Flexible truss system and method for transferring flexible composite parts using such a system

Abstract

This document describes flexible truss systems and methods for using these systems to transfer flexible composite parts. A flexible truss system includes a flexible truss mechanism and a composite pick-and-place mechanism that is supported on the flexible truss mechanism and designed to attach to various composite parts. The flexible truss mechanism includes flexible elongated members and slidable ribs coupled to each flexible elongated member. Specifically, each rib is slidably coupled to at least one flexible elongated member. In some examples, each rib is also fixedly coupled to another flexible elongated member. The slidable coupling allows the flexible truss mechanism to bend and conform to the shape of the supported part, enabling the composite pick-and-place mechanism to contact and support different regions of the composite part. In this way, the same flexible truss mechanism can support flexible composite parts with different shapes.

Description

Background Art

[0001] Modern aircraft use various composite parts that are large and flexible. Handling these parts during their machining, assembly, and other operations can be very challenging. Conventional methods involve manually handling these parts. However, manual handling requires multiple operators to support the part simultaneously at different locations. More importantly, the forces of multiple operators must be carefully coordinated to prevent insufficient support in some areas of the part and / or excessive stress in other areas. Such coordination (involving multiple operators) is difficult to achieve. On the other hand, even for a brief moment, a lack of coordination can damage the part. In addition, the fabrication, use, storage, and handling of support fixtures dedicated to the part are expensive.

[0002] What is needed are new methods and systems for transferring flexible composite parts. Summary of the Invention

[0003] Described herein are flexible truss systems and methods of using these systems to transfer flexible composite parts. The flexible truss system includes a flexible truss mechanism and a composite pick-and-place mechanism that is supported on the flexible truss mechanism and is designed to attach to various composite parts. The flexible truss mechanism includes flexible elongate members and slidable ribs coupled to each flexible elongate member. Specifically, each rib is slidably coupled to at least one flexible elongate member. In some examples, each rib is also fixedly coupled to another flexible elongate member. The slidable coupling allows the flexible truss mechanism to bend and conform to the shape of the supported part, such that the composite pick-and-place mechanism can contact and support different areas of the composite part. In this way, the same flexible truss mechanism can support flexible composite parts having different shapes.

[0004] In some examples, the flexible truss mechanism includes flexible elongate members extending along a major axis of the flexible truss mechanism, and slidable ribs coupled to each flexible elongate member and supporting the flexible elongate members relative to one another. The slidable ribs are spaced apart from one another along the major axis of the flexible truss mechanism. The slidable ribs are configured to receive and support one or more composite pick-and-place mechanisms. Each slidable rib is slidably coupled to at least one flexible elongate member, thereby allowing each slidable rib to slide relative to at least one flexible elongate member along the major axis and allowing the flexible elongate members to bend perpendicular to the major axis about at least one axis.

[0005] In some examples, a flexible truss system includes a flexible truss mechanism that includes a flexible elongate member extending along a major axis of the flexible truss mechanism and a slidable rib coupled to each flexible elongate member and a pick-and-place mechanism. Each pick-and-place mechanism is supported by a corresponding one of the slidable ribs. Each slidable rib is slidably coupled to at least one flexible elongate member, thereby allowing each slidable rib to slide relative to the at least one flexible elongate member along the major axis and allowing the flexible elongate member to bend about at least one axis perpendicular to the major axis.

[0006] In some examples, a method of transferring a flexible composite part using a flexible truss system that includes a flexible truss mechanism and a pick-and-place mechanism is provided. The method includes contacting the flexible composite part with each pick-and-place mechanism supported on the flexible truss mechanism. The flexible truss mechanism includes flexible elongate members and slidable ribs that are coupled to each flexible elongate member and support the flexible elongate members relative to each other. The method further includes contacting the flexible composite part, which includes sliding at least one slidable rib relative to at least one flexible elongate member, thereby allowing the flexible elongate member to bend and allowing each pick-and-place mechanism to contact the flexible composite part. The method further includes locking the slidable rib relative to the at least one flexible elongate member in a set position, thereby retaining the shape of the flexible elongate member and maintaining the contact between each pick-and-place mechanism and the flexible composite part. The method further includes transferring the flexible composite part using the flexible truss system while maintaining the contact between each pick-and-place mechanism and the flexible composite part. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1A is a schematic view of a flexible truss system including a flexible truss mechanism and a pick-and-place mechanism according to some examples.

[0008] Figure 1B is according to some examples Figure 1A A schematic view of a portion of the flexible truss system in, which shows various details of the flexible truss mechanism and the composite pick-and-place mechanism.

[0009] Figure 1C is a block diagram representing a flexible truss system according to some examples.

[0010] Figure 1D is a schematic view of a portion of a flexible truss mechanism according to some examples.

[0011] FIGS. 2A and 2B are schematic views of a flexible truss mechanism including two slidable ribs before (FIG. 2A) and after (FIG. 2B) bending according to some examples.

[0012] FIG. 2C and FIG. 2D are schematic diagrams of another example of a flexible truss mechanism including two sliding ribs and one fixed rib before (FIG. 2C) and after (FIG. 2D) bending.

[0013] Figure 3A is a schematic diagram of a sliding mechanism of a flexible truss mechanism according to some examples.

[0014] Figure 3B is a schematic diagram of the sliding mechanism in FIG. 2B according to some examples with the roller support removed.

[0015] Figure 4A is a schematic diagram of a positioning lock of a flexible truss mechanism according to some examples.

[0016] FIG. 4B is a schematic diagram of a cut nut and a threaded positioning shaft in an axis-engaged position according to some examples.

[0017] FIG. 4C is a schematic diagram of a cut nut and a threaded positioning shaft in an axis-disengaged position according to some examples.

[0018] Figure 5 is a process flow diagram corresponding to a method of transferring a flexible composite part using a flexible truss system according to some examples.

[0019] Figure 6A is a schematic diagram of a flexible truss system positioned above a flexible composite part before conforming the shape of the flexible truss system to the flexible composite part according to some examples.

