Frame production line

Abstract

This disclosure provides a frame production line. Systems and methods for producing aircraft frames are provided. A method for producing a frame (150) for an aircraft (10) includes receiving a frame; advancing the frame through one of a workstations arranged in an arcuate array (160) and / or through a series of workstations arranged in a spiral corresponding to the shape of the frame; and performing work on the frame via at least one of the workstations. A system for manufacturing a frame (150) for an aircraft (10) includes an array (160) of workstations arranged in an arcuate array and simultaneously performing work on the frame, and / or includes a spiral stack (1750) comprising a curved track (1720) advancing vertically in a spiral shape at a spiral angle and workstations (1722) arranged along the curved track (1720), the workstations performing work on the frame as the frame advances along the curved track (1720); and a drive unit (102) that advances the frame through the workstations.

Description

Technical Field

[0001] This disclosure relates to the field of manufacturing, and more specifically to the manufacture of components for aircraft. Background Technology

[0002] The mechanical structure of an aircraft is called its fuselage. The fuselage itself is made of individual components, such as longitudinal spars, wing spars, skin, and frames, which, when assembled together, define the shape of the aircraft. A single aircraft can be manufactured from many such components. For example, an aircraft can utilize approximately one hundred circular frames to reinforce its fuselage. Frames are typically made from frame sections spliced ​​together. If the frames are not manufactured quickly enough to meet the aircraft's desired assembly timing, the aircraft's manufacturing may be unintentionally delayed.

[0003] Therefore, it is desirable to have a method and apparatus that take into account the above-mentioned problems and other possible problems.

[0004] The abstract of US2007 / 175573 describes the manufacture of thermoplastic composite parts with integrated metal fittings using a continuous compression molding process. Automated equipment or manual lay-up is used to arrange composite material layers and metal fittings into multi-layer stacks. Each stack contains all layers, including layer stacking areas, bonded in place to maintain orientation and position. Multiple stacks can be cut from the individual stacks. The stacks are set in a tool containing the part features and are continuously fed through an execution station where the stacks are pre-formed into an approximate shape of the finished part. After pre-forming, the tool is progressively moved through a settling station, where a press extrudes consecutive portions of the tool to form a single integrated thermoplastic composite laminate with integrated metal fittings, which may include areas of varying thicknesses. Summary of the Invention

[0005] The embodiments described herein provide an assembly line for frames of an aircraft fuselage, producing the frames as fully circular arc sections. For example, individual frames may correspond to a 90-degree arc of a complete circumferential frame. The assembly line utilizes the bending characteristics of the frames to increase the work density performed on the frames by workstations and is capable of operating on multiple frames that move synchronously along the assembly line. The assembly line also advances the frames according to a desired cycle time based on the cycle time of the entire aircraft.

[0006] Other illustrative embodiments (e.g., methods and computer-readable media related to the foregoing embodiments) may be described below. The features, functions, and advantages already discussed may be implemented independently in various embodiments or may be combined in other embodiments, as can be seen in further detail with reference to the following description and accompanying drawings. Attached Figure Description

[0007] 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.

[0008] Figure 1A This is a schematic diagram of an aircraft manufactured using a semi-cylindrical section.

[0009] Figure 1B An assembly line for the frame in the illustrative embodiment is shown.

[0010] Figure 2 An example is given of performing work on multiple frames that are moving in sync in an illustrative implementation. Figure 1B The assembly line.

[0011] Figure 3 This is a flowchart illustrating a method for operating an assembly line of a frame in an illustrative embodiment.

[0012] Figure 4 It is a front view of a portion of the fuselage including the mounting frame in the illustrative embodiment.

[0013] Figure 5 This is an illustrative implementation method. Figure 4 The end view of the frame.

[0014] Figure 6 A stack designed for use with fasteners of a predetermined length is depicted in an illustrative embodiment.

[0015] Figure 7 This is a flowchart illustrating a method for cutting the feet of a shear system in an illustrative embodiment to produce a stack for use with fasteners of a predetermined length.

[0016] Figure 8 The frame, as depicted in the illustrative embodiment, awaits demolding from the mandrel.

[0017] Figures 9A to 9B and Figure 10 The illustrative embodiment is described by Figure 1B The NDI station performs non-destructive inspection (NDI) operations.

[0018] Figures 11 to 12 The illustrative embodiment is described by Figure 1B The cutting operation performed at the cutting station.

[0019] Figures 13 to 14 The illustrative embodiment is described by Figure 1B The cutting operation is performed at the cutting station.

[0020] Figure 15This is a flowchart illustrating another method for assembling a frame in an illustrative implementation.

[0021] Figure 16 This is a flowchart illustrating another method for assembling a frame in an illustrative implementation.

[0022] Figure 17 An arrangement of spiral stacks for assembling the frame is depicted in the illustrative embodiment.

[0023] Figure 18 This is a flowchart illustrating another method for operating an assembly line with spiral stacks to assemble a frame, as exemplified in the illustrative embodiment.

[0024] Figure 19 This is a flowchart illustrating the aircraft manufacturing and maintenance methods in the illustrative implementation.

[0025] Figure 20 This is a block diagram of the aircraft in the illustrative implementation. Detailed Implementation

[0026] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. Therefore, it should be understood that those skilled in the art will be able to design various constructions that, while not expressly described or shown herein, embody the principles of this disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and should be construed as not being limited to these specifically enumerated 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.

[0027] Airframe components, including those discussed herein, can be manufactured as metal parts or as composite components made from spliced ​​frame segments, such as carbon fiber reinforced polymer (CFRP) components. CFRP components are initially laid out in multiple layers, which together are referred to as a preform. Individual fibers within each layer of the preform are aligned parallel to each other, but different layers exhibit different fiber orientations to increase the strength of the resulting composite component along different dimensions. The preform includes a viscous resin, which cures 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 “prepreg.” Other types of carbon fibers include “dry fibers” that are not impregnated with thermosetting resins but may include tackifiers or adhesives. Dry fibers are impregnated with resin prior to curing. For thermosetting resins, curing is a unidirectional process called hardening, while for thermoplastic resins, if the resin is reheated, it reaches a viscous form, after which it can be solidified into the desired shape and cured. As used herein, the comprehensive term for methods of transforming a preform into a final hardened shape (i.e., transforming a preform into a composite part) is “hardening,” and the term encompasses both the curing of thermosetting preforms and the formation / curing of thermoplastic preforms into the final desired shape.

[0028] Turn now Figure 1A A schematic diagram of an aircraft 10 is depicted, in which the manufacturing system and methods described herein can be implemented. In this illustrative example, the aircraft 10 has wings 15 and 16 connected to a fuselage 38. The aircraft 10 includes an engine 14 connected to the wing 15 and an engine 16 connected to the wing 16. The body 38 has a tail section 18. Horizontal stabilizers 20, 21, and 22 are connected to the tail section 18 of the body 38.

[0029] The aircraft 10 is an example of an aircraft 10 in which at least a portion of the fuselage 12 is formed by semi-cylindrical sections 24. The fuselage 12 is manufactured from the semi-cylindrical sections 24, with the upper semi-cylindrical section 26 connected to the lower semi-cylindrical section 28 to form a full-cylindrical section 29. The full-cylindrical sections 29 are connected in series to form the fuselage 12. Not all full-cylindrical sections 29 have the same shape or the same length. The semi-cylindrical sections 24 are made by attaching multiple frames 150 to the skin 50. The frames 150 are either single-piece frames or frame sections fastened together.

[0030] Figure 1BAn assembly line 100 of a frame 150 is illustrated in an illustrative embodiment. The assembly line 100 includes an array of workstations 160 arranged along an arc 140, performing work on the frame 150 (e.g., an arc-shaped frame or any other suitable frame shape) as the frame 150 advances in a circular motion through the assembly line 100. It should be understood that this (and other) circular motion and the arc 140 may have three-dimensional elements, thus achieving a helical arrangement. In other embodiments, the arc 140 preferably corresponds to the shape of the frame 150. The workstations simultaneously perform work on different sections of the frame 150. In some illustrative examples, the workstations may be referred to as “processing workstations.” The array of workstations 160 is arranged in the arc 140 and configured to simultaneously perform work on the frame 150. Because the arc 140 of assembly line 100 corresponds to the shape / radius of frame 150 (e.g., its dimensions are between the inner and outer radii of frame 150, or between half the inner radius and 1.5 times the outer radius of the frame), frame 150 advances through stations without the stations needing to simultaneously accommodate the entire length 156 of frame 150. In other words, each station performs work only on a portion of frame 150 within its area. This reduces the total floor space occupied by assembly line 100 in the factory floor. Furthermore, because each station handles a different section of the longitudinal segment 154 of frame 150, multiple stations can perform work on a single frame 150, but simultaneously on different sections. For example, a cutting station can remove material from frame 150 in the first section, while an NDI station inspects frame 150 in the second section. This feature greatly increases work density, enabling the production of frame 150 at high rates without requiring large assembly lines (e.g., long or bulky assembly lines). In another embodiment, the frame 150 advances along a path that does not precisely match the radius of the frame 150.

