Methods, systems, devices, and media for inconsistency checking structures

Abstract

This application relates to methods, systems, apparatuses, and media for inspecting structures for inconsistencies. Systems and methods for inspecting an aircraft fuselage are provided. A non-destructive inspection (NDI) station inspects a section of the fuselage through a pulsing line assembly technique. After each pulse, the section of the fuselage is moved less than its length, and one or more NDI stations are positioned at different portions of the section to inspect the section of the fuselage for out-of-tolerance conditions. A method for inspecting a structure for inconsistencies includes advancing the structure along a track in a process direction through a non-destructive inspection (NDI) station, indexing the structure to the NDI station, and inspecting the structure using the NDI station.

Description

Technical Field

[0001] This invention relates to the field of assembly, and more particularly to the assembly of racks. Background Technology

[0002] The frame defines the mechanical structure of an aircraft. The frame is made of multiple components that provide the required structural performance. For example, a portion of the frame for an aircraft fuselage may include frames, skins, and longitudinal beams mechanically joined together according to design parameters (e.g., via co-bonding, co-curing, or fasteners). As currently practiced, the components of the frame are manufactured and assembled in predetermined units on a factory floor. For example, prefabricated components for an aircraft fuselage section may be hardened into composite parts in one unit and then transferred to a new unit dedicated solely to the inspection process. The composite parts are then scanned and rotated as part of the inspection process.

[0003] While the manufacturing process described above is reliable, delays occur when work on specific parts of a component is completed more slowly than expected. For example, if a particular part of a fuselage section takes longer than expected to install the frame, the entire section remains in the unit until all delayed work is completed, or the entire section is moved out of the unit, where the delayed work is completed outside the unit.

[0004] Therefore, there is a need for a method and apparatus that takes into account the above-mentioned problems as well as other possible problems. Summary of the Invention

[0005] The embodiments described herein provide non-destructive inspection (NDI) stations that inspect sections of the fuselage that have been manufactured using pulsed assembly technology. After each pulse, a section of the fuselage is moved less than the length of the fuselage, and one or more NDI stations located at different parts of that section inspect the section for out-of-tolerance conditions. This technique provides technical benefits by integrating the transport process into the inspection process.

[0006] One implementation is a method for inspecting an inconsistency structure, comprising: advancing the structure along a trajectory in a process direction through a non-destructive testing (NDI) station; rotating the structure toward the NDI station; and inspecting the structure at the NDI station.

[0007] Another embodiment is a non-transitory computer-readable medium containing programmable instructions operable, when executed by a processor, to perform a method for inspecting a non-conformity structure. The method includes: advancing the structure along a track in a process direction through a non-destructive testing (NDI) station; transposing the structure toward the NDI station; and inspecting the structure using the NDI station.

[0008] Another embodiment is a system for inspecting inconsistencies in structures, comprising a track and a non-destructive testing (NDI) station that advances the structure along the track in the process direction during manufacturing. The NDI station is located at the track and is designed for inspecting inconsistencies in structures. The NDI station includes at least one NDI head that characterizes the internal features of the cross-section of each structure.

[0009] Another embodiment relates to an apparatus for inspecting inconsistencies in a structure, comprising a non-destructive testing (NDI) station. The NDI station includes a frame, at least one NDI end mounted to the frame, a track for advancing the structure relative to the NDI end, and a transfer system for transmitting information about the structure within the range of the NDI station.

[0010] 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.

[0011] The instruction manual also includes the following clauses:

[0012] 1. A method (200) for checking inconsistencies in a structure, the method (200) comprising:

[0013] The structure is advanced (202) along the track (110, 110-1) in the process direction (199, 199-1) through the non-destructive inspection station (140, 140-1);

[0014] The structure is rotated (204) to the NDI station (140, 140-1); and

[0015] The structure described in (206) is inspected using the NDI station (140, 140-1).

[0016] 2. The method (200) according to Clause 1, wherein:

[0017] The inspection (206) of the structure includes operating the NDI end (150, 150-1) at the NDI station (140, 140-1) to characterize the internal features of the cross-section of the structure.

[0018] 3. The method (200) according to clause 1 or 2, wherein:

[0019] Advancing (202) the structure includes making the structure pulsate less than the length of the structure; and repeatedly performing the steps of advancing (202) the structure, transposing (204) the structure, and inspecting (206) the structure to characterize multiple cross sections of the structure along the length of the structure.

[0020] 4. The method (200) according to any one of clauses 1 to 3, wherein:

[0021] Perform structural checks during pauses between structural pulses (206).

[0022] 5. The method (200) according to any one of clauses 1 to 4, wherein:

[0023] The inspection (206) of the structure includes operating an NDI end array arranged at the NDI station (140, 140-1) to follow the contour of the structure, and the method further includes combining inputs from the NDI end array (150, 150-1) to generate an image of the cross-section of the structure.

[0024] 6. The method according to any one of clauses 1 to 5, wherein the method further comprises:

[0025] While manipulating the NDI end (150, 150-1), advance the NDI end (150, 150-1) along the contour of the structure.

[0026] 7. The method (200) according to any one of clauses 1 to 6, said method further comprising:

[0027] Detecting conditions exceeding tolerance based on the internal characteristics of this structure; and

[0028] The report indicates a situation exceeding the tolerance limit, which will be used for rework.

[0029] 8. The method (200) according to any one of clauses 1 to 7, wherein:

[0030] The examination (206) structure includes performing operations selected from the group consisting of ultrasound pulse echo examination and transmission ultrasound examination of the structure.

[0031] 9. The method (200) according to any one of clauses 1 to 8, said method further comprising:

[0032] A model of the structure is generated based on the input from the NDI station (140, 140-1);

[0033] Align the model with the design of the structure; and

[0034] Identify the differences between the model and the design of the structure.

[0035] 10. The method (200) according to any one of clauses 1 to 9, wherein:

[0036] Advance (202) the structure along the process direction (199, 199-1) so that the structure moves through the workstation where the work is performed on the structure.

[0037] 11. A portion of an aircraft assembled according to any one of clauses 1 to 10.

[0038] 12. A non-transient computer-readable medium comprising programming instructions that, when executed by a processor, are operable for performing a method (200) for an inconsistency checking structure, the method (200) comprising the steps of:

[0039] The structure is advanced (202) along the track (110, 110-1) in the process direction (199, 199-1) through the non-destructive inspection station (140, 140-1);

[0040] To rotate the structure to the NDI station (140, 140-1) (204); and

[0041] The structure described in (206) is inspected using the NDI station (140, 140-1).

[0042] 13. The medium as described in Clause 12, wherein:

[0043] The steps of inspecting the structure (206) include: operating the NDI end (150, 150-1) at the NDI station (140, 140-1) to characterize the internal features of the cross-section of the structure.

[0044] 14. The medium as described in Clause 12 or 13, wherein:

[0045] The step of advancing (202) the structure includes: making the pulsation of the structure less than the length of the structure; and

[0046] The steps of advancing (202), transposing (204), and inspecting (206) the structure are repeatedly performed to characterize multiple cross sections of the structure along its length.

[0047] 15. The medium as described in Clause 12 or 13, wherein:

[0048] The step of advancing (202) the structure includes: making the pulsation of the structure less than the length of the structure; and

[0049] The steps of advancing (202), rotating (204), and inspecting the structure are repeatedly performed to characterize multiple cross sections of the structure along its length.

[0050] 16. The medium as described in Clause 12, wherein:

[0051] The steps of inspecting the structure (206) include: manipulating an array of NDI terminals (150, 150-1) arranged at NDI stations (140, 140-1) to follow the contour of the structure, and the method further includes the step of: combining the inputs from the array of NDI terminals (150, 150-1) to generate an image of the cross-section of the structure.

[0052] 17. The medium according to any one of clauses 12 to 16, wherein the method further comprises the following steps:

[0053] While manipulating the NDI end (150, 150-1), advance the NDI end (150, 150-1) along the contour of the structure.

[0054] 18. The medium according to any one of clauses 12 to 17, wherein the method further comprises the following steps:

[0055] Detecting conditions exceeding tolerance based on the internal characteristics of this structure; and

[0056] The report indicates a situation exceeding the tolerance limit, which will be used for rework.

[0057] 19. The medium according to any one of clauses 12 to 18, wherein:

[0058] The steps for examining the (206) structure include performing an operation selected from the group consisting of ultrasound pulse echo examination and transmission ultrasound examination of the structure.

[0059] 20. The medium according to any one of clauses 12 to 19, wherein the method further comprises the following steps:

[0060] A model of the structure is generated based on the input from the NDI station (140, 140-1);

[0061] Align the model with the design of the structure; and

[0062] Identify the differences between the model and the design of the structure.

[0063] 21. The medium according to any one of clauses 12 to 20, wherein:

[0064] Advance (202) the structure along the process direction (199, 199-1) so that the structure moves through the workstation where the work is performed on the structure.

[0065] 22. A part of an aircraft assembled according to the method defined by instructions stored on a computer-readable medium of any of Articles 12 to 21.

[0066] 23. A system (100) for inconsistency checking structures, the system (100) comprising:

[0067] Tracks (110, 110-1) that advance the structure along the track in the process direction (199, 199-1) during manufacturing; and

[0068] A non-destructive inspection (NDI) station (140, 140-1), located at the track (110, 110-1) and used for inspecting the structure for inconsistencies, the NDI station (140, 140-1) includes:

[0069] At least one NDI end (150, 150-1) characterizes the internal features of the cross-section of each structure.

[0070] 24. The system (100) as described in Clause 23, wherein:

[0071] The at least one NDI terminal (150, 150-1) includes:

[0072] Ultrasonic transducer (154, 154-1);

[0073] A flexible surface (155, 155-1) that elastically deflects to conform to the contour of the structure;

[0074] Feed lines (152, 152-1), the feed lines being filled with liquid into the chambers (156, 156-1) between the ultrasonic transducers (154, 154-1) and the flexible surfaces (155, 155-1); and

[0075] An adjustable connector (158, 158-1) is provided, which allows the at least one NDI end (150, 150-1) to deflect relative to the NDI station (140, 140-1) when the NDI head (150, 150-1) follows the contour.

[0076] 25. The system (100) as described in Clause 24, wherein:

[0077] The adjustable connector (158, 158-1) includes a motion chain that operates according to instructions in a numerical control (NC) program to advance the at least one NDI end (150, 150-1) along the contour of the structure.

[0078] 26. The system (100) described in accordance with clause 23 or 24, wherein:

[0079] The at least one NDI terminal (150, 150-1) comprises an array of NDI terminals (150, 150-1) arranged along an arc of a frame (159, 159-1), the arc of which follows the contour of the structure.