[0020] Figure 6B is a schematic diagram of a flexible truss system positioned above a flexible composite part after conforming the shape of the flexible truss system to the flexible composite part according to some examples.

[0021] Figure 6C is a schematic diagram of a flexible truss system positioned above another flexible composite part after conforming the shape of the flexible truss system to this other flexible composite part according to some examples.

[0022] Figure 7 is a process flow diagram corresponding to a method for manufacturing and maintaining an aircraft.

[0023] Figure 8 shows a block diagram of an example aircraft according to some examples. Detailed Description

[0024] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the presented concepts. In some examples, the presented concepts are practiced without some or all of these specific details. In other instances, well-known process operations are not described in detail so as not to unnecessarily obscure the described concepts. While some concepts will be described in conjunction with specific examples, it should be understood that these examples are not intended to be limiting.

[0025] Introduction

[0026] As noted above, handling large flexible parts can be challenging. Conventional methods involve manual handling (e.g., using multiple operators) or custom tools (e.g., designed to conform to a specific shape). However, manual handling is time-consuming and can damage the parts (e.g., if the operators' movements are not synchronized). Custom support tools are expensive and require dedicated tools for each type of part. At the same time, modern aircraft use many unique parts, which requires many individual support tools, leading to complex logistics issues (e.g., retrieval, storage, and cost).

[0027] The flexible truss systems described herein are configured to change shape to provide adequate support to flexible composite parts while using these flexible truss systems to transfer these parts or otherwise process them. In particular, the flexible truss system includes a flexible truss mechanism and a composite pick-and-place mechanism supported on the flexible truss mechanism. The composite pick-and-place mechanism is configured to engage a flexible composite part during part transfer. The flexible truss mechanism is configured to change shape, for example, to follow the shape of the flexible composite part. In some examples, the flexible composite part is an uncured composite part. One of ordinary skill in the art will recognize that uncured composite parts tend to be more flexible than cured composite parts. In some examples, the flexible composite part is at least 1 meter long or even at least 2 meters long or even 3 meters long. One of ordinary skill in the art will recognize that longer composite parts tend to be more flexible than their corresponding shorter ones.

[0028] This shape change is used to ensure that the composite pick-and-place mechanism contacts the flexible composite part at multiple different locations and provides adequate support to the flexible composite part. This multi-location support is very important during the transfer of the flexible composite part. In some examples, the flexible truss mechanism is configured to fix the new shape (e.g., maintain the shape during transfer) to ensure continuous support of the flexible composite part.

[0029] This ability to change shape is provided by the special design and structural features of the flexible truss mechanism. Specifically, the flexible truss mechanism includes flexible elongate members and slidable ribs. The slidable ribs are coupled to each flexible elongate member. More specifically, each rib is slidably coupled to at least one flexible elongate member. The flexibility of the elongate members and the ability of the ribs to slide allow the flexible truss mechanism to bend and change shape. In other words, the same flexible truss mechanism can be configured to support multiple different composite parts having different shapes.

[0030] Accordingly, when the flexible truss mechanism is reconfigured to support a new composite part having a new shape, these ribs are able to slide relative to at least one flexible elongate member. This sliding action allows all of the flexible elongate members to bend and reform. However, when these ribs are locked in place relative to the flexible elongate members, the truss mechanism is able to maintain that shape, for example, during the transfer of a flexible composite part. The process of reconfiguring the flexible truss mechanism is repeatable. Thus, the same flexible truss mechanism can be used on a variety of different composite parts.

[0031] Examples of Flexible Truss Mechanisms and Systems

[0032] Figure 1A is a schematic perspective view of a flexible truss system 199 including a flexible truss mechanism 100 and a pick-and-place mechanism 190, according to some examples. Figure 1B is Figure 1A a schematic perspective view of a portion of the flexible truss system 199 in Figure 1C which shows additional features of the flexible truss mechanism 100. Finally,

[0033] The pick-and-place mechanism 190 is configured to support different flexible composite parts, various examples of which are listed above. As further described below, the pick-and-place mechanism 190 is attached and supported by the flexible truss mechanism 100. Referring Figure 1C to, in some examples, the composite pick-and-place mechanism 190 includes suction cups 192 controllably connected to a vacuum source 191. In some examples, the operation of the vacuum source 191 and other components of the flexible truss system 199 (e.g., a pressure source 193 for actuating the positioning locks 150) is controlled by a system controller 194. In some examples, the system controller 194 is communicatively coupled to the pressure source 193 and is configured to selectively connect and disconnect the linear actuator 152 of the positioning lock 150 of each slidable rib 120 from the pressure source 193.

[0034] In some examples, the flexible truss system 199 includes a lifting mechanism 195 for supporting the flexible truss mechanism 100. Specifically, the lifting mechanism 195 is for particularly large and heavy flexible composite parts. In one example, the lifting mechanism 195 is a robotic system that includes one or more robotic arms configured to support and move the flexible truss mechanism.

[0035] In some examples, each slidable rib 120 of the flexible truss mechanism 100 supports a corresponding one of the composite pick-and-place mechanisms 190. In other examples, the flexible truss mechanism 100 includes a plurality of slidable ribs, some of which have pick-and-place mechanisms 190 attached to the rib while other slidable ribs do not have a composite pick-and-place mechanism 190 attached to the rib, such as having no pick-and-place mechanism at all. For example, Figure 1D An example flexible truss mechanism 100 is shown having a slidable rib 120 without a composite pick-and-place mechanism 190. In some examples, the composite pick-and-place mechanism 190 may be attached to every other slidable rib 120. In other examples, the composite pick-and-place mechanism 190 is attached at other intervals, including, for example, at intervals of every two slidable ribs 120 or every three slidable ribs 120. As described above, in other examples, the pick-and-place mechanism 190 is attached to each slidable rib 190 in the flexible truss mechanism 100 to form, for example, a flexible truss system 199 as shown in Figure 1A and Figure 1B shown. In other examples, the flexible truss mechanism 100 is used without the pick-and-place mechanism 190, for example, to perform other operations that do not involve handling composite parts.

