550 advances past the NDI station, the NDI station 524 inspects a portion of the wing panel 550 at a time.

[0115] In some embodiments, the position of wing panel 550 relative to NDI station 524 is monitored by transposing the wing panel to the NDI station, for example, by means of various transposition features and / or RFID chips, as described above. In some embodiments, transposing the wing panel directly or via a positioning plate supporting the wing panel to the station transmits information about the wing panel to the NDI station controller, which can then guide the NDI inspection of the wing panel based at least in part on this information. In some embodiments where the transposition feature is located within the manufacturing allowance of the wing panel, the manufacturing allowance is typically not inspected.

[0116] In some implementations, the method continues Figure 7 Additional steps are not shown. For example, the method can continue by advancing the wing panel to the next station (e.g., a cutting station such as cutting station 526). In embodiments where the wing panel is suspended below the positioning plate, the method can advance the wing panel to the next station while keeping the wing panel suspended below the positioning plate. Some embodiments utilize multiple NDI stations for inspection, while others utilize NDI stations (or more than one NDI station) for NDI inspection of additional components. For example, in some such embodiments, the NDI station scans the stiffening rib flange while scanning the wing panel, and additional NDI stations scan the longitudinal beams attached to the wing panel.

[0117] As noted above, in some implementations, an NDI check is performed as the wing panel is advanced past the NDI inspection head. This can be done regardless of how the wing panel is conveyed (e.g., via a positioning plate or other means). Figure 8 A method 840 for inspecting wing panel 550 in an exemplary embodiment is further described. According to... Figure 8 Step 842 includes receiving the wing panel 550 at NDI station 524. Step 844 includes inspecting a portion of the wing panel 550 via NDI station 524 while the wing panel moves through the NDI station. The wing panel may be pulsed or continuously advanced through the NDI station, and inspection is performed while the wing panel moves through the NDI station. Similar to method 820, in method 840, the NDI station may include a movable and / or fixed NDI inspection head. In one embodiment, the wing panel remains suspended below a positioning plate when it is at the NDI station. In a further embodiment, the movable inspection head of the NDI station individually passes through different area portions of the wing panel (via the movable inspection head of the NDI station). In this manner, inspection includes moving the inspection head relative to the wing panel while operating an array of inspection heads at the NDI station.

[0118] Back Figure 5AThe intermediate length section 578 of the wing panel 550 is shown within the cutting station 526. Broadly speaking, the cutting station 526 is configured to remove material from the wing panel 550, for example, within the manufacturing allowance 554 or elsewhere. In some embodiments, the cutting station 526 cuts away one or more areas of the wing panel 550, for example, to install openings (e.g., hatches to be used in downstream stations), for example, to provide access to the internal volume between the wing panels (after they are joined together at the joining station). Although not necessary in all embodiments, such hatches are typically installed in the lower wing panel, as opposed to the upper wing panel. This is based on discussions related to the shim-filling operation (e.g., as concerning...). Figures 16A to 16C and Figures 17A to 17C As will become clear herein (as shown and described), in some embodiments, the lower wing panel is provided with several hatches that provide access to the spacer area between adjacent ribs, for example, to facilitate the installation of pads by a robotic arm. Therefore, in such embodiments, the cutting station 526 can perform more work operations on the lower wing panel than on the upper wing panel. In either case, the cutting station 526 can install hatch covers and / or doors into the wing panel 550, as well as edge sealing, painting, and performing fastener drilling and installation (as applicable to wing panels). In some embodiments, edge trimming for manufacturing allowances and hatch trimming are performed at separate stations.

[0119] In the illustrated embodiment, for convenience, the terms "upper surface" and "lower surface" for wing panel 550 are used to indicate the relative orientation of opposite surfaces of the wing panel, since the wing panel is suspended below the positioning plate 540. However, it will become clear here that additional components (such as ribs and spars) can be mounted to the lower surface 574 of the wing panel 550, as the upper surface 576 of the wing panel 550 continues to be held by the vacuum coupling 548 of the spring member 545 to produce the wing assembly 600. Therefore, in Figures 5A to 5G The surface shown as the lower surface of wing panel 550 can be considered as the internal surface of wing assembly 600, while the surface shown as the upper surface of wing panel 550 can be considered as the external surface of wing assembly 600. Therefore, the terms "upper surface" and "lower surface" should not be interpreted in a limiting sense.

[0120] Figure 5C Corresponding to Figure 5A The diagram shows a top view of assembly line 500, but with the positioning plate 540 shown as having been advanced in the machining direction 541, such that the wing root section 577 of the wing panel 550 is located within the rib mounting station 528. For simplicity, Figure 5A Some aspects of it (e.g., various feed lines, etc.) are in Figure 5C Not shown in the image. Figure 5DIt shows the corresponding Figure 5C A simplified side view of the view arrow "5D", where in Figure 5C Some visible components are omitted to better illustrate the ongoing construction / progress of the wing panel 550 to the wing assembly 600. As mentioned above, rib mounting station 528 attaches (i.e., temporarily and / or permanently) ribs 572. For ease of explanation, ribs 572 are shown in a simplified form in these views, although they are generally more complex in configuration and appearance, as described in more detail below.

[0121] Figure 5C It is also shown that, at spar installation station 530, spar 580 has been advanced from the feed line (not shown) to station 530. As described above, the supply of spar 580 to spar installation station 530 can be coordinated for timely delivery for installation onto the wing panel. Therefore, Figure 5C The state of the assembly line 500 can be shown just before the wing panel 550 is moved to the spar installation station 530 to install the spar 580 (the spar 580 is just supplied to this station).

[0122] Figure 5C The use of a moving station 552 (also referred to as a “slave”) is further illustrated, which is configured to engage with wing panel 550 and positioning plate 540 and perform work (e.g., trimming, fastening, applying sealant, etc.) by traveling across wing panel 550, for example, along a moving station track 551 that can be removably mounted to wing panel 550. While not required in all embodiments, moving station 552 can perform work during pulsations (e.g., micro-pulsations), pauses (e.g., between micro-pulsations), or as wing panel 550 travels through assembly line 500 during continuous movement of wing panel 550. Depending on the design, moving station 552 can “ride” (or “follow”) wing panel 550 for multiple pulsations across multiple stations 520 and can operate independently of other stations on assembly line 500. In this process, the position and size of the gap (e.g., interval) between the positioning plates 540 allow for the placement of the moving station track 551 and / or the moving station 552. In a further embodiment, chute and other complementary elements are provided at the factory such that the moving station 552 passes over or through these elements during the manufacturing process. The moving station 552 can travel along the return line ( Figure 5C The locating plate 540 (shown at position 547) is removed and sent, for example, in a direction opposite to the processing direction 541 (e.g., upstream of assembly line 500) to be installed on the next wing panel as needed. In a further embodiment, one or more locating plates 540 form a “smart bridge” by dynamically moving relative to the wing panel 550 to provide greater proximity of the moving station 552 to the wing panel 550.

[0123] As mentioned above, Figure 5D This is a simplified side view of a portion of assembly line 500, showing a wing panel 550 with attachment ribs 572 being transported along track 510 while suspended below a set of three positioning plates 540. As described above, one or more adapters 543 can facilitate the movement of the positioning plates 540 along track 510. Ribs 572 are attached to the lower surface 576 of the wing panel 550 at a suitable angle, denoted as angle θ. As will be explained below, in some embodiments, ribs 572 are vertically aligned and raised to a position for attachment to the lower surface 576 of the wing panel 550 (or more specifically, the upper wing panel). Thus, the wing panel can be suspended below the positioning plates at an angle corresponding to and / or facilitating the mounting of the ribs at angle θ. This in Figure 5D As shown, the wing panel 550 is slightly tilted upward from the trailing edge or wing root section 577 to the leading edge or wingtip section 579.

[0124] Figure 5D Another view is also provided showing an exemplary configuration of the spring 545 and the vacuum connector 548. In the illustrated embodiment, the vacuum connector 548 is angularly deflectable relative to the spring 545 and the positioning plate 540. Angular deflection can be facilitated by a universal type joint at the point where the vacuum connector 548 is attached to the spring 545 and / or at the point where the spring 545 is attached to the positioning plate 540. Angular deflection can adapt to the connection to the wing panel 550 during changes in the wing panel's profile, such as suspending the wing panel at a desired angle (as shown). Due to the angular flexibility of the vacuum connector, the wing panel can be suspended at any desired angle by adjusting the spring to the appropriate length. In a further embodiment, a carrier 545, constructed in a different manner, clamps the upper surface 574 of the wing panel 550 (e.g., by clamping, tight fit, etc.). As explained in detail above, a desired profile can be applied by adjusting the spring 545 to a predetermined length, which corresponds to the desired vertical tilt angle of the profile at each of a plurality of chordal and spanwise positions.

[0125] As described above, several factors determine the position of the spring 545 and its respective vacuum connector 548 relative to the upper surface 574 of the wing panel 550, for example, to contour the wing panel 550. In some embodiments, one factor is the manner in which the ribs and spars are attached to the wing panel. For example, the spring 545 and vacuum connector 548 may be positioned such that the position of the vacuum connector 548 on the upper surface 574 is spaced apart from the corresponding position on the lower surface 576 of the wing panel where the rib 572 will be attached to the wing panel (e.g., ...). Figure 5D(See view shown). For example, this can be done to allow for the creation of a mounting area close to rib 572, and can facilitate manual or automated drilling and fastener installation to attach the rib to the wing panel.

[0126] exist Figure 5D In the diagram, one rib 572 is shown attached to the portion of the wing panel 550 located within the rib mounting position 528. Other ribs 572 shown attached to the portions of the wing panel 550 that have been pushed through the rib mounting position 528 are installed while these portions are within the rib mounting position 528. Although four are shown, the number of ribs 572 in the actual wing assembly 600 can and often is more. Figure 5D Wing panels, ribs, spars, and other components in the accompanying drawings are for illustrative purposes only and are not necessarily drawn to scale or in outline. For example, rib 572 is shown in a simplified schematic form in this series of drawings. Subsequent drawings (e.g.) Figures 11A to 11D and Figures 17A to 17C The illustrative ribs are shown in more detail. The rib configuration or number of ribs 572 in the actual wing assembly 600 may differ from those depicted herein.

[0127] Figure 5E It corresponds to Figure 5A and Figure 5C The top view of assembly line 500 shows that wing panels 550 have been transported via positioning plates 540 to spar mounting stations 530, where spars 580 are attached (e.g., as part of a full-pulse process). In this embodiment, spar 580 is installed after rib 572, but in some embodiments, rib 572 is installed before spar 580. Figure 5E Each spar (generally denoted as 580) is shown to be assembled from a plurality of individual spar segments, each spar segment being designated 580-1 to 580-7 (however, unless otherwise specifically indicated, reference numeral 580 is used herein to refer to the spar, and spar segment or spar section). The spar assembly station 530 can be accessed from one or more feed lines 570 ( Figure 5EA representative feed line (shown in the diagram) receives pre-assembled spar 580, or individual spar segments or sections (e.g., 580-1 to 580-7) assembled at the spar installation station, or both. In embodiments where spar segments are provided to the spar installation station 530, the spar segments may be assembled to each other before being installed to the wing panel, for example, to form a partial or complete spar, which is then installed to the wing panel; and / or the spar segments may be installed to the wing panel as segments of a spar, thus forming a spar as they are installed individually. Additional components such as fasteners and sealants are also provided to the spar installation station 530 to facilitate installation. After installation, the positioning plate 540 transports the wing panel 550 back to the track 510, and the wing panel 550 is further transported to receive additional work. In the illustrated embodiment, the positioning plate 540 travels to the wing sparb mounting station 530 in any suitable manner, such as being configured to allow movement along a redirection track (not shown) of the wing sparb mounting station 530 in direction 1004. After installation, the positioning plate can travel back to track 510 via the same redirection track in direction 1006, for example, for further travel along track 510 (e.g., toward the plate joining station), or be guided to another track, or travel along a track different from track 510. Another embodiment has a wing sparb mounting station 530 arranged along track 510, such that advancement of the positioning plate 540 in the processing direction will introduce, pass through, and withdraw the wing panel from the station.

[0128] The illustrated configuration is an example of a configuration that allows selective bypassing of workstations 520 (such as spar installation workstation 530). As described above, in some embodiments, the ribs and spars are attached only to the upper wing panel and not to the lower wing panel. In such embodiments, efficiency is achieved in transporting and / or performing work on the wing panels in configurations that allow one or more workstations 520 to be selectively bypassed (e.g., advancing the upper wing panel into the spar installation workstation 530, but advancing the lower wing panel through the workstation). In some such embodiments, the lower wing panel may alternatively be guided to a workstation configured specifically for working on the lower wing panel rather than the upper wing panel, such as a workstation for cutting the hatch into the lower wing panel (e.g., a workstation such as cutting workstation 526). In these embodiments, the attached spar and / or spar segment is then fed to the spar installation workstation 530 to be attached to the next wing panel 550 traveling along track 510.

[0129] Figure 5FOne embodiment is shown in which, after work is completed at the spar installation station 530, the wing panel 550 has moved back to track 510 in direction 1006 and is ready to be advanced (in a pulsed or continuous manner) along track 510 in processing direction 541 to another station 520, shown as a rib-to-spar attachment station 598 and a plate bonding station 599, at which the lower wing panel can be bonded to the wing panel to which the rib and spar have been attached. This operation leaves the wing assembly 600 awaiting installation of, for example, additional components and / or electrical and other systems.