[0080] 27. The system (100) according to Clause 26, wherein:

[0081] The arc along the frame (159, 159-1) follows the inner mold line (IML) of the structure.

[0082] 28. The system (100) as described in Clause 26, wherein:

[0083] The arc along the frame (159, 159-1) follows the outer mold line (OML) of the structure.

[0084] 29. The system (100) according to any one of clauses 23 to 28, wherein:

[0085] The at least one NDI terminal (150, 150-1) is translatable.

[0086] 30. To manufacture a part of an aircraft using the system (100) pursuant to any one of clauses 23 to 29.

[0087] 31. An apparatus for checking inconsistencies in a structure, the apparatus comprising:

[0088] Non-destructive testing (NDI) stations (140, 140-1), wherein the NDI stations (140, 140-1) include:

[0089] Frame (159, 159-1);

[0090] At least one NDI terminal (150, 150-1), said at least one NDI terminal is mounted to the frame;

[0091] Tracks (110, 110-1), said tracks being propulsion structures relative to said at least one NDI end (150, 150-1); and

[0092] The indexing system is used to transmit information about the structure within the field of view of the NDI station (140, 140-1).

[0093] 32. The apparatus according to clause 31, wherein:

[0094] The at least one NDI terminal (150, 150-1) includes:

[0095] Ultrasonic transducer (154, 154-1);

[0096] Flexible surface (155, 155-1);

[0097] The chamber (156, 156-1) is located between the ultrasonic transducer (154, 154-1) and the flexible surface (155, 155-1).

[0098] The feed line (152, 152-1) is filled with liquid into the chamber (152, 152-1); and

[0099] An adjustable connector (158, 158-1) is provided between the ultrasonic transducer (154, 154-1) and the NDI station (140, 140-1).

[0100] 33. The device according to Clause 32, wherein the flexible surface (155, 155-1) is elastically deflected to conform to the contour of the structure.

[0101] 34. The device according to clause 32 or 33, wherein, when the at least one NDI end (150, 150-1) follows the contour of the structure, the adjustable connector (158, 158-1) enables the at least one NDI end (150, 150-1) to deflect relative to the NDI station (140, 140-1).

[0102] 35. The apparatus according to clause 32 or 34, wherein:

[0103] The adjustable connector (158, 158-1) includes a motion chain that operates according to instructions in a numerical control (NC) program to advance at least one NDI end (150, 150-1) along the contour of the structure.

[0104] 36. The equipment according to any one of clauses 32 to 35, wherein:

[0105] The at least one NDI terminal (150, 150-1) comprises an array of NDI terminals (150, 150-1) arranged in an arc along the frame (159, 159-1).

[0106] 37. The apparatus according to clause 36, wherein:

[0107] The array of NDI terminals (150, 150-1) follows the contour of this structure.

[0108] 38. The apparatus described in clause 36 or 37, wherein:

[0109] The arc along the frame (159, 159-1) follows the inner mold line (IML) of the structure.

[0110] 39. The equipment according to any one of clauses 36 to 38, wherein:

[0111] The arc along the frame (159, 159-1) is complementary in shape to the IML.

[0112] 40. The equipment according to any one of clauses 36 to 39, wherein:

[0113] The arc along the frame (159, 159-1) follows the outer mold line (OML) of the structure.

[0114] 41. The equipment according to any one of clauses 36 to 40, wherein:

[0115] The arc along the frame (159, 159-1) is complementary in shape to OML.

[0116] 42. The equipment according to any one of clauses 31 to 41, wherein:

[0117] The at least one NDI terminal (150, 150-1) is translatable.

[0118] 43. The apparatus according to clause 42, wherein:

[0119] The at least one NDI end (150, 150-1) can be translated along the arc of the frame (159, 159-1).

[0120] 44. To manufacture a part of an aircraft using the equipment pursuant to any one of clauses 33 to 43. Attached Figure Description

[0121] 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.

[0122] Figure 1 This is an illustration of an aircraft that can be implemented in an illustrative manner.

[0123] Figure 1A and Figure 1BIt is a block diagram of an assembly line including the non-destructive testing (NDI) station in the illustrative embodiment.

[0124] Figure 2 This is a flowchart illustrating a method for operating an assembly line to inspect fuselage sections in an illustrative embodiment.

[0125] Figure 3A and Figure 3B This is a front view of the NDI station for inspecting the arc-shaped section of the machine body in the illustrative embodiment.

[0126] Figure 4 This is an enlarged view of the ultrasound examination in the illustrative embodiment.

[0127] Figure 5 The control components of the production system that performs ultrasonic examinations in the illustrative embodiment are shown broadly.

[0128] Figure 6 An example of a motion path that incorporates various operations that can be performed in the production of a composite component is shown in the illustrative embodiment.

[0129] Figure 7 This is a flowchart illustrating the aircraft production and service method in the illustrative implementation.

[0130] Figure 8 This is a block diagram of the aircraft in the illustrative implementation. Detailed Implementation

[0131] 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 arrangements that, while not explicitly 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.

[0132] The frame can be made of metal or can be realized as a composite component. Composite components (such as carbon fiber reinforced polymer (CFRP) components) are initially laid out in multiple layers, collectively referred to as a preform. 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. The preform may include a cured viscous resin to harden the preform into a composite component. 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 can be impregnated with resin before curing. For thermosetting resins, curing is a one-way process called curing, while for thermoplastic resins, if the resin is reheated, it can reach a viscous form.

[0133] Turn now Figure 1 , Figure 1 An illustration depicts an aircraft that can implement an illustrative embodiment. The aircraft 10 can be constructed from... Figure 1A An example of an aircraft formed by a semi-cylindrical section 24 of a fuselage 12. An example of an aircraft 10 formed by a semi-cylindrical section 24 of a fuselage 12.

[0134] In this illustrative example, the aircraft 10 has wings 15 and 16 attached to the fuselage 12. The aircraft 10 includes an engine 14 attached to the wing 15 and an engine 16 attached to the wing 16.

[0135] The fuselage 12 has a tail section 18 and a nose section 38. Horizontal stabilizers 20, 21 and 23 are connected to the tail section 18 of the fuselage 12.

[0136] The fuselage 12 is made of semi-cylindrical sections 24, wherein the upper semi-cylindrical sections 81-1, 81-2, 81-3, 81-4, and 81-5 are connected to the lower semi-cylindrical sections 79-1, 79-2, 79-3, 79-4, and 79-5 to form complete cylindrical sections 29-1, 29-2, 29-3, 29-4, and 29-5. The complete cylindrical sections 29-1 and 29-2 correspond to view AA, and the complete cylindrical section 29-5 corresponds to view BB, and are successively fastened to the fuselage 12.

[0137] Wings 15 and 16 are formed by wing panels including an upper wing panel 195-2 and a lower wing panel 195-1 connected together.

[0138] Figure 1AThis is a block diagram of assembly line 100, which includes a non-destructive testing (NDI) station 140 for a semi-cylindrical section 120 being manufactured in the illustrative embodiment. Assembly line 100 includes any system, equipment, device, or component operable to repeatedly advance a structure (e.g., a semi-cylindrical section 120 of a fuselage) along track 110, or to continuously move a structure along track 110. Full pulsation 118 advances the semi-cylindrical section 120 to its length or greater, or micro-pulsation 149 advances the semi-cylindrical section 120 to less than its length. Assembly line 100 is also capable of inspecting the semi-cylindrical section 120 by NDI inspection (e.g., visual, ultrasonic, laser, etc.) when the semi-cylindrical section 120 is paused between and / or during micro-pulsations 149, or when the semi-cylindrical section 120 is continuously moved in the process direction 199. Micro-pulsation 149 is configured to... Figure 1 The frame spacing 147 between the frames 146 is a fraction or multiple. In another embodiment, the NDI inspection is performed by fixed inspection devices that perform the inspection as the half-cylinder section 120 is advanced. Figure 1 The upper half-cylinder sections 81-1, 81-2, 81-3, 81-4, 81-5 and the lower half-cylinder sections 79-1, 79-2, 79-3, 79-4, 79-5 are fully assembled forms of half-cylinder sections 120 and are ready to be connected to other fully assembled upper or lower half-cylinder sections.

[0139] Half-tube section 120 comprises a portion of a frame approximately 20 feet to approximately 40 feet in length. Half-tube section 120 is shown as having a length 109, which is not shown to scale. Similarly, half-tube section 120 is shown as having a manufacturing excess 129, which is not shown to scale. Likewise, half-tube section 120 is shown relative to NDI stations 140 and 99 and micro-pulsation 149, which are not shown to scale. The manufacturing excess 129 is located above and includes the support edge 119. Another manufacturing excess 135 is material removed to form a window. In some embodiments, half-tube section 120 includes a hardened composite component, such as a section of aircraft skin awaiting the installation of longitudinal beams and frame 146 to enhance rigidity. Half-tube section 120 includes an outer mold line (OML) 122 and an inner mold line (IML) 128, and defines a concave surface 126 (in... Figure 1 (Clearly visible in the middle).

[0140] In this embodiment, assembly line 100 includes a track 110 on which a semi-cylinder section 120 moves along a process direction 199. The track 110 includes one or more guide rails 111, rollers 114, and supports 112, which facilitate the movement (e.g., rolling or sliding) of the semi-cylinder section 120 along the track 110. In another embodiment, the track 110 includes a chain drive, a motorized trolley, a power roller 114 on top of the support 112, or other power system capable of moving the semi-cylinder section 120 in the process direction 199.

[0141] Assembly line 100 also includes indexing units 130. Each indexing unit 130 is designed to be physically coupled to indexing features 124, such as machining features like holes or slots and / or additional features like pins in half-barrel sections 120. Indexing features 124 are positioned along half-barrel sections 120. In one embodiment, each indexing feature 124 is spaced a certain distance along half-barrel sections 120, for example, micro-pulsations 149 or a fraction or multiple thereof. In one embodiment, each of the indexing features 124 is spaced a different distance along half-barrel sections 120. In another embodiment, each of the indexing features 124 is not linearly aligned along the longitudinal direction 198 of the half-barrel section 120. In yet another embodiment, the indexing features 124 are arranged within manufacturing allowances 129, 135 of the half-barrel section 120, which are trimmed off before the half-barrel section 120 is put into service.

