Method and system for assembling a wing

Abstract

The present disclosure relates to assembly line manufacturing and assembly of aircraft wings, and more particularly, to methods and systems of assembling a wing. Systems, methods, and apparatuses of assembling a wing are provided. Methods include the steps of coupling a robotic arm to a bracket on a rib, holding the rib against a wing panel, and operating the coupled robotic arm to install shims between the rib and the wing panel. Some methods also include (e.g., removably) installing the bracket, such as by aligning it with an index feature at the rib. In some methods, the bracket imparts a profile to the rib. Systems include a carriage coupled to a rib and a robotic arm extending from the carriage and configured to perform a task (e.g., inspecting, installing shims and / or fasteners, etc.) at an interface between the rib and a wing panel. Apparatuses include a robotic arm sized to be placed at an interface between a rib and a wing panel, where the robotic arm includes an end effector to perform a task (e.g., inspecting, installing shims and / or fasteners, etc.) at the interface.

Description

Technical Field

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

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

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

[0004] Patent document EP3354396A1, according to its abstract, describes a method comprising the steps of: identifying a first location on a first part to place a first gasket tab, thereby forming a first portion of a composite gasket. The method further comprises the step of: applying the first gasket tab to the first location on the first part using an end effector. The method further comprises the step of: identifying a second location on the first part directly adjacent to the first location to place a second gasket tab. The method further comprises the step of: applying the second gasket tab to the second location on the first part using an end effector to form a second portion of the composite gasket. The method further comprises the step of: applying a third gasket tab to the second gasket tab at the second location to increase the thickness of the second portion of the composite gasket.

[0005] Patent document EP3048416A1, according to its abstract, describes a system that may include a remote device configured to move along a first path relative to a first carrier structure. The remote device may be configured to move sensor devices along a plurality of measurement points included in the first path. A base device may be configured to identify the position of the sensor devices at each measurement point. The base device may be configured to generate measurement data including a first plurality of measurement results identifying at least one structural dimension of a first surface of the first carrier structure. A controller may be configured to control the operation of the base device and the remote device based on engineering data associated with the first carrier structure. The controller may also be configured to determine at least one gasket dimension associated with the first surface.

[0006] Patent document US2014 / 365061A1, according to its abstract, describes a system comprising one or more omnidirectional ground vehicles configured to move within a facility-defined work area and an engineering-defined work space leading to a calibration station, wherein the engineering-defined work space includes a part to be measured. The system also includes a multi-axis robot removably coupled to each of the omnidirectional ground vehicles and configured to move a laser scanner, wherein the laser scanner of each of the multi-axis robots is configured to move in at least two linear directions and one rotational direction. The system further includes a processor configured to automatically generate a surface preparation output file based on measurement data received from the laser scanner, wherein the surface preparation output file is configured to instruct a machine to manufacture a component that matches the part.

[0007] Patent document US2017 / 312923A1, according to its abstract, describes a portable programmable machine having a body supporting a programmable telescopic arm configured to extend through an inlet to reach a confined space. The arm includes an articulated wrist for holding and manipulating a tool for autonomously processing work parts. The machine can move semi-autonomously to accommodate operator intervention to cover and fine-tune the interaction between the tool and the work part for proper work processing. The arm communicates with a computer within the body to process digital data, and the operator can use a reference camera to fine-tune any particular process. The machine includes multiple processing functions, all passing through an aircraft wing inlet. The body has lockable wheels to secure it near the inlet.

[0008] Patent document EP2813350A2, according to its abstract, describes a liquid gasket material having a magnetically conductive component being applied at a gasket location between multiple composite parts. A magnetic field is applied to the magnetically conductive material at this location. The magnetic field is configured to heat the liquid gasket material to a temperature, causing the liquid gasket material to solidify and form a gasket. Summary of the Invention

[0009] Therefore, it is desirable to have a method and apparatus that takes into account at least some of the problems discussed above, as well as other possible problems.