[0031] In this embodiment, frame 150 includes indexing features 158 disposed within manufacturing allowances 157 (e.g., excess thickness, build-up, tabs, ramps, etc.) that are later trimmed off from frame 150. These indexing features 158 may include hard stops, pins, holes, or slots that complement these sections (and / or tools, such as lamination mandrels for these sections) to physically attach them. In a further embodiment, indexing features 158 may include laser, ultrasonic, or visual inspection systems that track the indexing features 158 located at the section, or even an RFID chip. Indexing can be performed using non-contact technologies, for example, in assembly lines where body parts move continuously. In some illustrative examples, individual stations are configured to index onto frame 150 and perform work on frame 150. In one embodiment, a station indexes onto the indexing feature 158 at the manufacturing allowance 157 of frame 150. Frame 150 is exemplified as having a constant radius, but it can be represented by various radii depending on the design parameters.

[0032] During movement or between pulses (e.g., “micro-pulses” smaller than the frame length, or “full-pulses” equal to or greater than the frame length), the station encounters the indexing feature 158. The station physically interacts with or non-destructively examines the indexing feature 158 at a longitudinal segment 154 of the frame in a manner that allows the segment 154 of the frame 150 exposed to the station to be aligned with the station before work is performed. That is, the pulsed structure includes the indexing feature 158. The indexing feature 158, such as a physical feature or a radio frequency identifier (RFID) chip, is engaged by an indexing engagement device associated with the station. In one embodiment, the indexing feature 158 also transmits to the station a 3D representation of the inner mold line (IML) and / or outer mold line (OML) shape of the structure (e.g., a particular frame among many different manufacturable frames 150) within the station's range, as well as instructions indicating the work to be performed by the station on that structure. In some illustrative examples, the segment is one segment of the longitudinal segment 154. For different (longitudinal) sections 154 of frame 150, the process can be performed simultaneously by multiple stations. In addition, the circular characteristics of assembly line 100 are adapted to the radius of the assembled frame 150 and have a radius corresponding to the radius of frame 150 (e.g., between half and twice the radius).

[0033] In this embodiment, the workstation includes a loading station 110 that receives a frame 150 supplied by a supply line 162-1. Prior to receiving, the frame 150 undergoes rough finishing (if necessary) at a stacking mandrel (not shown) at the supply line 162-1 after hardening, and is then demolded. In these illustrative examples, the frame 150 may be referred to as a hardened composite frame. In some other illustrative examples, the frame 150 is a metal frame. The frame 150 is positioned on the loading station 110 and supplied to a drive unit 102. The drive unit 102 is configured to advance the frame through the assembly line 100. In some illustrative examples, the drive unit 102 is configured to advance the frame 150 by pulsating it through the station at a distance less than the length of the frame 150. In some of these illustrative examples, a workstation array 160 is configured to perform work on the frame 150 during pauses between pulsations. In some other illustrative examples, the workstation array 160 is configured to perform work on the frame 150 as it advances during pulsations. In some illustrative examples, the drive unit 102 is configured to physically interlock with the tool 159 that carries the frame 150. In some illustrative examples, the drive unit 102 is configured to physically interlock with a manufacturing allowance 157 of the frame 150. In some illustrative examples, the drive unit 102 is configured to advance the frame 150 by following the circular motion of an arc 140 having a radius corresponding to the radius of the frame 150.

[0034] Drive unit 102 utilizes power roller 104, which aligns and advances frame 150 along arc 140 through multiple stations of station array 160 (e.g., counterclockwise, clockwise, or any other direction). According to embodiments, roller 104 may utilize clamping force to prevent frame 150 from slipping during drive operation, or it may utilize a toothed or timing system to engage or physically interlock with frame 150 and advance frame 150 in a predictable manner. For example, in one embodiment, the toothed or timing system is physically interlocked with manufacturing allowance 157 of frame 150. Thus, in one embodiment, advancing frame 150 includes physically interlocking drive unit 102 to manufacturing allowance 157 of frame 150. In another embodiment, drive unit 102 is interlocked or engaged with a mandrel or tool 159 carrying frame 150. In this case, the station may be indexed to indexing feature 158 at tool 159 and / or frame 150. In such an implementation, the frame 150 is held by a tool 159, and the tool 159 includes an indexing feature 158. The tool 159 is then advanced through the workstation array, for example, by interlocking the drive unit 102 with the tool 159 while the tool 159 carries the frame 150.

[0035] In one embodiment, drive unit 102 advances frame 150 in a pulsating manner (i.e., by pulsating frame 150) along processing direction 197 (e.g., curved, clockwise or counterclockwise, or any other suitable type of direction), wherein frame 150 is “micro-pulsated” by a pulsation distance P less than its length along arc 140, then paused, and then advanced the same amount again. In another embodiment, frame 150 pulsates through the station at a distance equal to its length, or advances through the station continuously. Drive unit 102 causes frame 150 to circumferentially move by bending operating power roller 104 along frame 150. That is, arc 140 has a radius similar to that of frame 150, and frame 150 bends along arc 140 as it advances through station array 160. Circumferential motion follows arc 140, which has a radius corresponding to the radius of frame 150. In another embodiment, drive unit 102 advances frame 150 continuously. In a further embodiment, multiple drive units 102 are arranged along an arc to align and advance multiple frames 150 in a stable and predictable manner.

[0036] Drive unit 102 advances to NDI stations 112 and 114. NDI stations 112 and 114 are positioned upstream of cutting stations 120 and 122 in array 160 and inspect frame 150. In some illustrative examples, NDI station 112 is configured to inspect the web and flanges of the frame. Specifically, NDI station 112 inspects the web and flanges of frame 150 to determine the dimensions of longitudinal section 154 of frame 150. It detects out-of-tolerance conditions and inconsistencies (e.g., out-of-tolerance holes, out-of-tolerance total thickness deviations, etc.). As used herein, flange can refer to, for example, as with respect to... Figure 5 Further shown are either or both of the shear system foot 562 or flange 566. In some illustrative examples, the station array 160 also includes an additional NDI station 114 configured to inspect the radius of the frame 150. The NDI station 114 inspects the radius of the frame 150. In one embodiment, this includes coupling the NDI station 114 to the inner mold line (IML) 151 of the frame 150, or coupling the NDI station 114 to the outer mold line (OML) 153 of the frame 150, and then determining the deflection of the NDI station 114 relative to the expected IML or OML as the NDI station 114 moves relative to the frame 150. The supply line 162-2 supplies material, such as water, to the NDI stations 112 and 114 to facilitate the operation of these stations and can also be used to output inspection information from the NDI stations 112 and 114.

[0037] Frame 150 advances from NDI stations 112 and 114 to a rework station (not shown if rework is required) located directly downstream of NDI stations 112 and 114. In normal operation, drilling station 116 follows NDI stations 112 and 114. In some illustrative examples, station array 160 includes drilling station 116, located downstream of NDI station 112, configured to drill decisive component (DA) holes 155 in longitudinal sections 154 of frame 150. Drilling station 116 is located downstream of NDI stations 112 and 114 and drills / installs decisive component (DA) holes 155 in longitudinal sections 154 of frame 150. DA holes 155 facilitate the assembly of frame 150 to other fuselage components.

[0038] Frame 150 further advances to dressing stations 118 and cutting stations 120 and 122, located downstream of drilling station 116. However, in another embodiment, the order of dressing stations 118, cutting stations 120 and 122, and / or drilling station 116 differs from the depicted order. Cutting stations 120 and 122 dress longitudinal sections 154 of the frame to form a reference plane at frame 150. In some illustrative examples, station array 160 includes cutting station 122, located downstream of drilling station 116, and configured to dress longitudinal sections 154 of frame 150 to form a reference plane at frame 150. In another embodiment, an additional reference plane is formed by lamination and curing at a stacked mandrel prior to cutting or milling. Specifically, cutting stations 120 and 122 cut the frame 150 to remove sacrificial material (e.g., from the shear member foot 562 of the frame 150 at longitudinal section 154). Figure 5 (as shown in the diagram) removes sacrificial material until the desired reference plane is obtained to facilitate alignment of frame 150 during assembly. In this embodiment, cutting station 120 removes sacrificial material from the flange of frame 150 during pauses between pulses of frame 150, while cutting station 122 removes sacrificial material from the web 564 of frame 150 as frame 150 advances during pulses. Figure 5 (As shown in the diagram) Removal of sacrificial material. In such an embodiment, the drive unit 102 advances the frame 150 by pulsating it through cutting stations 120, 122 less than the length of the frame 150. This is referred to as “micro-pulsation”. In a further embodiment, the frame 150 undergoes full pulsation, wherein it is pulsated for at least its length. In another embodiment, one or more NDI stations 112 and 114 are located upstream or downstream of one or more of cutting stations 120 and 122.