[0142] In other embodiments, radio frequency identification (RFID) is used for tracking during transposition. RFID tag 124-1 is located in manufacturing allowances 129, 135 as part of transposition feature 124. RFID scanner 134-1 is part of complementary feature 134. RFID tag 124-1 is installed alone or together with other transposition features 124 at a location optimal for transmitting transposition information to NDI station 140. RFID scanner 134-1 is installed alone or together with other complementary features 134 at a location optimal for communicating with transposition feature 124 including RFID tag 124-1 to transmit transposition information to NDI station 140. Transposition transmits information about the half-cylinder segment 120 within field of view 113 of NDI station 140. In such an implementation, the RFID tag 124-1 itself is used as a transposition feature 124 and is sequentially positioned (e.g., linearly or non-linearly aligned) on the manufacturing allowances 129, 135 of the half-section 120. The transposition feature 124 including the RFID tag 124-1 is aligned with complementary features 134 positioned relative to the NDI station 140 and the work station 99. The transposition feature 124 including the RFID tag 124-1 transmits details of the desired 3D characterization, representation, and / or orientation of the half-section 120's IML 128 and OML 122 to the controller 160 via the transposition unit 130. The operation of the track 110, the NDI station 140, the work station 99, and / or other components is managed by the controller 160. In some implementations, these transposition features 124 including the RFID tag 124-1 also include instructions for the operations performed by the NDI station 140 and the work station 99. For example, in embodiments where work is performed simultaneously at NDI station 140 and / or work station 99 within the field of view 113, 113-1 of half-cylinder section 120. One embodiment has upper half-cylinder sections 81-1, 81-2, 81-3, 81-4, 81-5, followed by lower half-cylinder sections 79-1, 79-2, 79-3, 79-4, 79-5, which advance sequentially along assembly line 100. Another embodiment has a single-model half-cylinder section 120, followed by half-cylinder sections 120 of different models. The indexing feature 124 on each half-cylinder segment 120 communicates to the NDI station 140 and / or the work station 99 what work (if any) needs to be performed on a specific segment within the field of view 113, 113-1 when it pauses between or during micro-pulses 149 at the NDI station 140 and / or the work station 99. The indexing feature 124 also transmits OML 122 and IML 128 information during indexing.

[0143] In one implementation, controller 160 determines the progress of half-cylinder segment 120 along track 110 based on indexing input from a technician or on artificial intelligence of the automated process (e.g., input from a camera or physical sensor, such as a linear or rotary actuator). Based on the indexing information transmitted to NDI station 140 and / or work station 99, operations are performed on half-cylinder segment 120 in fields of view 113, 113-1 at NDI station 140 and / or work station 99, respectively. Controller 160 then instructs NDI station 140 and / or work station 99. Controller 160 uses this input to manage the operation of half-cylinder segment 120 in fields of view 113, 113-1 at NDI station 140 and / or work station 99 according to instructions stored in a numerical control (NC) program. Controller 160 may be implemented as, for example, custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

[0144] In this embodiment, each indexing unit 130 includes a complementary feature 134 for insertion into, holding, or otherwise engaging with the indexing feature 124. The complementary feature 134 for insertion, holding, or otherwise engaging with the indexing feature 124 provides a hard stop at the end of the micro-pulse 149. The indexing unit 130 is positioned relative to the NDI station 140 and / or the work station 99 and the track 110. The indexing unit 130 is fixed relative to the NDI station 140 and / or the work station 99 to achieve a hard stop at the end of the micro-pulse 149. The indexing unit 130 is not fixed relative to the NDI station 140 and / or the work station 99 for indexing during the micro-pulse 149 or continuous assembly. One embodiment includes a semi-cylindrical segment 120 with micro-pulsations 149, the distance of which is at least equal to the shortest distance between the indexing features 124, and is indexed to the indexing unit 130 and processed by the NDI station 140. That is, the semi-cylindrical segment 120 is indexed as part of the micro-pulsations 149 or as part of a continuous system. The position of the semi-cylindrical segment 120 is indexed to a known position as long as the indexing features 124 in the semi-cylindrical segment 120 and the complementary features 134 in the indexing unit 130 are paired, and the 3D characterization, representation, and / or orientation of the semi-cylindrical segment 120 relative to the track 110, the indexing unit 130, and the NDI station 140 and / or the work station 99 are known. Specifically, one embodiment has each indexing unit 130 located at a known offset (O) from the NDI station 140 and / or the work station 99 (e.g., along three axes), meaning that the action of indexing the half-cylinder segment 120 toward the indexing unit 130 results in the position of the OML 122 and / or IML 128 of the half-cylinder segment 120 relative to the NDI station 140 being known. This embodiment is illustrated with indexing units 130 offset (O) from the NDI station 140. Another embodiment has each indexing unit 130 located without offset (O) from the NDI station 140 and / or the work station 99. This embodiment shows an indexing unit 130 at the work station 99. With or without offset relative to NDI station 140 and / or work station 99, the rotation of half-cylinder section 120 toward indexing unit 130 such that the position of half-cylinder section 120 relative to OML 122 and / or IML 128 relative to NDI station 140 is known.

[0145] In one embodiment, the indexing is performed at least according to the following description. A structure in the form of a semi-cylindrical segment 120 is supported on a track 110, which includes guide rails 111 embedded in or connected to a floor 108. The track 111 is positioned relative to the indexing unit 130 and NDI station 140 and / or station 99. The semi-cylindrical segment 120 has been manufactured to precise dimensions on a lamination mandrel 622 ( Figure 6The precise stacking allows the indexing feature 124 to be precisely positioned within the manufacturing allowance 129 of the semi-cylinder segment 120. Coarse finishing of the semi-cylinder segment 120 occurs on the stacking mandrel 622. The manufacturing allowance 129 is partially trimmed to form the support edge 119. Thus, once the support edge 119 of the semi-cylinder segment 120 is positioned on the precisely positioned track 111, the micro-pulsation 149 of the semi-cylinder segment 120 passes through NDI station 140 and / or station 99. When the indexing feature 124 is engaged, the 3D characterization, representation, and / or orientation of the semi-cylinder segment 120 is precisely known without requiring a full scan at each micro-pulsation 149 using probes or optical techniques via NDI station 140 and / or work station 99. In another embodiment, the NDI check is used as an initial station during the processing of the half-cylinder section 120 to perform an initial baseline scan during micro-pulsations 149, during pauses between micro-pulsations 149, or both, or during continuous movement. This baseline scan is used in subsequent processing of the half-cylinder section 120 and is transferred to the work station 99 during subsequent indexing.

[0146] The relative stiffness of the semi-cylindrical segment 120, formed by demolding or otherwise, helps it retain the required IML 128 and / or OML 122, as well as the precisely positioned railing 111 and precisely positioned support edge 119, for micro-pulsation 149 of the semi-cylindrical segment 120, during which no basic-shape tools are required for assembly. In this arrangement, the indexing feature 124 is precisely positioned relative to the IML 128 and / or OML 122 within the semi-cylindrical segment 120, and the precisely positioned track 111 helps to transport the semi-cylindrical segment 120 across the NDI station 140 through station 99 in the process direction 199 without deformation. Therefore, the 3D characterization, representation, and / or orientation of the semi-cylindrical segment 120 within the field of view 113, 113-1, including the OML 122 and / or IML 128, can be quickly and accurately obtained from the NDI station 140 and / or the work station 99. This information is transmitted via the controller 160 after each micropulse 149 via a transposition, without requiring a rescan of the field of view 113, 113-1 of the semi-cylindrical segment 120 each time. In this way, the 3D representation, representation, and / or orientation of the OML 122 and / or IML 128 of the semi-cylindrical segment 120 at a specific portion within the field of view 113, 113-1 of the NDI station 140 and / or the work station 99 is rapidly transmitted to that specific station.

[0147] Due to the precise indexing performed, tools at NDI station 140 and each station 99 can be positioned as needed relative to the OML 122 and / or IML 128 of the half-tube segment 120 when the half-tube segment 120 is positioned by the micro-pulsation 149. During pauses between micro-pulsations 149, tools and technicians can rapidly position themselves relative to the OML 122 and / or IML 128 within NDI station 140 and work station 99, improving throughput and efficiency. The 3D characterization, representation, and / or orientation of the half-tube segment 120 within the OML 122 and / or IML 128 of the half-tube segment 120 in the field of view 113, 113-1 is then established or indexed to any CNC programming or automation system used at NDI station 140 and / or work station 99. Therefore, no setup time in the form of a scan is required after each micropulse 149 exposing the field of view 113, 113-1 of the semi-cylindrical section 120 within the NDI station 140 or work station 99. Similarly, no setup time is required during the micropulse 149, or during the pause between micropulses 149, or both, for bringing tools and technicians to the field of view 113, 113-1 of the semi-cylindrical section 120 within the NDI station 140 or work station 99. In some embodiments, a plurality of sequentially arranged NDI stations 140 and / or work stations 99 perform work on the semi-cylindrical section 120 during the same pause between micropulses 149. In one embodiment, the first station in the sequentially arranged stations is the NDI station 140. Furthermore, structures added to or removed from the semi-cylinder section 120 in the previous work station 99 can be added to the electronic model or representation of the semi-cylinder section 120 within the system and transmitted via transposition without needing to scan changes in the semi-cylinder section 120 after and / or during the micro-pulsation 149.

[0148] In other words, the indexing of the semi-cylinder segment 120 can be performed by aligning the indexing feature 124 with the indexing unit 130. The NDI station 140 and the indexing unit 130 have a known positional relationship. When they are in a known relationship, the NDI end 150, located within the NDI station 140, is inherently indexed toward the semi-cylinder segment 120 because the NDI end 150 is already in a known relationship with the NDI station 140. Therefore, indexing the semi-cylinder segment 120 involves mates the indexing feature 124 at the semi-cylinder segment 120 with the complementary feature 134 at the indexing unit 130, which has a known physical offset from the NDI station 140, such that the mate immediately results in the OML 122 and IML 128 of the semi-cylinder segment 120 having a known position relative to the NDI station 140. This relationship is because the complementary feature 134 at the indexing unit 130 is pre-positioned and its dimensions are determined to suit the semi-cylinder segment 120 in a specific and precisely defined position. In another embodiment, the indexing unit 130 includes a camera, laser, acoustic sensor, or other components that index the semi-cylindrical section 120 without physically connecting it to the indexing feature 124 of the semi-cylindrical section 120.