[0036] Refer to Figure 1A 、 Figure 1B and Figure 1D, the flexible truss mechanism 100 includes a flexible elongated member 110 extending along the main axis 101 of the flexible truss mechanism 100. The drawings show three flexible elongated members 110, for example, a first flexible elongated member 111, a second flexible elongated member 112, and a third flexible elongated member 113. However, other numbers of flexible elongated members 110 (e.g., four, five, six, etc.) are also within the scope of the present invention. The number of flexible elongated members 110 determines the flexibility of the flexible truss mechanism 100 and the support provided by the flexible truss system 199 (e.g., support for a flexible composite part). In some examples, each of the flexible elongated members 110 is formed of carbon fiber. Carbon fiber has low weight, is sufficiently flexible, and provides significant structural support, especially in the direction along the main axis 101. The length of the flexible elongated member 110 (along the main axis 101) is determined by the length of the longest composite part that the flexible truss system 199 is designed to support. In some examples, the length of the flexible elongated member 110 is at least about 1 meter, at least about 2 meters, or even at least about 5 meters.

[0037] Reference Figure 1A , Figure 1B and Figure 1D , the flexible truss mechanism 100 further includes a slidable rib 120. Specifically, Figure 1A shows 11 slidable ribs 120 positioned between and spaced apart from each other along the main axis 101 at opposite ends of the flexible elongated members 110. However, other numbers of ribs are also within the scope of the present invention. The slidable ribs 120 are coupled to each flexible elongated member 110 and support the flexible elongated members 110 relative to each other. Various examples of these couplings are described below.

[0038] Reference Figure 1A and Figure 1B , in some examples, the slidable ribs 120 are configured to receive and support a composite pick-and-place mechanism 190. In more specific examples, each of the slidable ribs 120 supports a corresponding one of the composite pick-and-place mechanisms 190 (e.g., the composite pick-and-place mechanism 190 is attached to a first support arm 123 of the slidable rib 120). Alternatively, in other examples, at least one of the slidable ribs 120 does not support any of the composite pick-and-place mechanisms 190, such as the slidable rib 120 shown in Figure 1D . Further, in some examples, at least one of the slidable ribs 120 supports multiple ones of the composite pick-and-place mechanisms 190. In some examples, one or more composite pick-and-place mechanisms 190 are attached to one or more of the flexible elongated members 110.

[0039] Reference Figure 1D, in some examples, each slidable rib 120 includes a plurality of support arms 121. Each of the plurality of support arms 121 at least partially defines the distance between a corresponding pair of flexible elongate members 110. For example, the first support arm 123 extends between the first flexible elongate member 111 and the second flexible elongate member 112, or more specifically, between the sliding mechanisms 130 that are slidably coupled to the first flexible elongate member 111 and the second flexible elongate member 112. The second support arm 124 extends between the first flexible elongate member 111 and the third flexible elongate member 113. In the illustrated example, the second support arm 124 is fixedly directly coupled to the third flexible elongate member 113. The second support arm 124 is also connected to the sliding mechanism 130 that is slidably coupled to the first flexible elongate member 111. Finally, the third support arm 125 extends between the second flexible elongate member 112 and the third flexible elongate member 113. In the illustrated example, the third support arm 125 is fixedly directly coupled to the third flexible elongate member 113. The third support arm 125 is also connected to the sliding mechanism 130 that is slidably coupled to the second flexible elongate member 112. Similarly, Figure 1B shows a slidable rib 120, where each slidable rib 120 includes a plurality of support arms 121 (specifically, a first support arm 123, a second support arm 124, and a third support arm 125).

[0040] In some examples, the length of each of the plurality of support arms 121 is the same. In this way, the first flexible elongate member 111, the second flexible elongate member 112, and the third flexible elongate member 113 are positioned at the same distance from each other. Additionally, in some examples, each of the plurality of support arms 121 is straight. In some examples, the support arms 121 are formed of a rigid material such as aluminum.

[0041] Each slidable rib 120 is slidably coupled to at least one flexible elongate member 110. For example, in such a slidable coupling, at least one flexible elongate member 110 projects through each slidable rib 120. In some examples, each slidable rib 120 is slidably coupled to only one flexible elongate member 110 and fixedly coupled to all the remaining elongate members. Alternatively, each slidable rib 120 is slidably coupled to all but one of the flexible elongate members 110 and fixedly coupled to the remaining elongate member. In some examples, each slidable rib 120 is slidably coupled to two of the flexible elongate members 110 and fixedly coupled to one remaining elongate member. For example, Figure 1A and Figure 1BShows an example where each slidable rib 120 is slidably coupled to each of a first flexible elongate member 111 and a second flexible elongate member 112. In the same example, each slidable rib 120 is fixedly coupled to a third flexible elongate member 113. In some examples, each slidable rib 120 is slidably coupled to all of the flexible elongate members 110. As described above, being slidably coupled to at least one of the flexible elongate members 110 allows the flexible elongate members 110 to bend about one or more axes perpendicular to the main axis 101 (e.g., Figure 1D the axes 102a and 102b shown in). For example, in some examples, the main axis 101 corresponds to the Y axis, and being slidably coupled to at least one of the flexible elongate members 110 allows the flexible elongate members 110 to bend about one or more of the axis 102b (corresponding to the X axis) and the axis 102a (corresponding to the Z axis). This feature will be described with reference to FIGS. 2A-2D.