[0039] Cutting stations 124 and 126 are located downstream of cutting stations 120 and 122. Cutting stations 124 and 126 remove material from longitudinal sections 154 of frame 150 to form rat holes 152. In some illustrative examples, station array 160 includes a cutting station 126 located downstream of cutting station 122, configured to cut rat holes 152 from longitudinal sections 154 of frame 150. Rat holes 152 accommodate longitudinal beams (such as those connecting to fuselage skin 50 of aircraft 10) by allowing longitudinal beams to pass through frame 150 without physical interference. Figures 1A to 1B and Figure 4 (As shown). That is, the rat hole 152 allows the frame 150 to span any longitudinal beam at the fuselage skin 50. In this embodiment, cutting stations 124 and 126 include a cutter that is driven into the frame 150 during a pause between pulses and then retracts. Cutting station 124 cuts the flange of the frame 150, while cutting station 126 cuts the web of the frame 150. The rat hole 152 is formed after the flange and web are cut at their respective locations. Additional and / or alternative stations (not shown) may perform further reduction manufacturing operations on the frame 150.

[0040] Depending on design constraints and constraints imposed by other components of the aircraft production system, array 160 may also include other stations, such as end-sealing stations (e.g., edge-sealing stations, trimmed edge-sealing stations, etc.), painting stations, stations for mounting containers and wire supports, or other small parts. For example, these stations may be downstream of trimming stations 118 and / or cutting stations 120 and 122 and upstream of sealing and / or painting stations and edge scanning NDI stations (not shown). Furthermore, the number of each type of station can vary depending on the amount of work expected to be performed during each pulse. For example, if a cutting station cannot operate at a speed matching the cycle time of frame 150, additional cutting stations may be added during the design phase to ensure that the cycle time is always met.

[0041] Supply lines 162-1 and 162-2 can manufacture any suitable components for use at the workstations. These components may include fasteners, adhesives, blades, etc., for just-in-time (JIT) insertion of components into assembly line 100. For example, supply line 162-1 provides frame 150, and supply line 162-2 provides water to NDI workstations 112 and 114. Supply lines 162-1 and 162-2 can be implemented in parallel to each other to feed material to the same or different workstations in time to meet the requirements of those workstations.

[0042] Dust, debris, and manufacturing allowances removed during operations at stations 116-126 are removed from assembly line 100 via outlets 170-1 to 170-4. Depending on the implementation and application, outlets 170-1 to 170-4 may include a vacuum system, chutes, conveyors, or other systems for physically removing the material from assembly line 100. In many implementations, removal is automated to ensure that workers do not have to stop the production line and spend time periodically cleaning. In this implementation, outlet 170-1 removes waste from drilling and finishing, outlet 170-2 removes cutting debris, outlet 170-3 removes rat-hole waste, and outlet 170-4 provides inspection data for use by downstream stations and / or controllers 180 that manage the operation of assembly line 100.

[0043] In another embodiment, the workstation array 160 is adjustable and capable of accommodating frames 150 of various sizes for various models of the aircraft 10. For example, a workstation may include blades with adjustable positions, exhibiting a dynamic range of motion, etc. In one embodiment, the workstations include space within the production line to handle frames 150 of larger or smaller diameters. The assembly line 100 may also accommodate frames 150 of the same or different models of varying lengths. Workstations that remain stationary as a frame 150 passes by perform “pass-through processing,” while workstations fixed to the frame 150 or carrying tools that move with the frame 150 are referred to as performing “hitchhiking processing.” Workstations performing hitchhiking processing can return to their initial starting position after completing work on the frame 150, ready to receive the next frame 150. Workstations may even be mounted to the frame 150 during transport to move with the frame 150 and perform work as the frame 150 moves (e.g., by moving along a track mounted to the frame 150).

[0044] In a further embodiment, assembly line 100 extends more than 360 degrees in a vertical spiral or helical pattern by ascending or descending, such that workstations separated by 360 degrees from each other are vertically separated. In an embodiment where assembly line 100 forms a complete circle, frame 150 may circulate through assembly line 100 multiple times to receive work from workstations before frame 150 is completed and ready to leave assembly line 100. Technicians can enter assembly line 100 by walking through an open section (represented by a "technician passage"), although in another embodiment, technicians step below or above portions of assembly line 100 and / or frame 150. In another embodiment, these workstations are arranged across multiple circular or spiral silos that move vertically upward in a spiral and are connected together to receive all desired processing operations. That is, each spiral silo moves vertically upward or downward in a spiral pattern over multiple rotations, and workstations are positioned along the length of these spiral silos. This arrangement increases work density by reducing the floor space required for assembly line 100.

[0045] Finally, frame 150 reaches unloading station 130, where the entire frame 150 is removed from assembly line 100 and fed to another assembly line (e.g., an assembly line for a section of fuselage 12). At unloading station 130, a frame installation station installs frame 150 onto that section of fuselage 12 (e.g., onto half-cylinder section 24). In one embodiment, the productivity of assembly line 100 is based on the expected cycle time of the assembly line it feeds to.

[0046] Controller 180 manages all operations of workstation array 160 and can further manage the operations of supply lines 162-1 and 162-2 and outlets 170-1 to 170-4 discussed herein. In a pulsating environment, the pulsation length, pulsation time, and pause time are synchronized by one or more controllers 180 on all workstations and frames 150 according to a predetermined cycle time (i.e., the expected productivity of the factory as a whole). Therefore, the workload allocated to each workstation is based on a uniform pulsation length, pulsation time, and / or pause time (depending on whether the workstation performs its work during a pulsation or a pause). Because the workstations perform their work synchronously (e.g., during the same pause or pulsation), because the workload allocated to each workstation corresponds to the expected travel rate, and because the frames 150 move synchronously through assembly line 100 according to predetermined cycle times, the frames 150 are produced according to the expected productivity. In one embodiment, controller 180 is implemented as custom circuitry, as a hardware processor executing programmed instructions stored in memory, or some combination thereof.

[0047] Figure 2 Examples Figure 1BThe assembly line 100, in the illustrative embodiment, performs work on multiple frames 150 that move forward synchronously. The frames 150 can be different types of frames 150 for a single model of aircraft 10, or even different types of frames 150 for different models of aircraft 10. Figure 2 In the process, multiple frames 150 advance through the workstation array 160 to receive work, and the completed frames 150, including DA holes 155 and mouse holes 152, leave the assembly line 100 to be supplied to the downstream assembly line where the frames 150 are mounted onto the fuselage skin 50. Figure 2 This is provided by illustrating how multiple frames 150 are processed at once along assembly line 100. Figure 1B Additional context. Figure 2 In this assembly line 100, the first frame 150 is located within the area of ​​NDI station 112, and the second frame 150 downstream of the first frame is located within the areas of drilling station 116, trimming station 118, cutting stations 120 and 122, and excision stations 124 and 126. In another embodiment, multiple stations operate simultaneously on one frame 150, while multiple stations operate simultaneously on another frame 150 arranged in series in the assembly line 100. For example, NDI stations 112 and 114 may perform inspection processes on the first frame, while drilling station 116 and trimming station 118 perform cutting on the first frame, and cutting stations 120 and 122 may perform cutting on the second frame located downstream of the first frame.

[0048] Reference Figure 3 Illustrative details of the operation of assembly line 100 are discussed. For this embodiment, it is assumed that the frame (e.g., frame 150 is curved and includes 90-degree, 60-degree, 120-degree, or any suitable arc) has been hardened from a preform and is loaded at the supply line 162, which provides frame 150 according to the cycle time designed for assembly line 100. In another embodiment, a similar radial assembly line is used to manufacture the curved portions of window surrounds and door surrounds.

[0049] Figure 3 This is a flowchart illustrating a method 300 for operating an assembly line to produce frames, as exemplified in an illustrative embodiment. (See also...) Figure 1B The assembly line 100 describes the steps of method 300, but those skilled in the art will understand that method 300 can be performed in other systems. The steps in the flowchart described herein are not exhaustive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0050] Figure 3 This is a flowchart illustrating a method 300 for operating assembly line 100 to produce frame 150 in an illustrative embodiment. According to... Figure 3Method 300 includes receiving a frame 150 in step 302. The frame 150 includes either a metal frame 150 or a hardened composite frame 150. Receiving the frame 150 includes positioning the frame 150 at a loading station 110. Step 304 includes advancing the frame 150 through one of a series of stations arranged in an arcuate pattern in an array of stations 160. In some illustrative examples, step 304 includes advancing the frame 150 through one or more stations arranged in an arcuate pattern corresponding to the shape of the frame 150. In some illustrative examples, the frame 150 is referred to as an arcuate frame. In some illustrative examples, advancing the frame 150 through one of the stations in the array of stations 160 includes advancing the frame 150 in a clockwise arcuate pattern. In some illustrative examples, advancing frame 150 through a station of station array 160 includes advancing frame 150 along a counter-clockwise arc. In one embodiment, advancing frame 150 includes pulsating frame 150 through the station by a distance less than its length (i.e., “micro-pulsation”), then pausing frame 150, then pulsating frame 150 again, and so on. In this embodiment, advancing frame 150 includes causing frame 150 to perform a circular motion as frame 150 follows arc 140. That is, the circular motion follows arc 140 having a radius corresponding to the radius of frame 150.