[0149] In another embodiment, tracking is performed by scanning RFID tags 124-1, which are mounted on manufacturing allowances 129, 135 of the semi-cylinder section 120 and are read as part of the rotation of the field of view 113, 113-1 of the semi-cylinder section 120 within a specific NDI station 140 and / or work station 99. The RFID tags 124-1 are rotation features 124 and are sequentially positioned, but linear alignment on the manufacturing allowance 129 of the semi-cylinder section 120 is not required. In one embodiment, each RFID tag 124-1 serving as a rotation feature 124 is aligned with each of the sequentially positioned plurality of NDI stations 140 and / or work stations 99 and conveys details of the 3D characterization, representation, and / or orientation of the semi-cylinder section 120, as well as instructions for the work performed at the NDI station 140 and / or work station 99. As needed, NDI station 140 and / or work station 99 operate within the field of view 113, 113-1 of the semi-cylindrical section 120, followed by different semi-cylindrical sections 120, and then different or the same type of aircraft, or different or the same type of aircraft as the previous two sections. RFID tag 124-1 interprets for the work station what work (if any) should be performed on a specific section of the NDI work station 140 or work station 99 that is pulsating through it. NDI station 140 includes one or more NDI ends 150, 150-1. NDI ends 150, 150-1 characterize the internal inconsistency 430 of the cross-section of each semi-cylindrical section 120 advancing along track 110. Figure 4The segments are mounted (e.g., fixedly or movably) to frames 159, 159-1. Frame 159 is located in a concave surface 126, and when the semi-cylindrical segment 120 micro-pulsations 149 pass through the NDI station 140 and are above frame 159, frame 159 has a shape complementary to IML 128. When the semi-cylindrical segment 120 micro-pulsations 149 pass through the NDI station 140 and are below frame 159-1, frame 159-1 has a shape complementary to OML 122. NDI ends 150, 150-1 characterize the internal inconsistencies 430 of the cross-section of each of a series of semi-cylindrical segments 120 having uniform or non-uniform shapes that advance along the track passing through the NDI station 140. Internal inconsistencies 430 include voids, foreign matter fragments, resin-rich areas, resin-poor areas, etc.

[0150] In one embodiment, NDI ends 150, 150-1 are arranged in arrays 157 along frame 159 and 157-1 along frame 159-1, respectively. In one embodiment, each NDI end 150, 150-1 is movable in an arcuate manner along frame 159, 159-1 and within field of view 113 relative to semi-cylindrical section 120. The movement of NDI ends 150, 150-1 is synchronized to prevent collisions. For example, NDI ends 150, 150-1 may move clockwise and then synchronously counterclockwise within field of view 113 complementary to semi-cylindrical section 120, while semi-cylindrical section 120 is in micro-pulsations 149 or paused between micro-pulsations 149 and / or both. In another embodiment, NDI ends 150, 150-1 are arranged in arrays 157, 157-1. In another embodiment, the movement of NDI ends 150, 150-1 relative to the half-section 120 is provided by the movement of the half-section 120 along the assembly line 100. During micro-pulsations 149 or pauses between micro-pulsations 149, an NDI station 140 scan is performed on the half-section 120 within a range 113 of the NDI ends 150, 150-1. Therefore, the entire NDI scan is the sum of one or more scans acquired while within the field of view 113 of the half-section 120, regardless of whether the movement relative to the half-section 120 is full pulsation 118, micro-pulsation 149, or continuous relative to the half-section 120 or the NDI end 150. Images acquired from the NDI ends 150, 150-1 are overlaid to create an image of the cross-section 321 of the half-section 120 at once. The specific implementation and timing of the scan can vary depending on the number of NDI ends 150 and 150-1, the occupancy time of NDI station 140 and work station 99, and whether the half-cylinder section 120 moves forward with full pulsation 118, micro pulsation 149 or continuously.

[0151] According to one embodiment, the NDI station 140 may form an inner frame 159 following the IML 128 of the semi-cylindrical section 120, or an outer frame 159-1 following the OML 122 of the semi-cylindrical section 120. In such an embodiment, pulse echo inspection is used to scan for internal inconsistencies 430 (especially out-of-tolerance conditions) within the semi-cylindrical section 120. In a further embodiment, the NDI station 140 has a pair of frames 159, 159-1, one inside the IML 128 of the semi-cylindrical section 120 and one outside the OML 122 of the semi-cylindrical section 120. In one embodiment, one frame 159, 159-1 is dedicated to an ultrasonic transducer that transmits ultrasonic energy, while the other frame 159, 159-1 is dedicated to an ultrasonic transducer that receives ultrasonic energy, and scanning is performed in transmission mode.

[0152] In this embodiment, NDI terminals 150, 150-1 include ultrasonic sensors. Each NDI terminal 150, 150-1 includes supply lines 152, 152-1 for supplying liquid (e.g., water) to the NDI terminals 150, 150-1. Each NDI terminal 150, 150-1 also includes ultrasonic transducers 154, 154-1. Liquid from the supply lines 152, 152-1 travels to the structure of the NDI terminals 150, 150-1 and the surfaces 323, 323-1 being scanned. Figure 3A The chambers 156 and 156-1 are defined. This forms a path for ultrasonic energy to travel from the ultrasonic transducers 154 and 154-1 into the semi-cylindrical section 120. Flexible surfaces 155 and 155-1 abut against the semi-cylindrical section 120 to hold the NDI ends 150 and 150-1 in place, ensuring the existence of an effective ultrasonic path while limiting fluid leakage from the chambers 156 and 156-1. Adjustable connectors 158 and 158-1, such as bellows, spring arms, or kinetic chains (actuable robotic arms), allow the NDI ends 150 and 150-1 to respond to the contours 322 and 322-1 of the semi-cylindrical section 120. Figure 3AThe flexible surfaces 155, 155-1 thus deflect elastically in response to changes in the profiles 322, 322-1 of the semi-cylinder section 120. Adjustable connectors 158, 158-1 include universal connector fittings that facilitate deflection of the NDI ends 150, 150-1. Adjustable connectors 158, 158-1 allow the NDI ends 150, 150-1 to pass through the frames 159, 159-1 for scanning. One side of the adjustable connector 158 is positioned between the NDI ends 150, 150-1 and the frames 159, 159-1, for example, offset or automatically connected, and provides flexibility to facilitate deflection of the NDI ends 150, 150-1 relative to the frames 159, 159-1. An adjustable connector 158-1, such as a bellows, is located on the other side between the NDI ends 150, 150-1 and the semi-cylindrical section 120, providing flexibility in chambers 156, 156-1 between the NDI ends 150, 150-1 and the semi-cylindrical section 120. This allows the NDI ends 150, 150-1 to engage in subsequent contours 322, 322-1, since the last surface of chambers 156, 156-1 is the surface being inspected. In one embodiment, the adjustable connector 158 includes a kinematic chain that operates according to instructions in a numerical control (NC) program to advance the NDI ends 150, 150-1 along contours 322, 322-1 of the semi-cylindrical section 120, which scans in an arc along frames 159, 159-1 and / or longitudinal direction 198 to cover field of view 113. Adjustable connectors 158, 158-1 help to keep the NDI ends 150, 150-1 in contact with the half-cylinder 120 as the half-cylinder 120 advances along the process direction 199 and / or as the NDI end 150 moves along the frame 159, 159-1 across the half-cylinder 120.

[0153] In one embodiment, NDI station 140 includes one of a plurality of stations arranged along track 110 and spaced less than the length of half-cylinder section 120. Operations performed by work station 99 may include installing new components onto half-cylinder section 120 using fasteners, removing material (e.g., drilling or trimming), adding material, etc. In one embodiment, each work station 99 performs one type of operation, such as installing new components (e.g., frames, longitudinal beams, door surrounds, window surrounds, ribs), cutting door openings, or cutting window openings. As part of the installation process, these various components being installed may be positioned and rotated relative to half-cylinder section 120. For example, a cup-cone indexing system may be used to place components onto half-cylinder section 120, and hard-stop indexing may be used to index half-cylinder section 120 toward work station 99.

[0154] Figure 1BThis is a block diagram of assembly line 190, which includes NDI stations 140-1 for wingplates 195 of a frame being manufactured in the illustrative embodiment. Assembly line 190 includes components similar to those of assembly line 100, except that the systems and components are designed to operate on the wingplates 195 with embedded indexing features 124-2 rather than on a section of the fuselage. Similarly, this type of system suitable for a particular structure can also be used for other composite structures, such as stabilizers, floor beams, frames, wing spars, flap components, slats, door components, etc.

[0155] The wingplate 195 shown has a length of 109-1, which is not shown to scale. Similarly, the wingplate 195 shown has manufacturing allowances 129-1 and 135-2 along its edges. Likewise, the wingplate 195 is shown relative to NDI station 140-1 and work station 99-1, as well as micro-pulsation 149-1, which are not shown to scale. Another manufacturing allowance 135-2 is for removing material to form the wing inlet plate, typically found on the lower wingplate. In some embodiments, the wingplate 195 includes a hardened composite component. The wingplate 195 includes an outer mold line (OML) 122-2 and an inner mold line (IML) 128-2.

[0156] In this embodiment, assembly line 190 includes a track 110-1 on which wingplate 195 moves along a process direction 199-1. Track 110-1 carries one or more strong backing materials (not shown) that connect wingplate 195 to track 110-1. Track 110-1 facilitates movement (e.g., rolling or sliding) of wingplate 195. In a further embodiment, track 110-1 includes a chain-driven device, motorized trolley, or other power system capable of moving wingplate 195 along the process direction 199-1.

[0157] Assembly line 190 also includes indexing units 130-1. Each indexing unit 130-1 is designed to be physically coupled to an indexing feature 124-2, which is, for example, a machined feature (e.g., a hole or slot) and / or an additional feature (e.g., a pin in wingplate 195). The indexing features 124-2 are positioned along wingplate 195 within manufacturing allowances 129-1, 135-2. In one embodiment, each of the indexing features 124-2 is spaced along wingplate 195 by, for example, a micropulsation 149-1 or a fraction or multiple thereof. In another embodiment, each indexing feature 124-2 is spaced at a different distance along wingplate 195. In yet another embodiment, the indexing features 124-2 are positioned within the manufacturing allowances 129-1, 135-2 of wingplate 195, which are trimmed off before wingplate 195 is put into service.

