Method and system for assembling a structure

Abstract

The present application relates to methods and systems for assembling structures. One illustrative method includes moving a mandrel in a processing direction relative to a station comprising a plurality of pick-and-place (PNP) machines; identifying a tray storing a preform comprising unhardened fiber-reinforced material; placing a strongback at the preform via at least one of the PNP machines; applying a vacuum to hold the preform in contact with the strongback; transporting the preform to the mandrel via the PNP machines; and placing the preform onto the mandrel.

Description

Technical Field

[0001] This disclosure relates to the field of assembly, and more particularly to the placement of prefabricated components for assembling composite parts. Background Technology

[0002] Multilayer preforms of constituent materials (e.g., carbon fiber reinforced polymer (CFRP)) can be formed into any of a variety of shapes for curing into composite parts. When manufacturing complex composite parts, multiple preforms can be placed together on a mandrel for curing into a single monolithic component. However, whether performed manually or automatically, placing the preforms together for curing is a rather time-consuming process, which reduces the speed of composite part manufacturing.

[0003] Therefore, it is desirable to have a method and system that takes into account at least some of the above-mentioned problems, as well as other possible problems.

[0004] Patent document WO 2020 / 263093 A1, according to its abstract, describes a prefabrication system for automatically and sequentially laying sheets, particularly fiber-reinforced sheets, at desired locations in a preselected posture to prefabricate a composite structure. The prefabrication system includes at least one buffer with two or more carriages, a controller, a placement robot equipped with sheet manipulation components, and a substrate. Each carriage is arranged to carry at least one pre-sorted sheet. The controller keeps track of the position, type, and sequence of at least one pre-sorted sheet on each carriage. Furthermore, the controller controls the placement robot to manipulate at least one sheet from a selected carriage among the two or more carriages using the sheet manipulation components and transport the at least one sheet to the substrate, placing the at least one sheet at a desired location in a preselected posture.

[0005] Patent document US 2019 / 047158 A1, according to its abstract, describes a system and method for picking up and placing sheets of reinforcing material. An apparatus includes an end effector of a robot. The end effector includes a frame and cup assemblies attached to the frame. Each cup assembly includes an axis and a head. The end effector also includes a Bernoulli cup attached to the head of the cup assembly, and a gripper attached to the head of the cup assembly.

[0006] Patent document US 9873230 B1, according to its abstract, describes a mobile vehicle for placing, compacting, and inspecting composite sheets at selected locations on a tool. The vehicle includes an onboard supply unit for the composite sheets, a transfer platen for transferring the sheets to the tool, a compactor for compacting the sheets on the tool, and an inspection device for inspecting the sheets on the tool, wherein the onboard supply unit, transfer platen, compactor, and inspection device are all operated and manipulated by an onboard manipulator, such as a robot.

[0007] Patent document DE 4226822 A1, according to its abstract, describes a suction panel incorporated into a liner, which in turn is fixed to a reinforcing plate. The suction panel has multiple suction positions where perforations extend downwards to a transverse channel system and a main channel connected to a vacuum source. Each perforation is surrounded by a raised ring spaced a distance from its diameter. This forms a closed suction area around each perforation on the working surface of the panel. The raised ring has sides that taper in thickness from its base to its top on the panel surface. Summary of the Invention

[0008] The embodiments described herein provide a system and method for coordinated control of a pick-and-place (PNP) machine to place preforms onto a mandrel. When placing large objects, the PNP machines operate sequentially, while when placing smaller objects, the PNP machines operate independently. This increases the overall speed of preform placement, which in turn increases the speed of composite component laying (and thus manufacturing).

[0009] One embodiment is a method for placing a preform onto a mandrel. The method includes: moving the mandrel in a processing direction relative to a station comprising a plurality of pick-and-place (PNP) machines; identifying a tray storing a preform comprising uncured fiber-reinforced material; placing a reinforcing backing plate at the preform via at least one of the PNP machines; applying a vacuum to maintain contact between the preform and the reinforcing backing plate; transporting the preform to the mandrel via the PNP machines; and placing the preform onto the mandrel.

[0010] Another embodiment is a non-transitory computer-readable medium implementing programming instructions that, when executed by a processor, are operable for performing a method for assembling a structure. The method includes: moving a mandrel in a processing direction relative to a station comprising a plurality of pick-and-place (PNP) machines; identifying a tray storing a preform comprising uncured fiber reinforcement material; placing a reinforcing backplate at the preform via at least one of the PNP machines; applying a vacuum to maintain contact between the preform and the reinforcing backplate; transporting the preform to the mandrel via the PNP machines; and placing the preform onto the mandrel.

[0011] Another embodiment is a placement system for manufacturing structures. This placement system includes a pick-and-place (PNP) machine at a station within a cell, and a cell controller. The cell controller is operable to move a mandrel in a processing direction relative to the station, identify a tray storing a preform comprising uncured fiber-reinforced material, place a reinforcing backing plate at the preform via at least one of the PNP machines, apply a vacuum to maintain contact between the preform and the reinforcing backing plate, transport the preform to the mandrel via the PNP machine, and place the preform onto the mandrel.

[0012] Other illustrative embodiments may be described below (e.g., methods and computer-readable media related to the foregoing embodiments). The features, functions, and advantages already discussed may be implemented independently in various embodiments or combined in other embodiments, further details of which can be seen in the following description and drawings. Attached Figure Description

[0013] 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.

[0014] Figure 1 This is a schematic block diagram showing a manufacturing line with a placement system in an illustrative embodiment.

[0015] Figure 2 In the illustrative embodiments, it is possible to Figure 2 A schematic block diagram of the placement station used in the placement system of the manufacturing line.

[0016] Figure 3 In the illustrative implementation Figure 2 A three-dimensional view of the placement system shown.

[0017] Figure 4 In the illustrative embodiments, it is possible to... Figures 1 to 3 A perspective view of the first example tray used in conjunction with the placement system shown.

[0018] Figure 5 Is it possible to... Figures 1 to 3 A perspective view of a second example tray used with the placement system shown, the second example tray including example prefabricated parts that can be placed by the placement system.

[0019] Figure 6 yes Figure 4 and Figure 5 The image shows a side cross-sectional view of the tray taken at point 6-6 along line 6, where no prefabricated components are present.

[0020] Figure 7 yes Figure 6 The diagram shows prefabricated components (e.g.) Figure 5 The diagram shows a side cross-sectional view of the tray of the prefabricated component.

[0021] Figure 8 yes Figure 6 and Figure 7 The tray shown can be used with Figures 1 to 3 The diagram shows a side cross-sectional view of the strong backplate used in conjunction with the placement system.

[0022] Figure 9 Is with Figure 8 The tray joint Figure 8 A side cross-sectional view of the strong back plate.

[0023] Figure 10 It has prefabricated components Figure 8 and Figure 9 The diagram shows a side cross-sectional view of the strong backplate.

[0024] Figure 11 Is it possible to... Figures 1 to 3 The placement system shown and / or Figure 1 A side cross-sectional view of the mandrel used in the manufacturing line shown.

[0025] Figure 12 In the illustrative implementation Figures 6 to 11 The mandrel, backing plate, and preform shown are side cross-sectional views.

[0026] Figure 13 yes Figure 12 The mandrel, backing plate, and preform shown are side cross-sectional views, with the backing plate and / or preform placed on the mandrel.

[0027] Figure 14 yes Figure 12 and Figure 13 The diagram shows a side cross-sectional view of the mandrel, backing plate, and preform, with the preform already placed in the mandrel.

[0028] Figure 15 This is an end view of a mandrel in an illustrative embodiment, which can be used as... Figures 11 to 14 The shown spindle and / or may be with Figures 1 to 3 The placement system shown and / or Figure 1 Used together with the manufacturing line shown.

[0029] Figure 16 In the illustrative implementation Figure 15 An end view of the mandrel, which has a shaft that can be used as a... Figures 8 to 10 and Figures 12 to 14 The strong backplate assembly shown.

[0030] Figure 17 In the illustrative embodiments Figure 16 A bottom view of a strong backplate with one or more prefabricated components placed on it, taken from line 17-17 in the middle.

[0031] Figure 18 yes Figure 17 The mandrel and (one or more) preforms shown are end cross-sectional views.

[0032] Figure 19 Is it possible to... Figure 1A perspective view of a first example of multiple placement stations used together with the placement system shown.

[0033] Figure 20 Is it possible to... Figure 1 A perspective view of a second example of multiple placement stations used together with the placement system shown.

[0034] Figure 21 The illustrative embodiments shown are applicable to Figure 1 A three-dimensional diagram showing the arrangement of placement stations, assembly stations, and mandrel segments in the placement system.

[0035] Figure 22 The use is shown in the illustrative embodiments. Figures 1 to 3 The flowchart shows a method for assembling a structure using a placement system.

[0036] Figure 23 In the illustrative embodiments, it is possible to Figure 22 The message graph used during the method shown.

[0037] Figure 24A and Figure 24B The illustrative embodiments show the operation. Figures 1 to 21 The flowchart shows the placement method of the placement system.

[0038] Figure 25 The illustrative embodiments show the operation. Figure 1 The flowchart shown illustrates a method for placing a system and / or manufacturing line, which can be used in... Figure 24A and Figure 24B The post-placement method is executed before or during the placement method shown.

[0039] Figure 26 It is the preparation Figures 2 to 21 The flowchart shown illustrates a method using a mandrel that can be used for... Figure 25 The method shown is for reuse.

[0040] Figure 27 This is a flowchart of an illustrative embodiment of an aircraft manufacturing and maintenance method, in which the following can be used. Figures 1 to 21 The system and / or manufacturing line shown and / or Figures 22 to 26 The method shown.

[0041] Figure 28 It can be used in the illustrative embodiments Figures 1 to 21 The system and / or manufacturing line shown and / or Figures 22 to 26 A schematic block diagram of an aircraft manufactured using the method shown.

[0042] Figure 29 yes Figure 28The image shown is a 3D view of the aircraft. Detailed Implementation

[0043] The accompanying drawings and the following description provide specific illustrative embodiments of this disclosure. Therefore, it will be understood that those skilled in the art will be able to devise various arrangements that implement the principles of this disclosure and are included within its scope, although not expressly described or shown herein. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and are to be construed as not being limited to such specific examples and conditions. Therefore, this disclosure is not limited to the specific embodiments or examples described below, but is defined by the claims and their equivalents.

[0044] Composite components, such as carbon fiber reinforced polymer (CFRP) components, are initially laid out in multiple layers, which together are referred to as preforms. Individual fibers within each layer of the preform are aligned parallel to each other, but different layers can exhibit different fiber orientations to increase the strength of the resulting composite component along different dimensions. Preforms may include a tackifying resin that binds to harden the preform into a composite component (e.g., for use in aircraft). Carbon fibers already impregnated with uncured thermosetting or thermoplastic resins are referred to as “prepregs.” Other types of carbon fibers include “dry fibers,” which are not impregnated with thermosetting resins but may include tackifiers or adhesives. Dry fibers can be infused with resin before curing. For thermosetting resins, curing is a unidirectional process called curing, while for thermoplastic resins, the resin can reach a tack form if it is reheated.

[0045] The embodiments described herein provide a pulsed or moving line design and a system and method for coordinated control and synchronized manual assistance operations in conjunction with pick-and-place (PNP) machines to place preforms onto stationary or moving mandrels. In an example having continuously moving or pulsed moving segments (e.g., mandrel segments) or complete tools (e.g., mandrels) along the manufacturing line, the systems and methods described herein can increase the work density on the mandrel (e.g., by having more stations and / or more area coverage, while having increased parallel processing operations occurring in the feed lines to the stations). The systems and methods described herein can provide orders of magnitude reduction in work density and increase parallel processing operations within the manufacturing facility by a similar amount of tightly packed density. All operations, automatic and manual, can be synchronized to support line speed.

[0046] Figure 1This is a schematic block diagram showing a manufacturing line 10 having a placement system 50 for manufacturing or assembling structure 12. In the example herein, structure 12 moves along manufacturing line 10 in a processing direction 14 to become a composite component 16 after the uncured fiber-reinforced material 152 constituting structure 12 has been cured. Curing includes the solidification of thermosetting materials or the consolidation of thermoplastic materials. Structure 12 may be suitable for use in aircraft 750 ( Figure 28 and Figure 29 Part 768 of the fuselage 766 (as shown), for example, the semi-cylindrical section 770.

[0047] In order to move structure 12 along manufacturing line 10, mandrel 140 moves along manufacturing line 10 through at least placement system 50. In some examples, mandrel 140 includes mandrel segment 235, which will refer to Figure 21 To describe in more detail.

[0048] The placement system 50 is manufactured from or assembled from the object 18 of the structure 12. Each object 18 may include a preform 150 of uncured fiber-reinforced material 152 (e.g., Figure 2 and Figure 5 (As shown). Placement system 50 places prefabricated part 150 onto mandrel 140 for curing into composite part 16. One or more of the objects 18 can be of a first type, such as discrete object 20, and / or a second type, such as large object 22. Large object 22 is larger than discrete object 20. Therefore, placement system 50 can be manufactured or assembled from objects 18 including discrete object 20 and one or more large objects 22. In the example described below, large object 22 spans multiple pick-and-place (PNP) machines 130.

[0049] refer to Figure 1 , Figure 5 and Figure 18 When object 18 is prefabricated component 150, prefabricated component 150 can be a first type of prefabricated component, such as discrete prefabricated component 154 (e.g., frame filler prefabricated component 158), and / or a second type of prefabricated component, such as large prefabricated component 156 (e.g., longitudinal beam prefabricated component 159). Thus, in some examples, placement system 50 assembles structure 12 from prefabricated components 150 including discrete prefabricated component 154 and one or more large prefabricated components 156. When placement system 50 is used to form part 768 of fuselage 766 into structure 12, discrete object 20 can be frame filler prefabricated component 158 ​​(also called “postage stamp”) and / or short longitudinal beam, while large object 22 can be medium or long longitudinal beam prefabricated component 159. Because large prefabricated component 156 is an example of large object 22, large prefabricated component 156 spans multiple PNP machines 130.

[0050] Refer again Figure 1 The placement system 50 includes at least a placement station 100. The placement system 50 may optionally include at least one assembly station 105. The manufacturing line 10 may also include a hardening system 60, a separation system 70, a cleaning system 80, and / or other suitable systems, such as a lamination system (not shown) or a fastener installation system (not shown). The placement system 50, hardening system 60, separation system 70, and / or cleaning system 80 may be arranged in series or parallel depending on the structure being assembled and the manufacturing process used along the manufacturing line 10. Although Figure 1 The placement system 50, hardening system 60, separation system 70, and cleaning system 80 are shown in sequence, but the hardening system 60 may be positioned after the separation system 70, as per [reference to...]. Figure 25 A more detailed description.

[0051] The curing system 60 is configured to cure uncured materials, such as uncured fiber-reinforced material 152, into cured materials. The curing system 60 can cure thermosetting materials and / or solidify thermoplastic materials. For example, the curing system 60 includes an autoclave. The curing system 60 can also be configured to apply a release membrane 62 to structure 12 and / or mandrel 140 prior to curing structure 12. The release membrane 62 may include bagging material, release sheets, separation membranes, etc. In one example, a release membrane 62, such as a separation membrane and / or release sheets, is applied to mandrel 140, and a release membrane 62, such as bagging material, is applied to structure 12. The release membrane 62 may be applied to mandrel 140 prior to its entry into placement system 50.

[0052] After structure 12 is cured by hardening system 60, structure 12 can become hardened structure 64. When structure 12 is formed from uncured fiber-reinforced material 152, this hardened structure can be composite component 16. For example, hardened structure 64 is a cured structure forming composite component 16. Hardened structure 64 or composite component 16 moves along manufacturing line 10 to receive additional manufacturing processes. For example, composite component 16 and / or hardened structure 64 move to a new location in manufacturing line 10, such as to a different system, to receive additional manufacturing processes. The different system can be a manufacturing or assembly system, and the additional manufacturing processes can assemble composite component 16 into a final product, such as aircraft 750. Figure 28 and Figure 29 (as shown in the image).

[0053] Separation system 70 is configured to separate the hardened structure 64 from the mandrel 140 (e.g., demolding). In one example, separation system 70 is configured to vertically move the hardened structure 64 to separate it from the mandrel 140. Separation system 70 is configured to separate the hardened structure 64 from the mandrel segments 235 as the mandrel 140 is formed, either individually or as assembled with the mandrel 140. Separation system 70 is also configured to separate the mandrel segments 235 from each other. When a release membrane 62 is applied to the hardening system 60, separation system 70 removes the release membrane 62 from the hardened structure 64 and / or the mandrel 140. When the mandrel 140 is formed from the mandrel segments 235, the release membrane 62 is removed from the mandrel segments 235 after the hardened structure 64 is separated from the mandrel 140 and before the mandrel segments 235 are separated from each other.

[0054] When the mandrel 140 is reused in placement station 100, it moves in the opposite processing direction 24 after being separated from structures 12, 64 for reuse in placement system 50. More specifically, the mandrel 140 is transported to the starting position 52 for placement system 50 and / or placement station 100. Alternatively, the mandrel 140 may remain with structures 12, 64 and continue along manufacturing line 10 to support structures 12, 64 during additional assembly and manufacturing processes until the mandrel 140 is no longer needed to support structures 12, 64.

[0055] The cleaning system 80 is configured to clean the mandrel 140 and / or mandrel segment 235. For example, the cleaning system 80 is configured to apply at least one cleaning chemical 82 to the mandrel 140 and / or mandrel segment 235. The at least one cleaning chemical 82 may be a solvent, water, and / or soap. In one example, the at least one cleaning chemical 82 is selected from the group consisting of solvent, water, and soap. When the at least one cleaning chemical 82 includes multiple different cleaning chemicals 82 applied by the cleaning system 80, the cleaning system 80 may apply multiple different cleaning chemicals 82 sequentially and / or simultaneously.

[0056] Alternatively, the cleaning system 80 includes components for scrubbing, rubbing, or other cleaning processes using, for example, a moving brush, scrubber, etc. The cleaning device can be used before, during, or after the application of at least one cleaning chemical 82. In an alternative embodiment, the mandrel segments 235 are separated from each other after cleaning the mandrel 140; however, if the mandrel segments are separated from each other first, the mandrel segments 235 can be cleaned more thoroughly and / or cleaned in parallel.

[0057] The placement system 50 includes a pick-and-place (PNP) machine 130 at a placement station 100 and a unit controller 120 operable to perform the methods described herein. More specifically, the placement station 100 includes the PNP machine 130 and the unit controller 120. The unit controller 120 communicates with the PNP machine 130 to perform placement operations in the placement station 100. For example, the unit controller 120 is operatively coupled to the PNP machine 130 to use the PNP machine 130 to place an object 18 onto a mandrel 140. The placement station 100 may also include a strong backplate 180 and / or a tray 190. The tray 190 is configured to hold one type of object 20 or 22, or both types of objects 20 and 22, as per [reference needed]. Figure 4 and Figure 5 A more detailed description.

[0058] Placement system 50 includes one or more placement stations 100. When placement system 50 includes more than one placement station 100, 100', PNP machines 130, 130' can be distributed across multiple placement stations 100, 100'. Multiple placement stations 100, 100' can be programmed and / or arranged to perform parallel operations, or can be programmed and / or arranged to perform a series of operations. PNP machines 130, 130' in multiple placement stations 100, 100' can operate in the same mode or different modes, as per [reference needed]. Figure 22 A more detailed description.

[0059] When the placement system 50 includes a first placement station 100 and a second placement station 100', each placement station 100, 100' may include its own unit controllers 120 and 120', or have a shared unit controller 120 controlling multiple placement stations 100, 100'. In one example, when placement stations 100, 100' are in the same manufacturing unit 110 ( Figure 2 As shown, placement stations 100 and 100' share a common unit controller 120; however, placement stations 100 and 100' in different manufacturing units 110 can be operated by the same unit controller 120. When each placement station 100 and 100' includes its own unit controller 120 and 120', the unit controllers 120 and 120' are configured to communicate with each other to coordinate the operation of PNP machines 130 and 130' in the different placement stations 100 and 100'.

[0060] The placement system 50 may also include one or more assembly stations 105. When the mandrel 140 includes mandrel segments 235, the placement system 50 includes assembly stations 105. Assembly stations 105 are configured to assemble mandrel segments 235 together to form the mandrel 140. Assembly stations 105 include a mandrel support structure 106. The mandrel support structure 106 is configured to support the mandrel segments 235 before, during, or after they are assembled together. Even when the mandrel 140 is not formed by mandrel segments 235, the mandrel support structure 106 may be assembled to the mandrel 140 to provide support for the mandrel 140 during the manufacturing process. The mandrel support structure 106 is also configured to move along the manufacturing line 10 with the mandrel 140 to subsequent systems. The mandrel support structure 106 may detach from the mandrel 140 and / or mandrel segments 235 when support is no longer needed, regardless of where this occurs along the manufacturing line 10. Although assembly station 105 is shown after placement station 100, assembly station 105 may be before placement station 100 during placement operations performed at placement station 100, when mandrel 140 will be supported by mandrel support structure 106.

[0061] When the placement system 50 includes more than one assembly station 105, 105', the assembly stations 105, 105' can be programmed and / or arranged to perform parallel operations, or can be programmed and / or arranged to perform a series of operations. When the assembly station 105 is omitted from the placement system 50, the placement system 50 can be considered to include the PNP machine 130 and the unit controller 120 of the placement station 100.

[0062] The mandrel 140 is configured to move relative to the placement station 100 and thus through the placement system 50. More specifically, the mandrel 140 moves relative to the placement station 100 in a processing direction 14. The processing direction 14 is as the material (e.g., uncured fiber-reinforced material 152) and sub-assemblies (e.g., structures 12, 64) are transformed into the final assembly (e.g., aircraft 750, such as…). Figure 28 (As shown) The direction in which the mandrel 140 and sub-assemblies move along the manufacturing line 10. Sometimes, the mandrel 140 may move in a processing direction 24 opposite to the processing direction 14 or at an angle to the processing direction 14, depending on which manufacturing processes will be completed along the manufacturing line 10. When the mandrel 140 is at the placement system 100, the placement system 100 is considered to include the mandrel 140, but sometimes the placement system 50 may not have the mandrel 140. In addition, the unit controller 120 communicates with the mandrel 140 to move the mandrel 140 relative to the placement station 100.

[0063] Figure 2 It can be used Figure 1The diagram shows a schematic block diagram of the placement station 100 of the placement system 50. In the illustrative embodiment, the placement station 100 is configured to coordinate the operation of the PNP machine 130. The placement station 100 includes components operable to place prefabricated parts (e.g., for longitudinal beams) onto a mandrel 140 for subsequent curing into an integral composite component (e.g., composite component 16). Figure 1 Any system, apparatus, or component shown in the diagram. In this embodiment, to increase the rate at which the preform 150 is placed onto the mandrel 140, the placement station 100 has been enhanced to selectively synchronize the operation of the PNP machine 130.

[0064] Placement station 100 includes a PNP machine 130 and a unit controller 120. More specifically, placement station 100 includes multiple (i.e., two or more) PNP machines, such as three or more PNP machines 130a, 130b, and 130c. The PNP machines 130 can be divided into subsets, each subset having one or more PNP machines 130. For example, the PNP machines 130 are divided into a first subset 126 and a second subset 128. Figure 2 As shown, the first subset 126 includes a first PNP machine 130a, and the second subset 128 includes a second PNP machine 130b and a third PNP machine 130c. For clarity only, the first subset 126 and the second subset 128 are shown as having one PNP machine and two PNP machines respectively, and each subset 126 and 128 may include any number of PNP machines 130, regardless of whether the PNP machines 130 in the subsets are adjacent. The PNP machines 130 in the first subset 126 are different from the PNP machines 130 in the second subset 128. However, the PNP machines 130 can be configured according to the structure 12 being assembled. Figure 1 (As shown) and / or the placement method being performed is reallocated between the first subset 126 and the second subset 128.

[0065] Unit controller 120 is operable to control PNP machine 130. More specifically, unit controller 120 and PNP machine 130 are communicatively connected such that instructions 124 are transmitted from unit controller 120 to one or more PNP machines 130, and data 137 is transmitted from one or more PNP machines 130 to unit controller 120. For example, when placement station 100 includes three PNP machines 130a, 130b, and 130c, unit controller 120 receives first data 137a, second data 137b, and third data 137c from each of PNP machines 130a, 130b, and 130c.

[0066] Placement stations 100 and / or PNP machines 130 are located within manufacturing cell 110. Cell controller 120 is configured to control operations occurring with manufacturing cell 110, such as placement operations. Cell controller 120 is also operable to assign each PNP machine 130 in manufacturing cell 110 to a first subset 126 or a second subset 128. Cell controller 120 is operable to reassign PNP machines 130 to different subsets 126 and / or 128 as needed.