[0010] The embodiments described herein provide enhanced systems and technologies to facilitate the manufacture and assembly of aircraft wings via an assembly line. According to these embodiments, large components, such as winglets, are conveyed in a pulsed or continuous motion. Separate workstations along the assembly line perform various work tasks on the components (e.g., during pauses between pulses or while the components are in continuous motion). As discussed in more detail below, the embodiments herein focus on assembling wing assemblies by following a winglet as it moves along the assembly line, with other components (e.g., ribs and spars, then another winglet) progressively attached to it. In some embodiments, indexing features for indexing components (e.g., winglets) to one or more workstations are formed in the component. In embodiments where the component is a winglet, indexing features are formed as part of the winglet's formation in a manufacturing excess area that will eventually be trimmed away. The winglet can be indexed to the workstation by means of these indexing features. In some implementations, the workstations are positioned close enough to each other that the wingplate, due to its size, can encounter multiple workstations simultaneously. For example, an assembly line may include a series of workstations arranged in the process direction such that as the wingplate moves along the process direction, the front of the wingplate first encounters an inspection workstation (such as a non-destructive testing or NDI workstation), then a cutting workstation, and then a rib mounting workstation. These workstations can be positioned close enough to each other that, for example, when the front encounters a rib mounting workstation, the middle of the wingplate encounters a cutting workstation, and the rear encounters an NDI workstation, such that two or more workstations, or all three workstations, can perform work tasks on portions of the same wingplate located within the respective workstation range, such as simultaneously or overlapping in time. This assembly technology offers technical advantages by integrating the transfer process into the assembly process and by reducing the amount of work performed on large components each time a component is moved.

[0011] Some implementations are methods of assembling an airfoil, wherein the method includes the steps of: attaching a robotic arm to a bracket, the bracket being attached to a rib and holding the rib against a wingplate; and simultaneously, while the robotic arm is attached to the bracket, manipulating the robotic arm to install one or more spacers between the rib and the wingplate. Some methods further include the step of: attaching the bracket (e.g., detachably) to the rib, such as by aligning the bracket with a rotation feature at the rib. In some methods, the bracket conforms to a desired profile on the rib. Some methods further include the step of: repeatedly attaching the robotic arm to each of a plurality of ribs and manipulating the robotic arm to install the spacers. In some methods, the robotic arm inspects the rib-to-wingplate interface, such as to identify the location of the spacers. Some methods include the step of: fastening the rib to the wingplate.

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

[0013] Some embodiments are wing assembly systems, wherein the system includes: a carriage coupled to a rib; and a robotic arm extending from the carriage and operable to perform work at the interface between the rib and the wingplate. In some systems, the carriage is coupled to a support, which is mounted to the rib. In some such systems, the carriage is configured to drive along the support. In some systems, the work includes inspecting, installing shims, and / or installing fasteners.

[0014] Some embodiments are wing assembly devices, wherein the device includes a robotic arm sized to be positioned at the interface between the rib and the wingplate, and wherein the robotic arm further includes an end effector that performs operations on the interface, including inspecting the interface, installing shims at the interface, and / or installing fasteners at the interface. In some devices, the robotic arm is mounted to a carriage that travels along a support mounted to the rib. Attached Figure Description

[0015] Other exemplary embodiments (e.g., methods, computer-readable media, systems, etc. related to the foregoing embodiments) may be described below. The features, functions, and advantages already discussed may be implemented independently in various embodiments or may be combined in yet other embodiments, further details of which can be seen in the following description and figures.

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

[0017] FIG. 1 This is a block diagram of an exemplary embodiment of a system for laying out manufacturing allowances of preforms to be hardened into composite parts, using an indexing feature.

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

[0019] FIG. 2B An example of an exemplary embodiment is shown: a laying mandrel covered by composite parts.

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

[0021] FIG. 4 The takt timing of the feeder line for composite parts in an exemplary embodiment is depicted.

[0022] FIG. 5A to FIG. 5F This is a diagram of an assembly line for an airfoil in an exemplary embodiment.

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

[0024] FIG. 6 This is a flowchart illustrating a method for applying a contour to a wingplate in an exemplary embodiment.

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

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

[0027] FIG. 10 This is a flowchart illustrating another method for applying a contour to a wingplate in an exemplary embodiment.

[0028] FIG. 11A to FIG. 11D An exemplary embodiment shows the rib being mounted on the upper wing plate.

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

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

[0031] FIG. 16A to FIG. 16C This is an illustrative embodiment illustrating the automatic installation of a gasket between the rib and the flange.

[0032] FIG. 17A to FIG. 17C Another view illustrates the robotic arm performing automated inspections and installing shims between the ribs and wing plates in an exemplary embodiment.

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

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

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

[0036] FIG. 21 The control components of a production system performing ultrasonic inspection in an exemplary embodiment are illustrated in general.