[0158] In other embodiments, radio frequency identification (RFID) tracking is used for transposition. RFID tag 124-3 is located in manufacturing allowances 129-1, 135-2 as part of transposition feature 124-2. RFID scanner 134-3 is part of complementary feature 134-2. RFID tag 124-3 is installed alone or together with other transposition features 124-2 at a location optimal for transmitting transposition information to NDI station 140-1. RFID scanner 134-3 is installed alone or together with other complementary features 134-2 at a location optimal for communicating with transposition feature 124-2, including RFID tag 124-3, to transmit transposition information to NDI station 140-1. Transposition transmits information to NDI station 140-1 regarding the wingplate 195 within the field of view 113-2 of NDI station 140-1. In this implementation, the RFID tag 124-3 itself is used as a transposition feature 124-2 and is sequentially positioned (e.g., linearly or non-linearly aligned) on the manufacturing allowances 129-1 and 135-2 of the wingplate 195. The transposition feature 124-2, including the RFID tag 124-3, is aligned with complementary features 134-2 positioned relative to NDI station 140-1 and work station 99-1. The transposition feature 124-2, including the RFID tag 124-3, transmits the required 3D characterization, representation, and / or orientation details of the IML 128-1 and OML 122-1 of the wingplate 195 to the controller 160-1 via the transposition unit. The operation of track 110-1, NDI station 140-1, work station 99-1, and / or other components is managed by the controller 160-1. In some embodiments, these transposition features 124-2, including the RFID tag 124-3, also include instructions for the operations to be performed by the NDI station 140-1 and the work station 99-1. For example, in embodiments where the NDI station 140-1 and / or the work station 99-1 simultaneously perform operations in the field of view 113-2, 113-3 of the wingplate 195. One embodiment has a lower wingplate 195-1, followed by an upper wingplate 195-2 (see...). Figure 1 The upper wingplate 195-2 travels sequentially downwards along assembly line 190. Another embodiment has one model of wingplate 195 followed by different models. The indexing feature 124-2 on each wingplate 195 transmits the following to NDI station 140-1 and / or work station 99-1: what work (if any) needs to be performed on the specific wingplate 195 within the field of view 113-2, 113-3 when paused between or during micro-pulsations via NDI station 140-1 and / or work station 99-1. The indexing feature 124-2 also transmits OML122-1 and IML128-1 information during indexing.

[0159] In one implementation, controller 160-1 determines the progress of wingplate 195 along track 110-1 based on automated processes, such as input from a camera or physical sensor (e.g., a linear or rotary actuator), and on rotational input from a technician or artificial intelligence. Based on rotational information transmitted to NDI station 140-1 and / or work station 99-1, operations are performed on the wingplate 195 within fields of view 113-2, 113-3 in NDI station 140-1 and / or work station 99-1, respectively. Controller 160-1 then instructs NDI station 140-1 and / or work station 99-1. Controller 160-1 uses this input to manage the operation of the wingplate 195 within fields of view 113-2, 113-3 in NDI station 140-1 and / or work station 99-1 according to instructions stored in the numerical control (NC) program. The controller 160-1 can be implemented as, for example, a custom circuit, a hardware processor that executes programmed instructions, or some combination thereof.

[0160] In this embodiment, each indexing unit 130-1 includes a complementary feature 134-2 for insertion into, holding, or otherwise engaging with the indexing feature 124-2. The complementary feature 134-2 provides a hard stop at the end of the micro-pulsation 149-1. The indexing unit 130-1 is positioned relative to the NDI station 140-1 and / or the work station 99-1 and the track 110-1. The indexing unit 130-1 is fixed relative to the NDI station 140-1 and / or the work station 99-1 to implement the hard stop at the end of the micro-pulsation 149-1. The indexing unit 130-1 is not fixed relative to the NDI station 140-1 and / or the work station 99-1 and is used for indexing during the micro-pulsation 149-1 or continuous assembly. The implementation method causes the wingplate 195 to be micro-pulsated 149-1 at a distance at least equal to the shortest distance between the indexing features 124-2, indexed to the indexing unit 130-1, and processed by the NDI station 140-1. That is, the wingplate 195 is indexed as part of the micro-pulsation 149-1 or a continuous system. Whenever the indexing feature 124-2 in the wingplate 195 and the complementary feature 134-2 in the indexing unit 130-1 are paired, the position of the wingplate 195 is indexed to a known position, and the 3D characterization, representation, and / or orientation of the wingplate 195 relative to the track 110-1, the indexing unit 130-1, and the NDI station 140-1 and / or the work station 99-1 are known. Specifically, one embodiment has each indexing unit 130-1 positioned at a known offset (O) (e.g., along three axes) from NDI station 140-1 and / or station 99-1, meaning that the action of indexing the wingplate 195 toward the indexing unit 130-1 results in the known positions of the wingplate 195's OML122-1 and / or IML128-1 relative to NDI station 140-1. This embodiment is illustrated using indexing units 130-1 offset (O) from NDI station 140-1. Another embodiment has each indexing unit 130-1 arranged without offset (O) from NDI station 140-1 and / or work station 99-1. This embodiment is shown with indexing units 130-1 at work station 99-1. With or without offset (O) relative to NDI station 140-1 and / or station 99-1, the wingplate 195 is rotated toward indexing unit 130-1 such that the 3D characterization, representation and / or orientation of the wingplate 195 relative to wingplate 195 in position OML122-1 and / or IML128-1 relative to wingplate 195 is known relative to NDI station 140-1.

[0161] In one embodiment, the rotation is performed at least as described below. The wingplate 195 is supported by a strong backing (not shown) on track 110-1. The wingplate 195 has been manufactured to precise dimensions on a laminated mandrel 622 ( Figure 6 The precise lamination allows the indexing feature 124-2 to be precisely positioned within the manufacturing allowance 129-1 of the wingplate 195. Rough finishing of the wingplate 195 occurs on the lamination mandrel 622. When the indexing feature 124-2 is engaged, the 3D characterization, representation, and / or orientation of the wingplate 195 are precisely known, eliminating the need for a full scan via probes or optical techniques at each micropulse 149-1 passing through the NDI station 140-1 and / or the work station 99-1. In another embodiment, the NDI inspection is used as an initial station during the processing of the wingplate 195 to perform an initial baseline scan during micropulse 149-1, during pauses between micropulse 149-1, or both, or during continuous movement. This baseline scan is used in subsequent processing of the half-tube section 120 and is transferred to the work station 99-1 during subsequent indexing processes.

[0162] The relative stiffness of the demolding helps the wingplate 195 maintain the desired IML128-1 and / or OML122-1. In this arrangement, the indexing feature 124-2 is precisely positioned within the wingplate 195 relative to the IML128-1 and / or OML122-1, and the precisely positioned guide rail 111 helps to transport the wingplate 195 along the process direction 199-1 past the NDI station 140-1 and through the station 99-1 without deformation. Therefore, the 3D characterization, representation, and / or orientation of the wingplate 195 within the fields of view 113-2, 113-3 including the OML122-1 and / or IML128-1 are quickly and accurately obtained by the NDI station 140-1 and / or the work station 99-1. This information is transmitted via a transducer through controller 160-1 after each micro-pulse 149-1, without requiring a rescan of the field of view 113-2, 113-3 of the wingplate 195 each time. In this way, the 3D characterization, representation, and / or orientation of the wingplate 195, OML 122-1, and / or IML 128-1 at specific sections within the field of view 113-2, 113-3 of NDI station 140-1 and / or work station 99-1 is rapidly transmitted to that specific station.

[0163] Due to the precise indexing, when the wingplate 195 is positioned by the micro-pulsation 149-1, the tools at NDI station 140-1 and each station 99-1 can be positioned as needed relative to the OML122-1 and / or IML128-1 of the wingplate 195. During pauses between micro-pulsations 149-1, the rapid positioning of tools and technicians within NDI station 140-1 and work station 99-1 relative to the OML122-1 and / or IML128-1 increases throughput and efficiency. The 3D representation, representation, and / or orientation of the wingplate 195's OML122-1 and / or IML128-1 within the fields of view 113-2, 113-3 are then established or indexed to any CNC programming or automation system used at NDI station 140-1 and / or work station 99-1. Therefore, no setup time in the form of a scan is required after each micropulse 149-1 exposing the field of view 113-2, 113-3 of the wingplate 195 within NDI station 140-1 or work station 99-1. Similarly, no setup time is required during micropulses 149-1 or during pauses between micropulses 149-1, or both, to bring tools and technicians to the field of view 113-2, 113-3 of the wingplate 195 within NDI station 140-1 or work station 99-1. In some embodiments, multiple sequentially arranged NDI stations 140-1 and / or work stations 99-1 perform work on the wingplate 195 during the same pause between micropulses 149-1. In one embodiment, the first station in the sequential arrangement is NDI station 140-1. Furthermore, structures added to or removed from wingplate 195 in existing work station 99-1 can be added to the electronic model or representation of wingplate 195 within the system and transmitted via transposition without needing to scan changes to wingplate 195 after and / or during micropulsation 149-1.

[0164] That is, the indexing of the wingplate 195 can be performed by aligning the indexing feature 124-2 with the indexing unit 130-1. The NDI station 140-1 and the indexing unit 130-1 have a known positional relationship. When the two are in a known relationship, the NDI ends 150-2 and 150-3 are positioned within the NDI station 140-1 and are inherently indexed to the wingplate 195 because the NDI ends 150-2 and 150-3 are already in a known relationship with the NDI station 140-1. Therefore, the indexing wingplate 195 includes a mating component 124-2 at the wingplate 195 with a complementary component 134-2 at the indexing unit 130-1 (which has a known physical offset from the NDI station 140-1), such that the mating immediately results in the wingplates 195OML122-1 and IML128-1 having known positions relative to the NDI station 140-1. This is because the complementary feature 134-2 at the indexing unit 130-1 is pre-positioned and its dimensions are suitable for installation when the wingplate 195 is in a specific and precisely defined position. In another embodiment, the indexing unit 130-1 includes a camera, laser, acoustic sensor, or other components that index the wingplate 195 without being physically coupled to the indexing component 124-2 of the wingplate 195.