[0067] During the assembly of structure 12, the pick-and-place machine 130 picks up an object 18, such as a preform 150, and places it onto the mandrel 140. Preforms 150 can all be formed from uncured fiber-reinforced material 152. The preforms 150 discussed herein can be cured as short longitudinal beams, medium longitudinal beams spanning multiple PNP machines 130, or even long longitudinal beams spanning many PNP machines 130. Although Figure 1 The image shows an object 18 in the form of a longitudinal beam prefabricated component 159 (e.g., having an internal pouch, gap filler, and other components not shown), but in other embodiments, object 18 may include any suitable components, such as other prefabricated components, frame filler, spacer sheets, etc. In short, PNP machines 130 are arranged across discrete objects 20 (e.g., small prefabricated components and / or discrete prefabricated components 154, e.g.) spanning multiple PNP machines 130. Figure 5 The PNP machine 130 is positioned within the reach of the frame filler preform 158, mandrel 140, and large object 22 (e.g., large preform 156). In other words, the PNP machine 130 is positioned within the reach of object 18 and mandrel 140. When object 18 is preform 150, the PNP machine 130 is positioned within the reach of mandrel 140 and preform 150. Furthermore, mandrel 140 moves relative to the PNP machine 130, for example, in the processing direction 14.

[0068] Each PNP machine 130 can be similarly constructed and includes a body 131 having a lower end 133. The body 131 is configured to house the components of the PNP machine 130. Furthermore, each PNP machine 130 includes a PNP controller 132, one or more sensors 136, and an end effector 134. The PNP controller 132, one or more sensors 136, and end effector 134 may be positioned in and / or attached to the body 131. In some embodiments, the sensors 136 are included in both the body 131 and the end effector 134.

[0069] When the placement station 100 includes three PNP machines 130a, 130b, and 130c, the first PNP machine 130a includes a first body 131a, a first lower end 133a, one or more first sensors 136a, and a first end effector 134a. Similarly, the second PNP machine 130b includes a second body 131b, a second lower end 133b, one or more second sensors 136b, and a second end effector 134b, while the third PNP machine 130c includes a third body 131c, a third lower end 133c, one or more third sensors 136c, and a third end effector 134c.

[0070] The end effector 134 may optionally move along and / or extend and retract from the body 131 of the PNP machine 130. In one example, the body 131 includes a rail or other means that enables the end effector 134 to move at least vertically along the body 131. Alternatively or additionally, the end effector 134 is positioned near the lower end 133 of the body 131, and at least a portion of the end effector 134 extends vertically from the body 131. For example, the end effector 134 may move vertically to the lower end 133 of the body 131, and a portion of the end effector 134 (e.g., clamping system 139) extends vertically from the body 131 and retracts vertically back into the body 131.

[0071] The end effector 134 includes at least a clamping system 139, such as a vacuum system 138. In an alternative embodiment, the clamping system 139 and / or the vacuum system 138 are included separately from the end effector 134 in the PNP machine 130. In a particular example, the PNP machine 130 includes a vacuum system 138 to apply a vacuum pressure 160. Figure 10 and Figure 12 (As shown in the diagram), the vacuum pressure holds the large preform 156 and the discrete preform 154. The PNP machine 130 has a distal end 135. The distal end 135 may be defined by the end effector 134 and / or the clamping system 139 when the end effector 134 is positioned near or below the lower end 133 of the PNP machine 130 and / or when it extends from the PNP machine 130.

[0072] When the placement station 100 includes three PNP machines 130a, 130b, and 130c, the first PNP machine 130a includes a first distal end 135a, a first clamping system 139a, and / or a first vacuum system 138a. Similarly, the second PNP machine 130b includes a second distal end 135b, a second clamping system 139b, and / or a second vacuum system 138b, and the third PNP machine 130c includes a third distal end 135c, a third clamping system 139c, and / or a third vacuum system 138c.

[0073] The end effector 134 may include additional components to perform operations other than clamping, or may be removed and replaced in the PNP machine 130 to allow different types of end effectors to be coupled to the PNP machine 130. One or more sensors 136 are configured to supply data 137 to the unit controller 120 to enable control of the associated PNP machine 130. The one or more sensors 136 may be one or more position sensors (e.g., to measure or determine the position of the end effector 134 and / or the PNP machine 130). Alternatively or additionally, the sensors may be one or more pressure sensors (e.g., for measuring vacuum pressure applied by the vacuum system 138), one or more line break sensors, one or more hydraulic sensors, one or more image sensors (e.g., cameras), one or more radio frequency sensors (e.g., RFID and / or RADAR), one or more light sensors (e.g., LIDAR), barcode or QR code readers, etc.

[0074] During pick-up and place-down operations, the PNP machine 130 can operate the clamping system 139 at the end effector 134 to place the strong backplate 180 onto the object 18 set in the tray 190. The PNP machine 130 can move the object 18 to a position at the mandrel 140 via the strong backplate 180, for example, the mandrel 140 being sized to receive the object 18 within a cutout 142. The clamping system 139 can be a vacuum system 138 configured to apply a vacuum pressure 160. For example, the vacuum system 138 selectively applies a vacuum pressure 160. The vacuum pressure 160 is applied to or through the strong backplate 180 to clamp the object 18. Alternatively, when the strong backplate 180 is not included in the placement station 100, the vacuum pressure 160 is applied to the object 18. The tray 190 may be a vacuum tray configured to apply vacuum pressure to one or more objects 18 to maintain the position of one or more objects 18 relative to the tray 190.

[0075] Unit controller 120 coordinates the actions of PNP machine 130 by selectively operating it in synchronous and asynchronous modes, as shown in reference [reference needed]. Figure 22 and Figure 23 More detailed description. Loop placement operation (e.g., Figure 23 The operation shown (352) includes a series of phases, during which the PNP machine 130 operates in a specific mode. When the PNP machine 130 performs a cyclic placement operation, the PNP machine 130 operates in synchronous mode during the synchronous phase of the cycle and in asynchronous mode during the asynchronous phase of the cycle.

[0076] During synchronous mode, the unit controller 120 coordinates the delivery of instructions 124 from program 122 to multiple PNP machines 130. In one example, program 122 is a numerical control (NC) program 123, and instructions 124 are NC instructions 125. Instructions 124 are a series of instructions sent to each PNP machine 130 at appropriate times. Therefore, instructions 124 can be formatted as a series of instructions that includes previous instructions 124 and new instructions 124 sent after the previous instructions 124, for example... Figure 23 The series shown. Program 122 includes multiple sets of instructions 124 to correspond to different types of spindles 140 and / or spindle segments 235. Figure 21 (as shown) and corresponding to different types of objects 18 placed by the PNP machine 130. In addition, the vacuum system 138 selectively applies vacuum pressure 160 according to program 122.

[0077] In one implementation, the unit controller 120 blocks the transmission of new instructions 124 to the PNP machines 130 until each of the PNP machines 130 completes its current instruction. This allows the PNP machines 130 to lift, carry, and transport large objects 22 (e.g., precast longitudinal beams 159 to form intermediate longitudinal beams, long longitudinal beams, etc.) in a coordinated manner. During asynchronous mode, the unit controller 120 provides instructions from program 122 to each of the PNP machines 130 as soon as possible after each PNP machine 130 completes its operation, without waiting for progress reports from other PNP machines 130a, 130b, or 130c.

[0078] A first subset 126 of PNP machines 130 can operate in synchronous mode, and a second subset 128 of PNP machines 130 can operate in asynchronous mode. Alternatively, all PNP machines 130 may operate in either synchronous or asynchronous mode. In some examples, subsets 126 and / or 128 are distributed across multiple placement stations 100, 100'. For example, the first PNP machine 130 of subset 126 may be located in the first placement station 100, and the second PNP machine 130' of subset 126 may be located in the second placement station 100'.

[0079] When the placement system 50 includes multiple placement stations, such as a first placement station 100 and a second placement station 100', the unit controller 120 and / or 120' can operate the PNP machine 130 in the first placement station 100 to operate in synchronous or asynchronous mode, and the unit controller 120' can operate the PNP machine 130' in the second placement station 100' to operate in another mode, so that each placement station 100, 100' operates in different modes. The unit controller 120 and / or 120' can alternately operate the PNP machines 130, 130' in multiple placement stations 100, 100' to operate in the same mode.

[0080] PNP controller 132 manages the operation of each PNP machine 130 and interprets received instructions 124 to control the end effector 134. PNP controller 132 receives input from sensors 136 (e.g., vacuum sensors, position sensors, line break sensors, hydraulic sensors, LIDAR sensors, etc.) and can report data 137 to unit controller 120 for interpretation. Based on the data 137 from the sensors 136, unit controller 120 can suspend operation, notify technicians, or modify the instructions 124 provided to the PNP machine 130. Unit controller 120 and PNP controller 132 can be implemented as, for example, a custom circuit system, a hardware processor executing programmed instructions, or some combination thereof.

[0081] The placement station 100 may also include a tray 190. The tray 190 may be removed from the placement station 100 to load one or more preforms 150 into the tray 190, or one or more preforms 150 may be loaded into the tray 190 while it is in the placement station 100. The placement system 100 may also include a strong backplate 180. In embodiments where one or more PNP machines 130 directly hold one or more preforms 150, the strong backplate 180 may be removed from the placement station 100. The vacuum system 138 selectively applies vacuum pressure 160 (e.g., suction) to the strong backplate 180 and / or the preforms 150 (e.g., directly or via the strong backplate 180) according to instructions 124 in procedure 122.

[0082] The mandrel 140 is movable relative to the PNP machine 130, entering and passing through the placement station 100, and correspondingly through the manufacturing unit 110. This movement will refer to... Figure 3 A more detailed description is provided. The mandrel 140 has a wavy cross section 143 (in... Figure 3 (Shown in more detail below). More specifically, the mandrel 140 includes a cutout 142 defining a wavy cross-section 143 of the mandrel 140. The cutout 142 may be a channel, groove, recess, or other contour corresponding to an object 18 to be placed, manufactured, and / or assembled on the mandrel 140. Optionally, the mandrel 140 may have an associated vacuum system 144 to hold the preform 150 in the cutout 142. A vacuum channel 146 may be defined through the mandrel 140 to provide flow communication with the vacuum system 144, such that the vacuum system 144 applies a vacuum pressure 147 to the cutout 142 via the corresponding vacuum channel 146.

[0083] An optional vacuum system 144 is included in the placement system 50, the placement station 100, and / or the mandrel 140. When the vacuum system 144 is included in the placement station 100, the mandrel 140 is fluidly connected to the vacuum system after being positioned in the placement station 100, and is disconnected from the vacuum system 144 when the mandrel 140 is removed from the placement station 100. When the placement system 50 includes an assembly station 105, the placement system 50 includes the vacuum system 144, so a vacuum pressure 147 can be applied at the placement station 100 and the assembly station 105 until the mandrel 140 is removed from the placement system 50 and disconnected from the vacuum system 144. However, the placement system 50 may include a separate vacuum system 144 for placement station 100 and assembly station 105, such that when the mandrel 140 moves from placement station 100 to assembly station 105, the mandrel 140 is disconnected from and reconnected to the vacuum system 144. Alternatively, the vacuum system 144 may be integrated into the mandrel 140 and move along the manufacturing line 10 through various systems with the mandrel 140.

[0084] When the mandrel 140 includes mandrel segments 235, each mandrel segment 235 can be connected to and disconnected from a corresponding vacuum system 144 or a common vacuum system 144 at the placement system 50 and / or placement station 100. Alternatively, each mandrel segment 235 includes a corresponding vacuum system 144 that travels with each mandrel segment 235.

[0085] To aid in aligning the strong backplate 180 with the tray 190 and the mandrel 140, the strong backplate 180 includes a strong backplate indexing element 182, the tray 190 includes a tray indexing element 192, and the mandrel 140 includes a mandrel indexing element 148. The strong backplate indexing element 182 is configured to align with the tray indexing element 192 and the mandrel indexing element 148. In a particular embodiment, the strong backplate indexing element 182 engages with (e.g., is fitted into) the mandrel indexing element 148 and the tray indexing element 192.

[0086] Figure 3 This is a perspective view of the placement station 100, showing the PNP machine 130 arranged in the manufacturing unit 110 in the illustrative embodiment. The manufacturing unit 110 includes a frame 112 and a support member 114. The support member 114 is connected to the frame 112 and is configured to support the PNP machine 130. Figure 3 As shown, the PNP machine 130 is supported by a frame 112 and a support 114. The PNP machine 130 travels along the frame 112 and the support 114 to pick up and transport prefabricated parts 150 from the pallet 190. Figure 2(As shown) to be placed on a mandrel 140 having a corrugated cross section 143 and a cutout 142 for receiving longitudinal beams.

[0087] More specifically, the PNP machine 130 travels in the Y direction along the support 114. The support 114 may optionally move in the X direction along the frame 112. When the support 114 can move in the X direction on the frame 112, the program 122 in the unit controller 120 includes instructions 124 that prevent collisions between the PNP machine 130 and / or the end effector 134. Furthermore, the PNP machine 130 and / or the end effector 134 are configured to move vertically in the Z direction relative to the support 114. In one example, the PNP machine 130 moves in the Z direction along a track or other means that can vertically move the PNP machine 130. Alternatively or additionally, the end effector 134 and / or the clamping system 139 extend and retract relative to the PNP machine 130 in the Z direction, as described above. (See reference...) Figure 24A and Figure 24B In more detail, at least the distal end 135 and / or end effector 134 of the PNP machine 130 move in the Y and Z directions, and optionally in the X direction, to move to the appropriate position on the pallet 190 and transport the object 18 from the pallet 190 to the spindle 140.

[0088] Figure 4 In the illustrative embodiments, it is possible to... Figures 1 to 3 A perspective view of a first example tray 190 used in conjunction with the placement system 50. The tray 190 is configured to be applied to the mandrel 140 ( Figures 1 to 3 (as shown) hold at least one preform 150 ( Figure 2 As shown in the diagram). Tray 190 stores the longitudinal beam 778 (to be placed onto mandrel 140). Figure 29 (as shown in the image) or other prefabricated parts 150 of objects 18.

[0089] The tray 190 includes a body 194 having a surface 196 and one or more recesses 198 defined in the surface 196. The recesses 198 are configured to store objects 18. The tray 190 also includes a transposition cup 193 as a tray transposition element 192. The transposition cup 193 facilitates alignment of the strong backplate 180 with the tray 190. The recesses 198 have a length L. In some embodiments, a layer of fluorinated ethylene propylene (FEP) or another release membrane 26 ( Figure 6 (As shown) is positioned in the recess 198 to facilitate the separation of the preform 150 from the tray 190.

[0090] The tray 190 can be a first type of tray 190a comprising a plurality of recesses 198. Each recess 198 is configured to store a corresponding preform 150. Each recess 198 may have the same depth, or at least one recess 198 may be deeper or shallower than the others. Figure 4 In the example shown, multiple recesses 198 are similarly configured to store multiple prefabricated parts 150 of the same type. For example, tray 190a includes multiple recesses 198, each configured to store a corresponding large prefabricated part 156. Figure 5 (as shown in the diagram), such that tray 190a stores multiple large preforms 156. Alternatively, tray 190 can be a second type of tray 190b including a recess 198. Recess 198 can store one or more preforms 150. When recess 198 stores multiple preforms 150, the preforms 150 can be multiple discrete preforms 154 ( Figure 5 (As shown), a combination of multiple large preforms 156 or (one or more) discrete preforms 154 with (one or more) large preforms 156. For example, tray 190b may store an array of discrete preforms 154 within the same recess 198.

[0091] The two types of pallets 190a and 190b can be a group 191 of pallets 190 that can be used with placement station 100. When using group 191, the first type of pallet 190a can store multiple longitudinal beam prefabricated components 159 (e.g., Figure 5 (as shown), and the second type of tray 190b can store multiple frame filler prefabricated parts 158 (as shown). Figure 5 (As shown).

[0092] Figure 5 Is it possible to... Figures 1 to 3 The perspective view shows a second example tray 190 used in conjunction with the placement system 50, which includes example prefabricated components 150 that can be placed by the placement station 100. The prefabricated components 150 include a large prefabricated component 156 shown as a longitudinal beam prefabricated component 159 and discrete prefabricated components 154 shown as a frame filler prefabricated component 158. Figure 5 The tray 190 is a third type of tray 190c, which includes a recess 198 configured to store one or more large preforms 156 and discrete preforms 154. More specifically, the third type of tray 190c includes a recess 198 having a first shape 197 and a second shape 199. The first shape 197 corresponds to the discrete preform 154, and the second shape 199 corresponds to the large preform 156.

[0093] The recesses, having two different shapes, such as first shape 197 and second shape 199, allow a third type of tray 190C to store the kit prefabricated parts 150. When kitted, the discrete prefabricated parts 154 are arranged to be placed at position 781, relative to (one or more) the larger prefabricated parts 156 (i.e., relative to the longitudinal beam 778 formed by the longitudinal beam prefabricated parts 159). Figure 29 As shown in the figure, to install frame 780 ( Figure 29 (As shown in the diagram). In other words, discrete object 20 is positioned in tray 190c, where one or more large objects 22 are located at position 195, at which frame 780 is mounted relative to one or more large objects 22. Position 781 of fuselage 766 corresponds to position 195 in tray 190 either in full size or at a reduced scale. When the correspondence is full size, preforms 154 and 156 do not move relative to each other as they are transported from tray 190 to mandrel 140. When the correspondence is at a reduced scale, preforms 154 and 156 can be further unfolded to transform into full size as they move from tray 190 to mandrel 140.

[0094] exist Figure 5 In the example, discrete prefabricated member 154 is positioned at location 195 where the frame 780 will be installed relative to the large prefabricated member 156. More specifically, frame filler prefabricated member 158 is positioned at location 195 in a recess 198, corresponding to the location where the frame 780 will be positioned relative to a longitudinal beam 778 formed by longitudinal beam prefabricated member 159. For example, longitudinal beam prefabricated member 159 is stored in each recess 198 having a second shape 199, and frame filler prefabricated member 158 is stored at location 195 in a recess 198 having a first shape 197.

[0095] When prefabricated component 150 is mated, unit controller 120 operates PNP machine 130 to transport (one or more) large prefabricated components 156 and discrete prefabricated components 154, while maintaining the arrangement of (one or more) large prefabricated components 156 and discrete prefabricated components 154 relative to each other. Thus, the mating arrangement in tray 190c is maintained from tray 190c to placement on mandrel 140.

[0096] As a complementary alternative, an array of discrete preforms 154 fills the recess 198 in a first shape 197, and the PNP machine 130 picks up each discrete preform 154 from the tray 190c and places the discrete preforms 154 at specific locations on the mandrel 140 relative to the larger preform 156 and other discrete preforms 154. This example allows more discrete preforms 154 to be stored in the tray 190c compared to when the discrete preforms 154 are spaced apart at positions 195 in the recess 198. However, the complementary preforms 150 ensure that an appropriate number of preforms 150 are placed at the placement station 100 for the specific portion of structure 12 currently being assembled.

[0097] Figures 6 to 14 The illustration shows the transfer of preform 150 from tray 190 to backing plate 180 and from backing plate 180 to mandrel 140 in an illustrative embodiment.

[0098] Figure 6 yes Figure 4 and Figure 5 The diagram shows a side cross-sectional view of tray 190 taken at line 6-6, where prefabricated component 150 (one or more) is absent. Figure 6 In the middle, pallet 190 awaits loading of object 18 ( Figure 1 and Figure 2 (As shown in the diagram). The tray vacuum channel 200 is optional and is... Figure 6 As shown in the figure, each recess 198 of the tray 190 may have one or more vacuum channels 200 extending from the recess 198 through the body 194. The vacuum channels 200 are configured to provide flow communication between the respective recess 198 and the vacuum system 202 to apply vacuum pressure 204. Figure 7 (as shown in the image). Figure 6 An optional release membrane 26 is also shown, which can be positioned in one or more recesses 198 to facilitate removal of the preform 150 from the tray 190. Figure 7 (As shown).

[0099] Figure 7 yes Figure 6 The example shown has a prefabricated component 150 (e.g. Figure 5 A side cross-sectional view of tray 190 of (one or more) prefabricated components shown. Figure 7 In this process, the preform 150 has been loaded into the recess 198 (e.g., by the end effector of an automated machine, by a technician, etc.). This can be performed by laying the preform 150 into the recess 198 via the operation of a tape layer, physically picking up the preform 150 from the laying mandrel and placing the preform 150 into the recess 198, etc. Figure 7A vacuum pressure 204 is also shown, which can optionally be applied to the preform 150 positioned in the recess 198. When in use, the vacuum pressure 204 is supplied by a vacuum system 202 ( Figure 2 As shown in the diagram, it is applied through vacuum channel 200.

[0100] Figure 8 yes Figure 6 and Figure 7 The tray 190 shown is compatible with Figures 1 to 3 A side cross-sectional view of the strong backplate 180 used in conjunction with the placement system 50 shown. Figure 8 In this configuration, a strong back panel 180 is disposed on top of a tray 190. The strong back panel 180 includes recesses 184 for receiving preforms 150. More specifically, the strong back panel 180 includes a body 186 having a surface 185 and one or more recesses 184 defined in the surface 185. The strong back panel 180 may include recesses 184 for each preform 150 to be removed from the tray 190 and / or the same number of recesses 184 as the number of tray recesses 198. In a particular example, the tray 190 stores multiple preforms 150, and the strong back panel 180 includes multiple recesses 184. Figure 17 An example of a reinforcing backplate 180 including multiple recesses 184 is shown. The recesses 184 may also be fitted with an optional release membrane 26. In another embodiment, the reinforcing backplate 180 may be sized to carry multiple preforms 150 from a tray 190 at a time.

[0101] The backplate 180 also includes indexing pins 183 as indexing elements 182. The indexing pins 183 are used to align the backplate 180 with the tray 190. The shape of each indexing pin 183 corresponds to the shape of an indexing cup 193 of the tray 190. For example, when the cup 193 is a tapered bore, each indexing pin 183 can be configured as a cone. Therefore, when the backplate 180 engages with the tray 190 (see...),... Figure 9 Each indexing pin 183 can be received in the corresponding indexing cup 193.

[0102] Vacuum channel 188 is defined to extend from recess 184 through body 186. Vacuum channel 188 is configured to connect recess 184 and vacuum system 138 of PNP machine 130. Figure 2 The backplate 180 may provide flow communication between the recesses 184 and the PNP machine 130. The backplate 180 may include one or more vacuum channels 188 for each recess 184. When the backplate 180 includes more than one recess 184, the backplate 180 also includes more than one vacuum channel 188, so that at least one vacuum channel 188 is associated with each recess 184. The vacuum channel 188 is coupled to the recess 184. The vacuum channel 188 allows the PNP machine 130 to... Figure 2The vacuum pressure 160 (shown) applied by the end effector 134 Figure 10 As shown, the preform 150 can be drawn into the appropriate position on the strong backplate 180. Depending on the type, quantity, and / or size of the preform(s) 150 picked up by the strong backplate 180, each vacuum channel 188 can operate independently or in conjunction with other vacuum channels 188. For example, only vacuum channels 188 (where the preform 150 is being held) can be activated, without activating vacuum channels 188 that do not have an associated preform 150.

[0103] Figure 9 Is with Figure 8 The tray 190 joint Figure 8 The strong backplate 180 is shown in a side cross-sectional view. The strong backplate indexing element 182 is configured to engage with the pallet indexing element 192 when the strong backplate 180 moves toward the pallet 190. More specifically, the indexing pin 183 of the strong backplate 180 is shaped to contact the indexing cup 193 of the pallet 190 to guide the strong backplate 180 relative to the pallet 190, thereby aligning one or more recesses 184 of the strong backplate 180 with one or more recesses 198 of the pallet 190.

[0104] For example, the indexing pin 183 and the indexing cup 193 are tapered, such as conical, to allow for larger tolerances in the initial misalignment between the strong backplate 180 and the tray 190, and to reduce the misalignment as the strong backplate 180 and the tray 190 move closer together, until the indexing pin 183 is centered in the indexing cup 193 when the strong backplate 180 is in a position relative to the tray 190 to begin holding and lifting the preform 150. Alternatively, the tray 190 includes an indexing pin, while the strong backplate 180 includes an indexing cup for aligning the tray 190 and the strong backplate 180 as described above.