[0042] FIGS. 2A and 2B are schematic bird's-eye views of a flexible truss mechanism 100 including two slidable ribs 120, which may be referred to as a first slidable rib 120a and a second slidable rib 120b. The slidable rib 120a and the second slidable rib 120b are slidably coupled to each of a first flexible elongate member 111 and a second flexible elongate member 112 and fixedly coupled to a third flexible elongate member 113. FIG. 2A shows the flexible truss mechanism 100 where each of the first flexible elongate member 111, the second flexible elongate member 112, and the third flexible elongate member 113 is straight. Since the third flexible elongate member 113 is fixedly coupled to each of the first slidable rib 120a and the second slidable rib 120b, the distance between the connection points formed by these components (the first connection point between the third flexible elongate member 113 and the first slidable rib 120a and the second connection point between the third flexible elongate member 113 and the second slidable rib 120b) remains constant. These connection points corresponding to the fixed connections are identified by circles in FIGS. 2A and 2B. However, the distance between the connection points formed by the first flexible elongate member 111 or the second flexible elongate member 112 is adjustable. FIG. 2A identifies the distance between the connection points formed by the first flexible elongate member 111 (with the first slidable rib 120a and the second slidable rib 120b) as L1. FIG. 2A also identifies the distance between the connection points formed by the second flexible elongate member 112 (with the first slidable rib 120a and the second slidable rib 120b) as L1. These connection points corresponding to the slidable connections are identified by squares in FIGS. 2A and 2B. In this example of FIG. 2A, since the first flexible elongate member 111 and the second flexible elongate member 112 are straight and since the first slidable rib 120a and the second slidable rib 120b are parallel to each other, these distances are the same.

[0043] FIG. 2B shows the flexible truss mechanism 100, in which each of the first flexible elongate member 111, the second flexible elongate member 112, and the third flexible elongate member 113 is bent, for example, about an axis 102a perpendicular to the main axis 101 of the flexible truss mechanism 100. The distance between the connection points formed by the third flexible elongate member 113 and each rib remains the same. However, the distance between the connection points formed by the first flexible elongate member 111 and each rib has been reduced to L2, such that L2 < L1. On the other hand, the distance between the connection points formed by the second flexible elongate member 112 and each rib has been increased to L3, such that L3 > L1. The first flexible elongate member 111 and the second flexible elongate member 112 are no longer straight. In addition, the first slidable rib 120a and the second slidable rib 120b are no longer parallel to each other. In this way, the flexible truss mechanism 100 is reconfigured to, for example, correspond to the new shape of a particular flexible composite part. Those of ordinary skill in the art will understand that such bending and non-parallel configuration of adjacent ribs can be achieved with one rib fixedly attached to all the flexible elongate members. Such a rib may be referred to as a fixed rib. In other words, the flexible truss mechanism 100 can be bent with one fixed rib and at least one slidable rib. However, multiple fixed ribs may oppose the bending of the flexible truss mechanism 100. Additional features of the fixed rib will now be described with reference to FIGS. 2C and 2D.

[0044] FIGS. 2C and 2D are schematic views of another example of the flexible truss mechanism 100 including the first slidable rib 120a, the second slidable rib 120b, and the fixed rib 180. Similar to the examples shown in FIGS. 2A and 2B and described above, the first slidable rib 120a and the second slidable rib 120b are slidably coupled to each of the first flexible elongate member 111 and the second flexible elongate member 112 and fixedly coupled to the third flexible elongate member 113. However, the fixed rib 180 is fixedly coupled to each of the first flexible elongate member 111, the second flexible elongate member 112, and the third flexible elongate member 113. In FIG. 2C, all of the first flexible elongate member 111, the second flexible elongate member 112, and the third flexible elongate member 113 are straight. The first slidable rib 120a, the second slidable rib 120b, and the fixed rib 180 are all parallel to each other.

[0045] FIG. 2D shows the flexible truss mechanism 100, in which each of the first flexible elongate member 111, the second flexible elongate member 112, and the third flexible elongate member 113 is bent, for example, about an axis 102a perpendicular to the main axis 101 of the flexible truss mechanism 100. The distances between the connection points formed by the third flexible elongate member 113 and each rib remain the same. However, the distances between the connection points formed by the first flexible elongate member 111 and the fixed rib 180 and each slidable rib have decreased. On the other hand, the distances between the connection points formed by the second flexible elongate member 112 and the fixed rib 180 and each slidable rib have increased. The first flexible elongate member 111 and the second flexible elongate member 112 are no longer straight. The first slidable rib 120a, the fixed rib 180, and the second slidable rib 120b are no longer parallel to each other. Other example positions of the fixed rib 180 are also possible. For example, in one example, the fixed rib 180 is provided at one end of the flexible truss system 100.

[0046] Reference Figure 1D and Figures 3A - 3B , in some examples, each of the slidable ribs 120 includes one or more sliding mechanisms 130. The number of sliding mechanisms 130 depends on how many flexible elongate members 110 the particular slidable rib 120 is slidably coupled to. Briefly referring Figure 1D to the example of

[0047] Reference Figures 3A - 3B , in some examples, the sliding mechanism 130 includes one or more rollers 140 that rollingly engage at least one of the flexible elongate members 110 (e.g., Figures 3A - 3B the first flexible elongate member 111 shown in Figure 3B ). For example, the sliding mechanism 130 includes two rollers 140 such that the first flexible elongate member 111 is positioned between the two rollers 140. The two rollers 140 are supported by roller supports 142 of a support arm 121 attached to the slidable rib 120.

[0048] Although the sliding of the ribs relative to the flexible elongate member allows the flexible truss mechanism 100 to bend, for example, to follow the shape of the new composite part, fixing the ribs relative to the flexible elongate member allows the new shape of the flexible truss mechanism 100 to be maintained, for example, when transferring the new composite part. Reference will now be made to Figure 4A - Figure 4C to describe a positioning lock 150 used for this purpose.

[0049] Reference Figure 1B 、 Figure 1D and Figure 4A , in some examples, each of the slidable ribs 120 includes one or more positioning locks 150. Similar to the sliding mechanism 130, the number of positioning locks 150 depends on how many flexible elongate members 110 the particular slidable rib 120 is slidably coupled to. Briefly referring to the example of Figure 1D , the slidable rib 120 is slidably coupled to both the first flexible elongate member 111 and the second flexible elongate member 112. In this example, the slidable rib 120 includes two positioning locks 150, one for maintaining the position of the slidable rib 120 relative to the first flexible elongate member 111 and the other for maintaining the position of the slidable rib 120 relative to the second flexible elongate member 112. In other words, for each flexible elongate member 110 that is slidable relative to the slidable rib 120, each slidable rib 120 includes one positioning lock 150.