[0130] exist Figure 5F In the diagram, the rib-to-spar attachment station 598 is shown positioned on track 510, while the plate joining station 599 is shown positioned away from track 510, requiring the wing panel 550 to move in direction 1008 to the plate joining station 599. This could represent a configuration where only the upper wing panel travels along this portion of the assembly line 500, while the lower wing panel has been redirected to another track (not shown) or station (e.g., by bypassing the spar mounting station 530 and the rib-to-spar attachment station 598, and instead delivered to the plate joining station 599 to await joining to the upper wing panel). Alternatively, the lower wing panel could be simply transported through the rib-to-spar attachment station 598 without performing any work operations on it, thus effectively bypassing it. Alternatively, in some embodiments, one or more stations 520 could be configured to serve multiple purposes, for example, to perform certain work operations on, for example, the upper wing panel and other work operations on the lower wing panel. Such configurations are within the scope of this disclosure.

[0131] Based on the above... Figures 5A to 5FIt is apparent from the concepts, components, systems, and apparatus discussed that other embodiments of the assembly line 500 consistent with this disclosure may employ configurations different from those specifically illustrated and described. For example, some embodiments may use different sequences of operations combining wing panels, ribs, and spars to produce wing assemblies, and thus may include some or all of the various stations 520 in different sequences, or stations other than those shown, or multiple stations of station 520, or stations that also perform some or all of the functions of station 520 in addition to other tasks, etc. In some such embodiments, instead of individually mounting the spars and ribs to the wing panels (e.g., the upper wing panel) in the illustrated embodiment of assembly line 500, the spars and ribs may instead be attached to each other to form a trapezoidal structure (where the spars act as "balustrades" of the ladder, and the ribs form "runners"), and then mounted to the wing panels. Therefore, such implementations may include one or more stations for assembling spars to ribs (from which ribs, spars, or spar sections and fasteners may be supplied from appropriate feed lines), and one or more stations for installing rib and spar structures to wing panels and / or installing rib and spar structures between the upper and lower wing panels. As with the illustrated implementation of assembly line 500, the various components and structures supplied to the aforementioned stations may be configured for JIT delivery to the appropriate stations.

[0132] An example of this is... Figure 5G As shown, it illustrates an alternative construction of the assembly line (denoted as assembly line 500'). Figure 5G Roughly corresponding to Figure 5C and Figure 5E A top view of assembly line 500 is shown. However, although Figure 5C and Figure 5E The assembly line shown includes a rib mounting station 528 and a spars mounting station 530, at which ribs 572 and spars 580 are individually and separately mounted to the wing panel 550, respectively. Figure 5G The assembly line 500' shown here is instead represented as comprising different stations 520, specifically support structure assembly station 532 and support structure installation station 534. From one or more feed lines 570 (in Figure 5G The diagram shows a representative feed line that supplies ribs 572 and spar 580, as well as fasteners and / or seals, to the support structure assembly station 530. For example, feed lines corresponding to 491-6 and 491-7 (such as...) Figure 4(As shown) Wing beams and ribs can be provided to support structure assembly station 532 on time and in the desired order for assembly into the ladder-shaped support structure represented by 588. Wing beams 580 can be pre-assembled or completed before being provided to support structure assembly station 532, or can be provided to support structure assembly station 532 as separate wing beam segments or sections (not shown individually) for assembly into support structure 588 together with ribs 572.

[0133] During assembly, the support structure 588 is transported (e.g., laterally) to the support structure mounting station 534, as indicated by arrow 1014, and is mounted to the wing panel 550. A trolley or other type of shuttle can transport the support structure 588, which can then be raised onto the wing panel for installation. Alternatively or additionally, the wing panel can be lowered onto the support structure 588. Although in Figure 5G As not shown in the view, fasteners and other supplies may be provided together with the support structure to the support structure mounting station 534, or separately via one or more feed lines or supply lines. Therefore, Figure 5G The image shows the state of assembly line 500' just before the fully assembled support structure 588 is delivered to support structure mounting station 534 for installation onto the waiting wing panel 550. The movement of the wing panel 550 along track 510 via positioning plate 540 can be coordinated with the delivery of the assembled support structure 588, such that both the wing panel 550 and the support structure 588 are delivered to support structure mounting station 534 simultaneously, or one or the other can be delivered on time for installation, etc.

[0134] The wing panel 550 and the support structure 588, which is equipped with ribs 572 and spars 580, can travel to the plate joining station (e.g. Figure 5F The plate assembly station 599 shown allows another wing panel (e.g., the lower wing panel) to be installed onto the assembly. (The above refers to...) Figure 5G The alternative constructions discussed can offer advantages over the construction shown in assembly line 500, for example, by not involving lateral transport of wing panels relative to track 510 for spars installation (e.g. Figure 5E (as shown), or to achieve efficiency by installing the ribs and spars together instead of separately, etc.

[0135] refer to Figures 5A to 5G The various components, concepts, and operations implemented in assembly line 500 as described above, Figure 9This is a flowchart illustrating a method 860 for manufacturing a wing via an assembly line such as assembly line 500 in an exemplary embodiment. In step 862, a wing panel 550 is suspended below a shuttle (e.g., a positioning plate 540) that applies a contour 544 onto the wing panel 550. For example, in one embodiment, a carrier 545 is fixed to the wing panel 550 via a vacuum connector 548 and positioned vertically to apply the contour. As described above, in some embodiments, suspending the wing panel 550 includes indexing the positioning plate 540 using the wing panel. Indexing can be a physical connection (e.g., physically attached or otherwise linked) between the positioning plate 540 and one or more indexing features mounted in the wing panel 550 (e.g., within the manufacturing allowance of the wing panel 550). Additionally or alternatively, the transposition feature may include or incorporate a readable identification device, such as an RFID chip / tag or barcode, and transposition includes reading the identification device with a suitable reader, such as an RFID reader, scanner, or barcode reader (not shown).

[0136] In step 864, when applying (e.g., as...) Figure 5B While the wing panel 550 is advancing in the processing direction (e.g., processing direction 541) through at least one station 520 (and typically multiple stations 520) of the assembly line 500 via a positioning plate 540, the wing panel 550 is advanced along the profile 544 defined by the upper surface 574. For example, the positioning plate 540 may advance along a track 510 while the vacuum connector 548 of the carrier 545 to the wing panel 550 is positioned in a vertical position corresponding to the profile 544. As described above, the desired profile can be applied by aligning the respective carriers 545 of the wing panel at predetermined positions on the wing panel, and during this process, the wing panel 550 may be advanced through an NDI station (e.g., NDI station 524) where NDI is performed on the wing panel. During pauses between pulses, or during continuous movement, the wing panel 550 is rotated to the respective stations 520. This can be done by shifting station 520 to shifting feature 210 of wing panel 550 itself (e.g., as described above regarding shifting positioning plate 540 to wing panel), or by shifting station 520 to shifting feature of positioning plate 540 that carries wing panel 550.

[0137] In step 866, structural components such as rib 572 and spar 580 are mounted into wing panel 550 while contour 544 is applied (via a combination of positioning plate 540, carrier 545, and vacuum connector). This may include co-bonding and / or fastening rib 572 and spar 580 to wing panel 550 while wing panel 550 remains suspended from positioning plate 540. Alternatively, it may involve assembling rib 572 and spar 580 into support structure 588, and then mounting support structure 588 onto wing panel 550 while wing panel remains suspended from positioning plate 540. In one embodiment, propulsion of wing panel 550 includes pulsating wing panel in the processing direction (e.g., by full pulsation or micro pulsation) and performing the mounting of rib 572 and spar 580 during pauses between pulsations. In a further embodiment, propulsion of wing panel 550 includes continuously moving wing panel in the processing direction and performing installation of rib 572 and spar 580 while wing panel is continuously moving.

[0138] Although not in Figure 9 Specifically, in some embodiments, method 860 further includes arranging additional workstations 520 along the processing direction to perform various different work operations, such as installing ribs and / or spars, joining ribs and / or spars to each other and / or joining them to wing panels, performing rework, inspecting wing panels, cutting / installing hatches, etc. In some embodiments, multiple workstations 520 are provided to perform the same type of operation.

[0139] Method 860 can provide one or more technical advantages over the prior art, for example, because it enables the wing panel 550 or a portion thereof to remain rotated to each station 520 in the manufacturing environment, even as the wing panel is transported through multiple stations 520 to receive work. That is, the wing panel 550 remains rotated to the positioning plate 540 during transport, meaning that the station 520 can quickly rotate itself to the positioning plate 540, the wing panel 550, or both. Furthermore, the technique of suspending the wing panel 550 below the positioning plate 540 allows for greater and more ergonomic access and inspection of the wing panel 550 during the assembly process (e.g., by a technician).

[0140] Figure 10This is a flowchart depicting a method 880 for applying contours to a wing panel in an exemplary embodiment. According to method 880, step 882 includes positioning the wing panel of the aircraft below a positioning plate. As described in detail above, this step may involve moving the wing panel 550 below a positioning plate 540, which is configured to extend over a lateral section of the wing panel, thereby transposing the wing panel to the positioning plate via transposition features of the wing panel (e.g., physical transposition features and / or readable identification devices), hard stops, visual techniques and / or other processing. Step 884 includes engaging a spring member of the positioning plate to the upper surface of the wing panel at a location different from where corresponding structural components (e.g., ribs and spars) will be attached to the wing panel (e.g., corresponding locations on the lower surface of the wing panel). As described above, this is performed to allow for the creation of proximity to the rib or spar mounting area, for example, to facilitate manual or automatic drilling, fastener installation, etc., thereby allowing the ribs and spars to be mounted to the wing panel. The ribs may be made of metallic or composite materials. If the ribs are made of aluminum, one or more layers of glass fiber or other materials are placed at the intersection between the aluminum and carbon fiber. This can be achieved via a glass fiber insulating layer and a sealant at the area where the ribs are placed (sometimes referred to as the "rib plate area") on the wing panel. In one embodiment, this involves physically attaching a spring to the upper surface and activating a vacuum system that applies suction to the wing panel via the spring.

[0141] Step 886 includes controlling the length of the spring members to apply a profile to the wing panel while it is suspended below the positioning plate. The spring members are independently adjustable. In one embodiment, the length of the spring members is controlled by setting them to a predetermined length; in a further embodiment, this includes operating actuators or air pressure to apply a specific length to each spring member. When all spring members are set to their desired lengths, the wing panel is maintained to conform to the desired profile of the mountable rib, provided that the vacuum couplings of the individual spring members are correctly positioned for the specific wing panel.

[0142] As described above, in some implementations, a scan is performed to determine the initial wing panel profile. If the wing panel is already in the desired profile, it may not be necessary to apply a change to the profile. In this case, the holding force applied by each spring may be less than if the spring actively applied the wing panel profile. The adjustment for the length (i.e., longer or shorter) of each spring relative to the positioning plate is determined by the wing panel's design parameters, for example, to push and / or pull the wing panel to the desired profile. The position of the vacuum coupling of the spring is precisely positioned relative to the upper surface of the wing panel to ensure that when the spring is at the desired length, the profile applied by the spring corresponds to the expectation.

[0143] As mentioned above, in Figures 5A to 5GThe diagram illustrates various aspects of the assembly line 500 (or 500') for wing components, including operations that occur as the wing panel 550 travels through various stations 520 arranged along the assembly line. Many systems, operations, and components (e.g., ribs 572) are shown in simplified form and / or schematically for ease of explanation. Figures 11A to 11D The installation of additional components onto the wing panel 550 during the production of the wing assembly 600 is shown in more detail. Specifically, Figures 11A to 11D The installation of rib 572 to wing panel 550 is shown, which in the embodiment is shown as upper wing panel 550-1 at rib mounting position 528. Therefore, for convenience, wing panel 550 may be referred to as "upper wing panel 550-1" or simply "wing panel 550-1" in the following sections. The term "wing assembly" refers to the structure produced when wing components (e.g., wing panels), ribs, and / or spars are assembled together. This is described in detail below. Figure 11A This demonstrates how rib 572 is moved to a position below the upper wing panel 550-1 using a shuttle, and... Figure 11B and Figure 11C The diagram shows the rib being lifted upwards toward the lower surface of the upper wing panel for mounting thereon. Figure 11D The resulting wing assembly 600 is shown, wherein rib 572 is mounted to wing panel 550-1, and a pair of spars 580 are mounted at either end of rib 572.

[0144] Figure 11A and Figure 11B The view shown roughly corresponds to Figure 5C The view arrow "11" shows the wing panel 550-1 suspended below the positioning plate 540 by means of a spring 545, which, as explained above, is connected to the upper surface 574 of the wing panel via a vacuum coupling 548. Wing panel 550-1 (or at least...) Figure 11A The cross-sectional portion shown is arranged within the rib mounting station 528. As detailed in the discussion above, the wing panel 550-1 can be rotated to station 520 directly or via one or more positioning plates 540 supporting it. The wing panel 550-1 is shown having several longitudinal beams 640 mounted to its lower surface 576, the longitudinal beams 640 shown having a T-shaped cross-section. Although six longitudinal beams 640 are shown, more or fewer longitudinal beams may be used for specific upper wing panels and / or ribs 572, and / or for specific locations along the spanwise length of the wing panel. In the context of the assembly line, for example... Figures 5A to 5F Assembly line 500 shown (and / or Figure 5GIn the assembly line 500' shown, the longitudinal beam 640 can be installed prior to rib installation, for example at any point upstream of the rib installation station 528, or provided during the initial fabrication of the upper wing panel from the prefabrication.