[0105] When the reinforcing backplate 180 is aligned with the preform 150 and / or tray 190, vacuum pressure 160 is applied through vacuum channel 188. For example, unit controller 120 instructs one or more vacuum systems 138 to activate to apply vacuum pressure 160. When vacuum pressure 160 is applied, the preform 150 is held in contact with the reinforcing backplate 180. If optional vacuum pressure 204 has already been applied to the preform 150 through tray 190, unit controller 120 instructs vacuum system 202 to deactivate and stop applying vacuum pressure 204. Stopping vacuum pressure 204 at tray 190 facilitates the transfer of preform 150 from tray 190 to reinforcing backplate 180.

[0106] Figure 10 yes Figure 8 and Figure 9 The diagram shows a side cross-sectional view of a strong backplate 180 with prefabricated component 150. Figure 10 In the middle, when the strong back panel 180 and the prefabricated component 150 are lifted away from the pallet 190 ( Figure 10 When vacuum pressure 160 is applied (not shown), the strong back plate 180 is lifted, thereby keeping the preform 150 and any other large preforms 156 and / or discrete preforms 154 against the strong back plate 180. When the strong back plate 180 is lifted away from the tray 190, the indexing pin 183 engages with the indexing cup 193 (not shown). Figure 9 (As shown in the image) detachment.

[0107] Figure 11 Is it possible to... Figures 1 to 3 The placement system 50 and / or shown Figure 1 The mandrel 140 used in manufacturing line 10 is shown in a side cross-sectional view. The mandrel 140 awaits disassembly from the strong backing plate 180 (…). Figure 11 (Not shown in the image) Loading. The spindle 140 includes a body 141 having an outer surface 145 of the spindle 140. The spindle 140 also includes a cutout 142 defined in the outer surface 145. Figures 11 to 14 The cut 142 shown may be one of a plurality of cuts 142 in the mandrel 140, each cut being designed to receive one or more preforms 150. The outer surface 145 defines at least a portion of the wavy cross section 143 of the mandrel 140.

[0108] The outer surface 145 or at least each cut 142 optionally includes a release membrane 62 to facilitate the removal of one or more preforms 150 and / or hardened structures 64 from the mandrel 140. Figure 1 (As shown). When the release membrane 62 is used on the mandrel 140, the release membrane 62 is applied to the mandrel 140 before or when the mandrel enters the placement system 50.

[0109] Vacuum channel 146 is defined to extend through body 141 from cutout 142 and / or outer surface 145. Vacuum channel 146 is configured to connect with vacuum system 144 at outer surface 145 and / or cutout 142. Figure 2 A flow communication is provided between the cutouts 142 and the mandrel 140. The mandrel 140 may include one or more vacuum channels 146 for each cutout 142. Alternatively or additionally, the mandrel 140 may include one or more vacuum channels 146 to an outer surface 145 to, for example, hold the discrete preform 154 against the outer surface 145. When the mandrel 140 includes more than one cutout 142, the mandrel 140 also includes more than one vacuum channel 146, so that at least one vacuum channel 146 is associated with each cutout 142. The vacuum channel 146 is coupled to the cutout 142. The vacuum channel 146 allows a vacuum pressure 147 (as shown in the diagram) applied by the vacuum system 144 to be maintained. Figure 13As shown, the preform 150 can be drawn into the appropriate position on the mandrel 140. Depending on the type, number, and / or size of the preform 150 placed on the mandrel 140, each vacuum channel 146 can operate independently or in conjunction with other vacuum channels 146. For example, only the vacuum channel 146 where the preform 150 has been placed is activated, while vacuum channels 146 without associated preforms 150 are not activated.

[0110] Figure 12 In the illustrative implementation Figures 6 to 11 The diagram shows a side cross-sectional view of the mandrel 140, the reinforcing backplate 180, and the preform 150. Figure 12 In this configuration, a strong backplate 180 moves over a mandrel 140 having one or more cutouts 142. A strong backplate indexing element 182 is configured to engage a mandrel indexing element 148 as the strong backplate 180 moves toward the mandrel 140. More specifically, an indexing pin 183 of the strong backplate 180 is shaped to contact an indexing cup 149 of the mandrel 140 to guide the strong backplate 180 relative to the mandrel 140, thereby aligning one or more recesses 184 of the strong backplate 180 with the cutouts 142 of the mandrel 140.

[0111] For example, a transposition cup 193 similar to tray 190 (such as...) Figure 9 As shown, the indexing cup 149 of the mandrel 140 is tapered to allow for a larger tolerance in the initial misalignment between the strong backplate 180 and the mandrel 140, and to reduce the misalignment as the strong backplate 180 and the mandrel 140 move closer together, until the indexing pin 183 is centered in the indexing cup 149 when the strong backplate 180 is in the position to begin placing the preform 150 on the mandrel 140 relative to the mandrel 140. Alternatively, when the tray 190 includes an indexing pin and the strong backplate 180 includes an indexing cup, the mandrel 140 includes an indexing pin to engage the indexing cup of the strong backplate 180.

[0112] Each cutout 142 may include an associated replica of its own indexing cup 149 for alignment with the strong backplate 180, or multiple sets of cutouts 142 may share one or more sets of indexing cups 149. In another embodiment, a plurality of preforms 150 are placed side by side along the length L of the cutout 142 and are mechanically integrated via interlocking joints, lamination bevels, or other features.

[0113] Figure 13 yes Figure 12The diagram shows a side cross-sectional view of the mandrel 140, the reinforcing backplate 180, and the preform 150, wherein the reinforcing backplate 180 and / or the preform 150 have been placed on the mandrel 140. When the reinforcing backplate 180 is aligned with the mandrel 140, vacuum pressure 160 is released through vacuum channel 188. For example, unit controller 120 instructs vacuum system(s) 138 to deactivate to release vacuum pressure 160. When vacuum pressure 160 is released, preform 150 is placed in the cutout 142 of the mandrel 140. Alternatively or additionally, when vacuum pressure 160 is released, preform 150 is placed on the outer surface 145 of the mandrel 140. If an optional vacuum pressure 147 is applied to the preform 150 through the mandrel 140, then unit controller 120 instructs vacuum system 144 ( Figure 2 (As shown) Initiate and apply vacuum pressure 147. Applying vacuum pressure 147 at mandrel 140 facilitates fastening preform 150 to mandrel 140.

[0114] exist Figure 13 In the middle, release or reverse the vacuum pressure 160, and place the preform 150 (and any other (one or more) large preforms 156 and / or (one or more) discrete preforms 154) Figure 5 As shown in the diagram, it is positioned appropriately at the cut 142. The object 18 comprises an uncured preform of fiber-reinforced material 152 (both are in...). Figure 1 In the embodiment shown in the figure, the reinforcing backplate 180 can be operated to secure (e.g., adhere, press, bind, etc.) the preform 150 of the uncured fiber-reinforced material 152 to the mandrel 140. The vacuum system 144 is operated to additionally or alternatively secure the preform 150 to the mandrel 140 via vacuum pressure 147.

[0115] Figure 14 yes Figure 12 and Figure 13 The diagram shows a side cross-sectional view of the mandrel 140, the reinforcing backplate 180, and the preform 150, wherein the preform 150 has been placed on the mandrel 140. The vacuum pressure is released to 160 ( Figure 12 (As shown) After placing the preform 150 on the mandrel 140, it is passed through (one or more) PNP machines 130 ( Figures 1 to 3 (As shown) The strong backplate 180 is lifted away from the mandrel 140. As the strong backplate 180 is lifted, the indexing pin 183 disengages from the indexing cup 193. (One or more) PNP machines 130 move the strong backplate 180 to pick up additional preforms 150 from the tray 190 and place the additional preforms onto the mandrel 140 until the required number of preforms 150 have been placed.

[0116] Use the components placed at workstation 100 and Figures 6 to 14The technique shown, instruction 124 in the asynchronous phase ( Figure 2 (As shown) allows each of the PNP machines 130 to place the strong backplate 180 on the object 18, such as discrete object 20. Figure 1 and Figure 2 As shown), a vacuum pressure 160 is applied to hold the object 18 at the strong back plate 180, the strong back plate 180 is raised to the appropriate position on the mandrel 140, and the vacuum pressure 160 is released to remove the object 18 from the strong back plate 180 when the object 18 contacts the mandrel 140. Command 124 in the synchronization phase causes each of the PNP machines 130 to synchronously place the strong back plate 180 on the large object 22. Figure 1 As shown), a vacuum pressure 160 is applied, which is maintained at the strong backplate 180 across the large object 22 of the PNP machine 180, to raise the strong backplate 180 to the appropriate position above the mandrel 140, and the vacuum pressure 160 is released to remove the large object 22 from the strong backplate 180 when the large object 22 contacts the mandrel 140.

[0117] Figure 15 This is an end view of a mandrel 140 in an illustrative embodiment, which can be used as... Figures 11 to 14 The spindle 140 shown and / or may be with Figures 1 to 3 The placement system 50 and / or shown Figure 1 It is used together with the manufacturing line 10 shown. For example, Figure 15 yes Figure 3 The end view of the mandrel 140 is shown, and the cross-section of the mandrel 140 is observed at line 11. Figures 11 to 14 A view of the mandrel 140. For illustrative purposes, radial region Z1 shows the longitudinal beam preform 159 and layer 206 after the strong back plate 180 has been lifted away from the mandrel 140, and radial regions Z2 and Z3 show the mandrel 140 before the preform 150 is placed on the mandrel 140.

[0118] In the illustrative embodiment, the mandrel 140 has a cutout 142 (e.g., in the form of a channel) for receiving the preform 150. The cutout 142 and / or the outer surface 145 define a wavy cross-section 143 of the mandrel 140. Figure 3 and Figures 15 to 21 In the example, the wavy cross section 143 is arc-shaped. Figure 15In this process, cutouts 142 along the outer surface 145 are used to receive longitudinal beam preforms 159. Sheets of material forming the skin 782 of the aircraft 750 can then be laid on top of the longitudinal beam preforms 159 as one or more layers 206 and hardened to produce a semi-cylindrical section 770 (or a full-cylindrical section 776) as a single integral piece, which includes the skin 782 and longitudinal beams 778 (see...) for co-curing. Figure 29 ).

[0119] For ease of placement, the mandrel 140 is divided into radial portions 208, 210, and 212, corresponding to radial regions Z1, Z2, and Z3, respectively. In placement station 100, preforms 150 can be sequentially or parallelly placed at radial regions Z1, Z2, and Z3 and / or radial portions 208, 210, and 212 on the mandrel 140. Alternatively, the mandrel 140 can receive preforms 150 from different radial portions 208, 210, and 212 from different placement stations 100, 100', and 100" as follows: Figure 19 As shown. Can be modified. Figure 19 An example is the use of one or more placement stations 100 to place preforms 150 in parallel across multiple regions Z1, Z2, and / or Z3 by simultaneously operating multiple PNP machines 130 at different radial sections 208, 210, 212. One or more radial sections 208, 210, and / or 212 can be assigned to technicians for manual placement of the preforms 150. This coordinated placement across radial sections 208, 210, and 212 provides technical benefits by increasing the placement rate of the preforms 150 on a single mandrel 140.

[0120] When from the axial segment 235 ( Figure 21 When assembling the mandrel 140 (as shown), each mandrel segment 236, 238, and 240 is a different radial portion 208, 210, or 212 of the mandrel 140. Furthermore, when assembling the mandrel 140 from mandrel segment 235, each mandrel segment 236, 238, and 240 is positioned in a different radial region Z1, Z2, or Z3. Figure 25 Further details of assembling 504 and positioning 508 are shown.

[0121] Figure 16 This is an end view of the mandrel 140 with a strong backplate in the illustrative embodiment. In this example, the strong backplate 180 includes a strong backplate segment 181 and can be used as... Figures 8 to 10 and Figures 12 to 14A strong backplate is included. For example, strong backplate 180 includes a first strong backplate segment 181a, a second strong backplate segment 181b, and a third strong backplate segment 181c; however, strong backplate 180 may include any suitable number of strong backplate segments 181. For example, strong backplate 180 includes a single strong backplate segment 181, which is repositioned relative to mandrel 140 when preform 150 is placed on mandrel. Strong backplate segment 181 moves through radial regions Z1, Z2, and Z3 to be positioned (e.g., via transport 408). Figure 24A and Figure 24B (As shown) in each radial portion 208, 210, and 212 of the mandrel 140. Alternatively, the strong backplate 180 is continuous along the mandrel 140 and does not include the strong backplate segment 181.

[0122] The cross-sectional shape of the reinforcing backplate 180 corresponds to (e.g., is complementary to) the cross-sectional shape of the mandrel 140. Furthermore, the mandrel 140 and the reinforcing backplate 180 are shaped to correspond to the structure 12 assembled by the placement system 50. More specifically, as... Figure 16 As shown, the mandrel 140 is arcuate, and the backplate 180 is arcuate. When the backplate 180 includes backplate segments 181, each backplate segment 181 is arcuate. The mandrel 140 can be arcuate, and the backplate 180 can be correspondingly arcuate; the mandrel 140 and the backplate 180 can be used to assemble and / or manufacture part 768 of the fuselage 766 (e.g., Figure 29 (As shown).

[0123] like Figure 16 As shown, the backplate 180 and / or each backplate segment 181 includes a plurality of preforms 150. For example, the backplate 180 includes a large preform 156 for placement within a corresponding cutout 142. Furthermore, during placement, the backplate 180 and / or each backplate segment 181 includes discrete preforms 154 at the inner surface 185 of the backplate 180. In an exemplary embodiment, each discrete preform 154 is a set of buffer sheets (e.g., such as...). Figure 18 The uncured fiber-reinforced material 152 shown in layer 216), the set of buffer sheet layers forming a preform stack (i.e., multi-layer sheet stack) referred to as "stamps" or "frame filler" 784, which facilitates the placement of the frame 780 (e.g., Figure 29 (As shown). In such an embodiment, the large precast component 156 is the longitudinal beam precast component 159, and the discrete precast component 154 is the frame filler precast component 158.

[0124] Figure 17 In the illustrative embodiments Figure 16A bottom view of a strong backplate 180 on which one or more prefabricated components 150, cut at line 17-17, are placed. Figure 17 This is an inner diameter view of a strong backplate 180 and / or strong backplate segment 181 having discrete preforms 154 and large preforms 156. In this example, the strong backplate 180 includes a plurality of recesses 184. More specifically, the strong backplate 180 includes a recess 184 corresponding to each of the plurality of preforms 150 that will be picked up and placed using the strong backplate 180. Thus, each preform 150 is fitted within a specific recess 184 among the plurality of recesses 184 of the strong backplate 180.

[0125] The frame packing preform 158 is arranged at discrete locations on the inner surface 185 (e.g., at recesses 184) along the length L of the reinforcing back plate 180, while the longitudinal beam preform 159 is arranged parallel to the length L. In these embodiments, the associated tray 190 for holding the longitudinal beam preform 159 and the frame packing preform 158 may include recesses 198 for both the longitudinal beam preform 159 and the frame packing preform 158, such as... Figure 5 The tray 190c and prefabricated parts 158 and 159 are shown.

[0126] When a vacuum pressure of 160 is applied, each of the discrete preforms 154 is held in contact with at least one larger preform 156. For example, to be in contact with Figure 18 The arrangement shown is similar to that of the prefabricated components 154 and 156, which are kept in contact with each other at the strong backplate 180.

[0127] Although the recess 198 of the tray 190 ( Figure 4 (as shown), the cut 142 of the mandrel 140 Figure 11 The recess 198, cutout 142, and strong back plate 180 are both shown to have the same length L, but the lengths of the recess 198, cutout 142, and strong back plate 180 may be different from each other.

[0128] Figure 18 yes Figure 17 The diagram shows an end cross-sectional view of the mandrel 140 and (one or more) preforms 150, wherein the strong backplate 180 moves away from the mandrel 140. Figure 18The example shown includes a first longitudinal beam prefabricated member 159a and a second longitudinal beam prefabricated member 159b adjacent to the first longitudinal beam prefabricated member 159a. Each longitudinal beam prefabricated member 159 is positioned in a corresponding cut 142 in the mandrel 140. A frame filler prefabricated member 158 is positioned between adjacent first longitudinal beam prefabricated members 159a and second longitudinal beam prefabricated members 159b. In an exemplary embodiment, the longitudinal beam prefabricated members 159 and the frame filler prefabricated members 158 overlap at the ramp 214; however, the longitudinal beam prefabricated members 159 and the frame filler prefabricated members 158 may be abutted or spaced apart at their flat ends, such that a gap is defined between at least two prefabricated members in the prefabricated members 150.

[0129] Each frame filler preform 158 comprises multiple layers 216 of uncured fiber reinforcement material 152. The multiple layers 216 are coupled to the skin 782 in the intended frame 780. Figure 29 The stacking area is formed at position 781 (as shown). The stacking provided by the frame filler prefabrication 158 enables a simpler frame laying construction because the stacking area adjoining the frame 780 may be easier to achieve than adding flange engagement to the frame to adjoin the skin 782 or adding flange engagement to the longitudinal beam 778.

[0130] Each discrete precast component 154 is held in contact with at least one large precast component 156, for example, each frame filler precast component 158 ​​is held in contact with at least one longitudinal beam precast component 159. The discrete precast components 154 and the large precast components 156 are held in contact by gravity. When an optional vacuum system 144 is included in the placement system 50, the discrete precast components 154 and the large precast components 156 are held in contact by vacuum pressure 147. Figure 2 (As shown) are additionally or alternatively kept in contact. In addition to compaction, gravity and / or vacuum pressure 147, tape and media may be used to maintain the position of the preforms 150 relative to each other throughout the placement operation and subsequent operations.

[0131] Structure 12 may optionally include one or more layers 206 on a plurality of preforms 150, such as discrete preforms 154 and / or large preforms 156 disposed on a mandrel 140. Thus, one or more layers 206 are laid on top of the mandrel 140. Layers 206 are formed of uncured fiber-reinforced material 152, and therefore, preforms(one or more) can be considered to include layers 206 as a type of preform. When structure 12 is part 768 of fuselage 766, one or more layers 206 form the skin 782 of fuselage 766 (see...). Figure 29 Therefore, layer 206 can also be referred to as a “skin layer”. When structure 12 includes one or more layers 206, unit controller 120 is operable to place one or more layers 206 on the preform 150 set on mandrel 140.

[0132] Figures 19 to 21 The illustration shows the arrangement of placement stations on different portions of the mandrel 140, such as the first placement station 100, the second placement station 100', and the third placement station 100". In the following description, the PNP machine 130 may be distributed across multiple placement stations 100, 100', 100" and the unit controllers 120, 120', and / or 120" repeatedly operate the PNP machine 130 at each of the placement stations 100, 100', 100" in synchronous and asynchronous phases. ', 130". In one example, each of placement stations 100, 100', 100" operates PNP machines 130, 130', 130" to place object 18 onto different radial portions 208, 210, 212, or 213 of the wavy cross section 143 of mandrel 140. In another example, each of placement stations 100, 100', 100" can operate PNP machines 130, 130', 130" to place object 18 onto different longitudinal or elongated portions 224, 226, and 228 of mandrel 140. Figure 20 (as shown in the image)

[0133] Figure 19 Is it possible to... Figure 1 A perspective view of a first example of multiple placement stations 100, 100', and 100" used together with the placement system 50 shown. Specifically, Figure 19 A placement system 50 is shown, wherein placement stations 100, 100', and 100” operate PNP machines 130, 130', and / or 130” to place preforms 150 into different radial portions 208, 210, and 213 of a mandrel 140. This results in the mandrel 140 having a first set of 218 longitudinal beam preforms 159 placed by the first placement station 100, a second set of 220 longitudinal beam preforms 159 placed by the second placement station 100', and a third set of 222 longitudinal beam preforms 159 placed by the third placement station 100”. Frame filler preforms 158 may optionally be placed together with each set 218, 220, and 222 of the longitudinal beam preforms 159.

[0134] This embodiment facilitates pulsed circuit manufacturing or continuous movement manufacturing by enabling different placement stations 100, 100', and 100” to place different preforms 150, such as longitudinal beam preforms 159, in different radial portions 210, 212, and 213 of the mandrel 140 in the processing direction 14 when the mandrel 140 moves relative to the placement stations 100, 100', and 100”.

[0135] Figure 20 Is it possible to... Figure 1The diagram shows a perspective view of a second example of multiple placement stations 100, 100', 100" used together with the placement system 50. In this example, the mandrel 140 is divided into a first longitudinal section 224, a second longitudinal section 226, and a third longitudinal section 228; however, the mandrel 140 can be divided into any suitable number of longitudinal sections, depending on the size of the mandrel 140, the size of the object 18, and / or the number and position of the objects 18. When the object 18 (e.g., preform 150 or large preform 156) is shorter than the length of the mandrel 140, the object 18, such as preform 150, can be placed in the longitudinal sections 224, 226, and / or 228, or the object 18 can be divided into longitudinal segments shorter than the length of the mandrel 140, such that the object 18 can fit the length of the associated longitudinal sections 224, 226, or 228.

[0136] More specifically, Figure 20 The placement system 50 is shown, wherein stations 100, 100', 100" operate PNP machines 130, 130' and / or 130" to place objects 18, such as preforms 150, onto different longitudinal portions 224, 226 or 228 of mandrel 140. For example, a first placement station 100 places a first group 230 prefabricated components 150 in a first longitudinal section 224, a second placement station 100' places a second group 232 prefabricated components 150 in a second longitudinal section 226, and a third placement station 100" places a third group 234 prefabricated components 150 in a third longitudinal section 228. Each group 230, 232, and / or 234 of prefabricated components 150 includes a large prefabricated component 156 (e.g., a longitudinal beam prefabricated component 159). Alternatively or additionally, each group 230, 232, and / or 234 of prefabricated components 150 includes one or more large prefabricated components 156 (e.g., longitudinal beam prefabricated components 159) and one or more discrete prefabricated components 154 (e.g., frame filler prefabricated components 158). Thus, each placement station 100, 100', and 100" can be configured according to the structure 12 being assembled ( Figure 1 (As shown) The longitudinal beam precast component 159 and the frame filler precast component 158 ​​are placed in one or more longitudinal sections 224, 226 and / or 228.

[0137] Furthermore, any large preform 156 may span more than one longitudinal section 224, 226, and / or 228. When the large preform 156 extends into or through different longitudinal sections 224, 226, and / or 228, any suitable placement station 100, 100', or 100" may be used to place the large preform 156. For example, when the large preform 156 spans the first longitudinal section 224 and the second longitudinal section 226, the first placement station 100 or the second placement station 100' may be used to place the large preform 156.

[0138] This example could result in a mandrel 140 having a first set of 230 longitudinal beam prefabricated parts 159 placed at a first placement station 100, a second set of 232 longitudinal beam prefabricated parts 159 placed at a second placement station 100', and a third set of 234 longitudinal beam prefabricated parts 159 placed at a third placement station 100" to assemble longitudinal beam 778. Figure 29 (As shown in the diagram). Precast sections 150 spanning different longitudinal sections 224, 226, and / or 228 can be integrated together via any suitable splicing technique, such as interlocking joints, lap joints, or stepped lap joints. This segmented approach facilitates manufacturing environments with pulsating or continuous movement, because each of the first group 230, the second group 232, and the third group 234 of the longitudinal beam precast sections 159 can be integrated on manufacturing line 10 (as shown in the diagram). Figure 1 A series of placement stations 100, 100', and 100" were added (as shown).

[0139] Figure 21 The illustrative embodiments shown are applicable to Figure 1 A three-dimensional view of the arrangement of placement stations 100, 100' and 100" in the placement system 50 and assembly station 105. Figure 21 This is also a perspective view of a spindle segment 235 that can be used with any of the aforementioned spindle 140 figures. The spindle 140 includes a plurality of spindle segments 235. Spindle segments 235 include a first spindle segment 236, a second spindle segment 238, and a third spindle segment 240. Although three spindle segments 236, 238, and 240 are described herein, the spindle 140 may include any suitable number of spindle segments 235. Each spindle segment 235 includes the aforementioned components and features of the spindle 140, for example... Figure 2 , Figure 3 and Figures 11 to 16 The cut 142, wavy cross section 143, optional vacuum system 144, outer surface 145, optional vacuum channel 146 and / or spindle indexing element 148 (e.g., indexing cup 149) shown.

[0140] More specifically, Figure 21A placement system 50 is shown, wherein placement stations 100, 100', and 100" operate to place objects 18, such as preforms 150, onto mandrel segments 236, 238, and 240 of mandrel 140. At placement stations 100, 100', and 100" objects 18, such as preforms 150, are placed by PNP machines 130, 130', and 130" into corresponding mandrel segments 235. More specifically, the first placement station 100 places a first set 218 preforms 150 onto the first mandrel segment 236, the second placement station 100' places a second set 220 preforms 150 onto the second mandrel segment 238, and the third placement station 100" places a third set 222 preforms 150 onto the third mandrel segment 240. As described above, each group 218, 220 and 222 may include one or more longitudinal beam prefabricated elements 159 and / or one or more frame filler prefabricated elements 158.