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

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

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

[0040] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. Therefore, it will be understood that those skilled in the art will be able to design various arrangements, although not explicitly described or shown herein, which 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 referenced examples and situations. Therefore, this disclosure is not limited to the specific embodiments or examples described below, but is limited by the claims and their equivalents.

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

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

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

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

[0045] Over-bursting during machining (such as drilling or trimming) at the laying mandrel 110 after hardening requires rework of the potted surface before the next use of the laying mandrel 110. The preform 200 is laid onto the laying mandrel 110 above the profile 112 and surface features 114.

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

[0047] Compared to FIG. 2A The laying mandrel 110, awaiting installation, is shown. FIG. 2BA composite part (indicated by 250) is shown, which has been hardened from preform 200 and awaits demolding from laying mandrel 110. Indexing feature 210 of preform 200 has become indexing feature 210 of composite part 250.

[0048] In some embodiments, surface feature 114 is separated from adjacent surface features by a predefined distance (e.g., multiples of 2.5 cm (a few inches), multiples of 30.5 cm (a few feet), etc.), such as to create uniformly spaced indexable features 210 at / on / in the preform 200 and the resulting composite part 250. In another embodiment, surface features 114 are non-uniformly spaced from each other. The position and / or predefined distance between indexable features may depend in part on factors such as the arrangement of workstations on an assembly line.

[0049] The position of the surface feature 114 in the lay-up mandrel 110 is precisely tolerant (e.g., to 25 micrometers (to one-thousandth of an inch)), therefore, the position of the corresponding indexing feature 210 at the preform 200 is also known to be precisely tolerant, even after the preform 200 has hardened into the composite part 250 and been demolded from the lay-up mandrel 110. Thereafter, stations in the assembly line can utilize the indexing feature 210 to orient and position the resulting composite part in a desired manner, allowing work to be performed on the composite part. Furthermore, because the lay-up mandrel 110 is reusable, there is no need for a separate process applying the indexing feature to the preform. Performing the process at the lay-up mandrel located within the tolerance results in the indexing feature also being within the tolerance. The recess 118 (also known as the potting area) is filled with potting compound and is configured as described above to accommodate machining overcuts from machining operations (such as drilling operations) (which are used to install indexing features (e.g., through holes) after the composite part 250 has been hardened), and to be refilled and / or re-exposed as needed after machining and demolding in preparation for the next preform.

[0050] Some implementations include installing a readable identification device in the prefabricated component (in... FIG. 1(Generally shown as 126), such as a Radio Frequency Identifier (RFID) chip. In such an embodiment, one or more RFID chips are coupled, attached, or embedded in the manufacturing allowance 204 of the preform 200. A readable identification device such as an RFID chip can facilitate the transfer process by reporting information characterizing aspects of the resulting composite part to which the readable identification device is coupled. For example, an RFID chip can provide instructions to a work station regarding structural portions within the scope of a particular work station. One or more RFID chips can provide instructions to one or more work stations without requiring a one-to-one relationship between an RFID chip and a work station. In another example, an RFID chip reports to a work station the type of structure / wing, including right or left, top or bottom, or even model number.

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

[0052] FIG. 1 The illustrated laying system also includes a cutter 130 having a blade 132 (e.g., a reciprocating or circular blade) and an actuator 134 that drives the blade 132 to cut a portion of the composite part near a guide 116 in the laying mandrel 110. The guide is shown in the form of an adjacent groove surrounding a manufacturing allowance region 122. That is, the guide 116 positions the cutter 130 and / or defines the path of the cutter 130. Furthermore, as... FIG. 1 As shown, guide 116 can be filled with potting compound to accommodate the cutter's blade (and refilled after use, similar to recess 118). As FIG. 2B As shown, for example, in this figure, for clarity, the groove that together forms the guide 116 is shown as a rectangular perimeter, and the composite part 250 is shown as including a portion 252 located within the layup area 120 and a portion 254 conforming to the surface feature 114 in the manufacturing allowance area 122. The flash edge 256 of excess material is... FIG. 2BThe part is shown extending beyond the manufacturing allowance area 122. A cutting operation performed before demolding the composite part 250 from the laying mandrel 110 removes the flash 256 to define the manufacturing allowance edge 206 and leave sufficient manufacturing allowance 204 to include the indexing feature 210 for use at a station in the assembly line. During the manufacturing process, a rough cut provides a consistent edge (i.e., manufacturing allowance edge 206) for the part before finishing the edge to the final perimeter (i.e., final perimeter 202). This is desirable compared to working on parts that do not have a fixed, consistent perimeter relative to the manufacturing allowance. The operation of the cutter 130 is managed by a controller 140. The controller 140 may be implemented, for example, as custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