[0051] Step 306 includes performing work on frame 150 via a single station. In some illustrative examples, step 306 includes performing work on frame 150 via one or more stations, such as simultaneously performing work on different sections of frame 150 via multiple stations. In some illustrative examples, step 306 includes performing work on the frame on different sections of the curved frame 150 via multiple stations during the same time period. For some stations, such as cutting stations 124 and 126, the work on frame 150 occurs during pauses between pulses of frame 150. For other stations, such as cutting station 122, work is performed on frame 150 when frame 150 advances during pulses and / or during pauses between pulses, or when frame 150 advances continuously. For example, when it is desired that a cutting device (e.g., a milling machine or dressing machine) move relative to frame 150, some dressing or milling is performed during pauses, where the tool moves relative to frame 150.

[0052] Method 300 offers advantages over existing technologies because it enables the frame 150 to be assembled at a high rate while also increasing work density. This makes the radius of the frame 150 advantageous when performing post-curing production. This, in turn, reduces the amount of space occupied by the assembly line 100 in the factory floor and ensures strict compliance with cycle time requirements.

[0053] Figure 4This is a front view of the section of the fuselage 12 including the mounting frame 150 in the illustrative embodiment. Therefore, after the frame 150 has left the assembly line 100, it arrives at... Figure 4 The section 400 of the fuselage 12 shown. The mouse hole 152 of the frame 150 is aligned with the longitudinal beam 410 at the section 400 of the fuselage 12, while the OML 153 of the frame 150 is aligned with the IML 422 of the skin 50 of the section 400 of the fuselage 12.

[0054] Figure 5 This is an illustrative implementation method. Figure 4 An enlarged end view of frame 150, and corresponding to Figure 4View arrow 5. In this embodiment, frame 150 presents a cross-sectional shape of the form of a "Z"; however, any suitable shape can be selected, including "I", "C", "S", "T", "J" and other shapes. Frame 150 includes a first flange in the form of a shear link foot 562, a web 564, and a second flange in the form of an inner chord flange 566. The frame is primarily constructed of a material 552 such as CFRP. However, the frame also includes sacrificial material 554, which has been partially removed by cutting until the desired thickness and smoothness are achieved at frame 150. This cutting process allows the flange reference plane 572 and the web reference plane 574 to be obtained during assembly, which facilitates the alignment and setting of frame 150. Other references of any desired kind can also be used at any desired location. Furthermore, although fasteners 510 with crown heads are illustrated below, many fasteners are countersunk and / or installed using countersinking tools. The sacrificial material 554 is countersinked to establish a constant fastener hold length during installation. The holding length of each fastener 510 preferably includes a holding length through the frame 150 (flange) and a holding length through the skin 50. The versatility of the holding lengths for the various fasteners 510 on the frame stems from adjustments to the thickness of the frame (flange), which also take into account variations in the thickness of the skin 50 where the fasteners are mounted. While holding lengths are known, according to this disclosure, the thickness of the composite frame flange is reduced where the fastener penetrates to maintain a common holding length for all fasteners 510 connecting the frame 150 to the skin 50. Therefore, fasteners with a single holding length can be mounted, and if necessary, the sacrificial material 554 can be countersunk to reduce the holding length required for mounting the fasteners 510. Thus, countersunking allows the frame 150 to be customized to fit the desired fastener holding length without requiring milling the entire length of the flange. Adjacent fastener holes can be countersunk to different depths, which is more adaptable than varying the milling depth on the flange by the pitch of fastener 510 (e.g., a flange formed by one or more sacrificial layers on the IML side of the outer flange). In other embodiments, the sacrificial layer may comprise carbon fiber or glass fiber and may be added during the preform manufacturing stage before curing, or may be added as needed during the post-curing stage after curing.

[0055] Fastener 510 has been driven through a section of frame 150 and skin 50 of fuselage 12 to secure frame 150 to skin 50. In this embodiment, fastener 510 includes a latch having a rod 512, thread 513, neck 514, and pin 516. During the installation of fastener 510, a machine (not shown) grips pin 516 and forges a collar (not shown) onto thread 513, which protrudes from frame 150 (referred to in this figure as "grip length"). The machine then disconnects pin 516 from fastener 510, securing fastener 510 in place.

[0056] according to Figure 5 The length L_SHANK of the shank 512 corresponds to the stack thickness T_STACKUP defined by the thickness T_SKIN of the skin 50 and the thickness T_FRAME of the shear train foot 562. This yields a gripping length corresponding to the combination of skin and flange thicknesses. When the desired gripping length is obtained, sufficient amount of thread is exposed to install the nut or bolt collar into the appropriate position on the fastener 510. If the frame thickness varies between or along the frames 150, then fasteners 510 of different lengths are used to achieve the desired gripping length. However, using different fasteners 510 presents logistical difficulties and increases the complexity of the machine required to install the fasteners 510. To address this issue and implement a single-size fastener installation process on various frames 150, a technique is employed to implement a uniform frame thickness at the shear train foot 562. The adjustment of the frame 150 thickness takes into account variations in the thickness of the skin 50 on which the fastener 510 is installed. Reducing the thickness of the frame 150 through which the fastener 510 passes allows all fasteners connecting the frame 150 to the skin 50 to have a common hold-up length. In other embodiments, sacrificial material 554 is also disposed on the OMML of the shear tie foot 562 of the frame 150. In such embodiments, using a sacrificial layer on the OMML allows flexibility regarding reducing the flange thickness to maintain a consistent hold-up length for the fastener 510. Cutting the frame 150 allows for customization of the frame 150. Customizing the frame 150 results in a common hold-up length for the frame 150, allowing the frame 150 to be customized to fit a desired hold-up length. In another embodiment, a countersinking technique is used around the fastener hole location to provide a cutting surface for mounting the fastener 510. Countersinking can be performed after drilling the hole 610, and then the length can be checked.

[0057] Figure 6 A stack 600 is depicted, which is designed to be used with a fastener 510 of a predetermined length in the illustrative embodiment, and with... Figure 6 The view arrow 6 corresponds to this. According to... Figure 6The shear force member foot 562 is cut (when necessary) to thickness T_FRAME. This cutting process ensures that the combination of T_FRAME and T_SKIN of skin 50 provides the desired / designed holding length for the fastener 510 installed into hole 610. This ensures uniform utilization of fasteners 510 with a single holding length throughout the assembly of frame 150, which in turn makes just-in-time (JIT) delivery of fasteners 510 into holes much easier. Using a single type of fastener 510 with a specific holding length reduces supply line burden because there is no need to supply, store, and deliver fasteners 510 for multiple holding lengths prior to installation. That is, because only a single holding length is required, a stable and smooth supply of fasteners 510 is provided without the need for in-station inventory and picking from a variety of different holding lengths of fasteners 510.

[0058] Figure 7 This is a flowchart illustrating a method 700 for cutting shear train feet 562 to produce a stack 600 for use in fasteners 510 of a predetermined length, as exemplified in an illustrative embodiment. Step 702 includes receiving a frame 150, which includes a web 564, shear train feet 562, and sacrificial material 554 that increases the thickness of the shear train feet 562. In one embodiment, this includes advancing the frame 150 to expose a new portion of the frame 150 for receiving material from a cutting station, such as cutting station 120. Figure 1B (As shown in the diagram). According to one embodiment, the frame 150 pulsates along a curved path for a distance less than its length, or moves continuously toward the cutting station 120. According to one embodiment, the cutting station 120 cuts the frame 150 either during a pause between pulsations or while the frame 150 is moving forward during pulsations.

[0059] Step 704 includes cutting the shear link foot 562 to a thickness corresponding to the gripping length of the fastener 510 in conjunction with the thickness of the skin 50 by cutting sacrificial material from the shear link foot 562 (also referred to as the OML flange). Cutting the sacrificial material includes removing part or all of the sacrificial material 554 from the shear link foot 562 (also referred to as the OML flange). In one embodiment, the cutting is performed to obtain a desired fastener gripping length corresponding to the length of the shank 512 of the fastener 510. That is, as... Figure 5 and Figure 6As shown, the cutting achieves an assembly in which the holding length of the fastener 510 matches the required fastener holding length of the hole 610 to which it is installed. In one embodiment, this method 700 further includes counterspinning sacrificial material 554 from the shear system foot 562 to create a common holding length for the frame 150. In another embodiment, the cutting makes the thickness T_FRAME of the frame 150 equal along the length 156 of the frame 150, thereby creating a common holding length for the individual fasteners 510 installed via the skin 50 and the frame 150. In yet another embodiment, the method further includes cutting an additional frame 150 to present a thickness T_FRAME equal along the length 156 of the additional frame 150. The thickness of each additional frame 150 may be the same as or different from the thickness of the other frames 150.