[0141] Each mandrel segment 236, 238, and 240 corresponds to a corresponding radial portion 208, 210, or 212 of mandrel 140. For example, the first mandrel segment 236 corresponds to the third radial portion 212, the second mandrel segment 238 corresponds to the first radial portion 208, and the third mandrel segment 240 corresponds to the second radial portion 210. However, the correspondence between each mandrel segment 236, 238, or 240 and the radial portion 208, 210, or 212 can be any suitable allocation, depending on the structure 12 being assembled. Figure 1 (as shown) and the process performed by the placement system 50. Therefore, placing the object 18 onto different mandrel segments, such as the first mandrel segment 236, the second mandrel segment 238 and / or the third segment 240, can be considered as placing the object 18 onto different radial portions 208, 210 and 212 of the mandrel 140.

[0142] One or more unit controllers 120, 120' and / or 120" include those with instructions 124 ( Figure 2 All or part of the program 122 (shown in the diagram). Program 122 includes instructions 124 corresponding to each mandrel segment 236, 238, and 240. PNP machines 130, 130', and 130" receive instructions 124 from program 122, which correspond to a specific mandrel segment 236, 238, or 240 at placement station 100, 100', or 100" where PNP machines 130, 130', or 130" are operating.

[0143] Mandrel segments 235 (also referred to as “segments” or “segmented mandrels”) are assembled into mandrel 140 having radial portions 208, 210, and 212, each corresponding to a different mandrel segment among mandrel segments 238, 240, and 236. That is, mandrel segments 236, 238, and 240 can be fastened together using fasteners 242 to form mandrel 140.

[0144] Furthermore, seals can be installed between adjacent mandrel segments 235. For example, the seals between mandrel segments 235 are installed last. In one example, mandrel segments 236 and 238 are in place before mandrel segments 240 are assembled, so the seals are pressed normally rather than at an angle.

[0145] For example, after PNP machines 130, 130', 130” have completed instruction 124 in program 122, mandrel segment 235 moves from placement station 100, 100', 100” to assembly station 105. As mandrel segments 236, 238, and 240 move from placement stations 100, 100', and 100" respectively, each mandrel segment 236, 238, and 240 is moved to a corresponding radial region Z3, Z1, or Z2. More specifically, due to the correspondence between mandrel segments 236, 238, and 240 and radial portions 212, 208, and 210, when mandrel 140 is assembled from mandrel segments 236, 238, and 240, each mandrel segment 236, 238, and 240 is positioned in a corresponding radial region Z3, Z1, or Z2. Mandrel segments 236, 238, and 240 can be moved in any order to any suitable radial region Z1, Z2, or Z3 to assemble mandrel 140.

[0146] In one embodiment, mandrel segment 235 serves as a tray-like transport device. The mandrel segments 235 are then joined together, for example, by fastening, bolting, fixing, etc. For instance, mandrel segments 236, 238, and 240 are assembled together by applying fasteners 242 to them. More specifically, a second mandrel segment 238 is attached to one side of a third mandrel segment 240 using fasteners 242, and a first mandrel segment 236 is attached to the other side of the third mandrel segment 240 using fasteners 242. In this way, mandrel segments 236, 238, and 240 are assembled, with each mandrel segment 235 positioned in a different radial portion 212, 208, or 210 of the mandrel 140. The fasteners 242 can be applied after all mandrel segments 235 are positioned relative to each other, or they can be applied while each mandrel segment 235 is positioned. The seal may be installed between adjacent mandrel segments 235 before or after the fastener 242 is applied to the mandrel segment 235.

[0147] When assembly station 105 includes mandrel support structure 106, mandrel segments 235 are attached to mandrel support structure 106. For example, mandrel segments 235, either individually or together to form mandrel 140, are attached to mandrel support structure 106 using fasteners 244. In one example, mandrel segments 235 are joined together, and then mandrel 140 formed by mandrel segments 235 is attached to mandrel support structure 106. In another example, mandrel segments 235 are attached to mandrel support structure 106, and then to adjacent mandrel segments 235. Although fasteners 242 and 244 are assigned different reference numerals, fasteners 242 and 244 can be the same type of fastener or different types of fasteners.

[0148] Some implementations include assembling multiple mandrel segments 235 together into a semi-cylindrical segment 770 (or a full cylindrical segment 776 or smaller than a semi-cylindrical segment, such as a quarter panel) after the PNP machine 130 has completed instructions 124 in the program 122 (e.g., NC program 123) for mandrel segment 235 to place the preform 150 in the desired position. Figure 29 (As shown). This segmentation method facilitates a pulsed manufacturing environment because each group 218, 220, and 222 of the longitudinal beam preforms 159 can be placed on a mandrel segment 235 that travels in a pulsed or continuous motion, and then the mandrel 140, which forms a semi-cylindrical segment 770 or a complete cylindrical segment 776, can be assembled from the mandrel segments 235. This design concept can be implemented to form the complete cylindrical segment 776 as needed.

[0149] Reference Figures 22 to 26 Illustrative details of the operation of the placement system 50 are discussed. It is assumed that various objects 18, such as one or more precast longitudinal beams 159, are prepared at pallet 190 for placement onto mandrel 140 and await placement. Furthermore, unless mandrel segment 235 is specified, the methods described below can be applied to mandrel 140 or one or more mandrel segments 235 when referring to mandrel 140.

[0150] Reference Figures 22 to 26 The described method can be executed by the unit controller 120. For example, refer to... Figure 1 and Figure 2The steps of the method are included in program 122 implemented in unit controller 120, and are sent from unit controller 120 to PNP machine 130 and / or to mandrel 140 in instruction 124 to perform one or more of the method steps. Therefore, unit controller 120 is operable to perform methods 300, 400, 500, and 600, as well as the steps described herein. When the method steps are performed by a system in manufacturing line 10 instead of placement system 50, unit controller 120 communicates with controllers in other systems (e.g., hardening system 60, separation system 70, and / or cleaning system 80) to move mandrel 140 and perform the remainder of one or more method steps.

[0151] The following is for reference. Figure 1 The placement system 50 describes the steps of the method, but those skilled in the art will understand that the method described herein can be performed in other systems. The steps in the flowchart described herein are not exhaustive and may include other steps not shown, as well as optional steps that may be performed in some examples. The steps described herein may also be performed in an alternative order and / or may be skipped. Furthermore, the pick and / or place operations discussed herein may be performed synchronously or asynchronously.

[0152] Figure 22 It shows the method for use Figures 1 to 3 The flowchart describes a method 300 for assembling structure 12 using placement system 50. Method 300 operates placement system 50 to coordinate the actions of PNP machine 130. As described above, the pick and / or placement steps can be performed synchronously or asynchronously depending on the structure 12 being assembled. The pick and / or placement operation can occur when mandrel 140 pauses at placement station 100 between pulses, and unit controller 120 can pause mandrel 140 when at least a portion of mandrel 140 is positioned at placement station 100.

[0153] refer to Figure 1 , Figure 2 and Figure 22 Method 300 includes operation 302 in an asynchronous phase and operation 304 in a synchronous phase. When operation 302 is performed in the asynchronous phase, system 50 is placed to operate in asynchronous mode. Similarly, when operation 304 is performed in the synchronous phase, system 50 is placed to operate in synchronous mode. An example of mode 412 is... Figure 24A and Figure 24BThe following describes the placement of objects 18, such as discrete objects 20 and large objects 22; however, when object 18 is a prefabricated component 150, discrete object 20 includes discrete prefabricated components 154, such as frame filler prefabricated component 158, and large object 22 includes large prefabricated components 156, such as longitudinal beam prefabricated component 159. Therefore, the method 300 described below is equally applicable to the placement of prefabricated components 150, discrete prefabricated components 154, frame filler prefabricated components 158, large prefabricated components 156, and longitudinal beam prefabricated components 159.

[0154] In operation step 302, the unit controller 120 initiates an asynchronous phase in which the PNP machines 130 at placement station 100 operate independently to place objects 18, such as discrete objects 20, onto the mandrel 140. To initiate the asynchronous phase, the unit controller 120 sends instruction 124 to the PNP machines 130 to operate in asynchronous mode. The asynchronous phase is an operational phase in which each PNP machine 130 places objects 18 at its fastest rate, and the unit controller 120 does not perform coordination among the PNP machines 130.

[0155] In the asynchronous phase, instruction 124 of operation 302 causes each of the PNP machines 130 to place a strong backplate 180 404 on at least one discrete object 20, apply a vacuum pressure 160 406 to hold at least one discrete object 20 on the strong backplate 180, lift the strong backplate 180 454 to a suitable position on the mandrel 140, and release the vacuum pressure 160 470 to remove at least one discrete object 20 from the strong backplate 180 when at least one discrete object 20 contacts the mandrel 140. During mode 412, Figure 24A and Figure 24B The steps of placement 404, application 406, lifting 454, and release 470 are shown.

[0156] During operation 302 in the asynchronous phase, unit controller 120 provides 306 new instructions 124 to each of the PNP machines 130. The new instructions 124 are defined by program 122 and are provided 306 by unit controller 120 to PNP machine 130 in response to detecting that a previous instruction 124 from program 122 has been completed by PNP machine 130, regardless of the progress of other PNP machines 130 in placement station 100. Therefore, each PNP machine 130 receives instructions 124 independently of other PNP machines 130 in placement station 100. This allows each PNP machine 130 to operate efficiently without reference to other PNP machines 130.

[0157] As used herein, particularly with respect to steps 302 and 304, the instruction 124 from program 122 preferably originates from NC program 123 and may include commands to move the end effector 134 to a specific position, to control the operation of the vacuum system 138 and / or clamping system 139 at the end effector 134, and / or to control actuators, etc., to physically grip the strong backplate 180 (and any corresponding preform 150) or to apply vacuum pressure 160 to the strong backplate 180 (and any corresponding preform 150) to place the object 18 carried by the strong backplate 180. In response to each instruction 124, PNP machine 130 executes the requested action, and PNP controller 132 generates an acknowledgment to be received by unit controller 120. Upon receiving each acknowledgment from PNP machine 130, unit controller 120 provides 306 new instructions 124 from program 122 to PNP machine 130.

[0158] PNP controller 132 can use data 137 to confirm that instruction 124 has been executed in the expected manner. If data 137 indicates that PNP machine 130 cannot complete instruction 124 (e.g., due to delay exceeding a threshold amount, error code, etc.), then PNP controller 132 reports the situation to unit controller 120 for explanation and remediation.

[0159] Reference Figure 19 and Figure 22 In the asynchronous phase, operation 302 may include placing 308 of discrete object 20 onto different radial portions 208, 210, 212, or 213 of mandrel 140. When mandrel 140 includes mandrel segments 235, discrete object 20 is placed 310 onto one or more mandrel segments, which, when assembled together, become radial portions 208, 210, 212, and / or 213 of mandrel 140. (See also...) Figure 20 and Figure 22 Alternatively, operation 302 in the asynchronous phase may include placing discrete object 20 312 onto different longitudinal portions 224, 226 or 228 of mandrel 140.

[0160] When the PNP machine 130 is divided into a first subset 126 and a second subset 128, operation 302 in the asynchronous phase includes independently operating 314 the first subset 126 of the PNP machines 130a at the placement station 100 in the asynchronous phase to place the discrete object 20 onto the mandrel 140. Instruction 124a of operation 302 in the asynchronous phase causes each of the PNP machines 130a in the first subset 126 to place 404 a strong backplate 180 on the discrete object 20, apply 406 a vacuum pressure 160 to hold the discrete object 20 on the strong backplate 180, lift 454 the strong backplate 180 to the appropriate position on the mandrel 140, and release 470 the vacuum pressure 160 to remove the discrete object 20 from the strong backplate 180 when it contacts the mandrel 140.

[0161] When operating the first subset 126 in the asynchronous phase 314, 306 new instructions 124 are provided to each of the PNP machines 130 in the first subset 126. More specifically, in response to detecting that a previous instruction 124 from program 122 has been completed by the PNP machine 130, 306 new instructions 124 are provided from program 122 to each of the PNP machines 130 in the first subset 126, regardless of the progress of the other PNP machines 130 in the first subset 126. Preferably, program 122 is NC program 123, and instruction 124 is NC instruction 125.

[0162] When the placement system 50 includes multiple placement stations 100, 100', the PNP machines 130, 130' are distributed across the multiple placement stations 100, 100'. In this embodiment, operation 302 includes operating 316 the PNP machine 130 at the first placement station 100 in an asynchronous phase, or operating 316 the PNP machine 130' at the second placement station 100' in an asynchronous phase.

[0163] Depending on the configuration of the structure 12 being assembled and / or the placement system 50, any step of placement 308, placement 310, placement 312, operation 314 and / or operation 316 can be combined to operate 302 in an asynchronous phase.

[0164] In operation step 304, the unit controller 120 initiates a synchronization phase in which PNP machines 130 operate sequentially to place large objects 22 across multiple PNP machines 130 onto the mandrel 140. Therefore, the PNP machines 130 operate sequentially during the synchronization phase to cooperatively transport one or more large objects 22 to the desired position on the mandrel 140. To initiate the synchronization phase, the unit controller 120 sends instruction 124 to the PNP machines 130 to operate in synchronization mode.

[0165] During operation 304 in the synchronization phase, instruction 124 causes each of the PNP machines 130 to synchronously place the strong backplate 180 404 on the large object 22, apply a vacuum pressure 160 406 to hold the large object 22 at the strong backplate 180, raise the strong backplate 180 454 to the appropriate position on the mandrel 140, and release the vacuum pressure 160 470 to remove the large object 22 from the strong backplate 180 as it contacts the mandrel 140. Figure 24A and Figure 24B The steps of placement 404, application 406, lifting 454 and release 470 are shown as steps during mode 412.

[0166] During operation 304 in the synchronization phase, in response to the detection that all PNP machines 130 at placement station 100 have completed the previous instruction 124 from program 122, unit controller 120 provides new instruction 124 318 from program 122 (e.g., NC program 123) to each of the PNP machines 130. Operation 304 may result in a set of phased checkpoint operations performed by all PNP machines 130, such as positioning on the strong backplate 180, activating the vacuum system 138 at the end effector 134 to capture the preform 150 and keep the preform 150 in contact with the strong backplate 180, coordinating the movement of the strong backplate 180 on the mandrel 140, coordinating the release of vacuum pressure 160 to remove the preform 150 from the strong backplate 180, etc.

[0167] Reference Figure 19 and Figure 22 During the synchronization phase, operation 304 may include placing one or more large objects 22 320 onto different radial portions 208, 210, 212, or 213 of the mandrel 140. When the mandrel 140 includes mandrel segments 235, one or more large objects 22 are placed 322 onto one or more mandrel segments 235, which, when assembled together, become radial portions 208, 210, 212, and / or 213 of the mandrel 140. See reference. Figure 20 and Figure 22 Alternatively, operation 302 during the synchronization phase may include placing one or more large objects 22 324 onto different longitudinal portions 224, 226 or 228 of the mandrel 140.

[0168] When the PNP machine 130 is divided into a first subset 126 and a second subset 128, operation 304 in the synchronization phase includes operating 326 of the second subset 128 of the PNP machine 130 sequentially in the synchronization phase to place the large object 22 onto the mandrel 140 simultaneously with operation 314 of the first subset 126 of the PNP machine 130. Operation 326 may occur at the same placement station as operation 314 (e.g., the first placement station 100) and / or at a different placement station than operation 314 (e.g., the second placement station 100'). In one embodiment, PNP machine 130a in the first subset 126 is different from PNP machines 130b and 130c in the second subset 128.

[0169] During operation 304, instructions 124b and 124c, in a phase synchronized with multiple subsets 126 and 128, cause each of the PNP machines 130 in the second subset 128 to simultaneously place the strong backplate 180 on the large object 22, apply a vacuum pressure 160 to hold the large object 22 on the strong backplate 180, lift the strong backplate 180 to the appropriate position on the mandrel 140, and release the vacuum pressure 160 to remove the large object 22 from the strong backplate 180 when the large object 22 contacts the mandrel 140.

[0170] When operating the second subset 128 during the synchronization phase, 318 new instructions 124 are provided to the PNP machines 130 in the second subset 128. More specifically, in response to detecting that all PNP machines 130b, 130c in the second subset 128 have completed the previous instructions 124 from program 122, 318 new instructions 124b, 124c are provided from program 122 to each of the PNP machines 130b, 130c in the second subset 128.

[0171] In an example where structure 12 is assembled using different types of objects (e.g., discrete object 20 and large object 22), unit controller 120 can operate subsets 126 and 128 of 302 and 304 in different phases. For example, when object 18 includes discrete object 20, unit controller 120 is configured to operate each PNP machine 130a of the first subset 126 of 302 PNP machines 130 independently in an asynchronous phase to place discrete object 20 onto mandrel 140. Alternatively, when object 18 includes large object 22 spanning multiple PNP machines 130, unit controller 120 is configured to operate PNP machines 130b and 130c of the second subset 128 of 304 PNP machines 130 sequentially in a synchronous phase to place large object 22 onto mandrel 140. Preferably, unit controller 120 operates the first subset 126 and the second subset 128 simultaneously.

[0172] When the placement system 50 includes multiple placement stations 100, 100', the PNP machines 130, 130' are distributed across the multiple placement stations 100, 100'. In this embodiment, operation 304 includes operating 328 the PNP machine 130' at the second placement station 100' during a synchronization phase, or operating 328 the PNP machine 130 at the first placement station 100 during a synchronization phase.

[0173] Depending on the configuration of the structure 12 being assembled and / or the placement system 50, any step of placement 320, placement 322, placement 324 and / or operation 326 can be combined to operate 302 in the synchronization phase.

[0174] Unit controller 120 repeatedly operates PNP machines 130 304 and 302 in synchronous phases or synchronous mode and asynchronous phases or asynchronous mode. In a specific embodiment, PNP machines 130 are divided into subsets 126 and 128, and unit controller 120 repeatedly operates a first subset 126 and a second subset 128 of PNP machines 130 304 and 302 in synchronous and asynchronous phases. For example, refer to... Figure 2 and Figure 22 Method 300 includes repeatedly performing operations 332 and 302 on a first subset 126 in an asynchronous phase to place discrete objects 20 onto the mandrel 140, and then performing operations 304 on the first subset 126 in a synchronous phase to place one or more large objects 22 onto the mandrel 140. Similarly, a second subset 128 may repeatedly perform operations 332 and 302 and 304 between the two phases to place discrete objects 20 and large objects 22 onto the mandrel 140.

[0175] More specifically, when the first subset 126 is operated 302 in the asynchronous phase to place discrete objects 20, the second subset 128 is operated 304 in the synchronous phase to place one or more large objects 22. When the first subset 126 changes to operate 304 in the synchronous phase to place one or more large objects 22, the second subset 128 changes to operate 302 in the synchronous phase to place discrete objects 20. The change between operations 302 and 304 can be based on which objects 18 remain in the tray 190 and / or when a depleted tray 190 with no remaining objects 18 is replaced by a new tray 190 containing objects 18. This repeated operation 332 of subsets 126 and 128 allows discrete objects 20 and large objects 22 to be placed continuously by the placement station 100.

[0176] In an embodiment where the placement system 50 includes multiple placement stations 100, 100', the method includes repeatedly operating the PNP machine 130, 130' at each of the placement stations 100, 100' in synchronous and asynchronous phases. For example, refer to... Figure 1 and Figure 22 Method 300 includes repeatedly operating 302 on the first placement station 100 in an asynchronous phase to place discrete objects 20 onto the mandrel 140, and then operating 304 on the first placement station 100 in a synchronous phase to place one or more large objects 22 onto the mandrel 140. Similarly, the second placement station 100' may repeatedly operate 302, 304 between the two phases to place objects 20, 22 onto the mandrel 140.

[0177] More specifically, while the first placement station 100 is operated 302 in an asynchronous phase to place discrete objects 20, the second placement station 100' is operated 304 in a synchronous phase to place one or more large objects 22. When the first placement station 100 changes to operate 304 in a synchronous phase to place one or more large objects 22, the second placement station 100' changes to operate 302 in a synchronous phase to place discrete objects 20. The change between operations 302 and 304 can be based on which objects 18 remain in trays 190, 190' and / or when depleted trays 190, 190' with no remaining objects 18 are replaced by new trays 190, 190' containing objects 18. This repetitive operation of placement stations 100, 100' allows discrete object 20 and large object 22 to be continuously placed at a series of placement stations 100, 100' as the spindle 140 moves (e.g., pulsatingly or continuously). Strong backplates 180, 180' can be used to support these processes.

[0178] Furthermore, when the placement system 50 includes multiple placement stations 100, 100', 100" , each of the placement stations 100, 100' and / or 100" operates to place the object 18 308, 320 onto different radial portions 208, 210, 212 or 213 of the mandrel 140, such as Figure 19As shown. For example, method 300 includes repeatedly operating 302 on the first placement station 100 in an asynchronous phase to place a discrete object 20 onto the first radial portion 208, and then operating 304 on the first placement station 100 in a synchronous phase to place one or more large objects 22 onto the first radial portion 208. Similarly, the second placement station 100' may repeatedly operate 302, 304 between the two phases to place objects 20, 22 onto the second radial portion 210 in the same or opposite mode as the first placement station 100. Alternatively, the first placement station 100 operates 302 to place the discrete object 20 onto the first radial portion 208, and then the mandrel 140 moves to the second placement station 100' to place the large object 22 onto the first radial portion 208, while the first placement station 100 operates 302 in an asynchronous mode to place the discrete object 20 onto the second radial portion 210. Therefore, as the mandrel 140 moves along the placement stations 100 and 100', the mandrel 140 undergoes repeated cycles 334 between each stage.

[0179] Alternatively or concurrently, each of the operations in positions 100, 100', and / or 100" is used to place object 18 312, 324 onto different longitudinal portions 224, 226, or 228 of mandrel 140, such as Figure 20 As shown. For example, method 300 includes repeatedly operating 334 on the first placement station 100 in an asynchronous phase to place discrete objects 20 onto the first longitudinal section 224, and then operating 304 on the first placement station 100 in a synchronous phase to place one or more large objects 22 onto the first longitudinal section 224. Similarly, the second placement station 100' may repeatedly operate 334 on 302, 304 between the two phases to place objects 20, 22 onto the second longitudinal section 226 in the same or opposite mode as the first placement station 100. Alternatively, the first placement station 100 operates 302 to place the discrete object 20 onto the first longitudinal section 224, and then the mandrel 140 moves to the second placement station 100', which operates 304 in an asynchronous phase to place the large object 22 onto the first longitudinal section 224, while the first placement station 100 operates 302 in an asynchronous mode to place the discrete object 20 onto the second longitudinal section 226. Therefore, as the mandrel 140 moves along placement stations 100 and 100', the mandrel 140 undergoes repetition 334 between the phases.

[0180] Alternatively or concurrently, each of the operations at stations 100, 100', and / or 100" is used to place object 18 onto different mandrel segments 236, 238, or 240, such as Figure 21As shown. For example, method 300 includes repeatedly operating 334 on the first placement station 100 in an asynchronous phase to place a discrete object 20 onto the first mandrel segment 236, and then operating 304 on the first placement station 100 in a synchronous phase to place one or more large objects 22 onto the first mandrel segment 236. Similarly, the second placement station 100' may be repeatedly operated 334 on 302, 304 between the two phases to place objects 20, 22 onto the second mandrel segment 238 in the same or opposite mode as the first placement station 100. Alternatively, the first placement station 100 operates 302 to place the discrete object 20 onto the first mandrel segment 236, and then the first mandrel segment 236 moves to the second placement station 100', which operates 304 in an asynchronous phase to place the large object 22 onto the first mandrel segment 236, while the first placement station 100 operates 302 in an asynchronous mode to place the discrete object 20 onto the second mandrel segment 238. Therefore, as a series of mandrel segments 235 move through a series of placement stations 100, 100', the mandrel segments 235 undergo repetition 334 between the phases.

[0181] Method 300 may optionally include securing the object 18 to the mandrel 140 by fixing it by 336. For example, when the object 18 is a preform 150, the preform 150 may be secured by 336 to the mandrel 140. The securing by 336 may occur after each stage of operation 302 and / or operation 304 and / or after all repetitions 330 of the completion stage. Securing the object 18 by 336 may include adhering the object 18 to the mandrel 140 and applying vacuum pressure 147 ( Figure 13 (As shown) is applied to object 18, and / or object 18 is pressed, compacted and / or secured against mandrel 140 using a strong backing plate 180. An example of adhesion is the use of adhesive tape and media in addition to compaction, gravity and / or vacuum pressure 147 to maintain the position of preforms 150 relative to each other throughout the placement operation and subsequent operations along the manufacturing line 10.