[0145] Although various rib structures are possible and within the scope of this disclosure, Figures 11A to 11D Rib 572 is shown as an elongated solid structure including a web 646, which is reinforced by stiffening ribs 648 (e.g., beams or supports that apply a profile to the rib before it is secured to the wing panel 550), i.e., held within the profile. The top and bottom edges of rib 572 are shaped to follow the corresponding profile of the wing panel to which rib 572 will be mounted, and are provided with a plurality of openings or “mouse holes” 650, the size and position of which are designed to accommodate, for example, longitudinal beams 640, as well as cables and other structures (not shown) that can be mounted. For a similar purpose, web 646 also includes a plurality of hatch openings 652 positioned inwardly from the edge of the rib.

[0146] exist Figure 11A In this process, rib 572 is advanced to the workstation and, in one embodiment, enters the rib mounting station 528 from a feed line (denoted as 570), which may be a rib feed line (e.g., rib feed line 491-7) that supplies rib 572 to the rib mounting station 528 in a just-in-time or JIT (Just-In-Time) schedule. More specifically, in Figure 11AIn this configuration, rib 572 is kept vertically oriented while being transported via shuttle 700 (e.g., a manually operated or automated trolley pushed on a guide rail, an automated guided vehicle (AGV), etc.). As described above, rib 572 can be fed into shuttle 700 via a timely feed line and can move during pauses between pulses to enter rib mounting station 528. In the illustrated configuration, shuttle 700 is advanced perpendicular to the processing direction of wing panel 550. Shuttle 700 is shown driven by wheels 702 (e.g., motorized wheels) across floor 710, but alternatively arranged on guide rails or tracks, etc. Wheels 702 drive chassis 708, which translates horizontally / laterally in direction 1008, thus transporting rib 572 to a position / location directly below wing panel 550. The shuttle 700 may include indexing features (not shown) to facilitate indexing of the trolley relative to the rib mounting station 528 to ensure proper positioning relative to the rib mounting station before the shuttle is advanced to a position below the wing panel 550, and / or proper positioning of the shuttle (and the rib) relative to the upper wing panel 550-1 when the shuttle is advanced to the station. This indexing feature may take the form of the cup and cone of a cup-cone indexing system, a hard stop, and / or other constructions. The chassis 708 holds one or more actuators 704, and supports 706 fixed to the actuators 704. The supports 706 are configured to support the ribs 572 in a vertical orientation. The actuators 704 (or other lifting devices) are configured to vertically drive the supports 706, for example, vertically lifting the ribs 572 to contact the lower surface 576 of the wing panel 550.

[0147] Figure 11B Rib 572 is shown after it has been driven vertically upward in direction 1010 to contact the lower surface 576 of the upper wing panel 550-1 (e.g., onto the rib area). The size and position of the mouse hole 650, provided along the upper edge of rib 572, are now more clearly seen, designed to accommodate the longitudinal beam 640. The gap between rib 572 and beam 640 at the mouse hole 650 may be larger or smaller than shown. During attachment to the wing panel, rib 572 is held in the desired orientation and position by support 706. Although the term "installation" has been used in the preceding discussion in this disclosure, the term can encompass both temporary and permanent attachments. Therefore, when rib 572 is first brought into contact with the wing panel, the connection can be temporary, such as by clamping and / or nailing rib 572 into place, or permanent, such as by using temporary or permanent fasteners (e.g., by automatic or manual drilling and fastener installation techniques, before and / or after removal of shuttle 700), or rib 572 can be permanently fastened while being aligned with upper wing panel 550-1. In some embodiments, see reference below, for example. Figures 16A to 16C and Figures 17A to 17CFurther described, after rib 572 has been temporarily secured to the wing panel but before it is permanently installed to the wing panel, shims can be installed to fill the gap at the junction of the rib and the wing panel. In either case, once attached to the upper wing panel 550-1, the attachment device holds rib 572 in the desired position, so that shuttle 700 can be removed.

[0148] In other embodiments, one or more positioning plates 540 suspend the upper wing panel below via spring members 545, the spring members 545 forming a vacuum attachment with the wing panel, and lowering the wing panel to contact the rib 572 by adjusting the length of the spring members (and / or lowering the positioning plates 540), rather than raising the rib 572 upwards to the wing panel. Other embodiments may employ a combination of movement of both the rib 572 and the upper wing panel to bring the two components into contact. In some embodiments, the rib 572 is installed after the spar or spar segment (not shown in this view) is installed, and the spar facilitates maintaining the profile (e.g., spanwise profile, while the chordwise profile is maintained by the rib). Specifically, in such embodiments, the spar 580 can prevent lateral (e.g., chordwise) displacement of the rib 572, spanwise displacement of the ribs relative to each other, twisting of the rib 572 and the upper wing panel 550-1 about the spanwise axis 590, etc. Furthermore, in some embodiments, the support structure (e.g., support structure 588) is assembled from ribs and spars and then mounted to the wing panel. Such embodiments may involve using multiple shuttles and / or shuttles with different configurations compared to shuttle 700 to transport and / or lift the support structure to the wing panel.

[0149] Figure 11C Corresponding to Figure 11B The view arrow 11C further illustrates the relationship between shuttle 700, rib 572 and upper wing panel 550-1. Figure 11CFurther illustrating this embodiment, the upper wing panel 550-1 (and particularly its lower surface 576) includes an alignment feature 584 configured to align with a complementary alignment feature 586 at the rib 572. Alignment features 584 and 586 can be any structure that aligns the rib with the upper wing panel 550-1, such as a cup-cone structure. Each rib may have multiple corresponding pairs of indexing features. Furthermore, in some embodiments, the alignment feature 584 is installed as an indexing feature 210 during the fabrication of the upper wing panel 550-1. These alignment features facilitate the alignment of the rib 572 before it is fastened to the upper wing panel 550-1. Therefore, in one embodiment, lifting the rib 572 involves engaging the rib 572 with the alignment feature 584 at the wing panel 550. The rib 572 is delivered to the rib mounting station 528 in a just-in-time (JIT) manner from the parallel assembly line / feed line as needed. In this way, different ribs are created sequentially in a pulsating environment as needed for placement in the wing assembly 600.

[0150] Figure 11D This is an end view of wing assembly 600, which includes wing panels 550 (e.g., upper wing panel 550-1) with attachment ribs, wherein rib 572 is visible (i.e., rib 572 obscures the view of other ribs behind it). In an exemplary embodiment, the upper wing panel 550-1 is transported along an assembly line; for example, via a positioning plate 540, which transports the upper wing panel 550-1 (now part of wing assembly 600) along a track 510. Wing assembly 600 may be at least partially disposed within rib mounting stations 528, for example... Figure 5C The view presented is shown in the image. However, in... Figure 11D In the illustrated embodiment, the spar 580 is shown mounted on either side / end of the rib 572; therefore, the wing assembly 600 can be at least partially disposed within the spar mounting position 530 (e.g., in...). Figure 5E (as shown in the view presented), or located within the rib-to-spar attachment station 598 (e.g. Figure 5F (As shown in the view presented), this depends, for example, on the installation order of the spar 580 and the rib 572.

[0151] Based on the components and operations discussed above, Figure 12This is a flowchart illustrating a method 900 for mounting ribs to an upper wing panel during the production of a wing assembly, as exemplified in an exemplary embodiment. The description of this method will refer to the components and concepts discussed above and shown in the accompanying drawings; however, the method is applicable to various setups. Step 902 includes suspending the upper wing panel 550-1 of the aircraft below a shuttle (e.g., a positioning plate 540). According to many of the methods described above, this step may include (and / or prior to this) demolding the upper wing panel 550-1 from a laying mandrel, transposing the upper wing panel to the positioning plate 540, and / or engaging the wing panel to the positioning plate (e.g., via a vacuum connector 548 through a spring 545) to hold the upper wing panel while applying a contour to the upper wing panel.

[0152] Step 904 involves translating the rib to a position below the upper wing panel. This step can be performed while the wing panel pauses between pulses passing through the workstation. In some embodiments, this includes driving a shuttle (e.g., a trolley 700, which may be a manually operated trolley, AGV, or otherwise configured vehicle) to support the rib in the desired position. The trolley can be controlled according to an NC program and can be positioned based on a track / rail system that applies the desired orientation, or via markers indicating the desired placement position in the factory floor, such as radar or lidar, visual tracking, etc. In the illustrated embodiment, the rib is translated to a position directly below where the rib on the upper wing panel will be installed.

[0153] Method 900 is shown as including step 906 of vertically orienting rib 572. In some embodiments, rib 572 is assembled or otherwise processed, such as on a jig or similar frame, in an upright position after demolding, and therefore may not need to be vertically oriented for installation (e.g., assuming direct movement from jig to trolley 700 without changing its orientation). A jig can be used to place or apply a desired profile (e.g., a flat profile) onto the rib. As described above, stiffening ribs extending along the length of the rib are coupled to the rib after demolding to apply the profile onto the rib. In some embodiments, the rib may (or become) oriented in a direction other than vertical orientation, such as during assembly or when supplied to the rib mounting station, making vertical orientation required prior to installation. In some embodiments, orientation is performed by placing rib 572 on trolley 700, and then the rib is held in the desired vertical orientation by support 706. In some implementations, method 900 may include, for example, supplying ribs in a just-in-time (JIT) manner via a feed line configured to have a suitable production cycle time for JIT delivery.

[0154] Although in the illustrated embodiment, the "orientation" step 906 is shown after the "translation" step 904, this is not necessary in all embodiments. In some embodiments, the "orientation" step (906) is performed as part of or at least partially during the "translation" step (904). In some embodiments, orientation is performed before translation (e.g., during loading the rib 572 onto the trolley 700).

[0155] In step 908, rib 572 is positioned to contact the upper wing panel. As described above, this can be done by vertically lifting the rib, for example by using actuator 904 of the drive trolley 900 to raise rib 572 to contact the lower surface 576 of the upper wing panel 550-1. In some embodiments, this can be done by lowering the upper wing panel to contact the rib, for example by means of spring 545 of positioning plate 540. In some embodiments, a combination of lifting the rib and lowering the wing panel is performed to bring the components into contact. In some embodiments, positioning rib 572 to contact the upper wing panel 550-1 includes engaging the rib with one or more indexing features of the wing panel (e.g., by connecting alignment features 584 and 586, such as...). Figure 11C (As shown). This ensures the final, precise alignment of rib 572 with upper wing panel 550-1.

[0156] For example, such as Figure 5D As shown, in some embodiments, rib 572 can be fastened to at least one or more portions of the wing panel 550 or its lower surface at an angle (shown as mounting angle θ). Therefore, in a manufacturing method in which rib 572 is vertically oriented (or in other words, at an angle generally orthogonal to track 510 and / or floor (surface) 710) and then raised upwards to the lower surface of the wing panel, it is advantageous to mount the rib at the desired mounting angle θ relative to the wing panel by setting the wing panel in a suitable orientation (e.g., by setting the wing panel such that its lower surface is tilted at an angle complementary to the mounting angle θ). This can be done during the initial suspension of the upper wing panel 550-1 under the positioning plate in a suitable orientation, or the length of the spring can be adjusted prior to the rib installation procedure in a manner configured to change the orientation of the wing panel to suit the mounting of the rib.

[0157] In step 910, while the upper wing panel remains suspended from the positioning plate 540, the rib 572 is secured to the upper wing panel 550-1. The term "secured" as used herein encompasses both temporarily holding the rib in place (e.g., by means of tack pins, clamping, and / or other techniques) and permanent installation. In some embodiments, the rib 572 is held in place prior to permanent installation, for example, to allow for the selective installation of shims into the gap (if any) at the junction of the rib and the wing panel. In some embodiments, installation includes driving or otherwise installing fasteners through the upper wing panel 550-1 and the rib 572. These operations can be performed via an end effector that mounts locking bolts or by other means. In some embodiments, to avoid obstructing or interfering with the securing operation, vacuum attachment is performed via a vacuum connector 548 located between or in between (but in any case different from) the rib mounting positions. Therefore, in such an implementation, the vacuum connectors 528 are positioned on the wing panel 550 such that their position does not interfere with operations such as the thumbtack fastening and / or permanent fastener installation of the ribs 572 performed by technicians or automation.

[0158] Steps 904 (translating the rib), 908 (positioning the rib to contact the wing panel), and 910 (attaching the rib to the wing panel) are all performed while the wing panel 550 is suspended and / or while maintaining the rib 572 vertically. One or more, or all, of the steps of method 900 are performed at the rib mounting station. Method 900 or its sequence of steps can be performed iteratively to mount multiple ribs 572 onto the same wing panel 550.