[0060] In another embodiment, cutting the shear train foot 562 includes operating a cutting station 120 as the frame 150 advances along a curved path (e.g., arc 140), which cuts the shear train foot 562. The curved path is circular and has a radius corresponding to the radius of the frame 150. In one embodiment, the cutting station 120 is rotated to the shear train foot 562 prior to cutting. The cutting station 120 then removes sacrificial material until the desired thickness is achieved, for example by removing sacrificial glass fiber and / or carbon layers from the shear train foot 562, removing CFRP layers where an adhesive layer exists between the parent frame and the CFRP, etc.

[0061] In one embodiment, the cutting process is performed at the frame mounting station prior to drilling and filling, for example by measuring the thickness of the stack 600 between the frame 150 and the skin 50 before drilling. In another embodiment, if the desired dimensions are known a priori (e.g., due to inspection processes characterizing the frame 150 and / or skin 50), the cutting operation is performed via the assembly line 100, or after drilling 610 and measuring the hold length. To maintain the desired hold length, varying amounts of sacrificial layer removal can be performed to accommodate variations in the thickness of the skin 50. In many embodiments, thickness reduction is achieved by reducing the thickness of the sacrificial material on the frame flange adjacent to the skin 50 to facilitate the desired constant hold length of the fastener 510 connecting the two. The cutting can be performed along the length of the frame 150 landing on the semi-cylindrical section 24 of the fuselage 12. In one embodiment, a hole 610 is drilled through the skin 50 and the frame 150, the holding length of the hole 610 is measured, and the sacrificial material layer 554 is cut to obtain the desired holding length before the fastener 510 is installed.

[0062] The desired thickness is chosen such that the gripping length formed by the final stack of the shear link foot 562 and the skin 50 consistently provides the desired gripping length corresponding to a single length of the fastener 510. That is, the thickness of the shear link foot 562 is chosen such that even taking into account tolerance variations in the thicknesses of the shear link foot 562 and the skin 50, a single, uniform, and readily available fastener length will always provide the desired amount of gripping length.

[0063] After the shear train foot 562 has been cut and the frame 150 has left the assembly line (e.g., assembly line 100), step 706 includes setting the shear train foot 562 against the IML 422 of the skin 50 of the half-cylinder section 24 of the fuselage 12. In one embodiment, this includes aligning the DA hole (not shown) or other reference features that facilitate the assembly process, and / or clamping the frame 150 into place. After the frame 150 is aligned at the section of the fuselage 12, a drilling operation is performed at that section of the skin 50 for fasteners 510.

[0064] Step 708 includes installing fasteners 510 through the skin 50 and the shear train foot 562 of the frame 150 to secure the frame 150. In some illustrative examples, step 708 includes installing fasteners 510 through the shear train foot 562 of the skin 50 and the frame 150 to secure the frame 150. In some illustrative examples, installing fasteners 510 secures the frame 150 to a section of the skin 50 to form a section of the fuselage 12. Step 708 can be performed by a suitable latch mounting mechanism. Step 710 includes securing fasteners 510 in place. In one embodiment, this includes forging a latch collar onto fastener 510.

[0065] Method 700 provides a technical benefit by ensuring that the stack thickness (even when it varies) still allows the frame 150 to be mounted with a single-length fastener 510. This reduces the complexity required to supply the fasteners 510 to the frame assembly system (because there is no need to supply fasteners 510 with different gripping lengths), and further reduces the complexity required for such a frame assembly system. As a result, both cost and error rate are reduced.

[0066] Figure 8The illustrative embodiment depicts a frame 150 awaiting demolding from the mandrel 800. In this embodiment, one or more sacrificial layers of sacrificial material 554 (e.g., fiberglass layers) have been added to the frame 150 (e.g., before or after the frame 150 is hardened by the preform) to increase the thickness of the frame 150. This is done to ensure that the frame 150 does not exhibit dimensions smaller than desired, so that the frame 150 can be cut to the desired size. The sacrificial material 554 provides the ability to dynamically adjust frame parameters (e.g., thickness) during assembly. In this embodiment, the frame 150 has been pressed against the profile 812 defined by the body 810 of the mandrel 800 to give the frame 150 the desired shape. After the frame 150 has hardened, when mounted on the skin 50, the frame 150 will give the skin panel (e.g., Figures 1A to 1B and Figure 4 (50) Skin support and stiffness.

[0067] Figures 9A to 9B and Figure 10 The illustrative embodiment is described by Figure 1B Non-destructive inspection (NDI) operations are performed at NDI stations 112 and 114. Figure 9A Two NDI stations 112 (e.g., ultrasonic sensors) utilize wall 920 to form a chamber 930 filled with an incompressible liquid (e.g., water). The NDI stations 112 utilize ultrasonic transducers 910 to detect non-conforming conditions (e.g., voids 950) in the web 564, the flanges serving as shear force member feet 562, and the flanges 566 of the frame 150, such as voids, thickness variations, etc. In other embodiments, NDI checks are performed on the two flanges and the radii / corners that engage the respective flanges with the web 564.

[0068] Figure 9B An implementation is depicted in which the radius 940 of each of one or more corners of the frame 150 is scanned / inspected via NDI station 114. The inspection performed by these NDI stations 114 can occur... Figure 9A The same NDI station 112 described in the text, or the one located at the same location, is where the NDI station 112 is located. Figure 9A At an additional station upstream or downstream of NDI station 112.

[0069] exist Figure 10 In this process, NDI station 114 inspects the radius R of frame 150 (e.g., inner or outer radius, torsion along the circumferential length, etc.) to ensure that frame 150 is within the desired tolerance. In another embodiment, frame 150 already exhibits the desired curvature imparted by mandrel 800 and is therefore assumed to be at the desired radius. NDI can also be used to detect out-of-tolerance conditions in the flange of frame 150, such as clearance 950 (e.g., Figure 9A(As shown). In another embodiment, NDI checks are performed on flange 566 and shear system foot 562. In another embodiment, ultrasonic transducer 910 is also moved relative to the corners of the flange to detect the characteristics of these corners, such as radius.

[0070] Figures 11 to 12 The illustrative embodiment is described by Figure 1B The cutting operations are performed at cutting stations 120 and 122. Figure 11 In this embodiment, a cutting station 120 is located at the shear force member foot 562 and flange 566 of the frame 150, and removes sacrificial material 554 therefrom using a cutting tool 1110 (e.g., a reciprocating tool, a rotary tool, etc.). In another embodiment, depending on the need to assemble the frame 150 into the skin 50, the cutting station 120 is used to remove sacrificial material 554 from either side of the inner or outer flange of the frame 150. Figure 12 In the process, the cutting station 122, located at the web 564 of the frame 150, removes the sacrificial material 554 from the web 564 using the cutting blade 1110.

[0071] Figures 13 to 14 The illustrative embodiment is described by Figure 1B The cutting operations are performed at cutting stations 124 and 126. Specifically, in Figure 13 In the first cutting station 126, a blade 1310 (e.g., a reciprocating blade, a rotary blade, etc.) is used to cut into the web 564 of the frame 150, while... Figure 14 In the second cutting station 124, a blade 1310 is used to cut into the shearing member foot 562 of the frame 150 and remove waste material 1320, thereby forming a rat hole 1330. In another embodiment, the radius of the cut is made at the corner of the rat hole 1330 to complete the rat hole 1330. The removed material is considered a manufacturing allowance and may have indexing features 158 and / or timing features to facilitate transfer therein.

[0072] Figure 15 This is a flowchart illustrating another method 1500 for operating an assembly line 1000 of frame 150 in an illustrative embodiment. Step 1502 includes moving frame 150 along a processing direction (e.g., Figure 1B As indicated by arrow P, the frame 150 advances less than its length, passing through the first (processing) workstation and the second station, thereby presenting the longitudinal segment 154 of the frame 150 to the first and second stations. In one embodiment, advancing the frame 150 includes driving the frame 150 via a drive unit 102 to expose the new segment 154 of the frame 150 to the first and second stations.

[0073] Step 1504 includes transposing a segment 154 of the frame 150 to a first station and a second station. In one embodiment, transposing the frame 150 includes setting a transposing feature 158 of the frame 150 to contact an indexing member 158 at the first station.

[0074] Step 1506 includes performing work on a first section of frame 150 via a first station, while simultaneously performing work on that section 154 of frame 150 via a second station. In one embodiment, the work performed at the first station differs from that at the second station, for example, performing NDI instead of cutting. Any suitable number of stations can be used in this manner, one after the other.