[0182] When the spindle 140 includes spindle segments 235, method 300 includes assembling 504 together multiple spindle segments 235 after the PNP machine 130 has completed the instructions 124 in program 122 corresponding to the spindle segments 235. In one example, after the PNP machine 130 has completed the instructions 124 in program 122 corresponding to the spindle segments 235, multiple spindle segments 235 are assembled 504 together to form a semi-cylindrical segment 770 (e.g., ...). Figure 29 (As shown). Reference Figure 25Further details of assembly 504 are described, including moving mandrel 140 506 to assembly station 105 to perform assembly 504. If object 18 is secured 336 to mandrel segment 235, at least two mandrel segments 235 can be assembled together after object 18 is secured 336.

[0183] Used for assembling structure 12 ( Figure 1 Method 300 (shown) offers substantial advantages over existing systems because it enables a single program 122 (e.g., a single NC program 123) to control the actions of multiple PNP machines 130. Because the provision of instructions 124 from program 122 is synchronous across PNP machines 130 during the synchronous phase, PNP machines 130 can work together to carry objects such as large objects 22, which a single PNP machine could not carry. Furthermore, because the provision of instructions 124 is not synchronous during the asynchronous phase, each PNP machine 130 can operate efficiently when transporting objects such as discrete objects 20 that can be carried by only one PNP machine.

[0184] Figure 23 It is possible Figure 22 The message diagram 350 used during method 300 is illustrated. Message diagram 350 depicts communication between unit controller 120 and multiple PNP controllers 132a, 132b, 132c in the illustrative embodiment to selectively coordinate the operation of PNP machines 130a, 130b, 130c. PNP machine 130 performs a cyclic placement operation 352, which includes one or more series of asynchronous phases 354 and synchronous phases 356. During the asynchronous phase 354, placement station 100 is operated 302 in asynchronous mode. Similarly, during the synchronous phase 356, placement station 100 is operated 304 in synchronous mode.

[0185] like Figure 23 As shown, unit controller 120 initiates an asynchronous phase to operate PNP machine 130 302. In the asynchronous phase 354, after determining that PNP controllers 132a, 132b, or 132c have completed their latest instruction 124, unit controller 120 immediately issues new instructions 124a, 124b, or 124c to PNP controllers 132a, 132b, or 132c. This is performed regardless of the progress of the other PNP controllers 132a, 132b, and / or 132c at placement station 100.

[0186] However, in the synchronization phase 356, the actions are synchronized between PNP controllers 132a, 132b, and 132c. That is, unit controller 120 waits for operations from preceding and following actions to pick up object 18 (e.g., large object 22) before issuing a new instruction 124. Figure 18 The checkpoints (shown) confirm the status of all PNP controllers 132. This form of checkpoint ensures that all PNP machines 130 have reached the desired milestones before further progress is requested. In another embodiment, the unit controller 120 can implement a hybrid phase, where a subset 126 or 128 of the PNP machines 130 at placement station 100 operates in synchronous mode, while one or more other PNP machines 130 at placement station 100 operate in asynchronous mode.

[0187] Figure 24A and Figure 24B This illustrates the operation in the illustrative embodiment. Figures 1 to 21 The flowchart shows the placement method 400 at placement station 100. Method 400 operates placement system 50 (…). Figure 1 (As shown) to coordinate the operation of the PNP machine 130. The various steps of method 400 are related to... Figures 4 to 18 As shown. Method 400 is described with respect to placing the prefabricated part 150; however, method 400 can be used to place any suitable object 18.

[0188] refer to Figure 22 and Figure 23 Method 400 can be used during operation 302 in asynchronous phase 354 and operation 304 in synchronous phase 356. For example, mode 412 of method 300 is executed during operation 302 in asynchronous phase 354 and during operation 304 in synchronous phase 356. Mode 412 is described in more detail below.

[0189] Reference Figure 1 , Figure 2 , Figure 24A and Figure 24B Method 400 includes moving 402 the mandrel 140, placing 404 a strong backplate 180 on a tray 190 and / or (one or more) preforms 150, applying 406 a vacuum pressure 160 to hold (one or more) preforms 150, conveying 408 the strong backplate 180 and / or (one or more) preforms 150 to the mandrel 140, and placing (one or more) preforms 150 on the mandrel 140. Operating mode 412 includes at least placing 404 the strong backplate 180, applying 406 a vacuum pressure 160, conveying 408 to the mandrel 140, and placing 410 the preforms 150.

[0190] The movement 402 of the mandrel 140 includes moving the mandrel 140 in the processing direction 14 relative to the placement station 100 having multiple PNP machines 130. The movement 402 can be performed as part of a pulsating or continuous movement process along the manufacturing line 10, in which the central shaft 140 moves its entire length, or as part of a micro-pulsating process in which the mandrel 140 moves less than its entire length to expose new portions of the mandrel 140 for receiving jobs. The movement 402 of the mandrel 140 can be in the direction of the unit controller 120. The mandrel 140 can move 402 along tracks, guides, paths, etc., through the placement system 50 and / or along the manufacturing line 10.

[0191] The mandrel 140 moved 402 into manufacturing cell 110 may include identification devices, such as RFID tags and / or barcodes. In this example, moving mandrel 140 relative to placement system 50 may include obtaining data from the identification device for use by cell controller 120. For example, the data may include which mandrel 140 or mandrel segment 235 is located in placement system 50, which part or model will be assembled by placement system 50, which parts have been attached to mandrel 140 before entering placement system 50, etc. If PNP machine 130 obtains data from the identification device, cell controller 120 may use this data, which may be encoded in data 137, to send appropriate instructions 124 to PNP machine 130.

[0192] When the spindle 140 includes, as follows Figure 21 When multiple segments 235 are shown, moving the mandrel 140 402 includes moving the mandrel segments 235 414. More specifically, one or more mandrel segments 235 move 414 relative to the placement station 100 in the processing direction 14. The mandrel segments 235 may move 414 along one or more tracks, guides, paths, etc.

[0193] When the placement system 50 includes multiple placement stations 100, 100', 100”, each mandrel segment 235 moves 414 relative to a specific placement station 100, 100', or 100”, on which the preform 150 is placed. The mandrel segments 235 may move 414 through one or more placement stations 100, 100', and / or 100” at the same speed, or at variable and / or different speeds depending on the type and number of preforms 150 to be placed on the mandrel segments 235.

[0194] Method 400 may optionally include pausing 416 the mandrel 140 while at least a portion of the mandrel 140 is positioned at placement station 100. The mandrel 140 may be paused 416 once for a duration long enough for all preforms 150 to be placed on the mandrel 140. Alternatively, the mandrel 140 may be paused 416 for a shorter duration, causing the mandrel 140 to pulsate through placement station 100. This pulsating pause 416 can be used when groups 230, 232, and 234 of preforms 150 are placed at longitudinal portions 224, 226, and 228 of the mandrel 140, such as... Figure 20 As shown in the diagram. When the mandrel 140 is not paused 416, the mandrel 140 moves continuously 402 through the placement station 100 during the placement process.

[0195] refer to Figure 4 , Figure 5 and Figure 24A and Figure 24B Method 400 may further include identifying 418 pallet 190. For example, the type of pallets 190a, 190b, and 190c in pallet 190, the position of pallet 190 relative to placement station 100 and / or manufacturing unit 110, and / or the quantity and type of prefabricated parts 150 in pallet 190 are identified 418. Identification 418 may include identifying 420 pallet 190 storing prefabricated parts 150 of uncured fiber-reinforced material 152. Identification 420 pallet 190 also identifies the type and / or quantity of prefabricated parts 150 stored in pallet 190.

[0196] In use Figure 5 In the example of pallet 190c, identification 418 includes identification 422 of pallet 190c storing one or more large prefabricated parts 156 and discrete prefabricated parts 154. (See also: Regarding...) Figure 5 The discrete prefabricated component 154 may be positioned at location 195, where the frame 780 will be mounted relative to (one or more) the large prefabricated component 156. Figure 29 (As shown in the diagram). As described above, position 781 of the fuselage 766 corresponds to position 195 in the tray 190. Therefore, the discrete preform 154 is arranged for placement at position 781, where the frame 780 will be mounted relative to one or more large preforms 156. In such an example, identification 418 includes identification 422 of the tray 190c having the mated discrete preforms 154 and large preforms 156.

[0197] In use Figure 4In another example of group 191 shown, identification 418 includes identification 422 of one or more trays 190a and 190b having different types of prefabricated parts 150 (e.g., one or more large prefabricated parts 156 and discrete prefabricated parts 154). Identifications 420, 422 include indicating the type of prefabricated parts 154, 156 stored in each of the trays 190a, 190c identified by 420, 422. For example, step 418 includes identifying 420 that a first type of tray 190a includes discrete prefabricated parts 154 and a second type of tray 190b includes one or more large prefabricated parts 156.

[0198] Identifier 418 may also include identifier 424 of a tray 190 having one or more recesses 198. For example, identifier 420 may include identifier 424 of tray 190 including recesses 198 for storing a plurality of prefabricated parts 150. Figure 4 Group 191 or Figure 5 When the tray 190c is used to store different types of prefabricated parts 150, identification 418 includes identification 424 including trays 190a, 190b or 190c for recesses 198 for discrete prefabricated parts 154 and for one or more large prefabricated parts 156.

[0199] Identification 418 can be performed via a camera or other sensing components, or based on instruction 124 in procedure 122. (See reference) Figure 2 When identification 418 is performed via a camera or other sensing component, sensors 136 of one or more PNP machines 130 acquire information about the tray 190 and send the tray information as part of sensor data 137 to the unit controller 120. The acquired information may be image data of the tray 190 and / or one or more prefabricated components 150 in the tray 190, radio frequency (RF) data (e.g., from RF identification tags associated with the tray 190 and / or prefabricated components 150 detected and / or emitted at sensors 136 for detecting RF signals), data from barcodes or other codes on the tray 190 and / or prefabricated components 150, detection and ranging data indicating the position and / or shape of the tray 190 and / or prefabricated components 150 (e.g., from sensors 136 configured for RADAR or LIDAR), and / or any other data that enables the unit controller 120 to send appropriate instructions 124 to one or more PNP machines 130 based on the type of the tray 190 and / or prefabricated components 150.

[0200] Before identifying pallet 190, one or more prefabricated parts 150 are placed 426 in pallet 190. The placement 426 of the prefabricated parts 150 can occur when pallet 190 is positioned within placement station 100, or it can occur at different systems or stations within manufacturing line 10 before pallet 190 is moved to placement station 100. When using... Figure 5 When the tray 190c is in place, discrete object 20 is set 426 in tray 190, with large object 22 located at position 195, where frame 780 is located. Figure 29 (As shown) will be mounted relative to the large object 22. In this example, different types of objects 20 and 22, such as prefabricated parts 154 and 156, are set up and are considered to be fitted with objects 20 and 22 in tray 190c.

[0201] Setting one or more of the objects 18 in the tray 190 may also include associating identification tags (e.g., RFID tags, barcodes, or other optical codes) with the tray 190 and / or prefabricated parts 150. For example, data may include which tray 190 is in the placement system 50, which parts or models will be assembled by the placement system 50, which parts have been attached to the tray 190 before entering the placement system 50, which objects 18 have been set 426 in the tray 190, and where the objects 18 are located within the tray 190, etc. If the PNP machine 130 obtains data from the identification device, the unit controller 120 may use this data, which may be encoded in data 137, to send appropriate instructions 124 to the PNP machine 130.

[0202] When the tray 190 includes an optional vacuum channel 200 and a vacuum system 202, such as Figure 7 As shown, vacuum pressure can be applied after the preform 150 is set 426 in the tray 190. When using an optional release membrane 26, the release membrane 26 is applied to the tray 190 before setting the preform 150 426.

[0203] Reference Figure 24A and Figure 24B , Figure 1 and Figure 2The placement of the 404 strong backplate 180 is performed by at least one PNP machine 130. When an optional release membrane 26 is used with the strong backplate 180, the release membrane 26 is applied to the strong backplate 180 prior to the placement of the 404 strong backplate 180. During the placement of the 404, the strong backplate 180 is attached to at least one PNP machine 130, for example, by attaching one or more end effectors 134 to the strong backplate 180. However, the strong backplate 180 may be attached to the PNP machine 130 in proximity to the end effector 134. The attachment between the end effector 134 and / or the PNP machine 130 and the strong backplate 180 enables the clamping system 139 and / or the vacuum system 138 to work with the strong backplate 180 to pick up and place objects 18, as will be described in more detail below. One or more PNP machines 130 are configured to move the strong backplate 180 at least to the tray 190 and the mandrel 140, but may have additional degrees of freedom of movement within the placement station 100 depending on the operation to be performed and / or the structure 12 to be assembled. For example, the PNP machine 130 may also move the strong backplate 180 to a position within the placement station 100 where one or more layers 206 (such as...) are stored. Figure 18 (As shown).

[0204] In an exemplary embodiment, unit controller 120 controls one or more PNP machines 130 to place a strong backplate 180 404 at a pallet 190 and / or preform 150. In some examples, identification 418 of the pallet 190 is used to determine where to place the strong backplate 180 relative to the pallet 190 and / or preform 150. For example, when unit controller 120 identifies 418 multiple pallets 190 or multiple preforms 150 in placement station 100, unit controller 120 uses identification 418 to place 404 the strong backplate 180 relative to a particular pallet 190 and / or preform 150. Even when a pallet 190 or preform 150 has already been identified 418, unit controller 120 may use the location information in identification 418 to place the strong backplate 180 404 at a specific location in placement station 100.

[0205] Placing the 404 strong backplate 180 includes at least one of placing the strong backplate 180 428 on the tray 190 via at least one of the PNP machines 130 and placing the strong backplate 180 430 on the preform 150 via at least one of the PNP machines 130. Placing the strong backplate 180 428 on the tray 190 may include aligning the strong backplate 180 with the tray 190 using a strong backplate indexing element 182 and a tray indexing element 192. When the strong backplate indexing element 182 engages the tray indexing element 192, the strong backplate 180 is placed 428 aligned with the tray 190.

[0206] Alternatively or additionally, the strong backplate 180 is placed at the preform 150. For example, sensor 136 can determine where the preform 150 is within placement station 100 and / or tray 190, and one or more PNP machines 130 place the strong backplate 180 430 at the preform 150. For example, the strong backplate 180 is placed on an object 18 such as the preform 150. Determining where the preform 150 is located can be part of the identification 418 of the tray 190 or a separate step independent of whether the tray 190 is identified 418. Because the preform 150 is stored in the tray 190, placement 428 of the strong backplate 180 and the tray 190 also place the strong backplate 180 430 at the preform 150. In another example, excluding indexing elements 182, 192 and / or tray 190 not being identified 418, unit controller 120 operates PNP machine 130 to place strong backplate 180 430 at preform 150, which causes strong backplate 180 to also be placed 428 at tray 190.

[0207] When preform 150 is, for example, one or more layers 206 ( Figure 18 When (as shown), layer 206 (or other types of objects 18 or prefabricated parts 150) may not be stored in tray 190. Therefore, unit controller 120 can operate PNP machine 140 to place strong backplane 180 430 at prefabricated part 150 instead of at tray 190.

[0208] Reference Figure 16 The structure of the backplate 180 shown includes a backplate 180 that is arched. (See again...) Figure 24A and Figure 24B , Figures 8 to 10 According to the configuration of the strong backing plate 180, placing the strong backing plate 180 404 may include placing the recess 184 of the strong backing plate 180 432 on the preform 150 via at least one of the PNP machines 130. Placing 404 and / or 432 may include covering the preform 150 with the strong backing plate 180. This process may include transposing the strong backing plate 180 into the recess 198 of the tray 190, for example via, as per [reference to...] Figure 8 and Figure 9 The cup-cone indexing system is designed to ensure known and repeatable positioning of the strong back plate 180 relative to the recess 198.

[0209] When the strong backplate is 180 Figure 16 and Figure 17When configured to have multiple recesses 184, one or more recesses 184 of the strong backplate 180 are placed 432, 434 at one or more corresponding preforms 150. For example, multiple recesses 184 of the strong backplate 180 are placed 434 at multiple preforms 150. In one example, each of the multiple recesses 184 is placed 434 at a specific corresponding preform 150 among the multiple preforms 150. In another example, a recess 184 is placed 432, 434 at multiple preforms 150, such as multiple discrete preforms 154. Figure 17 As shown, the multiple recesses 184 of the strong backplate 180 can be configured to be placed 434 at a specific type of preform 150, such that the multiple recesses 184 maintain the matching arrangement of the discrete preforms 154 and the large preforms 156.

[0210] In embodiments where the PNP machine 130 picks up the preform 150 directly without using the strong backplate 180, the placement step 404 is modified by placing the end effector 134 of the PNP machine 130 instead of placing the strong backplate 180, to such an extent that the above description applies to the construction of the end effector 134.

[0211] When PNP machine 130 is in the asynchronous phase 354 ( Figure 23 Operation 302 (as shown) Figure 22 As shown, the placement 404 of each PNP machine 130 can vary depending on the prefabricated piece(s) 150 to be moved by each PNP machine 130. Furthermore, during the asynchronous phase 354, one or more PNP machines 130 may also include movement in one or more X directions during placement 404. Additionally or alternatively, when the PNP machines 130 are divided into subsets, each PNP machine 130 in the first subset 126 (e.g., Figure 2 (As shown) During any part of the placement 404 of each PNP machine 130 in the first subset 126, it moves toward or apart in the X direction.

[0212] When PNP machine 130 is in synchronization phase 356 ( Figure 23 Operation 304 (as shown) Figure 22 When (as shown), PNP machine 130 is simultaneously placed 404 on tray 190 and / or large preform 156. When a subset of PNP machine 130, such as the second subset 128 ( Figure 2 As shown), during the synchronization phase 356, the PNP machine 130 can operate in one or more X directions. Figure 3 (as shown) They move relative to each other to be properly spaced for the size of the large preform 156 during placement 404.

[0213] After the PNP machine 130 and / or the strong backplate 180 are positioned 404 relative to the preform 150, the preform 150 is picked up by the PNP machine 130 and / or the strong backplate 180. (Refer to...) Figure 24A and Figure 24B , Figure 2 A vacuum pressure of 406 ≤ 160 ≤ 1 ... Figures 9 to 12 As shown, vacuum pressure 160 is applied 406 to preform 150 through strong backplate 180. For example, vacuum system 138 is operated 436 to apply vacuum pressure 160 406 through vacuum channel 188 connected (e.g., in flow communication) to at least one recess 184 of strong backplate 180.

[0214] Reference Figure 24A and Figure 24B , Figure 2 and Figures 9 to 12 Applying vacuum pressure 160 406 includes maintaining preform 150 438 in contact with the strong backplate 180. For example, when vacuum pressure 160 406 is applied, preform 150 is removed from tray 190 and pulled against the strong backplate 180 by vacuum pressure 160. Thus, applying vacuum pressure 160 406 picks up preform 150. Depending on the dimensions of the strong backplate 180 and tray 190, the movement of preform 150 from tray 190 to strong backplate 180 caused by the application of vacuum pressure 160 406 can be slight or significant. If optional vacuum pressure 147 has already been applied through tray 190, vacuum system 144 is deactivated to stop vacuum pressure 147, so that the applied vacuum pressure 160 406 can begin to hold preform 150.

[0215] When the reinforcing backplate 180 includes one or more recesses 184, a vacuum pressure 160 is applied to maintain the preform 150 440 in contact with the recesses 184. When the reinforcing backplate 180 includes multiple recesses 184, such as Figure 16 and Figure 17As shown, applying vacuum pressure 160 406 includes maintaining 442 a plurality of preforms 150 in contact with a plurality of recesses 184. As discussed above with respect to step 434, each preform 150 may be maintained 442 in contact with a particular recess 184, or multiple preforms 150 may be maintained 442 in contact with a particular recess 184. Furthermore, the application of vacuum pressure 160 406 can be selectively applied only to the recess(s) 184 in which the preforms 150 have been received. Selectively applying vacuum pressure 160 406 to different recesses 184 prevents the picking up of objects that are not intended to be placed 410 on the mandrel 140.

[0216] When preform(s) 150 comprises multiple types of preforms (e.g., discrete preform 154 and one or more large preforms 156), a vacuum pressure 160 is applied 406 to the discrete preform 154 and one or more large preforms 156. More specifically, applying vacuum pressure 160 406 keeps one or more large preforms 156 and discrete preforms 154 in contact with the strong backplate 180. An example of keeping 444 is shown in... Figure 17 As shown in the figure. When the discrete preform 154 is at least partially in contact with the adjacent large preform 156, such as Figure 18 As shown, applying a vacuum pressure of 406 160 includes maintaining each of the 446 discrete preforms 154 in contact with at least one large preform 156. When the strong backplate 180 is as... Figure 17 When constructed as described above, holding steps 444 and 446 occur simultaneously; however, when a PNP machine 130 without a strong backplate 180 is used to place the mating preforms 154 and 156, holding step 446 may occur without holding step 444.

[0217] Furthermore, when different types of preforms 150 are used to assemble structure 12, holding step 442 can be combined with any or both of holding steps 444 and 446. For example, at least one of the plurality of recesses 184 holds one or more discrete preforms 154, and another of the plurality of recesses 184 holds one or more large preforms 156. Depending on the configuration of the plurality of recesses 184, when held 442 in the plurality of recesses 184, preforms 154 and 156 can also be held 446 in contact with each other.

[0218] Refer again Figure 24A and Figure 24B , Figure 2 and Figures 10 to 13The backing plate 180 and / or preform 150 are conveyed 408 to the mandrel 140. More specifically, the backing plate 180 and / or preform 150 are conveyed 408 while a vacuum pressure 160 is applied 406 to hold the preform 150. During the conveyance 408, the PNP machine 130 follows the path from the tray 190 to the mandrel 140 according to the program 122 in the unit controller 120.

[0219] For further reference Figure 3 The path is at least in the Y and Z directions and optionally in the X direction, and at least the distal end 135 of the PNP machine 130 moves along the path to perform transport 408. In one example, the PNP machine 130 moves in the +Y direction at the pallet 190, and the PNP machine 130 or the end effector 134 moves in the -Z direction toward the pallet 190 and / or the preform 150 to be placed 404. After the vacuum pressure 160 is applied 406, transport 408 includes moving the PNP machine 130 or the end effector 134 in the +Z direction to lift 454 the backplate 180 and / or the preform 150, moving the PNP machine 130 toward the mandrel 140 in the -Y direction, and moving the PNP machine 130 and / or the end effector 134 toward the mandrel 140 in the -Z direction.

[0220] When PNP machine 130 is operated 302 in asynchronous phase 354 (e.g.) Figure 22 As shown, the path of each PNP machine 130 can vary depending on the prefabricated pieces 150(s) to be moved by each PNP machine 130. Furthermore, during the asynchronous phase 354, the path of one or more PNP machines 130 may also include movement in the X direction(s) during placement 404 and / or transport 408. Additionally or alternatively, when the PNP machines 130 are divided into subsets, the first subset 126(s) Figure 2 Each PNP machine 130 in the first subset 126 moves toward or apart in the X direction during any part of the path of each PNP machine 130 in the first subset 408 during transport 408.

[0221] When PNP machine 130 is in synchronization phase 356 ( Figure 23 Operation 304 (as shown) Figure 22 As shown), the paths of all PNP machines 130 are parallel to each other to avoid deformation of the strong backplate 180 and / or preform 150 when the PNP machine 130 performs transport 408. When a subset of PNP machines 130, such as the second subset 128 ( Figure 2 As shown, when operated in synchronization phase 356, all PNP machines 130 in subset 128 follow parallel paths during transport 408, and any optional movement in the X direction (one or more) is similar for all PNP machines 130 in subset 128.

[0222] In one example, transporting 408 to mandrel 140 may include transporting 448 of preform 150 to mandrel 140 via PNP machine 130. For example, transporting 448 of preform 150 from a pick-up location to a location where preform 150 is placed on mandrel 140. When the strong backplate 180 is not used, PNP machine 130(one or more) transports preform 150 448 to mandrel 140.

[0223] Alternatively or concurrently, transporting 408 to the mandrel 140 includes transporting the reinforcing backplate 180 450 to the mandrel 140 via a PNP machine 130. Transporting the reinforcing backplate 180 450 includes simultaneously operating the PNP machine 130 to carry the reinforcing backplate 180, or independently operating a single PNP machine 130 to carry the reinforcing backplate 180. When using the reinforcing backplate 180, one or more PNP machines 130 transport the reinforcing backplate 180 and preform 150 450, 448 to the mandrel 140. More specifically, one or more PNP machines 130 transport the reinforcing backplate 180 450, which in turn holds the preform 150 438 for transporting the preform 150 448.