[0159] Method 900 offers technological advantages over existing systems and technologies because it is able to apply a profile to the wing panel 550 and rapidly install the rib 572 into the wing panel while maintaining the applied profile. By keeping the rib vertically oriented throughout the installation process, Method 900 can save labor and increase efficiency in the factory shop and / or assembly line.

[0160] In some embodiments, after at least one rib has been secured (e.g., mounted to the upper wing panel 550-1), the sparsity 580 is secured to the rib and the wing panel, for example, to close the leading and trailing edge portions of the wing panel / rib. In some such embodiments, sparsity segments are longitudinally joined to each other at the rib to form a sparsity, thereby making the rib part of the splice between the sparsity segments. In some such embodiments, the sparsity 580 is secured at a station downstream of the rib mounting station, such as the sparsity mounting station, for example... Figure 5E and Figure 5FThe assembly line 500 shown has a spar installation station 530. In one embodiment, the spar 580 consists of three spar sections, thus providing two spar / rib splices. In some embodiments, the spar 580 and rib 572 are simultaneously fixed to the wing panel 550, for example at two different stations and / or two different locations on the wing panel 550.

[0161] The mounting of the ribs and spars to the wing panels, and the mounting between them, can include any suitable technique, including those disclosed herein. Some embodiments of method 900 continue, for example, by joining the lower wing panel to the ribs and spars mounted to the upper wing panel. See below for reference. Figures 16A to 16C A more detailed description of one way to perform this operation is provided, illustrating one method of installing shims during the assembly of wing components.

[0162] In some embodiments, a station exists upstream of the wing spars installation station, where the wing panel is trimmed to its final production dimensions (e.g., its final perimeter) and shift features in the manufacturing allowance (i.e., along with the manufacturing allowance) are removed. Following trimming, sealing and painting are performed in a pulsed or continuous manner. In some embodiments, trimming (and / or sealing and painting) of the wing panel to its final perimeter is performed after the ribs and / or wing spars are installed.

[0163] Figure 13 This is a flowchart illustrating a method 920 for assembling a wing assembly in an exemplary embodiment. It relates to the components, concepts, and processes discussed in detail above, but focuses on the aspect of attaching ribs and spars to the upper wing panel while the wing panel is suspended below a shuttle. Therefore, step 922 includes suspending the upper wing panel 550 of the aircraft below a shuttle, such as a positioning plate (e.g., positioning plate 540). Step 924 includes attaching rib 572 to the upper wing panel 550-1. Step 926 includes attaching spars 580 to the upper wing panel 550-1. Step 928 includes fastening the spars 580 to the rib 572. Finally, step 930 includes joining the lower wing panel 550-2 to the spars 580 and rib 572.

[0164] As described above, the assembly of various wing component parts can occur in a different order than that shown in the illustrated embodiments. In some embodiments, one or more ribs are installed before the wing spars (or wing spars sections) are installed. In some embodiments, all ribs are installed before the wing spars (or wing spars sections) are installed. In some embodiments, ribs and wing spars are installed simultaneously or overlapping in time, for example, at multiple stations in the assembly line, and / or at multiple locations on the wing panels.

[0165] Furthermore, in some embodiments, the spar 580 (or spar segment) is attached to the rib 572 before the rib is fastened to the wing panel (e.g., upper wing panel 550-1) to create a horizontal, open ladder-like structure (such as support structure 588). Figure 5G The wing assembly is then mounted on the support structure 588, with the upper wing panel and lower wing panel 550 being the most visible part of the wing. Figure 14 This is a flowchart illustrating another method 940 for assembling a wing assembly in such an embodiment. This embodiment includes attaching a sparsity 580 to a rib 572 in step 942. Then, in step 944, attaching an upper wing panel 550 to one side of the sparsity 580 and rib 572, or support structure 588. This process may involve suspending the upper wing panel 550-1 below a shuttle (e.g., a positioning plate in other example methods) and raising the support structure 588 of the attached ribs and spars into position to secure the support structure 588 to the upper wing panel. In some such embodiments, all ribs and spars are secured together before attachment to the upper wing panel; in other such embodiments, additional ribs and / or spars or spar sections are attached to the wing assembly after the support structure 588 has been attached to the upper wing panel. In step 946, the lower wing panel is finally attached to the opposite side of the support structure 588 of the attached sparsity 580 and rib 572 to complete the wing assembly.

[0166] As described above, in some configurations of assembly lines for wing components, various workstations can be arranged in a manner that facilitates the simultaneous or overlapping execution of several operations on the wing panel as it moves along the assembly line in the processing direction. For example, Figure 5A The diagram illustrates a configuration where different sections of the same wing panel 550 are positioned within multiple workstations 520 (specifically, NDI workstation 524, cutting workstation 526, and rib mounting workstation 528). In other embodiments, additional workstations 520 (e.g., spar mounting workstation 530) are used. Figure 5E ), support structure assembly station 532 and / or installation station 534 ( Figure 5G ), and rib-to-spar attachment station 598 and / or plate bonding station 599 (see Figure 5F This can also be arranged like this.

[0167] Figure 15This is a flowchart illustrating aspects of multiple operations performed simultaneously or overlapping in time on a wing panel, and shows a method 960 for assembling a wing or wing assembly in an exemplary embodiment (e.g., by mounting ribs and spars to the upper wing panel). Step 962 includes suspending the upper wing panel 550-1 of the aircraft below a shuttle, such as a positioning plate (e.g., positioning plate 540). Step 964 includes mounting one or more ribs 572 and one or more spars 580 (or sections of spars 580) to the upper wing panel 550 simultaneously or at least overlapping in time via a station 520 provided at the upper wing panel, while the upper wing panel remains suspended. Step 966 includes pulsating the upper wing panel through station 520 in the processing direction. In some embodiments, the additional workstation 520 also performs operations on the wing panel during these operations, including installing hatches (at the cut-off workstation), attaching ribs to spars (at the rib-to-spar attachment workstation), and so on. In a further embodiment, the workstation installs the ribs and spars during pauses between pulses of the upper wing panel. In a further embodiment, the method also includes securing the lower wing panel to the ribs and spars attached to the upper wing panel.

[0168] Various aspects of wing assemblies (such as mounting ribs and spars to the wing panel) may involve installing shims between the wing panel and one or more ribs and / or spars, for example, if any gap between the individual components exceeds a certain size (e.g., a shim fill tolerance threshold). This can be done, for example, after the ribs and spars have been clamped and / or nailed into place, but after the ribs and spars have already been... Figure 5A In assembly line 500, shim installation is performed before or after the lower wing panels have been attached. Once the components have been positioned and nailed / clamped in place, shims are used to fill the gaps between the various components (e.g., between ribs and upper or lower wing panels, between spars and upper or lower wing panels, between ribs and spars, etc.).

[0169] Figure 16A and Figure 16B This diagram illustrates the automated installation of gaskets between ribs and wing panels in an exemplary embodiment, specifically by means of an end effector of a robotic arm that can be detachably attached to a stiffening rib of each rib. More specifically, as... Figure 16A and Figure 16B As shown, the wing assembly 600 is suspended below a positioning plate (not shown) by a length-adjustable spring 545, which includes a vacuum connector 548 connected to the upper surface 574 of the wing panel 550 of the wing assembly. Figure 16A An embodiment of the wing assembly 600 is shown, comprising a wing panel 550 in the form of an upper wing panel (denoted as 550-1), while Figure 16B An embodiment is shown in which the wing assembly 600 also includes a second wing panel 550 in the form of a lower wing panel (indicated by 550-2). The wing assembly 600 is shown as having a plurality of ribs 572 fixed to the lower surface 576 of the upper wing panel 550-1.

[0170] In some embodiments, one or more gaps may exist between the connecting components of the wing assembly 600 (e.g., between rib 572 and the surface to which it is mounted, between spar 580 and wing panel 550, between rib 572 and spar 580, etc.). If a gap is determined to exceed a certain size, i.e., one or more dimensions of the gap (e.g., width, depth, length, etc.) exceed a certain threshold (also referred to herein as a shim filling tolerance threshold), a shim of appropriate size and construction is installed into the gap to fill it. In the illustrated embodiment, this is done by a robotic arm 750, and more specifically by the end effector 752 of the robotic arm. The end effector 752 in Figure 16A The image shows a gripping device 754 configured to hold a shim 756, for example, to be installed into a gap that has been determined to be a shim location (denoted as 758). In some embodiments, the end effector 752 includes components or devices (not shown) for inspection, such as a camera, laser, ultrasonic device, probe, or feeler gauge, to scan or otherwise visually or physically detect or approach a gap along the joint between the mating components, and further determine or be able to determine whether the gap exceeds a shim filling tolerance threshold and is therefore a suitable location for installing the shim 756 (i.e., shim location 758). In some embodiments, the robotic arm 750 includes multiple end effectors 752, for example, one end effector for inspection and another end effector for installation.

[0171] While other configurations are possible, Figure 16AIn this design, the robotic arm 750 is shown as an actuator 760 and a kinematic chain of a rigid body 762 extending from a carrier 764. The carrier 764 is then mounted on a stiffening rib 648 of the rib 572. The stiffening rib 648 is also referred to herein as a “support”. In some embodiments, such as as described above, the support 648 is mounted to the rib 572 before the rib is mounted to the wing panel 550 to serve as a stiffening rib, i.e., to stabilize the rib and / or to apply a desired (e.g., flattened) rib profile to the rib. Thus, in some embodiments, the support 648 serves both as a stiffening rib and as a connection point for the robotic arm. In further embodiments, the support 648 may additionally or alternatively serve as a general connection point for machinery or equipment used to move or otherwise manipulate the rib during manufacturing and / or assembly operations. In some embodiments, for example, the support is removably attached using bolts or other similar fasteners. As further detailed below, the connection between the carrier 764 of the robotic arm 750 and the support 648 of the rib 572 is a removable connection, allowing the robotic arm to be connected to and disconnected from the carrier 764 by detachably mounting the carrier to the support. Furthermore, in the illustrated embodiment, the connection allows the carrier 764 to move independently along the length of the support, facilitating the robotic arm's access to the gap and / or shim location 758 along the length of the rib 572.

[0172] The robotic arm 750 can move (e.g., reposition) from one support to another, for example by disengaging from the first support and then attaching to the second, to operate at different locations along the wing assembly 600. Figure 16A In the illustrated embodiment, this is accomplished by means of a trolley 770. The trolley 770 includes a set of wheels 772 mounted to a surface and configured to support a trolley body 774 relative to the surface (e.g., a floor surface). One or more wheels 772 may be motorized or otherwise driven. The trolley body 774 then supports a telescopic lift 776, which is configured to engage and raise or lower a carrier 764. Thus, the trolley 770 is configured to position the carrier 764 for engagement with a bracket 648, or to move the carrier to a position where it can be engaged with a bracket of a second rib after disengagement from the bracket of the first rib 572, for example, by a combination of raising or lowering the lift 776 and moving the trolley body relative to the floor surface (and / or rib 572) by means of the wheels 772.

[0173] As shown in the figure, the trolley 770 also includes a controller 778, which can partially or completely control the movement of the trolley body 774 and / or the lift 776, and / or the engagement / disengagement of the support member 764 relative to the rib 572. The controller 778 can control the operation of the robotic arm 750 and its end effector 752, either wholly or partially. In some embodiments, the controller 778 operates the robotic arm 750 according to an NC program to visually inspect the position between the wing panel 550 and the rib 572 to determine whether a shim 756 will be used, and if so, what size shim will be used, and / or to install the shim. In other embodiments, some or all of these movements are remotely controlled, for example, by an operator or by a floor controller (not shown). Therefore, it is understood that... Figure 16A Several operations are illustrated. For example, the trolley 770 and the lift 776 are shown cooperating to position the carrier 764 in contact with the support 648 of the rib 572. Furthermore, the robotic arm 750 extending from the carrier 764 is shown holding a pad 756 with its end effector 752 for mounting into the pad position 758. For ease of explanation, various components of the trolley 770 and robotic arm 750 are shown in a simplified, partially schematic form. Wiring and connections, such as those supplying power to the robotic arm 750 and / or the trolley 770 from an external power source or an integrated power supply (not shown), are not shown in this view.

[0174] Figure 16A A shim feed line, schematically represented by 780, is also shown, configured in the illustrated embodiment to supply shims 756 for mounting by a robotic arm 750. In some embodiments, the shim feed line 780 is configured to dynamically fabricate shims 756 for mounting, for example, in response to signals or communications provided by an operator and / or controller 778, based on input received from an end effector 752, which is configured to measure or otherwise approach each gap encountered during analysis.