[0050] The positioning lock 150 is configured to lock the corresponding slidable rib 120 (of which the positioning lock 150 is a part) in a set position. This fixed position is relative to the flexible elongate member 110 to which such a slidable rib 120 is slidably coupled. For example, the positioning lock 150 is switchable between a locked position and an unlocked position. When the positioning lock 150 is in the locked position, the positioning lock 150 prevents the slidable rib 120 from sliding relative to the corresponding flexible elongate member 110. When the positioning lock 150 is in the unlocked position, the positioning lock 150 allows the slidable rib 120 to slide relative to the corresponding flexible elongate member 110.

[0051] Reference Figure 4A , in some examples, the positioning lock 150 includes a linear actuator 152, a slotted nut 154, and a threaded positioning shaft 156. The threaded positioning shaft 156 is fixedly connected to at least one of the flexible elongate members 110, for example, the first flexible elongate member 111 shown in Figure 4A . For example, a limiter 160 is used to fixedly connect the end of the threaded positioning shaft 156 to the first flexible elongate member 111 to provide such a fixed connection. The linear actuator 152 is coupled to the slotted nut 154 and is configured to move the slotted nut 154 relative to the threaded positioning shaft 156 between a shaft engagement position and a shaft disengagement position. In some examples, the linear actuator 152 is a pneumatic cylinder.

[0052] Figure 4B shows the shaft engagement position, which corresponds to the locked position of the positioning lock 150. At this position, the slotted nut 154 engages the threaded positioning shaft 156 (e.g., the threads of the slotted nut 154 interlock with the threads of the threaded positioning shaft 156, thereby preventing the slotted nut 154 from sliding along the threaded positioning shaft 156). Due to the fixed connection between the threaded positioning shaft 156 and the flexible elongate member 110, and the connection between the slotted nut 154 and other components of the slidable rib 120 (shown in Figure 4B), the slidable rib 120 cannot slide relative to the first flexible elongate member 111.

[0053] Figure 4C shows the shaft disengagement position, which corresponds to the unlocked position of the positioning lock 150. At this position, the slotted nut 154 moves away from the threaded positioning shaft 156, thereby allowing the mouth nut 154 to slide along the threaded positioning shaft 156 (e.g., in a direction parallel to the threaded positioning shaft 156). As a result, the slidable rib 120 can slide relative to the first flexible elongate member 111.

[0054] Example of a Method for Transferring Flexible Composite Parts

[0055] Figure 5 is a process flow diagram corresponding to method 500 for transferring flexible composite part 600 using flexible truss system 199 according to some examples. Various features of flexible truss system 199 including flexible truss mechanism 100 and pick-and-place mechanism 190 were described above.

[0056] In some examples, method 500 includes bringing flexible composite part 600 into contact with each pick-and-place mechanism 190 (block 510). The pick-and-place mechanisms 190 are supported on flexible truss mechanism 100 and distributed along the main axis 101 of flexible truss mechanism 100. As described above with reference to Figure 1A - Figure 4, flexible truss mechanism 100 includes flexible elongate members 110 and slidable ribs 120. The slidable ribs 120 are coupled to each of the flexible elongate members 110 and support the flexible elongate members 110 relative to each other. Additionally, in some examples, the composite pick-and-place mechanisms 190 are attached to or otherwise supported by the slidable ribs 120.

[0057] In some examples, bringing flexible composite part 600 into contact with each pick-and-place mechanism 190 (block 510) includes sliding at least one of the slidable ribs 120 relative to at least one of the flexible elongate members 110 (block 512), as described above with reference to Figures 2A - 2D. This feature allows the flexible elongate members 110 to bend, which in turn allows each of the pick-and-place mechanisms 190 to contact flexible composite part 600.

[0058] For example, Figure 6A shows a flexible truss system 199 with a straight flexible elongate member 110. As a result, the composite pick-and-place mechanism 190 is aligned along a straight line ( Figure 6A shown as a dashed line in). However, in this example, the flexible composite part 600 is not straight and many of the composite pick-and-place mechanisms 190 cannot contact the flexible composite part 600. Without being contacted by a sufficient number of composite pick-and-place mechanisms 190, the flexible composite part 600 is not sufficiently supported, for example, due to being flexible. The number, spacing, and other characteristics of the composite pick-and-place mechanisms 190 are determined based on the type of the flexible composite part 600 (e.g., size, weight, curing state, etc.).

[0059] Figure 6B shows the flexible elongate member 110 after at least one of the slidable ribs 120 is slid relative to at least one of the flexible elongate members 110 and (relative to Figure 6B ) the flexible elongate member 110 is bent. In this illustration, all of the composite pick-and-place mechanisms 190 contact the flexible composite part 600 to provide sufficient support to the flexible composite part 600.

[0060] In some examples, method 500 proceeds to lock the position of at least one of the slidable ribs 120 relative to at least one of the flexible elongate members 110 using, for example, the positioning lock 150 described above with reference to Figure 4A - FIG. 4C (block 520). In a more specific example, all of the slidable ribs 120 are locked relative to each flexible elongate member 110. It should be noted that in some examples, one or more of the flexible elongate members 110 are fixedly attached to the slidable ribs 120. This locking / fixed attachment maintains the shape of the flexible elongate member 110. As a result, for example, as Figure 6B shown, the contact between each of the pick-and-place mechanisms 190 and the flexible composite part 600 is maintained.

[0061] In some examples, method 500 proceeds to transfer the flexible composite part 600 using the flexible truss system 199 while maintaining the contact between each pick-and-place mechanism 190 and the flexible composite part 600 (block 530). For example, between various processes, such as between forming the flexible composite part 600 and curing the flexible composite part, the flexible composite part 600 is transferred using the flexible truss system 199. For example, the flexible composite part 600 is assembled manually or using a lifting mechanism 195 using the flexible truss system 199. It should be noted that during such an operation, the flexible composite part 600 is supported by the flexible truss system 199.

[0062] In some examples, method 500 proceeds to disengage the flexible composite part 600 from each pick - and - place mechanism 190 (block 540). For example, the vacuum applied to the suction cup 192 that serves as the pick - and - place mechanism 190 is released, allowing the suction cup 192 to separate from the flexible composite part 600.