[0224] Transporting the strong backplate 180 450 to the mandrel 140 may include positioning the strong backplate 180 452 on the mandrel 140. More specifically, the strong backplate 180 having the preform 150 is transported 450 from the pallet 190 to be positioned 452 on the mandrel 140, until the preform 150 is placed 410 on the mandrel 140. For example, the strong backplate 180 in the -Y direction ( Figure 3 (As shown) Move away from the tray 190 to position 452 on top of the spindle 140.

[0225] In some implementations, the strong backplate 180 is raised 454 (e.g., in...). Figure 3 (Movement in the +Z direction as shown). For example, lifting the 454 strong backplate 180 from the tray 190 to disengage the indexing elements 182 and 192, as shown. Figure 10 As shown. Lifting 454 may also include lifting the strong backplate 180 454 onto position 452 on the spindle 140. Position 452 and / or lifting 454 are part of the path for transport 408.

[0226] Transport 408 may also include aligning the strong backplate 180 with the mandrel 140 456. More specifically, the strong backplate 180 is aligned with the mandrel 140 456 when or after the strong backplate 180 is positioned 452 on the mandrel 140 and / or lifted 454 on the mandrel 140. Alignment 456 may include moving (e.g., lowering) the strong backplate 180 toward the mandrel 140. As the strong backplate 180 moves toward the mandrel 140, the strong backplate indexing element 182 engages the mandrel indexing element 148 to align the strong backplate 180 with the mandrel 140 456 during transport 408.

[0227] The transport 408 can end when the preform 150 contacts the mandrel 140. More specifically, the preform 150 can rest against the corrugated cross section 143 of the mandrel 140. Figure 3 The surface that will contact the mandrel 140 (as shown in the diagram) or within the tolerances of said surface. Alternatively, the strong backplate 180 may press the preform 150 against the mandrel 140 to end transport 408. Pressing the preform 150 may ensure the final shape of the preform 150 and / or fix the preform 150 in place 336. Figure 22 (as shown in the diagram) to the mandrel 140. When the reinforcing backplate 180 presses the preform 150 against the mandrel 140 for placement 410, an optional release membrane 26 can prevent the preform 150 from adhering to the reinforcing backplate 180.

[0228] For example, such as Figure 12 and Figure 13 As shown, transporting the strong backplate 180 450 to the mandrel 140 via the PNP machine 130 includes aligning 456 the indexing element 182 (e.g., an indexing pin 183 shaped as a cone) at the strong backplate 180 with the indexing element 148 (e.g., an indexing cup 149 shaped as a complementary cup) at the mandrel 140. For example, the strong backplate 180 is aligned in the -Y direction and / or -Z direction ( Figure 3 The backplate 180 (as shown) is transported 450 to bring the strong backplate indexing element 182 into contact with the spindle indexing element 148. As the strong backplate 180 is transported 450 toward the spindle 140, the shapes of the indexing elements 148 and 182 guide the strong backplate 180 to align 456 with the spindle 140. Alignment 456 may include, for example, a notch 142 that indexes the strong backplate 180 onto the spindle 140 via a cup-cone indexing system to ensure known and repeatable positioning of the strong backplate 180 relative to the notch 142.

[0229] Alternatively or alternatively, please refer to other sources. Figure 16Transporting the reinforcing backplate 180 450 to the mandrel 140 includes aligning 458 of the recess 184 of the reinforcing backplate 180 with 458 of the cutout 142 in the mandrel 140. The alignment 458 of the recess 184 and the cutout 142 may occur during the alignment 456 of the indexing elements 182 and 148. Alternatively or additionally, program 122 in unit controller 120 includes coordinates of the alignment 458 of the recess 184 and the cutout 142, and / or unit controller 120 uses position and / or image information from data 137 received from one or more sensors to align the recess 184 and the cutout 142 458. This example can be used when indexing elements 148 and / or 182 are omitted, but it can also be used in addition to indexing elements 148 and 182. Alignment 456 and / or 458 enables the preform 150 to be positioned in the cutout 142.

[0230] When multiple types of prefabricated components 150 are assembled into structure 12, such as Figure 17 and Figure 18 As shown, a first type of prefabricated component 150, such as a large prefabricated component 156, is conveyed 408 to the mandrel 140. Furthermore, a second type of prefabricated component 150, such as a discrete prefabricated component 154, is conveyed 408 and / or 460 to the mandrel 140. Different types of prefabricated components 150 may be conveyed continuously or simultaneously to the mandrel 140. In one example, a single PNP machine 130 continuously conveys 408 and 460 different types of prefabricated components 150. In another example, more than one PNP machine 130 continuously and / or simultaneously conveys 408 and 460 different types of prefabricated components 150 depending on the prefabricated component 150 placed on the mandrel 140 and / or the assembled structure 12. Alternatively or concurrently, transport 408 includes transporting one or more large preforms 156 and discrete preforms 154 460 to mandrel 140 via PNP machine 130 while maintaining the arrangement of the large preforms 156 and discrete preforms 154.

[0231] When the spindle 140 includes, as follows Figure 21 When transporting the preform 150 and / or the reinforcing backplate 180 to the mandrel segment 235 as shown, the transport 408 includes transport 462 to the mandrel segment 235 via a PNP machine 130. For example, transporting the preform 150 and / or the reinforcing backplate 180 462 to a specific mandrel segment 235 positioned in a placement station 100. When multiple placement stations 100, 100', 100" perform method 400 on the corresponding mandrel segment 235, the transport 462 at each placement station 100, 100', 100" may occur at different or the same rates.

[0232] Reference Figure 24A and Figure 24B , Figure 13 and Figure 14 One or more preforms 150 are placed 410 onto the mandrel 140. Placement 410 occurs after the strong backing plate 180 and / or the preform 150 are conveyed 408 onto the mandrel 140. Method 400 includes placing the preform 150 410 onto the mandrel 140. Preferably, the preform 150 is placed 410 into the mandrel 140 while the preform 150 is in contact with the mandrel 140. More specifically, the conveying 408 of the strong backing plate 180 and / or the preform 150 causes the preform 150 to contact the mandrel 140. In one particular embodiment, the conveying 408 of the strong backing plate 180 causes the strong backing plate 180 to press the preform 150 against the mandrel 140. Then, the preform 150 is placed 410 while in contact with the mandrel 140 to prevent deformation of the preform 150 that could be caused by it falling from a distance away from the mandrel 140. However, after transport 408, a small gap may exist between the preform 150 and the mandrel 140 depending on the dimensional tolerances of the backing plate 180, the preform 150, and the mandrel 140.

[0233] Placement 410 includes removing 464 preform 150 from the strong backplate 180 (or from the PNP machine 130 when the strong backplate 180 is not in use). After the strong backplate 180 is positioned 452 on and / or aligned with the mandrel 140 456, 458, the preform 150 is removed from the strong backplate 180. More specifically, the preform 150 is removed from the recess 184 or surface 185 of the strong backplate 180. Figure 17 (As shown) Remove 464 and transfer it to the cut 142 or surface 145 of the mandrel 140. Figure 3 (as shown in the image).

[0234] Placing 410 and / or removing 464 preform 150 may include lifting 468 of the reinforcing backplate 180 and / or PNP machine 130 away from the mandrel 140 and preform 150, especially when the reinforcing backplate 180 has pressed the preform 150 against the mandrel 140 and / or the release membrane 26 has been applied to surface 185. Figure 17 When (as shown in the diagram) is between the preform 150 and the preform 150.

[0235] Placement 410 may additionally or alternatively include releasing vacuum pressure 160 470 to place preform 150 410 onto mandrel 140. More specifically, unit controller 120 deactivates vacuum system 138 to release vacuum pressure 160 470, thereby holding preform 150 at strong backplate 180. For example, after or during placement, vacuum pressure 160 applied to strong backplate 180 406 may be released 470 to facilitate removal of preform 150 464 from strong backplate 180 and / or placement of preform 150 in a desired location (e.g., a desired location on mandrel 140). When placement 410 includes lifting strong backplate 180 468, the release of vacuum pressure 160 470 may occur before or simultaneously with lifting strong backplate 180 468.

[0236] When placing more than one type of prefabricated component 150, placement 410 includes placing one or more large prefabricated components 156 and discrete prefabricated components 154 onto the mandrel 140. The large prefabricated components 156 may be placed separately from the discrete prefabricated components 154. Alternatively, the large prefabricated components 156 may be placed together with the discrete prefabricated components 154 while maintaining the arrangement of the large prefabricated components 156 and discrete prefabricated components 154. For example, when maintaining this arrangement during transport 460, the large prefabricated components 156 and discrete prefabricated components 154 are transferred from the strong backing plate 180 to the mandrel 140 without changing the relative positions of the prefabricated components 154 and 156 to place 472 prefabricated components 154 and 156.

[0237] When (one or more) PNP machines 130 are in the asynchronous phase 354 ( Figure 23 Operation 302 (as shown) Figure 22 As shown), placement 410 includes releasing 470 vacuum pressure 160 to remove 464 at least one discrete object 20 from the strong backplate 180 of the contact mandrel 140 of the discrete object 20. During the synchronization phase 356 ( Figure 23 Operation 304 (as shown) Figure 22 (As shown) PNP machine 130 ( Figure 23 As shown), placement 410 includes releasing 470 vacuum pressure 160 to remove 464 large object 22 from strong back plate 180, while large object 22 contacts mandrel 140.

[0238] When the mandrel 140 includes multiple mandrel segments 235, placement 410 includes placing preforms 150 474 onto the mandrel segments 235. Placement 474 on the mandrel segments 235 may occur at one or more placement stations 100, 100', and / or 100”. When the mandrel segment 235 is to receive different types of preforms 150, placement 474 of different types of preforms 150 includes placing one or more large preforms 156 and discrete preforms 154 onto the mandrel segment 235.

[0239] During and / or after placement 410, the strong backplate 180 is lifted 468 away from the spindle 140 (e.g., by means of...). Figure 3 (Movement in the +Z direction shown). Pattern 412 is repeated by moving the strong backplate 180 away from the spindle 140 so that it is placed 404 again on the tray 190 and / or the preform 150. The steps of placing 404, applying 406, transporting 408, and placing 410 of pattern 412 are repeated until the asynchronous phase 354 and / or the synchronous phase 356 are completed. Figure 22 and Figure 23 (as shown in the diagram) and / or until all the preforms 150 have been placed 410 on the mandrel 140 or mandrel segment 235.

[0240] After placing each or all of the prefabricated parts 150, the prefabricated parts 150 may optionally be secured 336 to the mandrel 140, as per [reference needed]. Figure 22 As described. For example, method 40 also includes securing at least one or more large preforms 156 336 to the mandrel 140. In embodiments including an optional mandrel vacuum system 144 (such as... Figure 13 As shown in the diagram, fixation 336 includes fixing the preform 150 to the mandrel 140 and / or mandrel segments 235 via a vacuum system 144. When the mandrel 140 includes mandrel segments 235, fixation 336 may occur at each mandrel segment 235.

[0241] Furthermore, after the final placement 410, it can be used as part of method 400 and / or as post-placement method 500. Figure 25 (As shown in the image) to perform the post-placement steps. Regarding Figure 25 The post-placement steps are described in more detail; however, the following section on... Figure 24A and Figure 24B Some examples of these steps are provided. In addition, the data of the identification device of mandrel 140 can be updated to include which objects 18 have been placed on mandrel 140 for use by subsequent stations and / or systems in manufacturing line 10.

[0242] For example, when the spindle 140 includes spindle segments 235, method 400 may include assembling a plurality of spindle segments 235 together 504. More specifically, after the PNP machine 130 has completed the instructions 124 in program 122 corresponding to the spindle segments 235, the plurality of spindle segments 235 are assembled together 504. For example, the plurality of spindle segments 235 are assembled together 504 to form a semi-cylindrical segment 770 (e.g., ...). Figure 29 (As shown). Therefore, method 400 includes assembling the mandrel segments 235 together 504. In another embodiment, a vacuum pressure 147 is applied at the mandrel segments 235 to hold the preform 150 in place.

[0243] When one or more layers 206 are included in structure 12, method 400 includes placing (one or more) layers 206 516 on a plurality of preforms 150 disposed on mandrel 140. For example, a PNP machine 130 may be used to place 516 layers 206, similar to how preforms 150 are placed during mode 412. Alternatively, layers 206 may be placed manually and / or by different machines within manufacturing line 10. When mandrel 140 includes mandrel segments 235, layers 206 are placed 516 after mandrel segments 235 have been assembled 504. Layers 206 and preforms 150 are cured 520, for example, co-cured 524. In another embodiment, method 300 further includes placing 516 layers 206 of uncured fiber-reinforced material 152 on a plurality of preforms 150 disposed on mandrel 140, and curing 520, for example, co-curing 524 layers 206 and preforms 150.

[0244] Variations in the steps of combining movement 402, identification 418, placement 404, application 406, transport 408, and / or placement 410. Figure 24A and Figure 24B Method 400 can be adapted to the placement of components of system 50 and / or the specific structure 12 being assembled. The following examples are provided, but other combinations are also possible.

[0245] When the prefabricated component 150 is mated, method 400 may include identifying 422(one or more) trays 190, placing 428(a) reinforcing backplate 180 on 428(a) trays 190, transporting 460(a) large prefabricated component 156 and discrete prefabricated component 154 to mandrel 140 while maintaining the arrangement of the large prefabricated component 156 and discrete prefabricated component 154, and placing 472(a) large prefabricated component 156 and discrete prefabricated component 154 onto mandrel 140. In this example, method 400 may also include holding 442(a) multiple prefabricated components 150 in multiple recesses 184(a) of reinforcing backplate 180 and / or holding 444(a) and / or 446(a) prefabricated components 150 of first and second types.

[0246] In another example, when multiple types of prefabricated parts 150 are to be placed, the tray 190 stores an array of multiple prefabricated parts 154 and / or 156, such as... Figure 5 As shown, the strong backplate 180 includes a plurality of recesses 184 for each preform 154 or 156 in the array stored in the tray 190. In this embodiment, placing the recesses 184 of the strong backplate 180 at the preform 150 includes placing the plurality of recesses 184 of the strong backplate 180 at the plurality of preforms 154 and / or 156, and applying vacuum pressure 160 includes applying vacuum pressure 160 through a plurality of vacuum channels 188 to keep the plurality of preforms 154 and / or 156 in contact with the plurality of recesses 184.

[0247] When the mandrel 140 includes a plurality of radial mandrel segments 235 (e.g. Figure 21 When (as shown), method 400 includes at least moving 414 one or more mandrel segments 235, transporting 462 the preform 150 to one or more mandrel segments 235, and placing 474 the preform 150 on one or more mandrel segments 235.

[0248] When the strong backplate 180 includes multiple strong backplate segments 181, such as Figure 16 As shown, method 400 includes placing one or more strong backplate segments 181 404 on a tray 190 and / or a preform 150, applying a vacuum pressure 160 406 to one or more strong backplate segments 181, conveying one or more strong backplate segments 181 450 to a mandrel 140, and placing a preform 150 on the mandrel 140 using each strong backplate segment 181. Each strong backplate segment 181 can be used by a different PNP machine 130, allowing each strong backplate segment 181 to be used independently of one or more other strong backplate segments 181. Alternatively, more than one PNP machine 130 can be assigned to the strong backplate segments 181, allowing larger strong backplate segments 181 and / or preforms 150 to be moved sequentially or simultaneously with one or more other strong backplate segments 181 to the mandrel 140. All strong backplate segments 181 can move in the same direction at the same speed, or the movement of strong backplate segments 181 can be independent of the movement of any other strong backplate segments 181 (provided that the strong backplate segments 181 do not unintentionally come into contact by using independent movement).

[0249] When using a placement system 50 that does not include the strong backplate 180, method 400 includes: step 404, in which the placement 404 is modified to place the PNP machine 130 (instead of the strong backplate 180) at the tray 190 and / or preform 150; step 406, in which a vacuum pressure 160 is applied to the PNP machine 130 and / or end effector 134, the preform 150 is transported 448, and the preform 150 is placed 410 from the PNP machine 130 and / or end effector 134 onto the mandrel 140. Similarly, for such a placement system 50, mode 412 includes the steps of placement 404, application 406, transport 448, and placement 410 with the aforementioned modifications.

[0250] Figure 25 This shows the operation. Figures 1 to 21 The flowchart illustrates the post-placement method 500 of the placement system 50. More specifically, Figure 25 Showing for at least part in Figure 24A and Figure 24B The method shown 400 is used during and / or after the operation of the placement system 50 and / or manufacturing line 10. Figure 1 The placement method 500 (as shown) is as follows.

[0251] Reference Figure 25 and Figure 21 Method 500 includes an assembly process 502. Assembly method 502 is preferably performed when the mandrel 140 comprises a plurality of mandrel segments 235. Assembly process 502 includes assembling the plurality of mandrel segments 235 together 504. Assembling the mandrel segments 235 together 504 forms the mandrel 140. When the structure 12 being assembled is part 768 of the fuselage 766 (e.g., Figure 29 As shown, multiple mandrel segments 235 are assembled together to form a semi-cylindrical section 770.

[0252] Assembly method 502 may optionally include moving 506 the mandrel 140 and / or mandrel segments 235 and / or positioning 508 the mandrel segments 235. More specifically, the mandrel segments 235 may be moved 506 to assembly station 105 before being assembled 504 together. During or after the movement 506 of the mandrel segments 235, the mandrel segments 235 are positioned 508 relative to each other for assembly 504 together.

[0253] When each mandrel segment 235 is a radial segment of mandrel 140, each mandrel segment 235 is positioned 510 in a different radial region Z1, Z2, or Z3 of mandrel 140. For example, when mandrel segments 236, 238, and 240 are moved 506 from one or more placement stations 100, 100', and 100" to assembly station 105, each mandrel segment 236, 238, and 240 is moved 506 to be positioned 510 in the corresponding radial region Z3, Z1, or Z2. More specifically, due to the correspondence between mandrel segments 236, 238, and 240 and radial portions 212, 208, and 210, each mandrel segment 236, 238, and 240 is positioned 510 in the corresponding radial region Z3, Z1, or Z2 before mandrel 140 is assembled 504 by mandrel segments 236, 238, and 240.

[0254] Assembling mandrel segment 235 504 may include applying fastener 242 512 to mandrel segment 235. For example, by applying fastener 242 512 to second mandrel segment 238 and third mandrel segment 240, the second mandrel segment 238 is assembled 504 to one side of the third mandrel segment 240. Similarly, by applying fastener 242 512 to first mandrel segment 236 and third mandrel segment 240, the first mandrel segment 236 is assembled 504 to the other side of the third mandrel segment 240. Fastener 242 may be applied 512 after all mandrel segments 235 are positioned relative to each other, or may be applied 512 as each mandrel segment 235 is positioned.

[0255] In another example, assembling mandrel segment 235 504 includes installing a seal between adjacent mandrel segments 235 before or after fastener 242 is applied 512 to mandrel segment 235. In a particular example, the seal is installed such that a force acts on the seal in the normal direction.

[0256] Mandrel 140 and / or mandrel segments 235 may be attached 514 to mandrel support structure 106. More specifically, mandrel segments 235, individually or assembled together 504, are attached 514 to mandrel support structure 106 as mandrel 140. In one example, mandrel segments 235 are assembled 504 together, and then fastener 244 is used to attach mandrel 140 formed by mandrel segments 235 514 to mandrel support structure 106. In another example, mandrel segments 235 514 are attached to mandrel support structure 106, for example, using fastener 244, and then, for example, mandrel segments 235 are assembled 504 to adjacent mandrel segments 235 using fastener 242. Thus, assembling mandrel segments 235 504 together may include attaching mandrel segments 235 514 to mandrel support structure 106.

[0257] Postposition method 500 may further include placing (e.g., by laying) one or more layers 206 516 on the preform 150 and / or mandrel 140. The placement 516 of layers 206 can be done manually, automatically, or a combination of both. Layers 206 can be placed 516 before or after assembly method 502. When preforming is performed before assembly method 502, layers 206 516 are placed on the preform 150 that has already been placed 410 on the mandrel 140 and / or placed 474 on the mandrel segments 235. For example, layers 206 516 are placed on each mandrel segment 235 before moving 506 to assembly station 105. For example, layers 206 are placed 516 at placement station 100. After assembly method 502, layers 206 are spliced ​​518 together to produce, for example, skin 782. Figure 29 (As shown in the diagram). When layer 206 is placed after assembly method 502, layer 206 is placed on the assembled mandrel segment and / or on the mandrel 140 attached to the mandrel support structure 106. Layer 206 may be placed at assembly station 105 or at a layer placement station (not shown) after assembly station 105.

[0258] Postposition method 500 may further include hardening method 520. Hardening method 520 includes at least hardening preform 150. To perform hardening method 520, mandrel 140 and / or mandrel segment 235 are moved 522 to hardening system 60. Figure 1 (As shown). The curing method 520 can be performed before or after the assembly method 502, so the curing system 60 is positioned along the manufacturing line 10 before or after the assembly station 105. When one or more layers 206 are included in the structure 12, the curing method 520 includes co-curing 524 layers 206 and preform 150.

[0259] When mandrel segments 235 are used and curing method 520 is performed prior to assembly method 502, preform 150 and layer 206 (if included) are co-cured 524 on each mandrel segment 235, and then the mandrel segments 235 are moved 506 to assembly station 105 for assembly 504. The cured layers 206 are then joined together at 518. In one example, method 500 includes laying skin layer 206 516 on top of each mandrel segment 235 before the mandrel segments 235 have been assembled, co-curing the skin layer 206 on top of each mandrel segment 235 with the preform 150 on the corresponding mandrel segment 235 524 to form skin 782, and joining skin 782 together 518 after the mandrel segments 235 have been assembled.

[0260] When mandrel segment 235 is used and curing method 520 is performed after assembly method 502, mandrel segment 235 is assembled 504 together and moved 522 as mandrel 140 to curing system 60 so that preform 150 and layer 206 (if included) are co-cured 524. When mandrel segment 235 is assembled 504 together before curing method 520, splicing 518 of layer 206 is not required. In one example, method 500 includes laying skin layer 206 516 on top of mandrel segment 235 after mandrel segment 235 has been assembled 504 together, and co-curing skin layer 206 with preform 150 on mandrel segment 235 524.

[0261] When the mandrel 140 is not formed by multiple mandrel segments 235, the post-placement method 500 can still be performed. For example, method 500 may include moving the mandrel 140 506 to the assembly station 105 if the mandrel 140 will be supported by the mandrel support structure 106, and then attaching the mandrel 140 514 to the mandrel support structure 106. When one or more layers 206 will be included in the structure 12, method 500 includes placing the layers 206 516 before or after attaching the mandrel 140 514 to the mandrel support structure 106. The mandrel 140 (and the mandrel support structure 106) is moved 522 to the curing system 60, and the preform 150 and the layers 206 are co-cured 524.

[0262] After the skin 782 is spliced ​​together 518, or after the skin layer 206 and preform 150 are co-cured 524, the mandrel 140 can be reused 526. The mandrel 140 can be reused as a whole 526, or mandrel segments 235 can be reused 528. Regarding... Figure 26 The preparation method 600 shown describes the details of reusing 526 and 528.

[0263] Figure 26 This shows the preparation Figures 2 to 20 The flowchart of method 600 for mandrel 140 shown is provided. All or some of the steps of method 600 can be used to perform... Figure 25 The reuse of methods 526 and / or 528 is shown in method 500. Preparation method 600 may include separation method 602 and / or cleaning method 604. See reference... Figure 26 and Figure 1 Method 600 can occur after the laying has been completed and the precast component 150 has hardened 520.

[0264] To perform separation method 602, mandrel 140 may be moved 606 to separation system 70. When mandrel 140 includes mandrel segments 235, mandrel 140 is moved 606 to separation system 70, where the mandrel segments 235 are separable from each other. In a particular example, mandrel 140 is moved 606 from hardening system 60 to separation system 70 along manufacturing line 10 in processing direction 14. When object 18 is not made of unhardened fiber-reinforced material 152 and is placed and assembled into structure 12 without hardening, mandrel 140 is moved 606 along manufacturing line 10 from placement system 50 to separation system 70 to remove structure 12 from mandrel 140.

[0265] According to method 600, separation method 602 includes separating the mandrel 140 from the hardened structure 64 608. When the mandrel 140 includes a mandrel segment 235, separation 608 includes separating the mandrel segment 235 from the hardened structure 64 610. In a particular example, separating the mandrel segment 235 from the hardened structure 64 610 includes separating the mandrel segment 235 from the cured portion 768 of the fuselage 766 610. Figure 28 and Figure 29 (As shown). For example, separation 608 from the hardened structure 64 may include vertically moving 612 the mandrel segment 235 to separate the hardened structure 64 from the mandrel segment 235. In one embodiment, the mandrel segment 235 is moved vertically downward away from the hardened structure 64.