[0175] Therefore, it can be seen that the example operation of automatic shim installation of the wing assembly can be performed by approaching each of the positions in the sequence of positions in the wing assembly, for example, each of the following positions: for example, where previous analysis indicates that shim position 758 exists (or may exist), or the entirety of each joint between components joined together, etc. In one example, the carrier 764 of the robotic arm 750 is sequentially coupled to the bracket 648 mounted to each of the plurality of ribs 572 of the wing panel 550 to perform detection and analysis of each gap and / or shim installation of each shim position 758 in a space defined by one or two adjacent ribs 572. This space is also referred to as compartment 790. As described above, in such an example, the carrier 764 can move along the bracket 648 to allow inspection and / or installation of the entire length of the rib 572, or the side of at least a plurality of ribs (or one rib), which defines the compartment for installing the robotic arm 750. Figure 16A In the illustrated embodiment, five ribs 572 (also individually shown as 572-1, 572-2, 572-3, 572-4, and 572-5) are shown mounted to the upper wing panel 550-1, thereby forming six compartments 790 (which are shown individually only, such as 790-1, 790-2, 790-3, 790-4, 790-5, and 790-6). A carrier 764 is shown as a bracket 648 coupled to rib 572-4, thereby allowing the end effector 752 of the robotic arm 750 to not only inspect the pad 756 and / or mount the pad 756 to the side of rib 572-4 to which the bracket 648 is mounted, but also to the side of the next adjacent rib (i.e., rib 572-3) and any other accessible location in the interval 790-4. Therefore, by connecting the carrier 764 of the robotic arm 750 to the bracket 648 of each rib 572, shim mounting can be performed in each compartment 790-1, 790-2, etc. In compartments where the carrier 764 cannot be connected to the bracket 648, for example... Figure 16A In compartments 790-6, gap inspection and / or shim installation can be performed by moving the robotic arm 750 using a trolley body 774 and a telescopic lift 776. In other embodiments, additional brackets can be installed to allow for individual inspection and / or shim installation by means of the robotic arm 750 mounted on the brackets. Different wing assemblies may have more or fewer ribs (and correspondingly more or fewer compartments). In some embodiments, the robotic arm 750 is engaged with the bracket 648 of the rib 572 before the rib 572 is placed against the wing panel.

[0176] In some cases, the shim location 758 can be detected and / or approached from both sides of rib 572, in which case shim installation can be performed from either side where it is more efficient to operate. In some embodiments, multiple robotic arms are deployed simultaneously on the same wing assembly, which (among other benefits) can facilitate efficient shim installation at the shim location, which can be filled from either side. In some such embodiments, a single trolley can facilitate the positioning (and repositioning) of each of the multiple robotic arms, for example by lifting the carrier of the first robotic arm into place to mount it on a first support, then disengaging it from the carrier to leave the robotic arm on the first support, and then moving it to engage the carrier of the second robotic arm, for example, to move it into place to mount it on a second support (e.g., in a different compartment), etc.

[0177] exist Figure 16B As described above, the wing assembly 600 is shown to also include a lower wing panel 550-2. Furthermore, a telescopic lift 776 is shown extending through an access port 792 in the lower wing panel 550-2 to access the support 648, for example, to attach (or detach) the carrier 764 from the support. The access port 792 may already be installed at the upstream station 520, for example... Figure 5A The cutting station 526 is shown. The size of the access port 792 is designed to allow insertion and subsequent removal of the robotic arm 750 (including the carrier 764). To minimize the size of the access port 792, the robotic arm 750 may be extended, folded, or otherwise aligned to have a configuration with a minimum cross-section for insertion and withdrawal through the access port. Alternatively, the size and / or configuration of the robotic arm 750 may be designed to be particularly suited to a predetermined access port size. The lower wing panel 550-2 is shown to include a plurality of access ports 792, one access port per compartment, to allow the robotic arm 750 to be inserted and then coupled to perform inspection and / or shim installation in each compartment. In one embodiment, when the robotic arm 750 is positioned within a compartment, the sides of the two ribs defining the compartment are inspected by the robotic arm 750 and / or shimmed, which reduces the number of times the robotic arm 750 aligns with the access port 792 for insertion or removal.

[0178] In some implementations... Figure 16A and Figure 16B The sequential operation is described in two phases, in which the first step involves installing a shim 756 (e.g., an upper shim) onto a shim position 758 (e.g., between rib 572 and the lower surface of the upper wing panel 550-1). Figure 16A (As shown), then the lower wing panel 550-2 is installed onto the wing assembly 600, and then a shim (e.g., a lower shim) is installed at the shim position between the rib 572 and the upper surface 574 of the lower wing panel 550-2 (e.g. Figure 16B(As shown). In other words, in this embodiment, the lower wing panel 550-2 is installed after the upper shim is installed. In other embodiments, Figure 16A and Figure 16B Alternative operations are described, for example, Figure 16A This can represent the first stage of the above sequential operations, while Figure 16B This can represent the operation of installing the lower wing panel 550-2 onto the wing assembly 600 prior to installing any (upper or lower) shims 756. In either case, the robotic arm 750 can be moved along the length of the wing assembly from one compartment to another by means of a trolley 770 to perform shim installation in each compartment. As described above, in some embodiments, multiple robotic arms are deployed simultaneously in more than one compartment for shim position detection and / or analysis and / or shim installation.

[0179] Figure 16C A view depicting the rib 572 of the support member 764 for mounting the robotic arm 750 is shown, specifically, as... Figure 16A The rib shown is 572-4, and therefore corresponds to Figure 16A The view arrow is 16C. However, Figure 16C The component shown is applicable to any rib 572 in the illustrated embodiment. Figure 16C Only the carrier 764 of the robotic arm is shown in the view. For clarity, components of the positioning plate (such as springs and vacuum couplings) are also not shown in this view. Figure 16C A view is provided illustrating an exemplary construction of a bracket or stiffening rib 648, shown mounted against the web 646 of rib 572. More specifically, the bracket 648 is shown mates with an indexing feature at rib 572, typically shown as indexing feature 794. The indexing feature can facilitate alignment of the bracket 648 with rib 572 during mounting and can take any suitable form, such as a through-hole in the web 646 configured to receive a fastener, such as a bolt. Figure 16C Further illustrated, the support 648 includes a rack 796 with teeth 798, to which a carrier 764 is held or otherwise removably attached. The carrier 764 is configured to translate back and forth along the support 648 in a controlled and indexable manner using the teeth 798 (e.g., via a driven mechanism engaging with the teeth, such as a pinion, worm gear, etc.). Therefore, based on the position of the support 648 (or relative to the support 648) and the position of the carrier 764 along the support 648, the position of the robotic arm can be indexed relative to a rib (e.g., the rib to which the carrier of the robotic arm is attached). While not required in all embodiments, Figure 16C The bracket 648 is also shown to include a centering feature 654 that facilitates rotation, for example by enabling the bearing to be positioned relative to a known reference point more quickly.

[0180] In one embodiment, the carrier 764 is operable to drive a robotic arm (not shown) along a support 648 via a rack and pinion system, wherein teeth 798 form a rack. Other embodiments of the support 648 and / or the carrier 764 have different configurations to allow the carrier 764 to move along the support. In the illustrated embodiment, the carrier 764 is also capable of rotation as indicated by arrow 1012 to enhance the movement and access of the robotic arm.

[0181] Figure 16C A representative pair of spars 580, mounted at either end of rib 572 to upper wing panel 550-1, is also shown. Spars 580 are shown in a simplified form and therefore do not include, for example, specialized upper and lower covers, the shapes of which are designed to facilitate fastener attachment to the wing panel. Teeth 798 are shown extending sufficiently toward the end of bracket 648, which in this embodiment is connected to the rib 572 to which it is mounted, to allow the carrier 764 to move sufficiently close to the spars so that clearance approach and / or shim installation can be performed by a robotic arm at the joint between the spars and the wing panel and / or at the joint between the spars and the rib. In a further embodiment, bracket 648 facilitates rail mounting of collar and / or nut installers. This is particularly advantageous when the lower wing panel has already been installed and is only accessible via an approach port. Furthermore, although rib 572 and wing panel 550 are not shown to precise scale or dimensions, Figure 16C It is shown that there are multiple gaps between the rib 572 and the lower surface 576 of the upper wing panel 550-1, for example at the representative shim location 758.

[0182] As described above, in some embodiments, the robotic arm 750 performs operations other than gasket installation, such as gap detection and / or inspection to facilitate the identification of gasket position 758. In some embodiments, the robotic arm performs additional operations, including sealing, sealant inspection, fastener installation, collar or nut installation on fasteners, collar or nut installation inspection, etc. The robotic arm 750 can perform such operations via selecting an interchangeable end effector 752 (e.g., which can be replaced while the carrier 764 of the robotic arm 750 is attached to the bracket 648, for example, via access port 792), or with a multi-functional end effector 752, or with multiple robotic arms 750, each of which can be mounted and remain in the appropriate position on the bracket; in some cases, multiple such robotic arms are attached to the bracket. The robotic arm 750 can be operated automatically or remotely via a floor-based controller that enables a technician to operate the robotic arm (e.g., via remote control). After completing its work, the robotic arm 750 can be reattached to the cart 770 and removed.

[0183] Figures 17A to 17C This is a perspective view of robotic arms 750, each robotic arm 750 operating to inspect clearances in a compartment 790 located between two ribs 572 and defined by one side of the spar 580 of the example wing assembly 600, install gaskets 756 in gasket positions 758, install sealants or collars / nuts, etc. In the embodiments depicted in these figures, a technician sets up, operates, and maintains the robotic arm 750 after the carrier 764 of the robotic arm is placed on a support 648 via a trolley (not shown). For simplicity, the following discussion assumes that in each of these figures, the robotic arm 750 operates in the same compartment 790 between the same two ribs 572 (numbered 572-1 and 572-2, respectively). Figure 17A In this process, a robotic arm 750 is mounted on a bracket 648 that abuts against rib 572-1, and operates its end effector 752 to inspect the position of rib 572 abutting against the upper wing panel 550, particularly rib 572-2, and the surface of the wing panel where rib 572-2 abuts. Based on the inspection, the robotic arm 750 selectively installs a shim 756 at shim position 758 within the compartment. Figure 17B In the middle, rather than in Figure 17A Compared to the previous position, the carrier 764 of the robotic arm 750 has traveled along the support 648 to a position closer to the end of the support, and it is shown using its end effector 752 to inspect the position near the bottom of rib 572-2. Figure 17C In this configuration, the robotic arm 750 has used its end effector 752 to place a shim (not shown) at shim position 758 above the support 648, where rib 572-1 is secured to the upper wing panel 550. With the shim in place, fasteners can be installed through the upper wing panel 550 and rib 572-1 to secure the wing panel to the rib, or at least to a portion of the shim located on it. In some embodiments, the shim is secured in place by means of one or more fasteners; in other embodiments, the shim is held in place by friction engagement instead of friction, as the rib is secured to the wing panel.

[0184] Considering the above components and concepts, Figure 18This is a flowchart illustrating a method 920 for operating a robotic arm (e.g., robotic arm 750) to perform a task related to a wing assembly (e.g., in wing assembly 600) in an exemplary embodiment. Step 922 includes mounting a bracket 648 to a rib 572. In some embodiments, this is done before the rib is held or positioned against the wing panel 550, for example, after the rib is demolded and during (or after) other preparations for mounting the rib to the wing panel. In some embodiments, this is done after the rib is held or positioned against the wing panel. Mounting of the bracket 648 can be facilitated by aligning the bracket with indexing features of the rib 572 (e.g., complementary cup-cone features, through holes for receiving bolts, etc.). Once mounted, the bracket 648 applies a desired profile (e.g., a flat profile) to the rib 572. In some embodiments, the bracket is removably mounted.

[0185] Step 924 includes engaging the robotic arm 750 to the support after the bracket 648 has been installed to the rib 572. In some embodiments, this is performed by detachably mounting the carrier 764 to the support. In some such embodiments, a wheeled trolley 770 equipped with a telescopic lift 776 is deployed, which is configured to support the carrier, for example, for moving the carrier to a suitable orientation and / or position for mounting on the support. The engagement of the robotic arm 750 to the bracket 648 can be achieved via clamping, attraction, magnets, mechanical alignment with tracks on the bracket, etc. In some embodiments, the engagement is configured to allow the robotic arm 750 to move relative to the bracket 648, for example by means of the carrier 764 configured to move along the bracket. In some such embodiments, the bracket includes teeth that facilitate a rack and pinion system with the carrier. With the carrier 764 and / or the robotic arm 750 coupled to the bracket 648, the position of the robotic arm 750 within the reference system of the wing assembly 600 (e.g., relative to one or more components of the wing assembly, such as wing panels, ribs, or brackets mounted to ribs, or spars, etc.) is known. In that sense, coupling the robotic arm 750 to the bracket 648 may include repositioning the robotic arm relative to the bracket.

[0186] In step 926, once engaged, the robotic arm 750 is operated to install one or more shims between the rib and the wing panel at the junction of the rib and the wing panel (i.e., via the carrier 764 while the robotic arm is engaged to the bracket 648). As described above, this may include moving the robotic arm 750 along the length of the bracket 648 (e.g., by driving the carrier 764) to align the robotic arm 750 with the shim positions at the rib, and / or moving the robotic arm within the range of the additional shim positions.

[0187] In some embodiments of method 920, a robotic arm is operated via a suitably configured end effector to inspect the rib-to-wing panel interface, for example, to detect, inspect, and / or measure gaps between components. In some such embodiments, the results of the measurement are transmitted to, for example, a technician or controller to determine whether a particular gap exceeds a shim filling tolerance threshold, which may indicate an out-of-tolerance condition and is therefore considered a shim location (where the shim is installed). In some such embodiments, the results of the measurement are used to select a suitable shim to be installed, for example, by correcting for out-of-tolerance conditions through size, dimensions, taper, or other characteristics.