[0165] In another embodiment, tracking is performed by scanning RFID tag 124-3, which is mounted on manufacturing allowances 129-1 and 135-2 of the wingplate 195 and is read as part of the rotation of the wingplate 195's field of view 113-2 and 113-3 within a specific NDI station 140-1 and / or work station 99-1. RFID tag 124-3 is the rotation feature 124-2 and is positioned sequentially, but does not need to be linearly aligned on the manufacturing allowance 129-1 of the wingplate 195. In one implementation, each RFID tag 124-3, serving as the transposition feature 124-2, is aligned with each of a plurality of sequentially positioned NDI stations 140-1 and / or work stations 99-1, transmitting details of the 3D characterization, representation, and / or orientation of the wingplate 195, OML 122-1, and / or IML 128-1, as well as instructions for the operations performed at the NDI station 140-1 and / or work station 99-1. As needed, the NDI station 140-1 and / or work station 99-1 operate on the field of view 113-2, 113-3 of the wingplate 195, followed by different wingplates 195, then different wingplates 195 of the same or different aircraft models, or different wingplates 195 of the same model as the previous two sections. RFID tag 124-3 explains to the workstation what task (if any) should be performed on a specific wingplate 195 that is pulsating through NDI workstation 140-1 or workstation 99-1. NDI workstation 140-1 includes one or more NDI ends 150-2, 150-3. NDI ends 150-2, 150-3 characterize the internal inconsistency 430 of the cross-section of each wingplate 195 advancing along track 110-1. Figure 4 The wingplate 195 is mounted (e.g., fixedly or movably) to frames 159-2 and 159-3. Frame 159-2 is located on the underside of wingplate 195, and when the micro-pulsations 149-1 of wingplate 195 pass through NDI station 140-1 and are above frame 159-2, frame 159-2 has a shape complementary to IML 128-2. When the micro-pulsations 149-1 of wingplate 195 pass through NDI station 140-1 and are below frame 159-3, frame 159-3 has a shape complementary to OML 122-2. NDI ends 150-2 and 150-3 characterize internal inconsistencies 430 of wingplate 195 as it advances along track 110-1 through NDI station 140-1. Internal inconsistencies 430 include voids, foreign matter fragments, resin-rich areas, resin-poor areas, etc.

[0166] In one embodiment, NDI ends 150-2 and 150-3 are arranged in arrays 157-2 and 157-3, respectively, along frames 159-2 and 159-3. In one embodiment, each NDI end 150-2 and 150-3 is movable relative to the wingplate 195 in an arcuate manner along frames 159-2 and 159-3 and within a field of view 113-2. The movement of the NDI ends 150-2 and 150-3 is synchronized to prevent collisions. For example, the NDI ends 150-2 and 150-3 may move clockwise and then counterclockwise synchronously within a field of view 113-2 complementary to the wingplate 195, while the wingplate 195 pauses in or between micropulses 149-1 and / or both. In another embodiment, the NDI ends 150-2 and 150-3 are arranged in arrays 157-2 and 157-3. In another embodiment, the movement of NDI ends 150-2, 150-3 relative to the wingplate 195 is provided by the movement of the wingplate 195 along the assembly line 190. During micro-pulsations 149-1 or pauses between micro-pulsations 149-1, an NDI station 140-1 scan is performed on the wingplate 195 within the field of view 113-2 of the NDI ends 150-2, 150-3. Therefore, the entire NDI scan is the sum of one or more scans acquired within the field of view 113-2 of the wingplate 195, regardless of whether the movement relative to the wingplate 195 is due to full pulsations 118, micro-pulsations 149-1, or continuous movement relative to the wingplate 195 or the advancement of the NDI ends 150-2, 150-3. Images acquired from the NDI ends 150-2, 150-3 are overlaid to create a cross-sectional image of the wingplate 195 at once. The specific implementation and timing of the scan can vary depending on the number of NDI terminals 150-2 and 150-3, the occupancy time of NDI station 140-1 and work station 99-1, and whether the wingplate 195 moves forward with full pulsation 118-1, micro pulsation 149-1 or continuously.

[0167] According to one embodiment, the NDI station 140-1 has an internal frame 159-2 (following the IML 128-1 of the wingplate 195), or an external frame 159-3 (following the OML 122-1 of the wingplate 195) may be formed. In such an embodiment, pulse echo inspection is used to scan for internal inconsistencies 430, particularly out-of-tolerance conditions within the wingplate 195. In a further embodiment, the NDI station 140-1 has a pair of frames 159, 159-1, one inside the IML 128-1 of the wingplate 195 and one outside the OML 122-1 of the wingplate 195. In one embodiment, one frame 159-2, 159-3 is dedicated to an ultrasonic transducer that transmits ultrasonic energy, while the other frame 159-2, 159-3 is dedicated to an ultrasonic transducer that receives ultrasonic energy, and scanning is performed in transmission mode.

[0168] In this embodiment, NDI terminals 150-2, 150-3 include ultrasonic sensors. Each NDI terminal 150-2, 150-3 includes feed lines 152-2, 152-3 supplying liquid (e.g., water) to the NDI terminals 150-2, 150-3. Each NDI terminal 150-2, 150-3 also includes ultrasonic transducers 154-2, 154-3. Liquid from the supply lines 152-2, 152-3 travels into chambers 156-2, 156-3, defined by the structure of the NDI terminals 150-2, 150-3 and the scanned IML 128-2 or OML 122-2. This forms a path for ultrasonic energy to travel from the ultrasonic transducers 154-2, 154-3 into the wingplate 195. Flexible surfaces 155-2 and 155-3 abut against the wingplate 195 to hold the NDI tips 150-2 and 150-3 in place. This ensures the existence of an effective ultrasonic path while limiting fluid loss from chambers 156-2 and 156-3. Adjustable connectors 158-2 and 158-3, such as bellows, spring arms, or kinematic chains (actuable robotic arms), allow the NDI tips 150-2 and 150-3 to deflect in response to changes in the IML 128-2 or OML 122-2 of the wingplate 195. One side of the adjustable connector 158-2 is positioned between the NDI tips 150-2 and 150-3 and the frames 159-2 and 159-3, for example, offset or automatically connected, and provides flexibility to facilitate deflection of the NDI tips 150-2 and 150-3 relative to the frames 159-2 and 159-3. Adjustable connectors 158-2 and 158-3 include universal connector fittings that facilitate the deflection of NDI tips 150-2 and 150-3. Adjustable connectors 158-2 and 158-3 allow NDI tips 150-2 and 150-3 to traverse frames 159-2 and 159-3 for easy scanning. The other side of adjustable connector 158-1, such as a bellows, is located between NDI tips 150-2 and 150-3 and wingplate 195, and provides chambers 156-2 and 156-3 between NDI tips 150-2 and 150-3 and wingplate 195. This allows NDI tips 150 and 150-1 to engage after profiles 322 and 322-1, because the last side of chambers 156-2 and 156-3 is the surface being inspected. In one embodiment, the adjustable connectors 158-2, 158-3 include a motion chain that operates according to instructions in a numerical control (NC) program to advance the NDI ends 150-2, 150-3 along the IML128-2 or OML122-2 of the wingplate 195 in an arc scan along the frame 159-2, 159-3 and / or longitudinal direction 198 to cover the field of view 113-2.When the wingplate 195 travels in the process direction 199-1, and / or when the NDI ends 150-2, 150-3 move along the frame 159-2, 159-3 past the wingplate 195, the adjustable connectors 158-2, 158-3 help to keep the NDI ends 150-2, 150-3 in contact with the wingplate 195.

[0169] In one embodiment, NDI station 140-1 includes one of a plurality of stations arranged along track 110-1 and spaced apart from the length of wingplate 195. Operations performed by work station 99-1 may include installing new components onto wingplate 195 using fasteners, removing material (e.g., drilling or trimming), adding material, etc. In one embodiment, each work station 99-1 performs one type of operation, such as installing new components such as ribs, longitudinal beams, wing spars, cutting channel door openings, etc. As part of the installation process, these various components being installed can be positioned and rotated relative to wingplate 195. For example, a cup-cone indexing system can be used to place components onto wingplate 195, while a hard-stop indexing system can be used to index wingplate 195 toward work station 99-1.

[0170] Regarding Figure 2 Illustrative details of the operation of assembly line 100 are discussed. For this embodiment, it is assumed that one or more half-cylinder sections 120 or wing sections 195 have been placed sequentially on tracks 110, 110-1, and are ready for NDI scanning to detect internal inconsistencies 430.

[0171] Figure 2 This is a flowchart illustrating a method for operating an assembly line to inspect fuselage sections in an illustrative embodiment. (See reference) Figure 1A The assembly line 100 describes the steps of method 200, but those skilled in the art will understand that method 200 can be performed in other ways. 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. Furthermore, although the steps herein are described with respect to the half-tube section 120, they can be applied to any suitable bow-shaped section of the fuselage (e.g., full-tube section, quarter-tube section, or other section dimensions, or wingplate 195, flaps, horizontal stabilizers, or vertical stabilizers).

[0172] Step 202 includes advancing the semi-cylindrical section 120 or the wing section 195 along tracks 110 and 110-1 in process directions 199 and 199-1, respectively, through NDI stations 140 and 140-1 and work stations 99 and 99-1, whereby the NDI stations 140 and 140-1 and work stations 99 and 99-1 perform operations on the structure. In one embodiment, the semi-cylindrical section 120 advances along track 110 in process direction 199 by full pulsation 118 and micro pulsation 149. In another embodiment, the wing section 195 is pulsated along track 110-1 in process direction 199-1 by micro pulsation 149-1 of the wing section 195, or reaches the entire length 109-1 of the wing section 195. The semi-cylindrical section 120 or wing section 195 is pulsated in an incremental manner to expose the semi-cylindrical section 120 or wing section 195 to the field of view 113, 113-1 for inspection at the NDI station 140. When the length of the field of view 113, 113-1 is less than the length 109, 109-1, micro-pulsation 149, pulsation, or continuous pulsation exposes a new section of the semi-cylindrical section 120 or wing section 195 to the field of view 113, 113-1 of the NDI station 140. The distance traveled in micro-pulsation 149 can be, for example, equal to the frame pitch 147 or rib pitch on the semi-cylindrical section 120 or wing section 195, respectively. Pulsations equal to or greater than 109, 109-1 are referred to as pulsations. Continuous advancement without pause is also possible. In embodiments where tracks 110, 110-1 are powered, this includes driving one or more elements of tracks 110, 110-1 to move the semi-cylindrical section 120 or the winglet 195, respectively, in process directions 199, 199-1. In other embodiments, this includes operating an autonomous guided vehicle (AGV) or a powered trolley mounted on tracks 110, 110-1 to pulsate, micro-pulsate 149 the semi-cylindrical section 120 or the winglet 195 to a desired position along tracks 110, 110-1. In embodiments where additional fuselage sections are located on tracks 110, and... Figure 1A The pulsation synchronization of the semi-cylindrical section 120 shown is also advanced by full pulsation 118 and micro pulsation 149 to advance the additional section. In a further embodiment, the structure advances continuously. Structures such as the semi-cylindrical section 120 or the wing 195 are advanced along tracks 110, 110-1 in process directions 199, 199-1 through NDI stations 140, 140-1, thereby increasing the exposure of the structure to its field of view 113, 113-1, respectively.