[0075] Step 1508 includes repeating the steps of advancing, rotating, and performing work until the entire frame 150 has passed the first and second workstations. In one embodiment, advancing the frame 150 moves the frame 150 through a third workstation, and the method further includes rotating a third segment of the frame 150 to the third workstation while performing work on the third segment of the frame 150 through the third workstation, and simultaneously performing work on the second segment of the frame 150 through the second workstation.

[0076] Figure 16 This is a flowchart illustrating another method 1600 for operating an assembly line 100 of frame 150 in an illustrative embodiment. Step 1602 includes advancing frame 150 along an arc less than its length to a starting position (e.g., the position of drilling station 116). In one embodiment, advancing frame 150 includes operating drive unit 102, which is physically interlocked with manufacturing allowance 157 at frame 150. Step 1604 includes attaching a machining station (e.g., drilling station 116) to frame 150. This operation can be performed by interlocking the machining station with the manufacturing allowance 157 of frame 150. Step 1606 includes performing work on frame 150 via the machining station as frame 150 advances along the arc. That is, frame 150 along the arc processing direction 197 ( Figure 1B The machining station advances along frame 150 to perform work at another location along frame 150 before separating / detaching from frame 150. In one embodiment, this includes drilling a hole in a portion of frame 150. Step 1608 includes returning the machining station to the starting position. In one embodiment, this includes separating the machining station and returning it to the starting position via a separate return path.

[0077] Figure 17 The arrangement of the spiral stack for assembling the frame 150 in the illustrative embodiment is depicted. Specifically, Figure 17An assembly line 1700 is depicted, comprising a first helical stack 1750 and a second helical stack 1760. Frames are fed into the inlet 1710 of the first helical stack 1750 and advance along a curved track 1720 through an array 1721 of stations 1722 (i.e., stations 1722-1 to 1722-6). In one embodiment, the array 1721 of stations 1722-1 to 1722-6 includes a non-destructive inspection (NDI) station that inspects longitudinal sections of the frame 150 (e.g., an arcuate frame), or any other type of station discussed above with respect to the figures, such as those discussed above with respect to the figures. Figure 1B The workstation for discussion.

[0078] The curved track 1720 is inclined upwards. That is, the curved track 1720 advances vertically with a helix angle (not shown) of a spiral shape 1790, which corresponds to the frame 150 ( Figure 17 The spiral shape 1790 may have a radius 1791R corresponding to the radius of the frame 150. As production proceeds, the frame 150 advances upward at a helix angle (not shown) of the first spiral stack 1750. Thus, the frame 150 continues along the curved track 1720 through the first layer 1752, the second layer 1754, and the third layer 1756. In another embodiment, any number of layers and the frame 150 occupying any degree (e.g., 360 degrees, 180 degrees, etc.) may advance clockwise 1793 or counterclockwise 1792 through the spiral stacks 1750, 1760. During this time, as the frame 150 advances along the curved track 1720, workstations 1722-1 to 1722-6, arranged along the curved track 1720, perform work on the frame 150. In another embodiment, multiple workstations 1722 can operate simultaneously on the same frame 150, and individual workstations within the multiple workstations 1722 can operate simultaneously on different frames 150. The spiral characteristic results in a greater workstation density per square foot of manufacturing floor space.

[0079] Figure 17 The frame 150 is further depicted as being able to advance through the array 1723 of stations 1722-7 to 1722-12 at the second spiral stack 1760, and then advance vertically downward through the third layer 1766, the second layer 1764, and the first layer 1762 according to the helix angle (not shown) of the second spiral stack before exiting via the exit 1770. In another embodiment, the tool (e.g., Figure 1B The tool 159) carries the frame 150 along the curved track 1720. It should be understood that the curved track 1720 can also be considered a helical track, causing the frame to undergo a helical motion with a radius preferably corresponding to the radius of the frame. The track preferably advances vertically and / or at a pitch angle. In another embodiment, the drive unit (e.g., Figure 1B The drive unit 102 advances the frame 150 by causing it to pulse through stations 1722-7 to 1722-12 at distances less than the length of the frame 150. In one embodiment, modulation of the frame 150 is achieved by physically interlocking the drive unit 102 with the tool 159 that carries the frame 150.

[0080] The frame 150 is locally input into each spiral stack in the first spiral stack 1750 and / or the second spiral stack 1760, and is also locally output to enable timely delivery of the frame 150.

[0081] Figure 17 The diagram also illustrates supply lines 1795-1 to 1795-4, which provide materials to station 1722 in a timely manner. Each supply line 1795-1 to 1795-4 can provide the same or different types of materials based on the same or different cycle times. Outlets 1794-1 to 1794-4 remove materials (e.g., scrap) from station 1722. Each outlet 1794-1 to 1794-4 can remove different types of scrap or scrap of the same type as those from other outlets.

[0082] Figure 18 This is a flowchart illustrating, in an illustrative embodiment, another method 1800 for operating an assembly line having a first helical stack 1750 and a second helical stack 1760 to assemble a frame 150. Method 1800 includes receiving the frame 150 in step 1802 and advancing the frame 150 through a station of a helical structure corresponding to the shape of the frame 150 (e.g., ...). Figure 1B The workstation array 160. In some illustrative examples, frame 150 is referred to as an arc frame. In some illustrative examples, frame 150 advances clockwise through workstation array 160. In some illustrative examples, frame 150 advances counterclockwise through workstation array 160. In some illustrative examples, advancing frame 150 includes coupling drive unit 102 to manufacturing allowance 157 of frame 150. In some illustrative examples, coupling includes physically interlocking drive unit 102 to manufacturing allowance 157. In one embodiment, advancing frame 150 includes pulsating frame 150 through the workstation at a distance less than its length. In another embodiment, advancing frame 150 includes subjecting frame 150 to helical motion. For example, helical motion may follow an arc 140 having a radius corresponding to the radius of frame 150. In yet another embodiment, advancing frame 150 includes physically interlocking drive unit 102 to manufacturing allowance 157 of frame 150.

[0083] Step 1806 includes performing work on the frame 150 via at least one station in the station array 160 in step 1806. In one embodiment, performing work on the frame 150 is done simultaneously on different sections of the frame 150 via a series of stations. In another embodiment, performing work on the frame 150 occurs during a pause between pulses of the frame 150, or performing work on the frame 150 while the frame 150 is advancing during a pulse. In a further embodiment, the stations perform work on the continuously advancing frame 150. In a further embodiment, before receiving work, the stations (e.g., Figure 1B The workstations 112 to 126 are shifted to the shift feature 158 at the manufacturing allowance 157 of the frame 150. In another embodiment, the shift feature 158 is arranged at the tool 159 (e.g., the frame carrier).

[0084] Example

[0085] In the following examples, additional processes, systems, and methods are described in the context of a manufacturing system for an aircraft frame.

[0086] Referring more specifically to the accompanying drawings, embodiments of this disclosure can be implemented as follows: Figure 19 The aircraft manufacturing and maintenance methods shown in 1900 and as follows Figure 20 The description is presented within the context of the aircraft 1902. During pre-production, method 1900 may include the specification and design 1904 of the aircraft 1902 and the procurement of materials 1906. During production, the manufacturing of components and sub-components of the aircraft 1902 1908 and system integration 1910 may be carried out. Subsequently, the aircraft 1902 may undergo certification and delivery 1912 for use 1914. When in use by the customer, routine maintenance and upkeep 1916 are performed on the aircraft 1902 (this may also include modifications, reconfigurations, refurbishments, etc.). The equipment and methods specifically implemented herein may be employed during any one or more suitable stages of production and use as described in Method 1900 (e.g., Specifications and Design 1904, Material Procurement 1906, Component and Sub-component Manufacturing 1908, System Integration 1910, Certification and Delivery 1912, In Use 1914, Maintenance and Care 1916) and / or any suitable component of Aircraft 1902 (e.g., Frame 1918, System 1920, Interior 1922, Propulsion System 1924, Electrical System 1926, Hydraulic System 1928, Environment 1930).

[0087] Each process in Method 1900 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 description, a system integrator can include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party can include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator can be an airline, leasing company, military entity, service organization, etc.

[0088] like Figure 20 As shown, an aircraft 1902 produced according to method 1900 may include a frame 1918 having multiple systems 1920 and an interior 1922. Examples of systems 1920 include one or more of the following: a propulsion system 1924, an electrical system 1926, a hydraulic system 1928, and an environmental system 1930. Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention can be applied to other industries such as the automotive industry.

[0089] As mentioned above, the equipment and methods specifically implemented herein can be used during any or more suitable stages of the production and maintenance phases described in method 1900. For example, components or sub-components corresponding to component and sub-component manufacturing 1908 can be made or manufactured in a manner similar to that of components or sub-components produced when aircraft 1902 is in use. Moreover, during sub-component manufacturing 1908 and system integration 1910, one or more equipment implementations, method implementations, or combinations thereof can be utilized, for example, by significantly accelerating the assembly of aircraft 1902 or reducing the cost of the aircraft. Similarly, when aircraft 1902 is in use (e.g., and without limitation, during maintenance and servicing 1916), one or more equipment implementations, method implementations, or combinations thereof can be utilized. For example, the techniques and systems described herein can be used for material procurement 1906, component and sub-component manufacturing 1908, system integration 1910, in use 1914 and / or maintenance and servicing 1916, and / or can be used for rack 1918 and / or interior 1922. These technologies and systems can even be used in systems 1920, such as propulsion systems 1924, electrical systems 1926, hydraulic systems 1928, and / or environmental systems 1930.