[0188] The gasket 756 can be supplied via a gasket feed line in any suitable manner. For example, selected gaskets (e.g., different tapers and / or sizes, etc.) can be stored in a bin accessible to the robotic arm. In some embodiments, new gaskets are dynamically fabricated, or pre-fabricated gaskets are adjusted (e.g., trimmed) based on gap checks and / or measurements, and then the gaskets are delivered to be inserted into gasket position 758 and provided on time for placement.

[0189] The method may further include: after the shim 756 has been installed, retracting the robotic arm 750 and moving the carrier 764 along the bracket 648 to a new position for further shim installation and / or other operations. Once the shim 756 has been installed into a shim position 758 accessible from the bracket 648, the carrier 764 can be disengaged from the bracket and moved to a new position (e.g., to a bracket on another rib). In some embodiments, this is facilitated by a wheeled trolley equipped with a telescopic lift. In some embodiments, this involves removing the robotic arm 750 through an access gap (e.g., in the lower wing panel 550-2).

[0190] Regarding the above Figures 16A to 17CAs can be understood from the description, method 900 can be used in a wing assembly 600 that includes a variety of components and configurations. For example, although described in the context of an embodiment where one rib is held against a wing panel, the method can be used iteratively in a wing assembly that includes multiple ribs held against wing panels. In other words, once steps 922, 924, and 926 are performed to install a shim at a shim location between a first rib and a wing panel, these steps can be repeated to install the shim at a shim location between a second rib and a wing panel. Method 900 can also be used in a wing assembly 600 where multiple ribs 572 are held against wing panels (e.g., upper wing panel 550-1) at their upper edges, and where another wing panel (e.g., lower wing panel 550-2) abuts against the opposite (or lower) edge of a rib. In such a configuration, the lower wing panel 550-2 can be added to the wing assembly before or during the shim installation operation. In one example, the method includes first performing steps 922, 924, and 926 at the upper shim location between the rib and the upper wing panel, then adding the lower wing panel to the wing assembly, and then performing steps 922, 924, and 926 at the lower shim location between the rib and the lower wing panel. As described above, after the shim is installed between the rib and the wing panel, the rib can be fastened (e.g., mounted) to the wing panel. In another example, the method includes performing shim installation at both the upper and lower shim locations, for example in a configuration where the lower wing panel has already been placed. In any of these examples, the method includes, for example, repositioning the robotic arm by moving (e.g., retracting and inserting) it through an approach gap in the wing panel (e.g., the lower wing panel), for example to attach a carrier to a bracket of a different rib.

[0191] Now let's look at the diagram. (Reference) Figure 19 The illustration depicts a representative aircraft 1200, in which exemplary embodiments of wing panels and / or wing assemblies manufactured according to aspects of this disclosure can be implemented. In other words, aircraft 1200 is an example of an aircraft that can be formed using composite parts, wing panels, and / or wing assemblies manufactured according to one or more of the following aspects: Figure 1 as well as Figure 2A and Figure 2B The exemplary manufacturing method shown; Figure 4 Illustrative pattern shown; Figures 5A to 5F The exemplary assembly line 500 is shown. Figures 11A to 11D The illustrated rib and spar mounting techniques are shown. Figures 16A to 16C and Figures 17A to 17CThe illustrated shim mounting technique; one or more methods shown in the remaining figures; and / or any of the foregoing. In this illustrated example, the aircraft 1200 has wings 1202 attached to and extending to either side of the fuselage 1204. The aircraft 1200 includes engines 1206 attached to the respective wings 1202. Located at the rear end of the fuselage 1204 is a tail section 1208, which includes a pair of opposing horizontal stabilizers 1210 and a vertical stabilizer 1212. The wings 1202 are formed by an upper wing panel 550 and a lower wing panel (not shown) joined together, wherein assemblies of ribs and spars (not shown) at least partially form its internal structure.

[0192] Figure 20 This is a block diagram of the various components and systems (or stages) discussed herein in an exemplary embodiment. Specifically, Figure 20Workshop 1300 is depicted, comprising a first assembly line 1310 in a cleanroom environment (denoted 1312) and a second assembly line 1314 in a non-cleanroom environment 1316. A boundary (e.g., one or more walls or enclosures) (denoted 1318) separates the cleanroom 1312 and non-cleanroom 1316 environments. At layup 1320, indexing features (e.g., indexing feature 210) are integrated into a laminate 1322 (e.g., preform 200) for a wing panel. The laminate 1322 is cured in an autoclave 1324 to form a composite part 1326. According to embodiments herein, the composite part 1326 is a wing panel (e.g., wing panel 550), more specifically an upper wing panel; however, workshop 1300 may be configured to manufacture, process, and otherwise handle composite parts in the form of other aircraft components besides wing panels. Composite part 1326 is then transferred to assembly line 1314, which, in the illustrated embodiment, is shown as composite part 1326 traveling in the processing direction 1328 through various systems and stages specific to those suitable for the upper wing panel. For example, at assembly line 1314, trimming stage 1330 removes excess material and / or installs additional indexing features into composite part 1326. At demolding stage 1332, composite part 1326 is demolded (e.g., removed from the laying mandrel), and then contoured onto composite part 1326 via contouring stage 1334, wherein composite part 1326 is secured to shuttle 1336 (e.g., one or more positioning plates 540), shuttle 1336 including carrier 1338 (e.g., length-adjustable spring 545 including vacuum coupling 548). As the composite part advances along assembly line 1314, shuttle 1336 applies contours to composite part 1326, for example, via carrier 1338. As composite part 1326 travels past rib mount 1340 and spar mount 1342, ribs and spars are mounted onto composite part 1326. As needed, inspection of the rib and spar assemblies and shim installation are performed by robotic arm 1344. The lower wing panel 1346 is then attached to form a wing assembly (e.g., wing assembly 600). The various systems and stages described with respect to workshop 1300 can be incorporated into or adopted in the form of the various stations 520 described above. Furthermore, although for simplicity, assembly line 1314 may include stations such as one or more NDI stations 524, cutting stations 526, etc., not all of the aforementioned stations 520 are located in [specific locations]. Figure 20 This is shown in detail above. Figure 20 Other operations described above can be incorporated into or adopted. Figure 4 In the form of one or more feeders, laying or assembly lines shown in the diagram and in mode 480, for example, trimming 1330 and demolding 1332 can be performed in demolding operations 490-11.

[0193] Please note now. Figure 21 The exemplary embodiment illustrates control components of a production system performing (e.g., continuous) lamination and / or ultrasonic inspection. A controller 1400 coordinates and controls the operation of a laminator 1420 and the movement of one or more moving platforms 1470 along a movement line 1460 having a power system 1462. The controller 1400 may include a processor 1410 coupled to a memory 1412 storing a program 1414. In one example, the moving platforms 1470 are driven along a movement line 1460 continuously driven by a power system 1462 controlled by the controller 1400. In this example, the moving platforms 1470 include a utility tool connection 1472, which may include an electric, pneumatic, and / or hydraulic quick-disconnect device connecting the moving platforms 1470 to a utility tool 1440 from an external source. In other examples, as previously described, the mobile platform 2470 may include, for example, spindles and / or other tools, parts, supplies, etc., on an automated transport vehicle such as an Automated Guided Vehicle (AGV) including onboard facilities and a GPS / automatic navigation system 1474. In still other examples, a laser tracker 1450 is used to control the movement of the mobile platform 1470. A position and / or motion sensor 1430, coupled to a controller 1400, is used to determine the position of the mobile platform 1470 and the power system 1462.

[0194] Figure 22 The illustration depicts a view of the progression of an assembly line 1500 (e.g., a continuous assembly line) arranged along a moving line in a work area 1502 and configured to perform various operations. The work area includes a work zone for tool preparation 1510, including cleaning tool 1504 (e.g., laying mandrel 110), applying coatings and / or potting compounds to tool 1504, or repairing tool 1504, which is then transported on platform 1506 to an additional work area 1502. The additional work area includes a work zone 1520 for material application (e.g., where lamination operations are performed) to form a preform 1522 (e.g., preform 200). Preform 1522 can then be conveyed via the assembly line 1500 to downstream work areas, which include a work zone 1530 for volume reduction, a work zone 1540 for compaction, and a work zone 1550 for molding. Volume reduction and / or compaction of the preform 1522 may include vacuum compaction performed via vacuum bag 1532. Molded preform 1522 may be performed via pre-curing molding and / or via a combination of molding between tool 1504 and pad 1542.

[0195] The preform 1522 is further moved to a working area 1560 for hardening the preform 1522 into a composite part 1564 (e.g., composite part 250, which may be in the form of a wing panel 550), such as at an autoclave 1562, a working area 1570 for trimming (e.g., via a cutter 1572) the composite part 1564, a working area 1580 for inspecting (e.g., via an NDI machine 1582) the composite part 1564, a working area 1590 for rework, and / or a working area 1595 for surface treatment.

[0196] In one embodiment, the finishing process may include extensive finishing of the preform 1522 before it is hardened, followed by more specific finishing after the composite part 1564 has been formed. Inspection of the composite part 1564 may include visual inspection as well as inspection using NDI (non-destructive testing) equipment. Although it is possible to rework the composite part 1564 along the assembly line 500, in many cases rework may not be necessary. The composite part 1564 then travels along the assembly line 500 in the machining direction 541.

[0197] Example

[0198] In the following examples, additional processes, systems, and methods are described in the context of an aircraft wing manufacturing and assembly system.

[0199] For more specific details, please refer to the accompanying drawings, as shown in... Figure 23 Method 1600 and shown Figure 24 Embodiments of this disclosure are described within the context of aircraft manufacturing and servicing in the illustrated aircraft 1602. During pre-production, method 1600 may include the specification and design 1604 of aircraft 1602 and material procurement 1606. During production, the manufacturing 1608 of components and sub-assemblies of aircraft 1602 and system integration 1610 occur. Subsequently, aircraft 1602 can be certified and delivered 1612 for service 1614. When serviced by a customer, aircraft 1602 is scheduled for repair and maintenance 1616 (this may also include modification, reconfiguration, refurbishment, etc.). The apparatus and methods described herein may be employed during any or more suitable phases of production and service as described in method 1600 (e.g., specification and design 1604, material procurement 1606, component and sub-component manufacturing 1608, system integration 1610, certification and delivery 1612, service entry 1614, repair and maintenance 1616) and / or in any suitable component of aircraft 1602 (e.g., airframe 1618, system 1620, interior 1622, propulsion system 1624, electrical system 1626, hydraulic system 1628, environment 1630).

[0200] Each process of Method 1600 may be performed or executed by a systems integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a systems integrator may include, but is not limited to, any number of aircraft manufacturers and major systems subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service provider, etc.

[0201] like Figure 24 As shown, an aircraft 1602 produced by method 1600 may include an airframe 1618 having multiple systems 1620 and an interior 1622. Examples of systems 1620 include one or more of a propulsion system 1624, an electrical system 1626, a hydraulic system 1628, and an environmental system 1630. Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention can be applied to other industries, such as the automotive industry.

[0202] As mentioned above, the apparatus and methods implemented herein may be employed during any or more phases of the production and service described in method 1600. For example, components or sub-assemblies corresponding to component and sub-assembly manufacturing 1608 may be manufactured or produced in a manner similar to that of components or sub-assemblies produced during the service of aircraft 1602. Furthermore, one or more apparatus embodiments, method embodiments, or combinations thereof may be used during sub-assembly manufacturing 1608 and system integration 1610, for example, by significantly accelerating the assembly of aircraft 1602 or reducing its cost. Similarly, one or more apparatus embodiments, method embodiments, or combinations thereof may be used during the service of aircraft 1602, for example, but not limited to, during maintenance and repair 1616. Therefore, the present invention can be used at any stage or any combination thereof (e.g., specification and design 1604, material procurement 1606, component and sub-component manufacturing 1608, system integration 1610, certification and delivery 1612, service 1614, repair and maintenance 1616) and / or any suitable component of the aircraft 1602 (e.g., airframe 1618, system 1620, interior 1622, propulsion system 1624, electrical system 1626, hydraulic system 1628 and / or environment 1630).

[0203] In one embodiment, the part comprises a portion of the airframe 1618 and is manufactured during component and subassembly manufacturing 1608. The part can then be assembled into the aircraft in systems integration 1610 and used in service 1614 until wear renders it unusable. Then, in repair and maintenance 1616, the part can be discarded and replaced with a newly manufactured part. The components and methods of the present invention can be utilized throughout component and subassembly manufacturing 1608 to manufacture new parts.

[0204] Any of the various control elements (e.g., electrical or electronic components) shown in the accompanying drawings or described herein can be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination thereof. For example, an element can be implemented as dedicated hardware. A dedicated hardware element can be referred to as a “processor,” a “controller,” or some similar term. When provided by a processor, these functions can be provided by a single dedicated processor, a single shared processor, or multiple individual processors (some of which may share resources). Furthermore, the explicit use of the terms “processor” or “controller” should not be construed as referring specifically to hardware capable of executing software, and may implicitly include, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic, or certain other physical hardware components or modules.