[0173] Step 204 includes rotating a structure such as the semi-cylindrical section 120 or the wing section 195 toward NDI stations 140, 140-1 positioned relative to tracks 110, 110-1. In one embodiment, this includes fitting rotation features 124, 124-1, 124-2, 124-3 in the semi-cylindrical section 120 or the wing section 195 to complementary features 134, 134-1, 134-2, 134-3, which are positioned relative to tracks 110, 110-1 at a known offset from NDI stations 140, 140-1. For example, complementary features 134, 134-2 (e.g., pins disposed at tracks 110, 110-1) can be inserted at predetermined intervals into indexing features 124, 124-2, which, for example, have been machined into holes in manufacturing allowances 129, 129-1, 135, 135-2 of the semi-cylinder section 120 or the wing section 195, respectively. RFID tags 124-1, 124-3 can be applied to manufacturing allowances 129, 129-1, 135, 135-2 at desired locations. In another embodiment, any suitable indexing technique or system can be used to arrange the semi-cylinder section 120 or the wing section 195 in a desired relationship with NDI stations 140, 140-1. After the semi-cylindrical section 120 has been rotated, the positions of its IML128 and OML122 relative to the NDI station 140 are known, representing, and / or oriented. Similarly, after the wing section 195 has been rotated, the positions of its IML128-2 and OML122-2 relative to the NDI station 140-1 are known, representing, and / or oriented. Therefore, even for very large structures, operations can be performed with the desired level of accuracy. In embodiments where multiple semi-cylindrical sections 120 or wing sections 195 travel along tracks 110, 110-1 one at a time, the rotation of the semi-cylindrical sections 120 or wing sections 195 can be performed synchronously. In this manner, at the end of full pulsation 118 or micro pulsation 149, multiple sections of the semi-cylindrical section 120 or wing section 195 are shifted to multiple stations, such as NDI stations 140, 140-1 and / or work stations 99, 99-1, and during the pause, multiple stations simultaneously perform operations on sections of the semi-cylindrical section 120 or wing section 195. This operation may include an NDI inspection process performed upstream of work stations 99, 99-1. In other embodiments, input from a laser, camera, or other components is used to shift the structure to NDI stations 140, 140-1 without physical connection to the structure.

[0174] In step 206, controller 160 operates NDI terminals 150, 150-1, 150-2, and 150-3 at NDI stations 140 and 140-1 to characterize the internal inconsistencies 430 of the cross-sections 321 and 321-1 of the semi-cylindrical section 120 or wing section 195. Operation of NDI terminals 150, 150-1, 150-2, and 150-3 can be performed during pauses between full pulsations 118 or between micro pulsations 149 of the semi-cylindrical section 120 or wing section 195. Alternatively, NDI terminals 150, 150-1, 150-2, and 150-3 can continuously scan the structure as the semi-cylindrical section 120 or wing section 195 continuously moves through NDI stations 140 and 140-1. Operating NDI terminals 150, 150-1, 150-2, and 150-3 may include operating arrays 157, 157-1, 157-2, and 157-3 of NDI terminals 150, 150-1, 150-2, and 150-3 at NDI stations 140 and 140-1, respectively, where NDI stations 140 and 140-1 are arranged along the contours 322, 322-1, or IML 128, 128-2, or OML 122, 122-2 of the semi-cylinder section 120 or the wing plate 195. Inputs from arrays 157, 157-1, 157-2, and 157-3 of NDI terminals 150, 150-1, 150-2, and 150-3 are combined to generate images of cross-sections 321 and 321-1. In another embodiment, the step further includes advancing the NDI tips 150, 150-1, 150-2, 150-3 along the contours 322, 322-1 or IML128, 128-2 or OML122-2 while scanning with NDI tips 150, 150-1, 150-2, 150-3.

[0175] In embodiments where NDI terminals 150, 150-1, 150-2, and 150-3 are ultrasonic devices, operating NDI terminals 150, 150-1, 150-2, and 150-3 may include emitting ultrasonic energy that penetrates the thickness of the semi-cylindrical section 120 or the wing section 195, and determining a delay before receiving the reflected ultrasonic energy in order to perform an inspection of the semi-cylindrical section 120 or the wing section 195 (e.g., a pulse echo inspection), or a transmission inspection performed via an ultrasonic transducer and receiver separated to the thickness of the semi-cylindrical section 120 or the wing section 195, respectively. If the interior of the semi-cylindrical section 120 is homogeneous, the reflected ultrasonic energy is expected to take a predetermined amount of time to be received. However, if the reflected ultrasonic energy returns faster or slower than expected, the ultrasonic energy encounters an internal inconsistency 430. Changes in signal amplitude can also be monitored to detect the internal inconsistency 430. Depending on the amount of delay, the type of inconsistency can be analyzed to determine if it is part of an out-of-tolerance condition (e.g., a gap that is too wide or too long). In this way, controller 160 detects out-of-tolerance conditions based on internal inconsistencies 430 and reports out-of-tolerance conditions for rework.

[0176] Steps 202-206 can be repeated repeatedly to acquire internal images along the entire length 109, 109-1 of the semi-cylinder segment 120 or wing segment 195 at a desired resolution (e.g., down to a thousandth of an inch or a hundredth of an inch), thereby characterizing the semi-cylinder segment 120 or wing segment 195. That is, advancing the semi-cylinder segment 120 or wing segment 195, rotating the semi-cylinder segment 120 or wing segment 195, and manipulating the NDI ends 150, 150-1, 150-2, 150-3 are repeatedly performed to expose new portions of the semi-cylinder segment 120 or wing segment 195 for scanning, and characterizing multiple cross sections 321, 321-1 of the semi-cylinder segment 120 or wing segment 195 along the length 109, 109-1 of the semi-cylinder segment 120 or wing segment 195. The movement of NDI ends 150, 150-1, 150-2, 150-3 relative to the scanned half-cylinder section 120 or airfoil section 195 can be provided by the micro-pulsation 149 movement of the half-cylinder section 120 or airfoil section 195 itself, the independent movement of NDI ends 150, 150-1, 150-2, 150-3, or some combination of both.

[0177] In a further embodiment, based on inputs from NDI terminals 150, 150-1, 150-2, and 150-3, images from the NDI can be compiled to generate a three-dimensional (3D) model of the semi-tubular section 120 or wingplate 195. The 3D model is then aligned with a 3D model representing the design of the semi-tubular section 120 or wingplate 195. If internal inconsistencies 430, particularly those exceeding tolerances, exist between the 3D model of the manufactured semi-tubular section 120 or wingplate 195 and the 3D theoretical model of the design of the semi-tubular section 120 or wingplate 195, these inconsistencies can be reported for review and / or rework. In many embodiments, the NDI stations 140 and 140-1 are initially placed in a post-hardening assembly line to enable rapid detection of any internal inconsistencies 430 exceeding tolerances in the parts being manufactured. In such an implementation, the station set immediately following the NDI station 140, 140-1 can be implemented as a rework station to resolve this out-of-tolerance inconsistency before entering the work station 99, 99-1.

[0178] Figure 3A This is a front view of the NDI station 300 of the half-cylinder section 120, examined in the illustrative embodiment. Figure 3A In this embodiment, the NDI station is subdivided into one or more frames 159-1 (performing operations on OML 122) and frames 159 (performing operations on IML 128) (e.g., inner and / or outer frames 159, 159-1 complementary to the IML 128 and / or OML 122 of the half-cylinder segment 120). The half-cylinder segment 120 is transported along track 110, and the NDI ends 150, 150-1 advance along frames 159, 159-1 to image the half-cylinder segment 120 as needed, while pulsating or continuously moving the half-cylinder segment 120 out of the page in the process direction 199. In another embodiment, the NDI ends 150, 150-1 or frames 159, 159-1 are translational and advance / translate into or out of the page during pauses between full pulsations 118 or between micro pulsations 149 to scan a portion of the half-cylinder segment 120. The operation of NDI ends 150, 150-1 is synchronized with full pulsation 118 or micro pulsation 149, and / or paused based on indexing information indicating the advance of half-cylinder section 120 along the assembly line.

[0179] Figure 3B This is a front view of the NDI station 300 inspecting the arc-shaped section 320 of the machine body in the illustrative embodiment. Figure 3BIn this configuration, the NDI station 300 is subdivided into one or more outer frames 310 (performing operations on OML 122) and inner frames 390 (performing operations on IML 128) (e.g., inner and / or outer rings of IML 128 and / or OML 122 following the arcuate section 320). The arcuate section 320 is carried along track 330, and an array of NDI tips 340 is fixed at various circumferential positions 325, 325-1, but flexibly connected to their corresponding frames 310, 390 to allow for a limited degree of deflection. The NDI tips 340 scan during full pulsation 118 or micro pulsation 149 or continuous movement of the arcuate section 320, while the frames 310, 390 move in the longitudinal direction 198 or the opposite direction during pauses in the arcuate section 320 to perform the scan. The operation of the NDI end 340 is synchronized with full pulsation 118 or micro pulsation 149, and / or paused based on indexing information indicating the advance of the bow section 320 along the assembly line 100.

[0180] Figure 4 This is an enlarged view 400 of the ultrasound examination in the illustrative embodiment, and corresponds to... Figure 3A Area 4. Figure 4 A feed line 152-1 is shown that supplies water to an ultrasonic transducer 154-1, which applies ultrasonic energy to the semi-cylindrical section 120 via a chamber 156-1. As the semi-cylindrical section 120 and / or the NDI end 150-1 move relative to the other, a flexible surface 155-1 and an adjustable connector 158-1 hold the NDI end 150-1 in contact with the semi-cylindrical section 120.

[0181] according to Figure 4 Ultrasonic energy 410 is emitted by ultrasonic transducer 154-1 and propagates through the thickness T of the semi-cylindrical section 120. The reflected ultrasonic energy 420 then returns to ultrasonic transducer 154-1 and is sensed at transducer 154-1. Based on the timing and magnitude of the reflected ultrasonic energy 420, an internal inconsistency 430 within the semi-cylindrical section 120 is detected compared to the expected timing and magnitude of the ultrasonic energy 420 at that specific location along the semi-cylindrical section 120.