[0063] In some examples, method 500 proceeds to unlock the position of the slidable rib 120 relative to at least one of the flexible elongate members 110 (block 550). It should be noted that when the pick - and - place mechanism 190 engages and supports the flexible composite part 600, the slidable rib 120 is locked relative to at least one of the flexible elongate members 110 to maintain the shape of the flexible truss system 199. However, to reconfigure the flexible truss system 199 (e.g., to support a flexible composite part 610 with a different shape of attachment), the position of the slidable rib 120 is unlocked.

[0064] In some examples and referring Figure 5 to decision block 560 in, method 500 proceeds to transfer another flexible composite part using the same flexible truss system 199 (e.g., Figure 6C as shown). In this case, the various operations described above with reference to blocks 510 - 550 are repeated. For example, method 500 proceeds to bring an additional flexible composite part 610 into contact with each pick - and - place mechanism 190 supported on the flexible truss mechanism 100 (block 510). This contact operation for the additional flexible composite part 610 includes sliding at least one of the slidable ribs 120 relative to at least one of the flexible elongate members 110 (block 512). This sliding allows the flexible elongate members 110 to bend and allows each pick - and - place mechanism 190 to come into contact with the additional flexible composite part 610. As Figure 6B and Figure 6C shown, the additional flexible composite part 610 and the flexible composite part 600 have different shapes. In this way, the flexible truss system 199 is reconfigured during this operation to match the shape of the additional flexible composite part 610.

[0065] In some examples, method 500 further includes locking the slidable rib 120 relative to at least one of the flexible elongate members 110 in an additional set position (block 520). This locking maintains the shape of the flexible elongate members 110 (now matching the additional flexible composite part 610) and maintains the contact between each pick - and - place mechanism 190 and the additional flexible composite part 610. These additional set positions are different from the set positions used previously for the flexible composite part 600.

[0066] Example of an Aircraft

[0067] In some examples, the methods and systems described above are used on aircraft and, more generally, by the aerospace industry. Specifically, these methods and systems can be used during the manufacture of an aircraft and also during its service and maintenance.

[0068] Accordingly, the apparatus and methods described above are applicable to an aircraft manufacturing and maintenance method 900 as Figure 7 shown and to an aircraft 902 as Figure 8 shown. During pre-production, method 900 includes specification and design 904 of aircraft 902 and material procurement 906. During production, component and sub-component manufacturing 908 of aircraft 902 and system integration 910 are performed. Thereafter, for placement into service 914, aircraft 902 undergoes certification and delivery 912 in order to be put into use 914. When used by a customer, aircraft 902 is scheduled for routine repair and maintenance 916, which also includes modification, reconfiguration, refurbishment, etc.

[0069] In some examples, each process of method 900 is performed or completed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator includes, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party includes, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator can be an airline, a leasing company, a military entity, a service organization, etc.

[0070] As Figure 8 shown, an aircraft 902 produced by method 900 includes a fuselage 918 and a plurality of systems 920 and an interior 922. Examples of systems 920 include one or more of a propulsion system 924, an electrical system 926, a hydraulic system 928, and an environmental system 930. Any number of other systems can be included. Although aerospace examples are shown, the principles of the examples described herein are applicable to other industries, such as the automotive industry.

[0071] The apparatus and methods presented herein can be employed at any one or more stages of method 900. For example, components or sub-components corresponding to manufacturing 908 are processed or manufactured in a manner similar to components or sub-components produced when aircraft 902 is put into use. Additionally, one or more example apparatuses, example methods, or combinations thereof are utilized during manufacturing 908 and system integration 910, such as to fully accelerate the assembly of aircraft 902 or reduce its cost. Similarly, one or more example apparatuses, example methods, or combinations thereof are utilized when aircraft 902 is put into use, such as, but not limited to, for repair and maintenance 916.

[0072] Further Examples

[0073] Further, the specification includes examples according to the following clauses:

[0074] Clause 1. A flexible truss mechanism, comprising:

[0075] Flexible slender members extending along the main axis of the flexible truss mechanism;

[0076] Slidable ribs coupled to each of the flexible slender members and supporting the flexible slender members relative to each other, wherein:

[0077] The slidable ribs are spaced apart from each other along the main axis of the flexible truss mechanism;

[0078] The slidable ribs are configured to receive and support one or more compound pick-and-place mechanisms; and

[0079] Each of the slidable ribs is slidably coupled to at least one of the flexible slender members, thereby allowing each of the slidable ribs to slide relative to at least one of the flexible slender members along the main axis and allowing the flexible slender members to bend about at least one axis perpendicular to the main axis.

[0080] Clause 2. The flexible truss mechanism according to Clause 1, wherein:

[0081] Each of the slidable ribs includes a positioning lock slidable relative to the slidable rib for each of the flexible slender members; and

[0082] The positioning lock is configured to lock the corresponding one of the slidable ribs relative to at least one of the flexible slender members in a set position.

[0083] Clause 3. The flexible truss mechanism according to Clause 2, wherein:

[0084] The positioning lock is switchable between a locked position and an unlocked position;

[0085] When the positioning lock is in the locked position, the positioning lock prevents the corresponding one of the slidable ribs from sliding relative to at least one of the flexible slender members; and

[0086] When the positioning lock is in the unlocked position, the positioning lock allows the corresponding one of the slidable ribs to slide relative to at least one of the flexible slender members.

[0087] Clause 4. The flexible truss mechanism according to Clause 3, wherein:

[0088] The positioning lock includes a linear actuator, a slotted nut, and a threaded positioning shaft fixedly connected to at least one of the flexible slender members;

[0089] The linear actuator is coupled to the slotted nut and is configured to move the slotted nut relative to the threaded positioning shaft between a shaft engagement position and a shaft disengagement position;

[0090] The shaft engagement position corresponds to the locked position of the positioning lock; and

[0091] The shaft disengagement position corresponds to the unlocked position of the positioning lock.