[0205] Furthermore, control elements can be implemented as instructions executable by a processor or computer to perform the functions of the element. Some examples of instructions are software, program code, and firmware. Instructions are operable when executed by a processor to instruct the processor to perform the functions of the element. Instructions can be stored on a processor-readable storage device. Some examples of storage devices are digital or solid-state memory, magnetic storage media such as disks and tapes, hard disk drives, or optically readable digital data storage media.

[0206] Further illustrative and non-exclusive examples according to this disclosure are described in the following paragraphs.

[0207] In an example according to this disclosure, a method (900) for assembling an airfoil is provided, the method comprising:

[0208] The upper wing panel (550-1) of the aircraft is suspended (902) below the shuttle (540);

[0209] The rib (572) is translated (904) to a position below the upper wing panel;

[0210] Positioning the rib to contact the upper wing panel; and

[0211] While the upper wing panel remains suspended, the rib is fixed (910) to the upper wing panel.

[0212] Optionally, suspending (902) the upper wing panel (550-1) includes tilting at least a portion of the lower surface (576) of the wing panel at an angle complementary to the desired mounting angle (θ) of the rib (572).

[0213] Alternatively, positioning the rib (572) in contact with the upper wing panel (550-1) is performed by positioning the rib against the lower surface (576) of the upper wing panel at the desired mounting angle (θ).

[0214] Optionally, suspending (902) the upper wing panel (550-1) includes: rotating the upper wing panel to the shuttle (540).

[0215] Optionally, suspending (902) the upper wing panel (550-1) includes connecting a carrier (545) extending below the shuttle (540) to the upper surface (574) of the upper wing panel. Preferably, the carrier (545) applies a predetermined profile (544) to the upper wing panel (550-1) while the upper wing panel is suspended, and / or, wherein the rib (572) is fixed (910) to the upper wing panel (550-1) at a mounting position on the lower surface (576) of the upper wing panel, and wherein the carrier (545) is vacuum-connected at a position on the upper surface (574) of the upper wing panel that is different from the position corresponding to the mounting position.

[0216] Optionally, translating the rib (572) (904) includes moving the rib to a position on the upper wing panel (550-1) directly below the position where the rib will be fixed.

[0217] Optionally, translating the rib (572) (904) includes driving a trolley (700) supporting the rib. Preferably, the trolley (700) is an autonomous guided vehicle (AGV).

[0218] Alternatively, the shuttle (540) is configured to propel the upper wing panel (550-1) in a pulsating manner in the processing direction (541), wherein translation (904) of the rib (572) is performed during pauses between pulsations.

[0219] Optionally, the method further includes: orienting the rib (572) vertically (906). Preferably, orienting the rib (572) (906) is performed before translating the rib (572) (904). More preferably, the step of translating the rib (572) (904) is performed by means of a trolley (700), and wherein orienting the rib (906) is performed while the rib is being loaded onto the trolley (700).

[0220] Optionally, placing the rib (572) includes vertically lifting (908) the rib onto the upper wing panel (550-1) at the location where the rib will be secured. Preferably, the rib (572) is supported on a trolley (700) in a vertical orientation, and lifting (908) includes operating at least one actuator (704) of the trolley to lift the rib, and / or wherein placing the rib (572) further includes lowering the upper wing panel (550-1) toward the rib.

[0221] Optionally, placing the rib (572) includes aligning complementary alignment features (584, 586) on the rib and the upper wing panel (550-1).

[0222] Optionally, the method further includes applying a profile (544) to the rib (572) before securing (910) the rib. Preferably, applying the profile (544) to the rib (572) includes securing a stiffening rib (648) to the rib.

[0223] Optionally, securing the rib (572) to the upper wing panel (550-1) further includes mounting the rib to the upper wing panel. Preferably, mounting the rib (572) includes mounting fasteners through the rib and the upper wing panel (550-1) while the upper wing panel remains suspended.

[0224] Optionally, the method further includes fixing at least one spar (580) to the upper wing panel (550-1). Preferably, the spar (580) is fixed after the rib (572) is fixed (910) to the upper wing panel (550-1), and wherein the spar is fixed to the upper wing panel at the edge portion of the rib, and / or wherein the spar (580) is fixed in a spar section, the spar sections being longitudinally joined together at the rib (572), and / or wherein the rib (572) and the spar (580) are simultaneously fixed to the upper wing panel (550-1). More preferably, the method further includes joining the lower wing panel (550-2) to the rib (572) and the spar (580) fixed to the upper wing panel (550-1), preferably further including fixing at least one spar (580) to the rib (572). More preferably, before placing the rib into contact with the upper wing panel (550-1), at least one spar (580) is fixed to the rib (572) to create a support structure (588). Even more preferably, placing the rib (572) into contact with the upper wing panel (550-1) includes placing the support structure (588) into contact with the wing panel, and fixing the rib (910) to the upper wing panel preferably includes fixing the support structure to the wing panel. Preferably, the method further includes: predetermining the number of ribs (572) and spars (580) for fastening to the upper wing panel (550-1), wherein the support structure (588) is preferably produced from the predetermined number of ribs and spars, and / or wherein the support structure (588) is preferably produced at a support structure assembly station (532), and wherein preferably, the ribs (572) and at least one spar (580) are supplied to the support structure assembly station (532) on time via at least one feed line (570). Preferably, the method further includes: supplying the ribs (572) on time to the rib mounting station (528) via the feed line (570).

[0225] Optionally, the above method also includes maintaining the ribs (572) vertically during translation (904) and placement.

[0226] Optionally, the above method further includes: the translation (904), placement, and fixing (910) are performed at the rib mounting station (528). Preferably, the rib (572) is supplied to the rib mounting station (528) in a timely manner via a feed line (570).

[0227] Alternatively, in the above method, translation (904), placement and fixing (910) are performed while the upper wing panel (550-1) is suspended below the shuttle (540).

[0228] Alternatively, in the above method, the shuttle (540) is configured to propel the upper wing panel (550-1) in a pulsating manner in the processing direction (541), wherein translation (904), placement and fixing (910) are performed during one or more pauses between pulsations.

[0229] Alternatively, in the above method, translation (904), placement and fixing (910) are performed iteratively to fix multiple ribs (572) to the upper wing panel (550-1).

[0230] Optionally, the above method further includes selectively filling the gap between the rib (572) and the upper wing panel (550-1) with a shim to address situations exceeding tolerance.

[0231] In another example according to this disclosure, a portion (900) of the aircraft is assembled according to one of the foregoing methods.

[0232] In another example according to this disclosure, a non-transitory computer-readable medium is provided that implements program instructions operable, when executed by a processor, for performing a method (900) of assembling a wing, the method comprising:

[0233] The upper wing panel (550-1) of the aircraft is suspended (902) below the shuttle (540);

[0234] The rib (572) is translated (904) to a position below the upper wing panel;

[0235] Positioning the rib to contact the upper wing panel; and

[0236] While the upper wing panel remains suspended, the rib is fixed (910) to the upper wing panel. In a preferred embodiment of this medium, one or more of the above-described method steps are included.

[0237] In a further example according to this disclosure, the method includes:

[0238] The upper wing panel (550-1) of the aircraft is suspended (922) below the shuttle (540);

[0239] Install the rib (572) and spars (580) (924, 926) onto the upper wing panel; and

[0240] The lower wing panel (550-2) is joined (930) to the rib and wing spars;

[0241] The installation and assembly are carried out simultaneously with the suspension of the upper wing panel.

[0242] Optionally, in the above method of mounting the ribs (572) and spars (580) (924, 926) to the upper wing panel (550-1), one or more ribs are installed before any spars are installed. Preferably, mounting the ribs (572) and spars (580) (924, 926) to the upper wing panel (550-1) includes installing all the ribs before any spars are installed.

[0243] Optionally, in the above method of mounting the rib (572) and spar (580) to the upper wing panel (550-1), the spar (928) is fastened to the rib, wherein preferably the spar (580) is fastened to the rib (572) before any rib or spar (924, 926) is mounted to the upper wing panel (550-1) to create a support structure (588), and wherein mounting the rib (572) and spar (580) to the upper wing panel (924, 926) further preferably includes mounting the support structure (588) to the upper wing panel.

[0244] In another example according to this disclosure, the wing assembly (600) is assembled according to one of the methods described above.

[0245] In another example according to this disclosure, a non-transitory computer-readable medium is provided containing program instructions that, when executed by a processor, are operable for performing a method (920) of assembling a wing, the method comprising:

[0246] The upper wing panel (550-1) of the aircraft is suspended (922) below the shuttle (540);

[0247] Install the rib (572) and spars (580) (924, 926) onto the upper wing panel; and

[0248] The lower wing panel (550-2) is joined (930) to the rib and wing spars;

[0249] The installation and assembly are performed simultaneously with the suspension of the upper wing panel. In a preferred embodiment of this medium, one or more of the above-described method steps are included.

[0250] Optionally, in the above method, fixing the rib to the upper wing panel includes (in the following order):

[0251] The ribs (572) used for the wing assembly are combined (942) with the spars (580) used for the wing assembly to create a support structure (588);

[0252] The upper wing panel (550-1) of the aircraft is integrated with the supporting structure (944); and

[0253] The lower wing panel (550-2) of the aircraft is combined with the supporting structure (946).

[0254] Optionally, the above method also includes suspending the upper wing panel (550-1) below the shuttle (540) before combining it with the upper wing panel (550-1).

[0255] Alternatively, in the above method, while the upper wing panel (550-1) is suspended, the rib (572) is joined to the spar (580) (942).

[0256] Optionally, in the above method, the upper wing panel (550-1) of (944) includes a vertically raised support structure (588) to contact the upper wing panel.

[0257] Optionally, in the above method, joining the ribs (572) to the spars (580) (942) includes joining all the ribs and all the spars of the wing assembly before joining (944) to the wing panel (550-1).

[0258] Optionally, the method further includes: after attaching (944) the upper wing panel (550-1), attaching at least one or more ribs (572) or spars (580). Preferably, before attaching any ribs or spars (924, 926) to the upper wing panel (550-1), the spars (580) are fastened to the ribs (572) to create a support structure (588). More preferably, attaching the ribs (572) and spars (580) (924, 926) to the upper wing panel (550-1) includes attaching the support structure (588) to the upper wing panel.

[0259] In another example according to this disclosure, the wing assembly (600) is assembled according to one of the methods described above.

[0260] In another example according to this disclosure, a non-transitory computer-readable medium is provided comprising program instructions that, when executed by a processor, are operable for performing a method (940) of assembling a wing, the method comprising:

[0261] The ribs (572) used for the wing assembly are combined (942) with the spars (580) used for the wing assembly to create a support structure (588);

[0262] The upper wing panel (550-1) of the aircraft is integrated with the supporting structure (944); and

[0263] The lower wing panel (550-2) of the aircraft is combined with the support structure (946). In a preferred embodiment of this medium, one or more of the above-described method steps are included.

[0264] In a further example according to this disclosure, method (960) includes:

[0265] The upper wing panel (550-1) of the aircraft is suspended (922) below the shuttle (540);

[0266] While the upper wing panel remains suspended, at least one rib (572) and at least one spar (580) are simultaneously (964) installed (at a corresponding workstation (520) on the upper wing panel; and

[0267] The upper wing panel is made to pulsate (966) through the work station in the processing direction (541).

[0268] Optionally, in the above method, the pulsation (966) further includes causing the upper wing panel (550-1) to travel in the processing direction (541) less than the length of the upper wing panel (550-1).

[0269] Optionally, the method further includes simultaneously performing work on the upper wing panel (550-1) via multiple workstations (520) during pauses between pulses. Preferably, the ribs (572) and spars (580) are installed during one or more pauses between pulses.

[0270] Alternatively, in the above method, multiple workstations (520) perform work simultaneously on the upper wing panel (550-1).

[0271] Optionally, the above method also includes fixing the lower wing panel (550-2) to the rib (572) and spar (580) that are mounted to the upper wing panel (550-1).

[0272] In another example according to this disclosure, the wing assembly (600) is assembled according to one of the methods described above.

[0273] In another example according to this disclosure, a non-transitory computer-readable medium is provided comprising program instructions that, when executed by a processor, are operable for performing a method (960) of assembling a wing, the method comprising:

[0274] The upper wing panel (550-1) of the aircraft is suspended (962) below the shuttle (540).

[0275] While the upper wing panel remains suspended, at least one rib (572) and at least one spar (580) are simultaneously (964) installed (at a corresponding workstation (520) on the upper wing panel; and

[0276] The upper wing panel is pulsated (966) in the processing direction (541) as it passes through the workstation. In a preferred embodiment of this medium, one or more of the above-described method steps are included.

[0277] In another example of this disclosure, a system for assembling an aircraft wing is provided, the system comprising:

[0278] A shuttle (540), the shuttle (540) being configured to suspend the upper wing panel (550-1) of the aircraft below the shuttle (540); and

[0279] A trolley (700), said trolley (700) comprising:

[0280] Support member (706), the support member (706) being configured to vertically and upright hold the rib (572) for the wing assembly;

[0281] Chassis (708), the chassis (708) being configured to translate (904) the rib (572) onto the upper wing panel (550-1) at a position directly below where the rib (572) will be fixed; and

[0282] A lifting device (704) is configured to vertically lift the rib (572) and place it in contact with the upper wing panel (550-1).