[0182] Now pay attention Figure 5 , Figure 5The control components of a production system performing ultrasonic inspections in an illustrative embodiment are shown in general. A controller 160 coordinates and controls the operation of NDI stations 140, 140-1, 99, 99-1 and the movement of the semi-cylinder section 120 or wing section 195 along an assembly line 100 having tracks 110, 110-1. The controller 160 may include a processor 510 coupled to a memory 512 storing a program 514. In one example, the semi-cylinder section 120 or wing section 195 is driven along a motion line 560, which is either full-pulsation 118, micro-pulsation 149, or continuously driven by tracks 110, 110-1, controlled by the controller 160. In this example, the semi-tubular section 120 or wing section 195 includes a facility connector 572, which may include an electrical, pneumatic, and / or hydraulic quick disconnector connecting tracks 110, 110-1, NDI stations 140, 140-1, and / or work stations 99, 99-1 to an external source facility 540. In other examples, as previously described, the semi-tubular section 120 or wing section 195 advances along tracks 110, 110-1, which have automated guided vehicles (AGVs) including onboard facilities and a GPS / autonomous navigation system 574. In a further example, a laser tracker 550 is used to control the movement of the semi-tubular section 120 or wing section 195. Position and / or motion sensors coupled to a controller 160 are used to determine the position of the semi-tubular section 120 or wing section 195.

[0183] The principles of the aforementioned motion path can include other types of operations typically performed in the production of composite components. Figure 6An example of a motion path 600 incorporating various operations that can be performed in the production of composite components is shown. For example, a moving production line may include a station, area, or bench for mandrel preparation 602 (which includes cleaning or coating mandrels 622), followed by conveying the mandrels 622 to a laminator 604, where a preform 624 is formed on the mandrels 622. The preform 624, after hardening, becomes a semi-cylindrical section 120 or a flange section 195. The fully laid preform can then be conveyed on the moving line to a downstream location where extrusion 606 and compaction 608 of the preform are performed. Furthermore, the preform can be processed in additional locations where molding 610, hardening the preform 612 into a composite component, trimming 614, inspection 616, rework 618, and / or assembly 620 operations are performed. Inspection 616 corresponds to NDI stations 140 and 140-1, and the assembly corresponds to work stations 99 and 99-1. The mandrel 622 progresses from mandrel preparation 602 to lamination 604, extrusion 606, compaction 608, and molding 610 via hardening 612, where the preform 624, after hardening, becomes a semi-cylinder section 120 or a wing section 195. Rough finishing of the semi-cylinder section 120 or wing section 195 occurs at finishing 614. Demolding of the semi-cylinder section 120 or wing section 195 from the mandrel 622 also occurs at finishing 614, where the mandrel 622 progresses to mandrel preparation 602.

[0184] Example

[0185] In the following examples, additional processes, systems, and methods are described in the context of an NDI workstation.

[0186] Referring more specifically to the accompanying drawings, embodiments of this disclosure can be implemented as follows: Figure 1 The method shown in 700 and as follows Figure 1The description of aircraft 702 is within the context of aircraft manufacturing and servicing. During pre-production, method 700 may include the specification and design 704 of aircraft 702 and material procurement 706. During production, the manufacturing of components and sub-assemblies of aircraft 702 and system integration 710 occur. Thereafter, aircraft 702 may be certified and delivered 712 for service 714. When the customer is in service, aircraft 702 is scheduled for routine operations in maintenance and servicing 716 (which may also include modifications, reconfigurations, refurbishments, etc.). The equipment and methods implemented herein may be used during any or more suitable phases of production and services described in method 700 (e.g., specification and design 704, material procurement 706, component and sub-component manufacturing 708, system integration 710, certification and delivery 712, service 714, maintenance and service 716) and / or any suitable component of aircraft 702 (e.g., frame 718, system 720, interior 722, propulsion system 724, electrical system 726, hydraulic system 728, environment 730).

[0187] Each process of Method 700 may be performed or executed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0188] like Figure 8 As shown, an aircraft 702 produced by method 700 may include a frame 718 having multiple systems 720 and an interior 722. Examples of systems 720 include one or more of a propulsion system 724, an electrical system 726, a hydraulic system 728, and an environmental system 730. 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.

[0189] As mentioned above, the equipment and methods implemented herein can be used during any or more phases of production and service as described in method 700. For example, a component or sub-component corresponding to component and sub-component manufacturing 708 can be manufactured or produced in a manner similar to that of a component or sub-component produced when aircraft 702 is in service. Furthermore, one or more equipment implementations, method implementations, or combinations thereof can be used during sub-component manufacturing 708 and system integration 710, for example, by substantially accelerating the assembly of aircraft 702 or reducing the cost of aircraft 702. Similarly, when aircraft 702 is in service, such as, but not limited to, during maintenance and repair 716, one or more equipment implementations, method implementations, or combinations thereof can be used. For example, the techniques and systems described herein can be used for specification and design 704, material procurement 706, component and sub-component manufacturing 708, system integration 710, service 714 and / or maintenance and service 716, and / or can be used for rack 718 and / or interior 722. These technologies and systems can even be used in system 720, which includes, for example, propulsion system 724, electrical system 726, hydraulic system 728, and / or environmental system 730.

[0190] In one embodiment, the component includes a portion of a frame 718 and is manufactured during component and subassembly manufacturing 708. The component can then be assembled into the aircraft in system integration 710 and used in maintenance 714 until wear renders the component unusable. Then, in maintenance and servicing 716, the part can be discarded and replaced with a newly manufactured part. The components and methods of the present invention can be used throughout component and subassembly manufacturing 708 to manufacture new components.

[0191] 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 implementing software, a processor implementing firmware, or some combination thereof. For example, an element can 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, these functions can 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 referring specifically to hardware capable of executing software, but may implicitly include, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic, or some other physical hardware component or module.

[0192] Furthermore, control elements can be implemented as instructions executable by a processor or computer to perform the functions of that element. Some examples of instructions are software, program code, and firmware. Instructions are operable when executed by a processor to instruct the processor to perform the functions of the element. Instructions can be stored on a processor-readable storage device. Some examples of storage devices are digital or solid-state storage, such as magnetic storage media like disks and tapes, hard disk drives, or optically readable digital data storage media.

[0193] 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 appended claims and any equivalents thereof.

Claims

1. A method for inspecting inconsistencies in aircraft structures manufactured in an assembly line, the method comprising the steps of: The structure is advanced along a track in the process direction by making the structural pulsation less than the length of the structure, through one or more work stations to perform operations on the structure, and through a non-destructive inspection (NDI) station, wherein the NDI station includes a frame that includes an arc following the inner mold line (IML) of the structure; To transfer the structure to the NDI station and the one or more work stations; and During pauses between pulsations of the structure, the structure is inspected at the NDI station using NDI ends arranged along the arc of the frame, and the one or more work stations perform operations on the structure.

2. The method according to claim 1, wherein: The steps for inspecting the structure include: operating the NDI end at the NDI station to characterize the internal features of the cross-section of the structure.

3. The method according to claim 1 or 2, comprising one or more of the following: - in, The steps of advancing the structure include: repeatedly performing the steps of advancing the structure, rotating the structure, and inspecting the structure to characterize multiple cross-sections of the structure along the length of the structure; - The step of inspecting the structure includes: manipulating an array of NDI terminals arranged at the NDI station to follow the contour of the structure, and the method further includes the step of: combining inputs from the array of NDI terminals to generate an image of the cross-section of the structure; - The method further includes the step of advancing the NDI tip along the contour of the structure while manipulating the NDI tip; - The method further includes the steps of: detecting out-of-tolerance conditions based on the internal characteristics of the structure, and reporting the out-of-tolerance conditions for rework; - The step of inspecting the structure includes performing an operation selected from the group consisting of ultrasound pulse echo examination and transmission ultrasound examination of the structure; - The method further includes the following steps: generating a model of the structure based on input from the NDI station, aligning the model with the design of the structure, and identifying the differences between the model and the design of the structure; The step of advancing the structure in the process direction moves the structure through the workstation where the work is performed on the structure.

4. An apparatus for inspecting inconsistencies in aircraft structures manufactured in an assembly line, the apparatus comprising: Non-destructive testing (NDI) station, the NDI station including: A frame, the frame including arcs that follow the inner mold line (IML) of the structure; At least one NDI terminal is mounted to the frame along the arc; A track, wherein the track propels the structure through the NDI station by means of a structural pulsation less than the length of the structure relative to the at least one NDI end-head propulsion structure; and A transposition system that transmits information about the structure within the field of view of the NDI station. The NDI station is one of a plurality of stations arranged along the track at intervals less than the length of the structure, and the NDI station is configured to inspect the structure during pauses between pulsations of the structure.

5. The device according to claim 4, wherein: The at least one NDI terminal includes: Ultrasonic transducer; Flexible surface; A chamber between the ultrasonic transducer and the flexible surface; A feed line, wherein the feed line is filled with liquid into the chamber; and An adjustable connector is provided between the ultrasonic transducer and the NDI station.

6. The device according to claim 5, wherein, The flexible surface is elastically deflected to conform to the contour of the structure.

7. The device according to claim 6, wherein, The adjustable connector allows the at least one NDI end to deflect relative to the NDI station when the at least one NDI end follows the contour of the structure.

8. The device according to claim 5 or 6, wherein: The at least one NDI terminal comprises an array of NDI terminals arranged along an arc of the frame.

9. The device according to claim 8, wherein, The array of NDI terminals follows the outline of the structure.

10. The device according to claim 8, comprising one or more of the following: - in, The arc along the frame is complementary in shape to the IML; - Wherein, the at least one NDI end is translatable; - wherein the at least one NDI end can be translated along the arc of the frame.

11. A system for inspecting inconsistencies in aircraft structures manufactured in an assembly line, the system comprising: The device according to any one of claims 4 to 10; One or more workstations are arranged along the track and configured to perform work on the structure during pauses between pulsations of the structure. The transposition system is configured to transpose the structure to the NDI station and the one or more work stations.

12. A non-transient computer-readable medium comprising programming instructions that, when executed by a processor, operate a method for performing a non-transient check on an aircraft structure manufactured in an assembly line, the method comprising the steps of: The structure is advanced along a track in the process direction by making the structural pulsation less than the length of the structure, through one or more work stations to perform operations on the structure, and through a non-destructive inspection (NDI) station, wherein the NDI station includes a frame that includes an arc following the inner mold line (IML) of the structure; To transfer the structure to the NDI station and the one or more work stations; and During pauses between pulsations of the structure, the structure is inspected at the NDI station using NDI ends arranged along the arc of the frame, and the one or more work stations perform operations on the structure.

13. The non-transient computer-readable medium of claim 12, comprising one or more of the following: - in, The steps for inspecting the structure include: operating the NDI end at the NDI station to characterize the internal features of the cross-section of the structure; - The step of advancing the structure includes: repeatedly performing the step of advancing the structure, the step of transposing the structure, and the step of inspecting the structure to characterize multiple cross sections of the structure along the length of the structure.

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