[0090] In one embodiment, the component comprises a portion of a frame 1918 and is manufactured during component and sub-component manufacturing 1908. The component can then be assembled into the aircraft during systems integration 1910 and utilized during use 1914 until wear renders it unusable. Then, during maintenance and upkeep 1916, the component can be discarded and replaced with a newly manufactured component. The inventive components and methods can be utilized throughout component and sub-component manufacturing 1908 to produce new components.

[0091] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein can be implemented as hardware, a processor executing software, a processor executing firmware, or a combination thereof. For example, an element can be implemented as dedicated hardware. The dedicated hardware element can be referred to as a “processor,” a “controller,” or a similar term. When provided by a processor, the functionality can be provided by a single dedicated processor, a single shared processor, or multiple individual processors, some of which may share the functionality. Furthermore, the terms “processor” or “controller” as explicitly used should not be construed as referring specifically to hardware capable of executing software, but may implicitly include, but are not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) storing software, random access memory (RAM), non-volatile memory, logic, or some other physical hardware component or module.

[0092] Furthermore, control elements can be implemented as instructions executable by a processor or computer to perform the function of that element. Some examples of instructions are software, program code, and firmware. The instructions are operable when executed by a processor to instruct the processor to perform the function of the element. The instructions can be stored on a storage device that can be read by a processor. Some examples of storage devices are digital or solid-state memories, magnetic storage media such as disks and tapes, hard disk drives, or optically readable digital data storage media.

[0093] Further illustrative and non-exclusive examples according to this disclosure are described in the following paragraphs.

[0094] In an example according to this disclosure, a method for manufacturing a frame (150) for an aircraft (10) is provided, the method comprising the following steps:

[0095] Receive frame (150);

[0096] The frame (150) is advanced through one station in an arc-shaped array of stations (160) and / or through a series of stations arranged in a spiral corresponding to the shape of the frame (150); and

[0097] Work is performed on the frame (150) via at least one of the workstations.

[0098] Optionally, the arc corresponds to the shape of the frame (150).

[0099] Optionally, the frame (150) advances through the workstation array (160), and the steps of performing work on the frame (150) are completed simultaneously by the workstation array (160) on different sections (154) of the frame (150).

[0100] Optionally, the frame (150) advances through multiple workstations of the workstation array (160), and

[0101] The steps of performing work on the frame (150) are completed simultaneously on different sections (154) of the frame (150) via multiple workstations of the workstation array (160).

[0102] Optionally, the frame (150) advances clockwise through the workstation array (160) and / or the frame (150) advances counterclockwise through the workstation array (160).

[0103] Optionally, the steps of performing work on the frame (150) are performed simultaneously on different sections (154) of the frame (150) via a series of workstations.

[0104] Optionally, the step of advancing the frame (150) includes pulsating the frame (150) through the station by a distance less than the length of the frame (150), wherein preferably, the step of advancing the frame (150) includes pulsating the frame (150) through the station by a distance equal to the length of the frame (150), and / or wherein the step of advancing the frame (150) includes continuously moving the frame (150) through the station, and / or wherein the step of performing work on the frame (150) preferably occurs during a pause between pulsations of the frame (150), and / or wherein the step of performing work on the frame (150) is performed while the frame (150) is advancing during pulsations.

[0105] Optionally, the step of advancing the frame (150) includes making the frame (150) perform circular and / or spiral movements, wherein preferably, the circular movement follows an arc with a radius corresponding to the radius of the frame (150), or the spiral movement follows an arc with a radius corresponding to the radius of the frame (150).

[0106] Optionally, the method further includes shifting the workstation to a shifting feature (158) at the manufacturing allowance (157) of the frame (150).

[0107] Optionally, the step of advancing the frame (150) includes physically interlocking the drive unit (102) to a manufacturing allowance (157) of the frame (150).

[0108] Optionally, the frame (150) is held and advanced through the workstation array (160) by a tool (159) including a rotation feature (158), wherein preferably, the drive unit (102) is interlocked with the tool (159) while the tool (159) carries the frame (150).

[0109] Optionally, the step of advancing the frame (150) includes coupling the drive unit (102) to a manufacturing allowance (157) of the frame (150), wherein preferably, the coupling preferably includes physically interlocking the drive unit (102) to the manufacturing allowance (157).

[0110] Alternatively, the frame (150) may be moved along an arc to the starting position at a length less than its length;

[0111] Connect the processing station to the frame (150);

[0112] As the frame (150) advances along the arc, work is performed on the frame (150) via the machining station; and

[0113] The processing station is then returned to its starting position.

[0114] Preferably, the work includes drilling holes in a portion of the frame (150).

[0115] In another example according to this disclosure, a portion of the aircraft (10) is assembled according to one of the methods described above.

[0116] In another example according to this disclosure, a system for producing a frame (150) of an aircraft (10) is provided, the system comprising:

[0117] A workstation array (160) arranged in an arc shape, and simultaneously performing work on the frame (150), and / or the system includes:

[0118] A spiral stack (1750), the spiral stack comprising:

[0119] A curved track (1720) that advances vertically in a spiral shape at a spiral angle; and

[0120] A workstation (1722) arranged along the curved track (1720) performs work on the frame (150) as the frame (150) moves along the curved track (1720); and

[0121] A drive unit (102) that causes the frame (150) to move forward through the workstation.

[0122] The workstation of such a system is preferably configured to perform one of the methods described above.

[0123] Optionally, the drive unit (102) causes the frame (150) to advance along an arc through the workstation array (160); and the system further includes:

[0124] Non-destructive inspection NDI station (112), said NDI station inspects longitudinal sections (154) of said frame (150); and

[0125] A workstation array (160) comprising workstations that are transposed to a frame (150) and perform work on the frame (150).

[0126] Optionally, the workstation array (160) may further include workstations selected from the group consisting of: drilling workstation (116), finishing workstation (118), cutting workstation (120, 122), cutting workstation (124, 126), and additional NDI workstation (114) for checking the radius.

[0127] Optionally, the workstation array (160) includes a drilling workstation (116) arranged downstream of the NDI workstation (112) to drill the decisive component DA hole (155) into the longitudinal section (154) of the frame (150).

[0128] Optionally, the workstation array (160) includes a cutting station (122) arranged downstream of the drilling station (116) to trim the longitudinal section (154) of the frame (150) to form a reference plane at the frame (150).

[0129] Optionally, the workstation array (160) includes a cutting station (126) located downstream of the cutting station (122) to cut a mouse hole (152) from the longitudinal section (154) of the frame (150).

[0130] Optionally, the NDI station (112) inspects the web and flange of the frame (150), and the system also includes an additional NDI station (114) that inspects the radius of the frame (150).

[0131] Optionally, the system may also include an additional spiral stack (1760).

[0132] Optionally, the drive unit (102) advances the frame (150) by causing the frame (150) to pulse through the station at a distance less than the length of the frame (150).

[0133] In another example according to this disclosure, a part of the production of the aircraft (10) is performed using a system according to one of the aforementioned systems.

[0134] According to one aspect of this disclosure, a method for manufacturing a frame (150) for an aircraft (10) is disclosed, the method comprising the following steps:

[0135] A receiving frame (150) includes a web (564), a shear train foot (562), and a sacrificial material (554) that increases the thickness of the shear train foot (562).

[0136] The shear system foot (562) is cut to a thickness that corresponds to the holding length of the fastener (510) in combination with the thickness of the skin (50).

[0137] The shear system foot (562) is disposed against the inner mold line of the skin (50); and

[0138] The fastener (510) is installed through the skin (50) and the frame (150) to secure the frame (150).

[0139] Alternatively, the cutting is made such that the thickness is equal along the length of the frame (150), thereby producing a common holding length for the various fasteners (510) mounted through the skin (50) and the frame (150).

[0140] Optionally, the method further includes:

[0141] The additional frame (150) is cut to present a thickness equal to the length of the additional frame (150).

[0142] Alternatively, fasteners (50) are installed to secure the frame (150) to a section of the skin (50) to form a section of the fuselage (28).

[0143] Optionally, cutting the shear system foot (562) includes removing sacrificial material (554) from the shear system foot (562).

[0144] Optionally, the method further includes:

[0145] By counterspinning the sacrificial material (554) from the foot (562) of the shear system member, a common holding length of the frame (150) is obtained.

[0146] Optionally, the step of installing the fastener (510) includes installing the fastener (510) through the shear member foot (562).