[0283] Optionally, in the aforementioned system, the shuttle (540) includes a carrier (545) configured to be coupled to the upper surface (574) of the upper wing panel (550-1). Preferably, the carrier (545) includes a length-adjustable spring, and / or wherein the carrier (545) is configured to selectively lower the upper wing panel (550-1) suspended below the shuttle (540) to contact a rib (572) held by a trolley (700), and / or wherein the carrier (545) includes a vacuum connector (548) configured to be coupled to surfaces (574, 576) of the upper wing panel (550-1). Preferably, the trolley (700) is an autonomous guided vehicle (AGV).

[0284] Optionally, in the above system, the support (706) is fixed to the lifting device (704).

[0285] Optionally, the system also includes wheels (702) that drive the chassis (708).

[0286] In another example of this disclosure, a system for assembling an aircraft wing is provided, the system comprising:

[0287] A positioning plate (540) configured to suspend the upper wing panel (550-1) below the positioning plate (540) via a length-adjustable spring (548), the length-adjustable spring (548) being configured to connect with the upper wing panel; and

[0288] The trolley (700) further includes a support (706) configured to vertically and uprightly retain ribs (572);

[0289] The positioning plate (540) is configured to lower the upper wing panel to contact the rib (572) by adjusting the length of the spring member. Preferably, the trolley (700) is an autonomous guided vehicle (AGV), and the trolley (700) is preferably configured to translate the rib (572) onto the upper wing panel (550-1) at a position directly below where the rib (572) will be fixed.

[0290] In another example of this disclosure, a part of the aircraft is assembled according to one of the methods (900) described above.

[0291] In another example of this disclosure, a non-transitory computer-readable medium is provided containing program instructions that, when executed by a processor, are operable to perform one of the above-described methods (900) for assembling an airfoil.

[0292] In another example of this disclosure, one of the systems described above is used to create a part of an aircraft.

[0293] While specific embodiments have been described herein, the scope of this disclosure is not limited to these specific embodiments. The scope of this disclosure is defined by the appended claims.

Claims

1. A method (900) for assembling an aircraft wing, the method comprising the following steps: The upper wing panel (550-1) of the aircraft is suspended (902) below the shuttle (540), the shuttle (540) being configured to carry the upper wing panel (550-1), and wherein the shuttle (540) is also configured to propel the upper wing panel (550-1) in a pulsating manner in the processing direction (541); The rib (572) is translated (904) to a position below the upper wing panel (550-1); The rib (572) is positioned to contact the upper wing panel (550-1); While the upper wing panel (550-1) remains suspended, the rib (572) is fixed (910) to the upper wing panel (550-1). The step of placing the rib (572) includes: vertically lifting (908) the rib (572) to the position on the upper wing panel (550-1) where the rib (572) will be fixed; while the upper wing panel (550-1) remains suspended, simultaneously installing (964) at least one rib (572) and at least one spar (580) to the upper wing panel (550-1) via a corresponding workstation (520) located on the upper wing panel (550-1); and The upper wing panel (550-1) is pulsated (966) in the processing direction (541) and passed through the station (520), wherein the translation (904), the placement, and the fixing (910) steps are performed simultaneously when the upper wing panel (550-1) is suspended below the shuttle (540). The translation (904), placement, and fixing (910) steps are performed during one or more pauses between pulses.

2. The method according to claim 1, wherein, The step of suspending (902) the upper wing panel (550-1) includes tilting at least a portion of the lower surface (576) of the upper wing panel (550-1) at an angle complementary to the desired mounting angle (θ) of the rib (572), and / or wherein the step of placing the rib (572) in contact with the upper wing panel (550-1) is performed by placing the rib (572) against the lower surface (576) of the upper wing panel at the desired mounting angle (θ).

3. The method according to claim 1 or 2, wherein, The step of suspending (902) the upper wing panel (550-1) includes: rotating the upper wing panel (550-1) to the shuttle (540).

4. The method according to claim 2, wherein, The step of suspending (902) the upper wing panel (550-1) includes: connecting a carrier (545) extending below the shuttle (540) to the upper surface (574) of the upper wing panel (550-1), wherein the carrier (545) applies a predetermined profile (544) to the upper wing panel (550-1) while the upper wing panel (550-1) is suspended. The step of fixing the rib (572) to the upper wing panel (550-1) is completed at the mounting position on the lower surface (576) of the upper wing panel (550-1), and The carrier (545) is vacuum-connected at a position on the upper surface (574) of the upper wing panel (550-1) that is different from the position corresponding to the mounting position.

5. The method according to claim 1 or 2, wherein, The step of translating the rib (572) (904) includes: moving the rib (572) to a position on the upper wing panel (550-1) directly below the position where the rib (572) will be fixed, and / or wherein the step of translating the rib (572) (904) includes: driving a trolley (700) supporting the rib (572), wherein the trolley (700) is an autonomous guided vehicle (AGV).

6. The method according to claim 1 or 2, further comprising the following step: Orienting the rib (572) vertically (906), wherein the step of orienting the rib (572) (906) is performed before the step of translating the rib (572) (904), and The step of translating (904) the rib (572) is performed by means of a trolley (700), and The step of orienting the rib (572) (906) is performed simultaneously with loading the rib (572) onto the trolley (700). The rib (572) is vertically supported on the trolley (700), and The lifting (908) step includes: operating at least one actuator (704) of the trolley (700) to lift the rib (572), and The step of placing the rib (572) further includes lowering the upper wing panel (550-1) toward the rib (572). The step of placing the rib (572) includes: aligning the rib (572) with the complementary alignment features (584, 586) on the upper wing panel (550-1). The step of installing the rib (572) includes: while keeping the upper wing panel (550-1) suspended, installing fasteners through the rib (572) and the upper wing panel (550-1).

7. The method according to claim 1 or 2, further comprising the following step: Before fixing (910) the rib (572), the profile (544) is applied to the rib (572).

8. The method according to claim 7, wherein, The step of applying the contour (544) to the rib (572) includes fastening the stiffening rib (648) to the rib (572).

9. The method according to claim 1 or 2, further comprising the following step: At least one wing spars (580) are fixed to the upper wing panel (550-1); Wherein, the spar (580) is fixed after the rib (572) is fixed (910) to the upper wing panel (550-1), and wherein the spar (580) is fixed to the upper wing panel (550-1) at the edge portion of the rib (572), and / or wherein the spar (580) is fixed to a spar section, the spar sections being longitudinally joined together at the rib (572), and wherein the rib (572) and the spar (580) are simultaneously fixed to the upper wing panel (550-1). The method further includes the following steps: attaching the lower wing panel (550-2) to the rib (572) and the spar (580) that are fixed to the upper wing panel (550-1). The method further includes the step of fixing the at least one spar (580) to the rib (572), wherein the at least one spar (580) is fixed to the rib (572) before the rib (572) is placed in contact with the upper wing panel (550-1) to create a support structure (588). The step of placing the rib (572) in contact with the upper wing panel (550-1) includes: placing the support structure (588) in contact with the upper wing panel (550-1); and The step of fixing the rib (910) to the upper wing panel (550-1) includes fixing the support structure (588) to the upper wing panel (550-1). The method further includes the following steps: predetermining the number of ribs (572) and spars (580) for fastening to the upper wing panel (550-1); and The support structure (588) is formed by a predetermined number of ribs and wing beams, and the support structure (588) is formed at the support structure assembly station (532). The method further includes the step of supplying the rib (572) and the at least one wing beam (580) to the support structure assembly station (532) in a timely manner via at least one feed line (570). The method further includes the step of supplying the rib (572) to the rib installation station (528) in a timely manner via a feed line (570). The method further includes the step of maintaining the rib (572) vertically during the translation (904) step and the placement step.

10. The method according to claim 1 or 2, wherein, The translation (904), placement, and fixing (910) steps are performed at the rib mounting station (528), wherein the translation (904), placement, and fixing (910) steps are performed iteratively to fix the plurality of ribs (572) to the upper wing panel (550-1), and / or, The method further includes the following steps: selectively filling the gap with a shim based on the size of the gap between the rib (572) and the upper wing panel (550-1) to address situations exceeding tolerance.

11. The method according to claim 1 or 2, wherein, The step of mounting the rib (572) and the spar (580) (924, 926) to the upper wing panel (550-1) includes: installing one or more ribs before installing any spars, and / or wherein the step of mounting the rib (572) and the spar (580) (924, 926) to the upper wing panel (550-1) includes: installing all ... -1) The steps include: fastening the spars (928) to the rib, and / or wherein, before installing any rib or spars (924, 926) to the upper wing panel (550-1), the spars (580) are fastened to the rib (572) to create a support structure (588), and / or wherein the steps of installing the rib (572) and the spars (580) (924, 926) to the upper wing panel (550-1) include: installing the support structure (588) to the upper wing panel (550-1).

12. The method according to claim 1 or 2, wherein, The steps of securing the rib (572) to the upper wing panel (550-1) include the following steps in sequence: The ribs (572) for the wing assembly are combined (942) with the spars (580) for the wing assembly to create a support structure (588). The upper wing panel (550-1) of the aircraft is combined with the supporting structure (588) (944); and The lower wing panel (550-2) of the aircraft is combined with the support structure (588) (946). The method further includes the following steps: Before joining (944) the upper wing panel (550-1), the upper wing panel (550-1) is suspended below the shuttle (540), wherein the step of joining (942) the rib (572) with the spar (580) is performed simultaneously with the suspension of the upper wing panel (550-1), wherein the step of joining (944) the upper wing panel (550-1) includes: vertically raising the support structure (588) to contact the upper wing panel (550-1), wherein the step of joining (942) the rib (572) with the spar (580) includes: joining all the ribs and all the spars of the wing assembly before joining (944) the upper wing panel (550-1). The method further includes the following steps: after joining (944) the upper wing panel (550-1), joining at least one or more ribs (572) or spars (580), wherein, before installing (924, 926) any rib or spars to the upper wing panel (550-1), the spars (580) are fastened to the ribs (572) to create a support structure (588), wherein the step of installing (924, 926) the ribs (572) and the spars (580) to the upper wing panel (550-1) includes: installing the support structure (588) to the upper wing panel (550-1), wherein the pulsating (966) step further includes: advancing the upper wing panel (550-1) in the processing direction (541) by a length less than that of the upper wing panel (550-1). The method further includes the following steps: simultaneously performing work on the upper wing panel (550-1) via multiple workstations (520) during pauses between pulses, wherein the rib (572) and the wing spars (580) are installed during one or more pauses between pulses, wherein the multiple workstations (520) simultaneously perform work on the upper wing panel (550-1). The method further includes the following steps: fixing the lower wing panel (550-2) to the rib (572) and the spar (580) that are mounted to the upper wing panel (550-1).

13. A system for assembling an aircraft wing, the system comprising: A shuttle (540) is configured to suspend the upper wing panel (550-1) of the aircraft below the shuttle (540) and is configured to carry the upper wing panel (550-1), and wherein the shuttle (540) is further configured to propel the upper wing panel (550-1) in a pulsating manner in the processing direction (541); A trolley (700), said trolley (700) comprising: Support member (706), the support member (706) is configured to vertically and upright hold the rib (572) for the wing assembly; Chassis (708), the chassis (708) being configured to translate (904) the rib (572) onto the upper wing panel (550-1) at a position directly below where the rib (572) will be fixed; and Lifting device (704), the lifting device (704) being configured to vertically lift the rib (572) and position it in contact with the upper wing panel (550-1); and Workstation (520) is configured to fix (910) the rib (572) to the upper wing panel (550-1) while keeping the upper wing panel (550-1) suspended. The system is configured such that, while the upper wing panel (550-1) is suspended below the shuttle (540), the translation (904), placement, and fixing (910) steps are performed. The system further includes workstations (520) configured to simultaneously (964) install (at least one rib (572) and at least one spar (580) to the upper wing panel (550-1) via corresponding workstations (520) located at the upper wing panel (550-1) while the upper wing panel (550-1) remains suspended; and The upper wing panel (550-1) is pulsated (966) in the processing direction (541) as it passes through the station (520). The translation (904), placement, and fixing (910) steps are performed during one or more pauses between pulses.

14. The system according to claim 13, wherein, The shuttle (540) includes a carrier (545) configured to be coupled to the upper surface (574) of the upper wing panel (550-1), wherein the carrier (545) includes a length-adjustable spring, wherein the carrier (545) is configured to selectively lower the upper wing panel (550-1) suspended below the shuttle (540) to contact a rib (572) holding the trolley (700), wherein the carrier (545) includes a vacuum connector (548) configured to be coupled to the surfaces (574, 576) of the upper wing panel (550-1), wherein the trolley (700) is an autonomous guided vehicle (AGV), wherein the support (706) is fixed to the lifting device (704), and the trolley (700) further includes wheels (702) driving the chassis (708). The system also includes: A positioning plate (540) configured to suspend the upper wing panel (550-1) below the positioning plate (540) via a length-adjustable spring member configured to connect with the upper wing panel (550-1); and The trolley (700) further includes a support (706) configured to vertically and uprightly retain ribs (572); The positioning plate (540) is configured to lower the upper wing panel (550-1) to contact the rib (572) by adjusting the length of the spring member, wherein the trolley (700) is configured to translate the rib (572) to a position on the upper wing panel (550-1) directly below the position where the rib (572) will be fixed.

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