[0266] The separation method 602 may further include separating the mandrel segments 235 from each other 614. Separating the mandrel segments 235 614 may include removing 616 fasteners 242 that hold the mandrel segments 235 together. For example, separating the mandrel segments 235 from each other 614 includes removing 616 fasteners 242 from the mandrel segments 235. Therefore, when the mandrel 140 includes mandrel segments 235, the separation method 602 and thus the preparation method 600 include separating the mandrel segments 235 from the hardened structure 64 610 and separating the mandrel segments 235 from each other 614.

[0267] Alternatively or concurrently, separation 614 of the mandrel segment 235 may include disengaging the mandrel segment 235 from the mandrel support structure 106 618. For example, fastener 244 may be removed to disengage the mandrel segment 235 from the mandrel support structure 106 618. When the mandrel 140 does not include the mandrel segment 235 but is supported by the mandrel support structure 106, the mandrel 140 may be disengaged from the mandrel support structure 106 618. Disengagement 618 may occur during separation method 602 or after cleaning method 604.

[0268] When using one or more release membranes 62, separation method 602 includes removing 620 of the release membrane 62 from the spindle 140 and / or spindle segment 235. For example, after the hardened structure 64 is separated from the spindle 140 608, the release membrane 62 is removed 620 from the spindle 140 and / or the hardened structure 64. When using the spindle segment 235, the release membrane 62 is removed 620 from the spindle segment 235 after the spindle segment 235 is separated from the hardened structure 64 610 and before the spindle segments 235 are separated from each other 614.

[0269] As part of or after separation method 602, the hardened structure 64 may be moved 622 to a new location in manufacturing line 10 to receive additional manufacturing processes. For example, the composite component 16 and / or the hardened structure 64 may be moved 622 to a new location in manufacturing line 10, such as to a different system, to receive additional manufacturing processes. The different system may be a manufacturing or assembly system, and the additional manufacturing processes may assemble the composite component 16 into a final product, such as aircraft 750. Figure 28 and Figure 29 (as shown in the image).

[0270] Preparation method 600 may further include cleaning method 604. Cleaning method 604 may include moving mandrel 140 and / or mandrel segment 234 624 to cleaning system 80. Cleaning method 604 includes cleaning mandrel 140 626. When mandrel segment 235 is used, mandrel segment 235 is cleaned 626. Cleaning 626 may be performed by scrubbing, rubbing, or other cleaning processes such as using a moving brush, scrubber, etc.

[0271] Cleaning 626 includes applying 628 at least one cleaning chemical 82 to the mandrel 140 and / or (one or more) mandrel segments 235. The cleaning chemical 82 may be a solvent, water, and / or soap. When more than one cleaning chemical 82 is applied, the different cleaning chemicals 82 are applied sequentially and / or simultaneously. The application 628 of the cleaning chemical 82 may occur before, during, or after other cleaning processes (e.g., scrubbing, rubbing, etc.). In an alternative embodiment, after the mandrel 140 is cleaned as a whole 626, the mandrel segments 235 are separated from each other 614; however, if they are separated from each other 614 before cleaning 626, the mandrel segments 235 may be cleaned more thoroughly and / or in parallel.

[0272] When separation method 602 and optional cleaning method 604 have been performed, method 600 may include conveying mandrel 140 or mandrel segment 235 630 to a starting position 52 for picking up and placing preform 150 onto mandrel 140 or mandrel segment 235 (or one or more) of placement stations 100, 100' and / or 100"). The conveyance 630 of mandrel 140 may be performed in placement method 400 (… Figure 24A and Figure 24B The movement 402 that occurs during the process (as shown in the diagram) is then included in method 600, after the spindle segment 235 has been, for example, separated 614 and / or cleaned 626, placing the preform 150 400 on the spindle 140 or spindle segment 235 via PNP machine 130.

[0273] Reference Figure 1 and Figures 24A to 26 The diagram shows a general example of the flow of mandrel 140, such as a segmented mandrel with mandrel segments 235, through the assembly environment of manufacturing line 10. Figure 21 The spindle segments 235, 236, 238 and 240 and placement stations 100, 100' and 100” are shown, as well as assembly station 105.

[0274] Reference Figure 1 , Figure 21 and Figures 24A to 26 Mandrel segments 236, 238, and 240 individually receive preforms 150 at placement system 50, in which PNP machine 130 places 410 preforms 150 onto mandrel segments 236, 238, and / or 240 at predetermined positions. Mandrel segment 235 is moved 506 to assembly station 105. After mandrel segments 235 have been radially positioned 510, mandrel segments 235 are attached to each other in a single radial position (e.g., during assembly 504). Alternatively or additionally, mandrel segments 235 are attached 514 to mandrel support structure 106. For example, mandrel segments 235 are attached 514 to mandrel support structure 106 via fasteners 244.

[0275] One or more skin layers 206 may be placed on the preform 150 at mandrel segments 236, 238, 240 and co-cured with the preform 150 524 to form with the longitudinal beam 778. Figure 29(As shown) a single skin layer 782. This can be performed before or after the assembly 504 of mandrel segments 236, 238, and 240. If performed after the assembly 504 of mandrel segments 236, 238, and 240, the skin layer 206 and preform 150 can be hardened 520 into a single unit in a single step. However, if performed before assembly 504, additional splicing 518 can be performed after the skin layer 206 has been laid 516 and / or hardened 520 to facilitate assembly method 502. The mandrel support structure 106 continues to move 522 to the hardening system 60, in which the preform 150 is hardened. The hardening system 60 itself, or its upstream or downstream location, can form the boundary of the cleanroom environment.

[0276] The spindle support structure 106 advances to the separation system 70, which removes or separates the bent portion 768 of the fuselage 766 from the spindle segment 235 by vertically moving 612 of the bent portion 768 to separate it from the spindle segment 235. The solidified portion 768 of the fuselage 766 then continues to move 622 to a new position for receiving work (e.g., attaching to another section of the fuselage 766, installing a window or frame, etc.).

[0277] At separation system 70 or at another separation station (not shown), release membrane 62 (e.g., vacuum bagging material, release lamella, separation membrane, etc.) is also removed from mandrel segment 235. Then, mandrel segments 235 are separated from each other 614 by removing fasteners 242 616 from mandrel segments 235. For example, mandrel segments 235 are separated from each other 614 via separation system 70 or at another separation station (not shown). Each mandrel segment 235 can be cleaned 626 at cleaning system 80. Cleaning system 80 applies 628 cleaning chemicals 82, such as water, solvent, soap, etc., and may combine this with scrubbing, rubbing, or other cleaning 626 (e.g., moving brush, scrubber, etc.). Mandrel segments 235 are returned to placement system 50 via transport 630 to receive additional preforms 150. This includes placing the preform 150 onto the spindle segment 235 via a PNP machine 130 after the spindle segment 235 has been cleaned 626.

[0278] Example

[0279] In the following examples, additional processes, systems, and methods are described in the context of a system that coordinates the actions of a PNP machine, such as the PNP machine 130 described above.

[0280] Referring more specifically to the accompanying drawings, embodiments of this disclosure can be implemented as follows: Figure 27 The aircraft manufacturing and maintenance in method 700 shown and such Figure 28 and Figure 29The description is based on the background of the aircraft 750 shown. During pre-production, method 700 may include the specification and design 702 of the aircraft 750 and material procurement 704. During production, the manufacturing of components and sub-assemblies of the aircraft 750 and system integration 708 are carried out. Thereafter, the aircraft 750 may undergo certification and delivery 710 for entry into service 712. When used by the customer, the aircraft 750 is scheduled for routine work in maintenance and repair 714 (which may also include modification, remodeling, refurbishment, etc.).

[0281] The systems and methods implemented herein can be employed during any one or more suitable phases of production and maintenance described in method 700 (e.g., component and sub-component manufacturing 706, system integration 708, maintenance and repair 714) and / or in any suitable component of aircraft 750 (e.g., airframe 752, system 754, interior 756, propulsion system 758, electrical system 760, hydraulic system 762, environmental system 764). Each of the processes in method 700 can be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, system integrators can include, but are not limited to, any number of aircraft manufacturers and main system subcontractors; third parties can include, but are not limited to, any number of suppliers, subcontractors, and vendors; and operators can be airlines, leasing companies, military entities, maintenance organizations, etc.

[0282] like Figure 28 As shown, an aircraft 750 produced by method 700 may include an airframe 752 and an interior 756 having multiple systems 754. The airframe 752 includes a fuselage 766 defining at least a portion of the interior 756. Examples of systems 754 include one or more of a propulsion system 758, an electrical system 760, a hydraulic system 762, and an environmental system 764. Any number of other systems may be included. Although an aerospace example is shown, the principles of the systems and methods described herein can be applied to other industries, such as the automotive industry.

[0283] Figure 29 yes Figure 28 The image shows a perspective view of aircraft 750. Aircraft 750 includes fuselage 766. Fuselage 766 can form body 752. Figure 28 As shown in the diagram, the fuselage 766 is part of and defines the interior 756 of the aircraft 750. The fuselage 766 also houses at least a portion of the system 754. The fuselage 766 may be constructed from a separately manufactured portion 768, or from components used as part of the manufacturing line 10, placement system 50, and reference 754. Figures 1 to 26 The described methods 300, 400, 500 and / or 600 are composed of sub-components 768. For example, part 768 of the fuselage 766 may be structure 12 assembled by placement system 500.

[0284] As described above, the semi-cylindrical section 770 is an example of part 768 of the fuselage 766 assembled using placement system 50 and methods 300, 400, 500 and / or 600. Because the fuselage 766 constitutes at least a part of the body 752, part 768 and the semi-cylindrical section 770 can be considered components of the body 752. Figure 29 In the example, the fuselage 766 is made of semi-cylindrical sections 770 by joining upper semi-cylindrical sections 772 to lower semi-cylindrical sections 774 to form corresponding complete cylindrical sections 776-1, 776-2, 776-3, and 776-4. The complete cylindrical sections 776-1, 776-2, 776-3, and 776-4 are joined sequentially to form the fuselage 766.

[0285] Each part 768 or section 770 of the fuselage 766 includes a longitudinal beam 778, a frame 780, and a skin 782. The skin 782 is attached to the longitudinal beam 778 and the frame 780. In some embodiments, frame filler 784 may be positioned between the skin 782 and the frame 780. In hardening method 520 ( Figure 25 (As shown) After that, longitudinal beam precast component 159 ( Figure 5 and Figure 18 As shown) becomes longitudinal beam 778, while frame filler prefabricated component 158 ​​( Figure 5 and Figure 18 (As shown) becomes frame filler 784. When (one or more) layers 206 ( Figure 18 (as shown) is included in structure 12 ( Figure 1 In the process shown), after hardening method 520, one or more layers 206 laid 516 on preforms 158 and 159 become skin 782, as per the description. Figure 25 As stated above.

[0286] In one embodiment, the component comprises a portion of airframe 752 and is manufactured during component and subassembly manufacturing 706. The component can then be assembled into aircraft 750 during system integration 708 and used in service 712 until wear renders it unusable. During maintenance and repair 714, the component can then be discarded and replaced with a newly manufactured component. The components and methods of the present invention can be used throughout component and subassembly manufacturing 706 to manufacture new components.

[0287] Any of the various control elements (e.g., electrical or electronic components) shown in the accompanying drawings or described herein may be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination thereof. For example, an element may be implemented as dedicated hardware. A dedicated hardware element may be referred to as a “processor,” a “controller,” or some similar term. When provided by a processor, functionality may be provided by a single dedicated processor, a single shared processor, or multiple separate processors, some of which may be shared. Furthermore, the explicit use of the terms “processor” or “controller” should not be construed as exclusively referring 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 circuit systems, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile storage devices, logic, or some other physical hardware components or modules.

[0288] 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. When executed by a processor, the instructions operate 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 storage, magnetic storage media such as disks and tapes, hard disk drives, or optically readable digital data storage media.

[0289] Although specific embodiments have been described herein, the scope of this disclosure is not limited to those specific embodiments. The scope of this disclosure is defined by the claims and any equivalents thereof.

[0290] This disclosure also includes the following sets of provisions, which should not be confused with the appended claims that define the scope of protection.

[0291] Group 1 Clause:

[0292] 1. A method 400 for placing a preform 150 onto a mandrel 140, the preform 150 comprising an uncured fiber-reinforced material 152, the method 400 comprising:

[0293] The spindle 140 moves 402 in the processing direction 14 relative to the placement station 100, which includes multiple pick-and-place (PNP) machines 130;

[0294] Identify the tray 190 storing the prefabricated component 150;

[0295] The strong backplate 180 is placed 404 at the preform 150 via at least one of the PNP machines 130;

[0296] A vacuum pressure of 406160 is applied to maintain the preform 150 of 438 in contact with the strong back plate 180;

[0297] The preform 150 is transported 448 to the mandrel 140 via the at least one PNP machine 130; and

[0298] The preform 150 is placed 410 onto the mandrel 140.

[0299] 2. The method 400 of Clause 1, the method further comprising:

[0300] Pause 416 when a portion of the mandrel 140 is positioned at the placement station 100.

[0301] 3. The method 400 described in Clause 1 or 2, wherein:

[0302] Placing the preform 150 described in 410 includes releasing the vacuum pressure 160 described in 470.

[0303] 4. The method 400 of any one of clauses 1 to 3, wherein:

[0304] Placing the strong back plate 180 404 includes placing the recess 184 of the strong back plate 180 432 at the preform 150.

[0305] 5. The method 400 of Clause 4, wherein the tray 190 stores a plurality of prefabricated parts 150, and the strong backing plate 180 includes a plurality of recesses 184, and wherein:

[0306] Placing the recesses 184 of the reinforcing backplate 180 at the preform 150 includes placing the plurality of recesses 184 of the reinforcing backplate 180 at the plurality of preforms 150; and

[0307] Applying the vacuum pressure 160 described in 406 includes maintaining the plurality of preforms 150 in contact with the plurality of recesses 184 described in 442.

[0308] 6. The method 400 of any one of clauses 1 to 5, wherein:

[0309] Transporting the preform 150 to the mandrel 140 via the PNP machine 130 includes aligning the indexing element 183 at the strong back plate 180 with the indexing element 148 at the mandrel 140 456.

[0310] 7. Method 400 of any one of Clauses 1 to 6, wherein:

[0311] Transporting the preform 150 to the mandrel 140 includes aligning the recess 184 of the strong back plate 180 with the cutout 142 in the mandrel 140 458.

[0312] 8. The method 400 of any one of clauses 1 to 7, said method further comprising:

[0313] The uncured fiber-reinforced material 152 layer 206 is placed 516 on a plurality of preforms 150 disposed on the mandrel 140; and

[0314] The layer 206 and the preform 150 are co-cured.

[0315] 9. The method 400 described in any one of clauses 1 to 8, wherein:

[0316] Applying the vacuum pressure 160 by 406 includes operating the vacuum system 138 by 436 to apply the vacuum pressure 160 through the vacuum channel 188 connected to the recess 184 of the strong back plate 180.

[0317] 10. A portion 768 of an aircraft 750 assembled according to method 400 in any one of clauses 1 to 9.

[0318] 11. A non-transitory computer-readable medium implementing programming instructions 124, which, when executed by a processor, are operable for performing the method 400 for assembling a structure according to any one of claims 1 to 9.

[0319] 12. A portion 768 of an aircraft 750 assembled according to the method 400 defined by the instructions 124 stored on the computer-readable medium of claim 11.

[0320] 13. A placement system 50 for manufacturing structure 12, said placement system 50 comprising:

[0321] Pick-and-place (PNP) machine 130, said pick-and-place (PNP) machine being located within manufacturing unit 110; and

[0322] Unit controller 120, the unit controller being operable to:

[0323] The spindle 140 moves 402 units relative to the PNP machine 130 in the processing direction 14.

[0324] Identify 418 a pallet 190 storing prefabricated components 150 comprising uncured fiber-reinforced material 152.

[0325] The reinforcing backplate 180 is placed 404 at the preform 150 via at least one of the PNP machines 130.

[0326] A vacuum pressure of 406 ppm is applied to maintain contact between the preform 150 and the reinforcing backplate 180.

[0327] The preform 150 is transported 448 to the mandrel 140 via the at least one PNP machine 130, and

[0328] The preform 150 is placed 410 onto the mandrel 140.

[0329] 14. The placement system 50 described in Clause 13, wherein:

[0330] The unit controller 120 is operable to pause the mandrel 140 when a portion of the mandrel 140 is positioned at the placement station 100 with the PNP machine 130.

[0331] 15. The placement system 50 described in clause 13 or 14, wherein:

[0332] The unit controller 120 is operable to place the preform 150 by releasing the vacuum pressure 160 described in 470.

[0333] 16. The placement system 50 of any one of clauses 13 to 15, wherein:

[0334] The unit controller 120 is operable to place the strong backplate 180 at the preform 150 by placing the recess 184 of the strong backplate 180 at the preform 150.

[0335] 17. The placement system 50 described in Clause 16, wherein:

[0336] The tray 190 stores a plurality of prefabricated parts 150, and the strong back plate 180 includes a plurality of recesses 184.

[0337] 18. The placement system 50 of any one of clauses 13 to 17, wherein:

[0338] By aligning the indexing element 183 at the strong backplate 180 with the indexing element 148 at the mandrel 140 456, the unit controller 120 is operable to transport the preform 150 408 to the mandrel 140 via the PNP machine 130.

[0339] 19. The placement system 50 of any one of clauses 13 to 18, wherein:

[0340] The unit controller 120 is operable to transport the preform 150 408 by aligning the recess 184 of the strong backplate 180 with the cut 142 in the mandrel 140 458.

[0341] 20. The placement system 50 of any one of clauses 13 to 19, wherein:

[0342] The unit controller 120 is operable to place 516 of the uncured fiber-reinforced material 152 layer 206 on a plurality of preforms 150 disposed on the mandrel 140, and co-cur 524 the layer 206 and the preforms 150.

[0343] 21. To manufacture a portion 768 of the aircraft 750 using the placement system 50 as described in any one of Clauses 13 to 20.

[0344] Group 2 Clause:

[0345] 1. A method 300 for assembling a structure 12 formed of an object 18, the object comprising a discrete object 20 and a large object 22 larger than the discrete object 20, the method 300 comprising:

[0346] In asynchronous phase 354, operation 302 is performed, wherein the pick-and-place (PNP) machine 130 at placement station 100 operates independently to place the discrete object 20 onto mandrel 140; and

[0347] In the synchronization phase 356, operation 304 is performed, wherein the PNP machines 130 operate one after the other to place the large object 22, which spans multiple PNP machines 130, onto the mandrel 140.

[0348] 2. The method 300 described in Clause 1, wherein:

[0349] During operation 302 in the asynchronous phase 354, for each of the PNP machines 130: in response to detecting that a previous instruction 124 from program 122 has been completed by the PNP machine 130, a new instruction 124 is provided from program 122, regardless of the progress of other PNP machines 130, preferably wherein program 122 is a numerical control (NC) program 123 and instruction 124 is an NC instruction 125.

[0350] 3. The method 300 described in Clause 1 or 2, wherein:

[0351] During operation 304 in the synchronization phase 356, in response to the detection that all of the PNP machines 130 have completed the previous instruction 124 from the program 122, a new instruction 124 is provided from the program 122 to each of the PNP machines 130, preferably wherein the program 122 is an NC program 123 and the instruction 124 is an NC instruction 125.

[0352] 4. The method 300 of any one of clauses 1 to 3, wherein the mandrel 140 has a wavy cross section 143, and the PNP machines 130, 130' are distributed across a plurality of placement stations 100, 100', wherein the method 300 further comprises:

[0353] In the synchronous phase 356 and the asynchronous phase 354, the PNP machines 130 and 130' of 304 and 302 are repeatedly operated at each of the placement stations 100' and 100" for 334.

[0354] 5. The method 300 described in Clause 4, wherein:

[0355] Each of the operations 316, 328 in the placement stations 100, 100' of the PNP machine 130, 130' is to place the object 18 308, 320 onto different radial portions 208, 210, 212, 213 of the mandrel 140.

[0356] 6. The method 300 described in Clause 4 or 5, wherein:

[0357] Each operation 316, 328 of the placement stations 100, 100' of the PNP machine 130, 130' is performed to place the object 18 312, 324 onto different longitudinal portions 224, 226, 228 of the mandrel 140.

[0358] 7. The method 300 of any one of clauses 1 to 6, said method further comprising:

[0359] After the PNP machine 130 has completed the instructions 124 in the program 122 corresponding to each of the plurality of mandrel segments 235, the plurality of mandrel segments 235 are assembled together 504 into a semi-cylindrical section 770.

[0360] 8. The method 300 of any one of clauses 1 to 7, wherein each of the objects 18 comprises a preform 150 of uncured fiber-reinforced material 152, and the method 300 further comprises:

[0361] The preform 150 is fixed 336 to the mandrel 140.

[0362] 9. Method 300 of any one of Clauses 1 to 8, wherein:

[0363] In the asynchronous phase 354, instruction 124 causes each of the PNP machines 130 to place a strong backplate 180 404 on at least one discrete object 20, apply a vacuum pressure 160 406 to hold the at least one discrete object 20 at the strong backplate 180, lift the strong backplate 180 454 to a suitable position on the mandrel 140, and release the vacuum pressure 160 470 to remove the at least one discrete object 20 from the strong backplate 180 464 while the at least one discrete object 20 is in contact with the mandrel 140.

[0364] In the synchronization phase 356, instruction 124 causes each of the PNP machines 130 to synchronously place the strong backplate 180 404 on the large object 22, apply the vacuum pressure 160 406 to hold the large object 22 across the PNP machine 130 at the strong backplate 180, lift the strong backplate 180 454 to a suitable position on the mandrel 140, and release the vacuum pressure 160 470 to remove the large object 22 from the strong backplate 180 464 as the large object 22 contacts the mandrel 140.

[0365] 10. A portion 768 of the aircraft 750 assembled by method 300 according to any one of claims 1 to 9.

[0366] 11. A non-transitory computer-readable medium implementing programming instructions 124, which, when executed by a processor, are capable of performing a method 300 for assembling the structure 12 as described in any one of the provisions 1 to 9.

[0367] 12. A portion 768 of an aircraft 750 assembled according to the method 300 defined by the instructions 124 stored on the computer-readable medium of Clause 11.

[0368] 13. A placement system 50 for manufacturing a structure 12 from an object 18 comprising a discrete object 20 and a large object 22 larger than the discrete object 20, the placement system 50 comprising:

[0369] A pick-and-place (PNP) machine 130 is located at a placement station 100 within manufacturing unit 110. The PNP machine 130 is positioned within the reach of the object 18 and the mandrel 140. The large object 22 spans multiple PNP machines 130, wherein the mandrel 140 moves relative to the PNP machines 130.

[0370] The unit controller 120 is operable to initiate an asynchronous phase 302, in which the PNP machines 130 operate independently to place the discrete object 20 onto the mandrel 140, and is also operable to initiate a synchronous phase 304, in which the PNP machines 130 operate sequentially to place the large object 22 onto the mandrel 140.

[0371] 14. The placement system 50 described in Clause 13, wherein:

[0372] Each of the PNP machines 130 includes a controller 132, an end effector 134, and a sensor 136, preferably wherein the sensor 136 is a position sensor.

[0373] 15. The placement system 50 described in Clause 14, wherein:

[0374] Each of the PNP machines 130 includes an end effector 134 comprising a vacuum system 138 that selectively applies a vacuum pressure 160 according to a program 122, preferably wherein the program 122 is a numerical control (NC) program 123.

[0375] 16. To manufacture a portion 768 of the aircraft 750 using the placement system 50 as described in any one of Clauses 13 to 15.

[0376] Group 3 Clause:

[0377] 1. A method 300 for assembling a structure 12 from objects 18, said objects including discrete objects 20 and large objects 22 larger than said discrete objects 20, said method 300 comprising:

[0378] In the asynchronous phase 354, the first subset 126 of the pick-and-place (PNP) machine 130 is independently operated at the placement station 100 to place the discrete object 20 onto the mandrel 140.

[0379] When operating the first subset 126 in the asynchronous phase 354, for each of the PNP machines 130a in the first subset 126: in response to detecting that a previous instruction 124 from the program 122 has been completed by the PNP machine 130a, a new instruction 124 is provided from the program 122, regardless of the progress of the other PNP machines 130 in the first subset 126;

[0380] In synchronization phase 356, a second subset 128 of PNP machines 130 ...