[0092] Clause 5. The flexible truss mechanism according to clause 4, wherein the linear actuator is a cylinder.

[0093] Clause 6. The flexible truss mechanism according to clause 5, wherein each of the slidable ribs is fixedly coupled to at least one other of the flexible elongate members.

[0094] Clause 7. The flexible truss mechanism according to any one of clauses 1-6, wherein each of the slidable ribs is slidably coupled to at least two of the flexible elongate members, thereby allowing each of the slidable ribs to slide along the main axis relative to at least two of the flexible elongate members.

[0095] Clause 8. The flexible truss mechanism according to any one of clauses 1-7, wherein each of the slidable ribs is slidably coupled to all of the flexible elongate members, thereby allowing each of the slidable ribs to slide along the main axis relative to all of the flexible elongate members.

[0096] Clause 9. The flexible truss mechanism according to any one of clauses 1-8, wherein:

[0097] Each of the slidable ribs includes a sliding mechanism for each of the flexible elongate members that is slidable relative to the slidable rib; and

[0098] The sliding mechanism includes one or more rollers that are rollably engaged with at least one of the flexible elongate members.

[0099] Clause 10. The flexible truss mechanism according to any one of clauses 1-9, wherein each of the slidable ribs includes a plurality of support arms, and each of the plurality of support arms at least partially defines the distance between a corresponding pair of flexible elongate members.

[0100] Clause 11. The flexible truss mechanism according to clause 10, wherein each of the plurality of support arms has the same length.

[0101] Clause 12. The flexible truss mechanism according to clause 10, wherein each of the plurality of support arms is straight.

[0102] Clause 13. The flexible truss mechanism according to any one of clauses 1-12, wherein each of the flexible elongate members is formed of carbon fiber.

[0103] Clause 14. The flexible truss mechanism according to any one of Clauses 1 - 13, wherein each of the flexible slender members protrudes through each of the slidable ribs.

[0104] Clause 15. The flexible truss mechanism according to any one of Clauses 1 - 14, further comprising fixed ribs fixedly coupled to each of the flexible slender members.

[0105] Clause 16. A flexible truss system comprising:

[0106] A flexible truss mechanism comprising flexible slender members extending along a main axis of the flexible truss mechanism and slidable ribs coupled to each flexible slender member; and

[0107] A pick - and - place mechanism, wherein:

[0108] Each of the pick - and - place mechanisms is supported by a corresponding one of the slidable ribs; and

[0109] Each of the slidable ribs is slidably coupled to at least one of the flexible slender members, thereby allowing each of the slidable ribs to slide relative to at least one of the flexible slender members along the main axis and allowing the flexible slender members to bend about at least one axis perpendicular to the main axis.

[0110] Clause 17. The flexible truss system according to Clause 16, further comprising a vacuum source, wherein each of the pick - and - place mechanisms comprises a suction cup configured to be controllably connected to the vacuum source.

[0111] Clause 18. The flexible truss system according to any one of Clauses 16 - 17, wherein:

[0112] Each of the slidable ribs comprises a positioning lock slidable relative to the slidable rib for each of the flexible slender members; and

[0113] The positioning lock is configured to lock a corresponding one of the slidable ribs relative to at least one of the flexible slender members in a set position.

[0114] Clause 19. The flexible truss system according to Clause 18, wherein:

[0115] The positioning lock is switchable between a locked position and an unlocked position;

[0116] When the positioning lock is in the locked position, the positioning lock prevents a corresponding one of the slidable ribs from sliding relative to at least one of the flexible slender members; and

[0117] When the positioning lock is in the unlocked position, the positioning lock allows a corresponding one of the slidable ribs to slide relative to at least one of the flexible elongated members.

[0118] Clause 20. The flexible truss system according to Clause 19, wherein:

[0119] The positioning lock includes a linear actuator, a slotted nut, and a threaded positioning shaft fixedly connected to at least one of the flexible elongated members;

[0120] The linear actuator is coupled to the slotted nut and is configured to move the slotted nut relative to the threaded positioning shaft between a shaft engagement position and a shaft disengagement position;

[0121] The shaft engagement position corresponds to the locked position of the positioning lock; and

[0122] The shaft disengagement position corresponds to the unlocked position of the positioning lock.

[0123] Clause 21. The flexible truss system according to Clause 20, further comprising a pressure source, wherein the linear actuator of the positioning lock of each slidable rib is controllably coupled to a cylinder of the pressure source.

[0124] Clause 22. The flexible truss system according to Clause 21, further comprising a system controller communicatively coupled to the pressure source and configured to selectively connect and disconnect the linear actuator of the positioning lock of each slidable rib from the pressure source.

[0125] Clause 23. A method of transferring a flexible composite part using a flexible truss system including a flexible truss mechanism and a pick-and-place mechanism, the method comprising:

[0126] Bringing the flexible composite part into contact with each of the pick-and-place mechanisms supported on the flexible truss mechanism, wherein:

[0127] The flexible truss mechanism includes flexible elongated members and slidable ribs, the slidable ribs being coupled to each of the flexible elongated members and supporting the flexible elongated members relative to each other; and

[0128] Bringing the flexible composite part into contact includes sliding at least one of the slidable ribs relative to at least one of the flexible elongated members, thereby allowing the flexible elongated members to bend and allowing each of the pick-and-place mechanisms to form contact with the flexible composite part; and

[0129] Locking the slidable ribs relative to at least one of the flexible elongated members in a set position, thereby maintaining the shape of the flexible elongated members and maintaining the contact between each of the pick-and-place mechanisms and the flexible composite part; and

[0130] Transferring a flexible composite part using a flexible truss system while maintaining contact between each of the pick-and-place mechanisms and the flexible composite part.

[0131] Clause 24. The method according to clause 23, further comprising:

[0132] Detaching the flexible composite part from each of the pick-and-place mechanisms; and

[0133] Unlocking the position of the slidable rib relative to at least one of the flexible elongate members.