[0053] Regarding FIG. 3 The exemplary details of the operation of the laying system 100 are discussed in relation to method 300 shown therein. For this embodiment, it is assumed that after the composite part has been demolded from the laying mandrel 110, the laying mandrel 110 has been cleaned and returned to the beginning of the assembly line. Therefore, the laying mandrel 110 awaits the laying of preforms (such as preform 200) for the next composite part 250.

[0054] FIG. 3 This is a flowchart illustrating, as an exemplary embodiment, a method 300 for applying an indexing feature to a manufacturing allowance 204 of a preform 200 to be hardened into a composite part 250. (See also...) FIG. 1 , FIG. 2A and FIG. 2B The steps of method 300, which describes the components of the laying system 100 shown, are described herein; however, those skilled in the art will understand that method 300 can be performed in other systems. As with all methods illustrated and described herein, the steps shown in the flowcharts described herein are neither all-inclusive nor exclusive. Furthermore, the steps (such as...) mentioned herein... FIG. 3The flowcharts herein illustrate only a particular implementation of a specific method (such as method 300). It will be understood that other implementations of the methods consistent with and covered by this disclosure include fewer or more steps than shown, including steps performed in a different order than shown, and / or include other (e.g., additional, fewer, and / or alternative) actions different from those depicted. Furthermore, as will become clear according to this disclosure, because the various methods shown and discussed herein involve multiple different operations and sequences that can be performed during winglet formation and assembly into wing assemblies, the methods according to this disclosure can combine or otherwise include various steps and operations of two or more of the various methods shown. Moreover, although the reference numerals for the aforementioned components are used in the description of method 300, it will be understood that the method (and other methods described herein) is applicable to components that may have configurations different from those shown and described above.

[0055] In method 300, in step 302, a preform 200 is laid on a laying mandrel 110 (such as on a laying region 120) and on portions of the laying mandrel 110 outside the final trimming boundary (i.e., final perimeter 202) of the composite part 250 (such as on a manufacturing allowance region 122). The manufacturing allowance region 122 of the laying mandrel 110 includes a surface feature 114 configured to complementaryly form an indexing feature 210 in the preform 200. The laying mandrel 110 defines the outline 112 of the composite part at least in the laying region, and the preform 200 includes a manufacturing allowance 204 extending beyond the final perimeter of the composite part. Laying can be performed as the laying mandrel 110 moves pulsatingly or continuously through the assembly line, and can include simultaneous operation of multiple laminators at one time (e.g., during continuous movement of the laying mandrel, during pauses between movements of the laying mandrel, etc.). During the layup, multiple layers of unidirectional fiber reinforcement are applied sequentially to construct the preform 200 to the desired size and strength. The layup process extends the preform 200 beyond the final trimmed (e.g., component size) boundary (e.g., beyond the final perimeter 202), meaning that a portion of the preform 200 extends above surface feature 114. In this embodiment, the preform 200 is a multi-layered preform for the wing 550.

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

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

[0058] In another embodiment, additional indexing features 210 are added by milling or drilling to create a manufacturing allowance (e.g., by installing holes, notches, channels, and / or grooves to remove material from the manufacturing allowance). In a further embodiment, additional indexing features 210 are utilized and / or installed (such as pins, clips, rings, etc.).

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

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

[0061] In step 310, after material removal (such as split flash 256) and / or setting, causing one or more indexing features 210 to be indexed, the composite part is demolded from the laying mandrel 110. The composite part 250 is then proceeded (not shown) to an assembly line for further manufacturing and assembly, while the laying mandrel 110 is returned for cleaning and to receive another preform for the composite part. In one embodiment, the laying mandrel 110 is also reworked (e.g., after drilling or cutting through the potting area of ​​the punched recess 118 prior to demolding, repair, etc., and then refilled with potting compound as needed to restore the lay profile 112) and conveyed to the starting position for laying, such as on a flange laying line.