[0381] When the second subset 128 is operated in the synchronization phase 356, in response to the detection that all the PNP machines 130b, 130c in the second subset 128 have completed the previous instruction 124 from the program 122, a new instruction 124 is provided from the program 122 to each of the PNP machines 130b, 130c in the second subset 128.

[0382] 2. The method 300 of Clause 1, the method further comprising:

[0383] In the synchronous phase 356 and the asynchronous phase 354, the first subset 126 and the second subset 128 of the PNP machine 130 are repeatedly operated 332.

[0384] 3. The method 300 described in Clause 1 or 2, wherein:

[0385] The PNP machine 130a in the first subset 126 is different from the PNP machines 130b and 130c in the second subset 128.

[0386] 4. The method 300 according to any one of clauses 1 to 3, said method further comprising:

[0387] After the PNP machine 130 has completed the instruction 124 in the program 122 corresponding to the mandrel segment 235, the multiple mandrel segments 235 are assembled 504 together to form a semi-cylindrical section 770.

[0388] 5. The method 300 of any one of clauses 1 to 4, wherein each of the objects 18 comprises a preform 150 of uncured fiber-reinforced material 152, and the method 300 further comprises:

[0389] The preform 150 is fixed 336 to the mandrel 140.

[0390] 6. Method 300 of any one of Clauses 1 to 5, wherein:

[0391] In the asynchronous phase 354, instruction 124 causes each of the PNP machines 130a in the first subset 126 to place the strong backplate 180 404 on the discrete object 20, apply a vacuum pressure 160 406 to hold the discrete object 20 at the strong backplate 180, lift the strong backplate 180 454 to a suitable position on the mandrel 140, and release the vacuum pressure 160 470 to remove the discrete object 20 from the strong backplate 180 464 as the discrete object 20 contacts the mandrel 140.

[0392] In the synchronization phase 356, the instruction 124 causes each of the PNP machines 130b, 130c in the second subset 128 to synchronously place the strong backplate 180 404 on the large object 22, apply the vacuum pressure 160 406 to hold the large object 22 at the strong backplate 180, lift the strong backplate 180 454 to a suitable position on the mandrel 140, and release the vacuum pressure 160 470 to remove the large object 22 from the strong backplate 180 464 as the large object 22 contacts the mandrel 140.

[0393] 7. A portion 768 of the aircraft 750 assembled according to method 300 in any one of clauses 1 to 6.

[0394] 8. A non-transitory computer-readable medium implementing programming instructions 124, which, when executed by a processor, are capable of performing a method 300 for assembling the structure 12 as described in any one of clauses 1 to 6.

[0395] 9. A portion 768 of an aircraft 750 assembled according to method 300 defined by instruction 124 stored on the computer-readable medium of clause 8.

[0396] 10. A placement system 50 for manufacturing a structure 12 formed from an object 18, the placement system 50 comprising:

[0397] A pick-and-place (PNP) machine 130, located within manufacturing unit 110, is positioned within the reach of the object 18 and mandrel 140, the mandrel 140 being movable relative to the PNP machine 130; and

[0398] A unit controller 120 is operatively coupled to the PNP machine 130 to place the object 18 onto the mandrel 140 using the PNP machine 130.

[0399] 11. The placement system 50 of Clause 10, wherein the PNP machine 130 is divided into a first subset 126 and a second subset 128 of the PNP machines 130, preferably wherein the unit controller 120 is operable to assign each PNP machine 130 to the first subset 126 or the second subset 128.

[0400] 12. The placement system 50 as described in clause 10 or 11, wherein the object 18 comprises discrete objects 20 and large objects 22 larger than the discrete objects 20, and the unit controller 120 is configured to:

[0401] In the asynchronous phase 354, the first subset 126 of the 314PNP machine 130 is operated independently to place the discrete object 20 onto the mandrel 140;

[0402] When operating the first subset 126 in the asynchronous phase 354, for each of the PNP machines 130a in the first subset 126: in response to detecting that a previous instruction 124 from the program 122 has been completed by the PNP machine 130a, a new instruction 124 is provided from the program 122, regardless of the progress of the other PNP machines 130 in the first subset 126;

[0403] In synchronization phase 356, a second subset 128 of PNP machines 130 ...

[0404] When the second subset 128 is operated in the synchronization phase 356, in response to the detection that all the PNP machines 130b, 130c in the second subset 128 have completed the previous instruction 124 from the program 122, a new instruction 124 is provided from the program 122 to each of the PNP machines 130b, 130c in the second subset 128.

[0405] 13. The placement system 50 of any one of clauses 10 to 12, wherein:

[0406] The unit controller 120 is operable to repeatedly operate 326, 314 the first subset 126 of PNP machine 130 and the second subset 128 of PNP machine 130 in synchronous phase 356 and asynchronous phase 354.

[0407] 14. The placement system 50 of any one of clauses 10 to 13, wherein:

[0408] The PNP machine 130a in the first subset 126 is different from the PNP machines 130b and 130c in the second subset 128.

[0409] 15. The placement system 50 of any one of clauses 10 to 14, wherein:

[0410] The objects 18 all include preforms 150 of uncured fiber-reinforced material 152.

[0411] 16. The placement system 50 of any one of clauses 10 to 15, wherein the object 18 comprises discrete objects 20 and large objects 22 spanning multiple PNP machines 130, wherein the unit controller 120 includes a program 122 having:

[0412] In asynchronous phase 354, instruction 124 causes each of the PNP machines 130a in the first subset 126 to place a strong backplate 180 404 on a discrete object 20, apply a vacuum pressure 160 406 to hold the discrete object 20 at the strong backplate 180, lift the strong backplate 180 454 to a suitable position on the mandrel 140, and release the vacuum pressure 160 470 to remove the discrete object 20 from the strong backplate 180 464 as the discrete object 20 contacts the mandrel 140.

[0413] In synchronization phase 356, instruction 124 causes each of the PNP machines 130b, 130c in the second subset 128 to synchronously place the strong backplate 180 on the large object 22, apply the vacuum pressure 160 to hold the large object 22 at the strong backplate 180, lift the strong backplate 180 to a suitable position on the mandrel 140, and release the vacuum pressure 160 to remove the large object 22 from the strong backplate 180 as it contacts the mandrel 140.

[0414] 17. The placement system 50 of any one of clauses 10 to 16, wherein the object 18 comprises discrete objects 20, and wherein:

[0415] The unit controller 120 is configured to operate each of the first subset 126 of the PNP machines 130a independently in the asynchronous phase 354 to place the discrete object 20 onto the mandrel 140.

[0416] 18. The placement system 50 of any one of clauses 10 to 17, wherein the object 18 comprises a large object 22 spanning a plurality of PNP machines 130, and wherein:

[0417] The unit controller 120 is configured to operate PNP machines 130b and 130c in a second subset 128 of the 326 PNP machines 130 one after the other in the synchronization phase 356, to place the large object 22 onto the mandrel 140. Preferably, the unit controller 120 operates the first subset 126 and the second subset 128 simultaneously.

[0418] 19. To manufacture a portion 768 of an aircraft 750 using the placement system 50 as described in any one of Clauses 10 to 18.

[0419] Group 4 Clause:

[0420] 1. A method 400 for assembling a structure 12 from prefabricated components 150, the prefabricated components comprising discrete prefabricated components 154 and one or more large prefabricated components 156, each prefabricated component 150 comprising uncured fiber-reinforced material 152, the method 400 comprising:

[0421] The spindle 140 moves 402 in the processing direction 14 relative to the placement station 100, which includes multiple pick-and-place (PNP) machines 130;

[0422] Identify 422 a tray 190 storing the one or more large prefabricated components 156 and the discrete prefabricated components 154, the discrete prefabricated components 154 being arranged for placement on the frame 780 at a location 781 where the large prefabricated components 156 will be installed.

[0423] The strong backplate 180 is placed 428 on the tray 190 via at least one of the PNP machines 130;

[0424] A vacuum pressure of 406160 is applied to keep the one or more large preforms 156 and the discrete preforms 154 in contact with the strong backplate 180.

[0425] While maintaining the arrangement of the one or more large preforms 156 and the discrete preforms 154, the one or more large preforms 156 and the discrete preforms 154 are transported 460 to the mandrel 140 via the at least one PNP machine 130; and

[0426] The one or more large preforms 156 and the discrete preforms 154 are placed 472 onto the mandrel 140.

[0427] Preferably, the discrete prefabricated component 154 is a frame filler prefabricated component 158, and the large prefabricated component 156 is a longitudinal beam prefabricated component 159.

[0428] 2. The method 400 described in Clause 1, wherein:

[0429] Identifying the tray 190 as 422 includes identifying the tray 190 as including recesses 198 for the discrete preforms 154 and for the one or more large preforms 156 as 424.

[0430] Preferably, the recess 198 has a first shape 197 and a second shape 199, the first shape 197 corresponding to the discrete preform 154, and the second shape 199 corresponding to the one or more large preforms 156.

[0431] 3. The method 400 described in Clause 1 or 2, wherein:

[0432] The placement of the strong backplate 180, 428, includes the placement of the arched strong backplate 180, 404.

[0433] 4. The method 400 of any one of clauses 1 to 3, said method further comprising:

[0434] After the PNP machine 130 has completed the instructions 124 in the program 122 corresponding to the mandrel segment 235, the plurality of mandrel segments 235 are assembled together 504.

[0435] 5. The method 400 of any one of clauses 1 to 4, said method further comprising:

[0436] At least one or more large preforms 156 are fixed 336 to the mandrel 140.

[0437] 6. The method 400 of any one of clauses 1 to 5, wherein:

[0438] Applying the vacuum pressures 160 and 147 described in 406 includes maintaining each of the discrete preforms 154 described in 446 in contact with at least one large preform 156.

[0439] Preferably, each of the discrete preforms 154 is held 446 in contact with at least one large preform 156 at the strong backplate 180 and / or the mandrel 140.

[0440] 7. A portion 768 of the aircraft 750 assembled according to method 400 in any one of clauses 1 to 6.

[0441] 8. A non-transitory computer-readable medium implementing programming instructions 124, which, when executed by a processor, are capable of performing a method 400 for assembling the structure 12 as described in any one of clauses 1 to 6.

[0442] 9. A portion 768 of an aircraft 750 assembled according to method 400 defined by instruction 124 stored on a computer-readable medium of clause 8.

[0443] 10. A placement system 50 for manufacturing a structure 12 from preforms 150 comprising discrete preforms 154 and large preforms 156, each preform 150 comprising uncured fiber reinforcement 152, the placement system 50 comprising:

[0444] The tray 190 stores the large prefabricated component 156 and the discrete prefabricated component 154, which is positioned on the frame 780 at a location 195 relative to where the large prefabricated component 156 will be installed.

[0445] A pick-and-place (PNP) machine 130 is located at a placement station 100 within manufacturing unit 110 and is positioned within reach of mandrel 140 and the preform 150. The PNP machine 130 includes a vacuum system 138 to apply vacuum pressure 160 to hold the large preform 156 and the discrete preform 154, with mandrel 140 movable relative to the PNP machine 130.

[0446] A unit controller 120 is operable to move the mandrel 140 402 in the processing direction 14 relative to the placement station 100, identify the tray 190 422, place the strong backplate 180 428 on the tray 190 via at least one of the PNP machines 130, transport the large preform 156 and the discrete preform 154 460 to the mandrel 140 via the at least one PNP machine 130 while maintaining the arrangement of the large preform 156 and the discrete preform 154, and place the large preform 156 and the discrete preform 154 472 on the mandrel 140.

[0447] 11. The placement system 50 described in Clause 10, wherein:

[0448] The tray 190 includes recesses 198 for the discrete preform 154 and for the large preform 156.

[0449] Preferably, the recess 198 has a first shape 197 and a second shape 199, the first shape 197 corresponding to the discrete preform 154, and the second shape 199 corresponding to the one or more large preforms 156.

[0450] 12. The placement system 50 described in clause 10 or 11, wherein:

[0451] The strong backplate 180 is arched.

[0452] 13. The placement system 50 of any one of clauses 10 to 12, wherein:

[0453] Each of the discrete preforms 154 is kept in contact with at least one large preform 156.

[0454] Preferably, each of the discrete preforms 154 is held at the strong back plate 180 and / or the mandrel 140 in contact with at least one large preform 156.

[0455] 14. The placement system 50 of any one of clauses 10 to 13, wherein:

[0456] Each discrete preform 154 is a frame-filled preform 158 comprising multiple layers 216 of uncured fiber-reinforced material 152.

[0457] 15. To manufacture a portion 768 of an aircraft 750 using the placement system 50 as described in any one of Clauses 10 to 14.

[0458] 16. A method 400 for assembling a structure 12 from prefabricated components 150, the prefabricated components comprising discrete prefabricated components 154 and one or more large prefabricated components 156, each prefabricated component 150 comprising uncured fiber reinforcement material 152, the method 400 comprising:

[0459] The spindle segment 235 moves 414 times in the processing direction 14 relative to the placement station 100, which includes multiple pick-and-place (PNP) machines 130;

[0460] Identify 422 a tray 190 storing the one or more large prefabricated components 156 and the discrete prefabricated components 154, the discrete prefabricated components 154 being arranged for placement on the frame 780 at a location 781 where the one or more large prefabricated components 156 will be installed.

[0461] The strong backplate 180 is placed 428 on the tray 190 via at least one of the PNP machines 130;

[0462] A vacuum pressure of 406160 is applied to keep the one or more large preforms 156 and the discrete preforms 154 in contact with the strong backplate 180.

[0463] While maintaining the arrangement of the one or more large preforms 156 and the discrete preforms 154, the one or more large preforms 156 and the discrete preforms 154 are transported 460, 462 to the mandrel segment 235 via the PNP machine 130; and

[0464] Place the one or more large preforms 156 and the discrete preforms 154 onto the mandrel segment 235.

[0465] 17. The method 400 of Clause 16, the method further comprising:

[0466] The preform 150 is fixed 336 at the mandrel segment 235 via vacuum system 144.

[0467] 18. A portion 768 of the aircraft 750 assembled according to the method 400 described in Clause 16 or 17.

[0468] Group 5 Clause:

[0469] 1. A method 400 for placing a preform 150 onto a mandrel 140 for curing into a composite component 16, the mandrel 140 including a mandrel segment 235, the method 400 comprising:

[0470] The spindle segment 235 moves 414 times in the processing direction 14 relative to the placement station 100, which includes multiple pick-and-place (PNP) machines 130;

[0471] The strong backplate 180 is placed 430 on the preform 150 via at least one of the PNP machines 130;

[0472] A vacuum pressure of 406160 is applied to maintain the preform 150 of 438 in contact with the strong back plate 180;

[0473] The preform 150 is transported 448, 462 to the mandrel segment 235 via the at least one PNP machine 130; and

[0474] The preform 150 is placed 474 onto the mandrel segment 235.

[0475] 2. The method 400 of Clause 1, the method further comprising:

[0476] The identification 420 is a tray 190 storing the preform 150, wherein the preform 150 includes uncured fiber-reinforced material 152.

[0477] 3. The method 400 of clause 1 or 2, wherein the precast component 150 is a precast component of the first type, the method 400 further comprising:

[0478] The second type of preform 150 is transported 460, 462 to the mandrel segment 235, wherein the second type of preform 150 is a discrete preform 154.

[0479] 4. The method 400 of Clause 3, wherein the precast component of the first type is a large precast component 156, the method 400 further includes:

[0480] The discrete prefabricated component 154 is placed 426 in the tray 190c, wherein the large prefabricated component 156 is located on the frame 780 at the position 195 where the large prefabricated component 156 will be installed.

[0481] 5. The method 400 of any one of clauses 1 to 4, said method further comprising:

[0482] After the strong backplate 180 is positioned 452 on the mandrel segment 235, the vacuum pressure 160 is released 470 to facilitate the removal 464 of the preform 150 from the strong backplate 180.

[0483] 6. The method 400, 500 as described in any one of clauses 1 to 5, wherein the method further comprises:

[0484] Multiple spindle segments 235 are assembled together 504.

[0485] 7. Methods 400 and 500 as described in Clause 6, wherein:

[0486] Assembling the mandrel segments 235 together 504 includes applying fasteners 242 512 to the mandrel segments 235.

[0487] 8. The method 400, 500 described in Clause 6 or 7, wherein:

[0488] Assembling the mandrel segments 235 together 504 includes attaching the mandrel segments 235 514 to the mandrel support structure 106.

[0489] 9. The method 400, 500 as described in any one of clauses 6 to 8, said method further comprising:

[0490] After the mandrel segments 235 have been assembled 504 together, a skin layer 206 is laid 516 on top of the mandrel segments 235; and

[0491] The skin layer 206 and the preform 150 on the mandrel segment 235 are co-cured for 524.

[0492] 10. The method 400, 500 as described in any one of clauses 6 to 8, said method further comprising:

[0493] Before the mandrel segments 235 are assembled together 504, a skin layer 206 is laid 516 on top of each mandrel segment 235;

[0494] The skin layer 206 on top of each mandrel segment 235 is co-cured 524 with the preform 150 on the corresponding mandrel segment 235 to at least manufacture a skin 782; and

[0495] After the mandrel segments 235 are assembled together 504, the skin 782 on top of the mandrel segments 235 is spliced ​​together 518.

[0496] 11. The method 400, 500 of any one of clauses 6 to 10, wherein the method further comprises:

[0497] Each mandrel segment 235 is positioned 510 in different radial regions Z1, Z2, Z3 of the mandrel 140.

[0498] 12. A portion 768 of an aircraft 750 assembled according to any one of the methods 400, 500 in accordance with any one of the clauses 1 to 11.

[0499] 13. A method 600 for preparing a mandrel 140 for receiving a preform 150 in a manufacturing line 10, the mandrel 140 being formed of a mandrel segment 235, the method 600 comprising:

[0500] Separating the spindle segment 235 from the hardened structure 64 610; and

[0501] Separate the spindle segments 235 from each other 614.

[0502] 14. The method 600 of Clause 13, the method further comprising:

[0503] Clean the axial segment 235 described in 626.

[0504] 15. The method 600 of clause 13 or 14, the method further comprising:

[0505] The spindle segment 235 is moved 624 to the cleaning system 80.

[0506] 16. The method 600 described in Clause 14 or 15, wherein:

[0507] The cleaning 626 includes applying 628 of at least one cleaning chemical 82 to the spindle segment 235, the at least one cleaning chemical 82 being selected from the group consisting of solvents, water, and soap.

[0508] 17. The method 600 of any one of clauses 13 to 16, said method further comprising:

[0509] The hardened structure 64 is moved 622 to a new position in the manufacturing line 10 to receive additional manufacturing processes.

[0510] 18. The method 600 of any one of clauses 13 to 17, said method further comprising:

[0511] The mandrel 140 is moved 606 to the separation system 70, in which the mandrel segments 235 are separated from each other 614.

[0512] 19. The method 600 of any one of clauses 13 to 18, said method further comprising:

[0513] The mandrel segment 235 is transported 630 to the starting position 52 of the placement station 100, where the placement station picks up the preform 150 and places the preform onto the mandrel segment 235.

[0514] 20. The method 600 of any one of clauses 13 to 19, wherein:

[0515] Separating the mandrel segments 235 from one another 614 includes removing the fasteners 242 from the mandrel segments 235 616.

[0516] 21. The method 600 of any one of clauses 13 to 20, said method further comprising:

[0517] After separating the spindle segment 235 from the hardened structure 64 610, and before separating the spindle segments 235 from each other 614, the release membrane 62 is removed from the spindle segment 235 620.

[0518] 22. The method 600 of any one of clauses 13 to 21, wherein:

[0519] Separating the spindle segment 235 from the hardened structure 64 610 includes vertically moving 612 the hardened structure 64 to separate the hardened structure 64 from the spindle segment 235 610.

[0520] 23. The method 600 of any one of clauses 14 to 16, said method further comprising:

[0521] After the spindle segment 235 has been cleaned (604), the preform 150 is placed (400) onto the spindle segment 235 via a pick-and-place (PNP) machine (130).

[0522] 24. The method 600 of any one of clauses 13 to 23, wherein:

[0523] Separating the mandrel segment 235 from the hardened structure 64 610 includes separating the mandrel segment 235 from the hardened portion 768 of the body 750 610.

[0524] 25. A portion 768 of an aircraft 750 assembled according to any one of the methods 600 in accordance with clauses 13 to 24.

Claims

1. A method (400) for placing a preform (150) onto a mandrel (140), said preform (150) comprising an uncured fiber-reinforced material (152), said method (400) comprising: The mandrel (140) moves (402) in the processing direction (14) relative to the placement station (100) which includes multiple pick-and-place machines, namely PNP machines (130). Identify (418) the tray (190) storing the prefabricated component (150); The strong backplate (180) is placed on the preform (150) via at least one of the PNP machines (130), wherein placing the strong backplate (180) includes placing the recess (184) of the strong backplate (180) on the preform (150). Apply (406) vacuum pressure (160) to maintain (438) the preform (150) in contact with the strong back plate (180); The preform (150) is transported (408) to the mandrel (140) via the at least one PNP machine (130), wherein transporting the preform (150) (408) to the mandrel (140) includes aligning the recess (184) of the reinforcing backplate (180) with a cutout (142) in the mandrel (140); and The preform (150) is placed on the mandrel (140).

2. The method (400) according to claim 1, further comprising: The mandrel (140) is paused (416) when a portion of the mandrel (140) is positioned at the placement station (100).

3. The method (400) according to claim 1 or 2, wherein: Placing the preform (150) includes releasing (470) the vacuum pressure (160).

4. The method (400) according to claim 1 or 2, wherein, The tray (190) stores a plurality of prefabricated parts (150), and the strong back plate (180) includes a plurality of recesses (184), wherein: Placing the recesses (184) of the reinforcing backplate (180) at the preform (150) includes placing the plurality of recesses (184) of the reinforcing backplate (180) at the plurality of preforms (150); and Applying the vacuum pressure (160) (406) includes keeping (442) the plurality of preforms (150) in contact with the plurality of recesses (184).

5. The method (400) according to claim 1 or 2, wherein: Transporting the preform (150) (408) to the mandrel (140) via the PNP machine (130) includes aligning the indexing element at the strong back plate (180) with the indexing element at the mandrel (140).

6. The method (400) according to claim 1 or 2, further comprising: A layer (206) of the unhardened fiber-reinforced material (152) is placed on a plurality of preforms (150) disposed on the mandrel (140); as well as Co-curing (524) the layer (206) and the preform (150).

7. The method (400) according to claim 1 or 2, wherein: Applying the vacuum pressure (160) (406) includes operating (436) the vacuum system (138) to apply the vacuum pressure (160) through the vacuum channel (188) connected to the recess (184) of the strong back plate (180).

8. A placement system (50) for manufacturing a structure (12), the placement system (50) comprising: The pick-and-place machine, also known as the PNP machine (130), is located within the manufacturing unit (110); as well as Unit controller (120), the unit controller being operable to: The spindle (140) moves (402) relative to the PNP machine (130) in the processing direction (14). Identify (418) the pallet (190) storing prefabricated components (150) comprising uncured fiber-reinforced material (152). The reinforcing backplate (180) is placed at the preform (150) via at least one of the PNP machines (130). Apply (406) vacuum pressure (160) to maintain the preform (150) in contact with the reinforcing backplate (180). The preform (150) is transported (408) to the mandrel (140) via the at least one PNP machine (130) by aligning the recess (184) of the strong back plate (180) with the cutout (142) in the mandrel (140). The preform (150) is placed on the mandrel (140).

9. The placement system (50) according to claim 8, wherein: The unit controller (120) is operable to pause (416) the mandrel (140) when a portion of the mandrel (140) is placed at the placement station (100) with the PNP machine (130).

10. The placement system (50) according to claim 8 or 9, wherein: The unit controller (120) is operable to place the preform (150) by releasing (470) the vacuum pressure (160).

11. The placement system (50) according to claim 8 or 9, wherein: The unit controller (120) is operable to place the strong back plate (180) by placing the recess (184) of the strong back plate (180) at the preform (150).

12. The placement system (50) according to claim 8 or 9, wherein: The tray (190) stores multiple prefabricated parts (150), and the strong back plate (180) includes multiple recesses (184).

13. The placement system (50) according to claim 8 or 9, wherein: The unit controller (120) is operable to transport (408) the preform (150) to the mandrel (140) via the PNP machine (130) by aligning the indexing element at the strong backplate (180) with the indexing element at the mandrel (140).

14. The placement system (50) according to claim 8 or 9, wherein: The unit controller (120) is operable to place a layer (206) of the uncured fiber-reinforced material (152) on a plurality of preforms (150) disposed on the mandrel (140) and co-cur (524) the layer (206) and the preforms (150).

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