[0134] Clause 25. The method according to any one of clauses 23-24, further comprising:

[0135] Bringing an additional flexible composite part into contact with each pick-and-place mechanism supported on the flexible truss mechanism, wherein:

[0136] Bringing the additional flexible composite part into contact includes sliding at least one of the slidable ribs relative to at least one of the flexible elongate members, thereby allowing the flexible elongate members to bend and allowing each of the pick-and-place mechanisms to form contact with the additional flexible composite part; and

[0137] The additional flexible composite part has a different shape from the flexible composite part.

[0138] Clause 26. The method according to clause 25, further comprising locking the slidable rib relative to at least one of the flexible elongate members in an additional set position, thereby maintaining the shape of the flexible elongate members and maintaining contact between each of the pick-and-place mechanisms and the additional flexible composite part, wherein the additional set position is different from the set position for the flexible composite part.

[0139] Clause 27. The method according to any one of clauses 23-26, wherein locking each of the slidable ribs relative to at least one of the flexible elongate members is accomplished using a positioning lock.

[0140] Clause 28. The method according to clause 27, wherein:

[0141] The positioning lock includes a linear actuator, a slotted nut, and a threaded positioning shaft fixedly connected to at least one of the flexible elongate members;

[0142] The linear actuator is coupled to the slotted nut and is configured to move the slotted nut relative to the threaded positioning shaft between a shaft-engaged position and a shaft-disengaged position; and

[0143] Locking each of the slidable ribs relative to at least one of the flexible elongate members includes moving the slotted nut from the shaft-disengaged position to the shaft-engaged position.

[0144] Conclusion

[0145] Although the above concepts have been described in some detail for purposes of clear understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. It should be noted that there are alternative ways of implementing processes, systems, and apparatuses. Accordingly, the present examples are considered to be illustrative rather than restrictive.

Claims

1. A flexible truss mechanism (100), comprising: Flexible elongate members (110) extending along a main axis (101) of the flexible truss mechanism (100); Slidable ribs (120) coupled to each of the flexible elongate members (110) and supporting the flexible elongate members (110) relative to one another, wherein: The slidable ribs (120) are spaced apart from one another along the main axis (101) of the flexible truss mechanism (100); The slidable ribs (120) are configured to receive and support one or more compound pick-and-place mechanisms (190); and Each of the slidable ribs (120) is slidably coupled to at least one of the flexible elongate members (110), allowing each of the slidable ribs (120) to slide relative to the at least one of the flexible elongate members (110) along the main axis (101) and allowing the flexible elongate members (110) to bend about at least one axis (102a) perpendicular to the main axis (101).

2. The flexible truss mechanism (100) according to claim 1, wherein: Each of the slidable ribs (120) includes a positioning lock (150) slidable relative to the slidable rib (120) for each of the flexible elongate members (110); and The positioning lock (150) is configured to lock a corresponding one of the slidable ribs relative to the at least one of the flexible elongate members (110) in a set position.

3. The flexible truss mechanism (100) according to claim 2, wherein: The positioning lock (150) is switchable between a locked position and an unlocked position; When the positioning lock (150) is in the locked position, the positioning lock (150) prevents a corresponding one of the slidable ribs (120) from sliding relative to the at least one of the flexible elongate members (110); And When the positioning lock (150) is in the unlocked position, the positioning lock (150) allows a corresponding one of the slidable ribs (120) to slide relative to the at least one of the flexible elongate members (110).

4. The flexible truss mechanism (100) according to any one of claims 1 to 3, wherein each of the slidable ribs (120) is slidably coupled to at least two of the flexible elongate members (110), allowing each of the slidable ribs (120) to slide relative to the at least two of the flexible elongate members (110) along the main axis (101).

5. The flexible truss mechanism (100) according to any one of claims 1 to 3, wherein each of the slidable ribs (120) is slidably coupled to all of the flexible elongate members (110), allowing each of the slidable ribs (120) to slide relative to all of the flexible elongate members (110) along the main axis (101).

6. The flexible truss mechanism (100) according to any one of claims 1 to 3, wherein: each of the slidable ribs (120) includes a sliding mechanism (130) for each of the flexible slender members (110) to be slidable relative to the slidable rib (120); and the sliding mechanism (130) includes one or more rollers (140) that are rollably engaged with at least one of the flexible slender members (110).

7. The flexible truss mechanism (100) according to any one of claims 1 to 3, which is within a flexible truss system (199), the flexible truss system further including: a pick-and-place mechanism (190), wherein: each of the pick-and-place mechanisms (190) is supported by a corresponding one of the slidable ribs (120).

8. The flexible truss mechanism (100) according to claim 7, wherein the flexible truss system (199) further includes a vacuum source (191), and each of the pick-and-place mechanisms (190) includes a suction cup (192) configured to be controllably connected to the vacuum source (191).

9. A method (500) of transferring a flexible composite part (600) using a flexible truss system (199) including a flexible truss mechanism (100) and a pick-and-place mechanism (190), the method (500) including: bringing the flexible composite part (600) into contact (510) with each of the pick-and-place mechanisms (190) supported on the flexible truss mechanism (100), wherein: the flexible truss mechanism (100) includes flexible slender members (110) and slidable ribs (120), the slidable ribs (120) being coupled to each of the flexible slender members (110) and supporting the flexible slender members (110) relative to each other; and bringing the flexible composite part (600) into contact includes sliding (512) at least one of the slidable ribs (120) relative to at least one of the flexible slender members (110), thereby allowing the flexible slender members (110) to bend and allowing each of the pick-and-place mechanisms (190) to come into contact with the flexible composite part (600); and locking (520) the slidable rib (120) relative to at least one of the flexible slender members (110) in a set position, thereby maintaining the shape of the flexible slender members (110) and maintaining the contact between each of the pick-and-place mechanisms (190) and the flexible composite part (600); and transferring (530) the flexible composite part (600) using the flexible truss system (199) while maintaining the contact between each of the pick-and-place mechanisms (190) and the flexible composite part (600).

10. The method (500) according to claim 9, further including: Disengage the flexible composite part (600) from each of the pick-and-place mechanisms (190); and Unlock the position of the slidable rib (120) relative to at least one of the flexible elongate members (110).

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