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

[0063] Method 300 offers significant advantages over the prior art because it enables the mounting of indexing features 210 into the composite part 250 during layup by referencing precisely tolerant surface features 114 on the layup mandrel 110. This eliminates the need for precise measurements of the preform 200 for mounting the indexing features 210, as the indexing features are positioned at precisely known locations by means of the setting of the surface features and their placement relative to the layup mandrel 110. Therefore, the accuracy of the layup mandrel 110 and the layup process avoids the need for downstream contour scanning and indexing. Thus, the accuracy of the layup mandrel 110 is extended / utilized beyond the layup process to include post-hardening processes such as trimming, milling, or drilling to add indexing features before demolding the composite part 250. Therefore, the accuracy relationship between the multiple surface features 114 and the corresponding indexing features 210 formed in the composite part 250 by using the layup mandrel 110 is carried forward as the composite part progresses, enabling simultaneous manufacturing steps on the same part.

[0064] FIG. 4 An example diagram is shown illustrating how different feeder lines and assembly lines or laying lines can be coordinated in an assembly line used for assembling, for example, wing components. FIG. 4This is a flowchart illustrating an example of a mode in an exemplary implementation, shown as mode 480 for feeder line 490 and assembly / layout line 491. Mode 480 provides a detailed example flowchart of wing manufacturing in relation to feeder lines and cycle times. For a particular implementation, all feeder lines from laying material feeder lines to the connection operations for integrating the wing into the fuselage section are depicted. Furthermore, the individual steps indicated by the arrows are performed according to a desired cycle time based on the cycle time of the component being fed.

[0065] In this embodiment, each feeder line is designated by a different reference numeral 490 (e.g., 490-1, 490-2, etc.), and each assembly line or laying line is designated by a different reference numeral 491 (e.g., 491-1, 491-2, etc.). More specifically, feeder line 490-1 supplies laying material to flange laying line 491-1. Feeder line 490-2 supplies laying material to spar laying line 491-5. Feeder line 490-3 supplies laying material to rib laying line 491-3, and feeder line 490-4 supplies laying material to longitudinal beam laying line 491-2. Furthermore, the laying lines feed into other laying lines. Rib laying line 491-3 is fed into the rib rear manufacturing line 491-7, wing plate laying line 491-1 is fed into the wing longitudinal spars setting line 491-4, and wing spars laying line 491-5 is fed into the wing spars rear manufacturing line 491-6.

[0066] Each feeder line is shown with a cycle time that contributes to the manufacture of the parts it produces. The cycle times of the feeder lines are synchronized with the assembly lines they feed to provide just-in-time (“JIT”) delivery of parts to the corresponding workstations 520 or more that use these parts (e.g., as consumables, as input to a product being manufactured, etc.). The resulting parts move along the assembly line 500 with the workstations 520 and also advance according to the cycle time. The cycle times of each of feeder lines 490-1 to 490-9 and / or lines 491-1 to 491-9 may be the same, some may be the same, or all may be different. Each feeder line 490-1 to 490-9 advances according to the common cycle time of that particular line.

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

[0068] In this embodiment, for example, the rib laying line 491-3 advances at a cycle time of 7 and is fed into the rib rear manufacturing line 491-7. The wingplate laying line 491-1 advances at a cycle time of 3 and is fed into the wing longitudinal spars installation line 491-4. The wing spars laying line 491-5 advances at a cycle time of 5 and is fed into the wing spars rear manufacturing line 491-6.

[0069] The rib-back manufacturing line 491-7 advances at a cycle time of 6, the wing sparsor setting line 491-4 advances at a cycle time of 2, and the wing spars-back manufacturing line 491-6 advances at a cycle time of 4. All feed is directed to the wing assembly line 491-8, which advances at a cycle time of 1, and also receives inlet caps from the inlet cap feeder line 490-5, mixed material from the mixed material feeder line 490-6, fasteners from the fastener feeder line 490-7, and sealant from the sealant feeder line 490-8. The wingplate 550 is hardened in an autoclave on line 490-10. Then, before separating from the mandrel 110 on line 490-11 (e.g., in the demolding station), the composite part 250 is trimmed and (in some embodiments) an indexing feature 210 is added. Excess material removed during trimming is taken from wing assembly line 491-8 via a downward sloping groove 490-9. After the wing is manufactured, line 491-9 moves the wing toward the fuselage for connection. Each of the various lines discussed above can supply material and / or components to its feed line at any rate that may be desired. The cycle time of a downstream line may or may not be equal to that of the line or lines feeding it. Each line may have a unique cycle time.