[0147] Optionally, the step of cutting the shear system foot (562) includes operating a station of cutting the shear system foot (562) as the frame (150) advances along a curved path. Optionally, one or more stations remove sacrificial material (554) from the shear system foot (562).

[0148] Optionally, the curved path has a radius corresponding to the radius of the frame (150).

[0149] Optionally, the method further includes:

[0150] The frame (150) is made to pulsate along the curved path by a distance less than its length. Alternatively, this can be achieved by physically interlocking the tool (159) that carries the frame (150).

[0151] Optionally, the work performed on the frame (150) occurs during a pause between pulses of the frame (150).

[0152] Alternatively, the work performed on the frame (150) is performed while the frame (150) is pulsating.

[0153] Optionally, work on the frame (150) is performed as the frame (150) advances continuously.

[0154] Optionally, the step of removing the sacrificial material (554) includes removing the glass fiber from the shear member foot (562).

[0155] According to one aspect of this disclosure, a portion of the aircraft (10) is assembled according to the method of any of the foregoing examples.

[0156] According to one aspect of this disclosure, a system for manufacturing a frame (150) of an aircraft (10) is disclosed, the system comprising:

[0157] The workstation array (160) is configured in an arc shape corresponding to the shape of the frame (150), including:

[0158] Cutting stations (120, 122) that remove sacrificial material (554) from the frame (150); and

[0159] The drive unit (102) causes the frame (150) to move forward through the workstation.

[0160] Optionally, by physically interlocking with the tool (159) of the supporting frame (150), the drive unit (102) causes the frame (150) to advance by pulses through the station at distances less than its length. Optionally, the cutting stations (120, 122) are configured to remove sacrificial material (554) during pauses between pulses of the frame (150).

[0161] Optionally, the cutting stations (120, 122) are configured to remove sacrificial material as the frame (150) advances during pulsation.

[0162] Optionally, the drive unit (102) is configured to cause the frame (150) to undergo circular motion. Optionally, the circular motion follows an arc with a radius corresponding to the radius of the frame (150).

[0163] Optionally, the cutting stations (120, 122) are configured to remove sacrificial material (554) from the shear system foot (562) of the frame (150).

[0164] Optionally, the cutting stations (120, 122) are configured to remove the sacrificial material (554) to a thickness corresponding to the length of the shank of the fastener (510) in combination with the thickness of the surface layer (50).

[0165] Optionally, the system further includes:

[0166] The cutting station (124, 124), located downstream of the cutting station (120, 122), is used to cut a rat hole (152) from the frame (150).

[0167] Optionally, the system further includes:

[0168] NDI stations (112, 114) and inspection frame (150). Optionally, the NDI stations (112, 114) are located upstream of the cutting stations (120, 122). Optionally, the NDI stations (112, 114) are located downstream of the cutting stations (120, 122).

[0169] Optionally, the frame (150) includes a manufacturing allowance (157) and a shifting feature (158) disposed at the manufacturing allowance (157).

[0170] Optionally, the drive unit (102) is connected to the manufacturing allowance (157) of the frame (150).

[0171] Optionally, the sacrificial material (554) includes glass fiber.

[0172] According to one aspect of this disclosure, a portion of a system for manufacturing an aircraft (10) using one of the foregoing examples is disclosed.

[0173] While specific embodiments are described herein, the scope of this disclosure is not limited to those specific embodiments. The scope of this disclosure is defined by the appended claims.

Claims

1. A method for manufacturing a frame (150) for an aircraft (10), the method comprising the steps of: Receive frame (150); The frame (150) is advanced through one of the workstations in an arc-shaped array (160) and / or through a series of workstations arranged in a spiral corresponding to the shape of the frame (150). as well as The method further includes performing work on the frame (150) via at least one of the workstations: The workstation is shifted to the shift feature (158) at the manufacturing allowance (157) of the frame (150). The processing station is connected to the frame (150) so that the processing station moves forward with the frame (150); As the frame (150) advances along the arc, work is performed on the frame (150) via the machining station; and Return the processing station to its starting position.

2. The method according to claim 1, wherein: The step of advancing the frame (150) includes physically interlocking the drive unit (102) to the manufacturing allowance (157) of the frame (150).

3. The method according to claim 1 or 2, wherein: The arc corresponds to the shape of the frame (150).

4. The method according to claim 1 or 2, wherein: The frame (150) advances through the workstation array (160); and The steps of performing work on the frame (150) are completed simultaneously on different sections (154) of the frame (150) via the workstation array (160).

5. The method according to claim 1 or 2, wherein: The frame (150) advances through multiple workstations in the workstation array (160); and The steps of performing work on the frame (150) are completed simultaneously on different sections (154) of the frame (150) via multiple workstations in the workstation array (160).

6. The method according to claim 1 or 2, wherein: The steps of performing work on the frame (150) are completed simultaneously on different sections (154) of the frame (150) via the series of workstations.

7. The method according to claim 1 or 2, wherein: The step of advancing the frame (150) includes pulsating the frame (150) through the workstation at a distance less than the length of the frame (150).

8. The method of claim 1 or 2, wherein, The step of advancing the frame (150) includes moving the frame (150) continuously through the workstation.

9. The method according to claim 1 or 2, wherein: The step of moving the frame (150) forward includes making the frame (150) move in a circular motion and / or a spiral motion.

10. The method according to claim 1 or 2, wherein: The frame (150) is held by a tool (159) including a rotation feature (158) and moves forward through the workstation array (160).

11. The method according to claim 1 or 2, wherein: The step of advancing the frame (150) includes attaching the drive unit (102) to the manufacturing allowance (157) of the frame (150).

12. The method according to claim 1 or 2, wherein: The frame (150) is moved along an arc to the starting position at a length less than its length.

13. The method of claim 1 or 2, wherein, The work includes drilling holes in parts of the frame (150).

14. The method according to claim 1 or 2, wherein: The step of advancing the frame (150) includes pulsating the frame (150) through the workstation at a distance equal to the length of the frame (150).

15. The method according to claim 1 or 2, wherein: The steps of performing work on the frame (150) occur during pauses between pulses of the frame (150).

16. The method according to claim 1 or 2, wherein: The steps of performing work on the frame (150) are performed as the frame (150) advances during pulsation.

17. The method according to claim 9, wherein: The circular motion follows an arc with a radius corresponding to the radius of the frame (150), or the spiral motion follows an arc with a radius corresponding to the radius of the frame (150).

18. The method of claim 10, further comprising: While the tool (159) carries the frame (150), the drive unit (102) is interlocked with the tool (159).

19. The method according to claim 11, wherein: The connection includes physically interlocking the drive unit (102) to the manufacturing allowance (157).

20. A system for producing a frame (150) of an aircraft (10), the system comprising: A workstation array (160), the workstation array being arranged in an arc shape and simultaneously performing work on the frame (150), and / or the system comprising: Spiral stack (1750), the spiral stack comprising: A curved track (1720) that advances vertically in a spiral shape at a spiral angle; and A workstation (1722) arranged along the curved track (1720) performs work on the frame (150) as the frame (150) moves along the curved track (1720); and A drive unit (102) that causes the frame (150) to advance through the station, and the drive unit (102) is configured to rotate the station to a rotation feature (158) at a manufacturing allowance (157) of the frame (150). The workstation is configured to perform the method according to any one of claims 1 to 19.

21. The system of claim 20, wherein, The drive unit (102) causes the frame (150) to advance along an arc through the workstation array (160); and the system further includes: Non-destructive inspection NDI station (112), the NDI station inspects the longitudinal section (154) of the frame (150); and The workstation array (160) includes workstations that are transposed to the frame (150) and perform work on the frame (150).

22. The system according to claim 21, wherein, The workstation array (160) also includes workstations selected from the group consisting of: drilling workstation (116), finishing workstation (118), cutting workstation (120, 122), cutting workstation (124, 126) and additional NDI workstation (114) for checking the radius.

23. The system of claim 21, wherein, The workstation array (160) includes a drilling station (116) located downstream of the NDI workstation (112) in a longitudinal section (154) for drilling the decisive component DA hole (155) into the frame (150).

24. The system of claim 23, wherein, The work station array (160) includes a cutting station (122) located downstream of the drilling work station (116) for trimming the longitudinal section (154) of the frame (150) to form a reference plane at the frame (150).

25. The system of claim 24, wherein, The workstation array (160) includes a cutting station (126) located downstream of the cutting station (122) for cutting a rat hole (152) from a longitudinal section (154) of the frame (150).

26. The system of claim 21, wherein, The NDI station (112) inspects the web and flange of the frame (150), and the system also includes an additional NDI station (114) that inspects the radius of the frame (150).

27. The system of claim 20, further comprising an additional helical stack (1760).

28. The system of claim 20, wherein, The drive unit (102) advances the frame (150) by causing the frame (150) to pulsate through the workstation at a distance less than the length of the frame (150).

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