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

[0071] This parallel processing significantly increases the workload density within the plant. The cycle time of each of the micro-pulsating or full-pulsating components can be the same or different, or a defined fraction of the cycle time of another assembly line receiving that component. For example, the cycle time at feeder line 490-2 for spar layup material can differ from the cycle time at feeder line 490-1 for wing plate layup material, and the cycle time at feeder line 490-1 for wing plate layup material can differ from the cycle time of sealant supplied via sealant feeder line 490-8. In one embodiment, the cycle time is constant for each exemplary section.

[0072] As described above, the individual feeder lines discussed herein can be pulsating or continuously operating. Pulsating lines can achieve micro-pulsation (where the manufactured parts advance less than their length before receiving work from the work station during a pause) or full pulsation (where the parts advance an amount equal to their length). Furthermore, various components (e.g., wing assemblies, winglets, ribs, spars, etc.) can be manufactured as composite parts or via additive or subtractive manufacturing techniques for metals. For example, in one embodiment, ribs are manufactured via subtractive manufacturing of metal parts at rib post-manufacturing line 491-7, while winglets are manufactured as composite parts (e.g., preforms) at winglet laying line 491-1.

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

[0074] FIG. 5A to FIG. 5F Various aspects of an example assembly line 500 for an aircraft wing in an exemplary embodiment are depicted. Assembly line 500 can be used to assemble components via the methods described above. FIG. 1 to FIG. 4 The technology and systems provided by China are used to manufacture wing panels (such as wing panel 550) to perform operations. FIG. 5A to FIG. 5F The descriptions of the structures, components, and operations exemplified therein are provided with respect to the winglet, but apply to any composite part. Winglet 550 is described somewhat generally and can be an upper or lower winglet, or a right or left winglet. In cases describing the operation or characteristics of a particular type of winglet 550 (e.g., an upper winglet), the winglet will be indicated accordingly. Assembly line 500 (its top view is shown in...)FIG. 5A (Illustrated schematically) Includes a track 510, along which a shuttle device, shown in the form of a set of three strong backing materials 540, travels in the process direction 541 (e.g., in a pulsating manner from station to station, or continuously). The track 510 includes one or more guide rails, rollers, or other elements that facilitate the movement of the shuttle device along the track 510 (e.g., rolling or sliding). The track 510 can be mounted to the floor, suspended from above, etc., depending on the specific environment in which it is used. In the illustrated embodiment, the track 510 is positioned above the respective stations, and the shuttle device (strong backing material 540) carries the wing plate 550 in the process direction. Specifically, as FIG. 5D As shown, the reinforcing backing material 540 includes an adapter 543 that engages with and is movable via the track 510. For example, the adapter 543 may drive the reinforcing backing material 540 along the track 510, or the track 510 may be able to drive the reinforcing backing material 540. Either way, this configuration is intended to broadly encompass any suitable structural design for conveying the wingplate 550 in the process direction 541. In another embodiment, the track 510 includes a chain drive, a motorized trolley, or other power system (not shown) capable of moving the reinforcing backing material 540 in the process direction 541.

[0075] One or more strong backing materials 540 propel the wingplate 550 through various work stations, typically denoted as 520, where work is performed on the wingplate 550. FIG. 5A In this configuration, three strong backing materials 540 cooperate to support a single wingplate 550. However, more or fewer strong backing materials 540 may be used, if appropriate. For convenience, the term "strong backing material" herein generally refers to a single structure configured to extend over a transverse section (such as a chordal section) of the wingplate 550, but for convenience, the term may be used herein to refer generally to a shuttle device comprising multiple such structures. When two or more strong backing materials 540 cooperate to support components such as the wingplate 550, they may be coupled to each other (not shown) in a manner that maintains their constant relative position, such that only one strong backing material 540 is driven along the track 510. In this way, wingplates 550 of varying lengths may be carried via the assembly line 500, such as by joining a suitable number of strong backing materials 540 together to support the entire length of the wingplate 550.

[0076] In some embodiments, indexing features of the wing 550 (such as being located within manufacturing allowances) can be used to index the wing 550 together with the strong backing material 540 supporting the wing 550. In corresponding to FIG. 5A The view arrow "5B" in the middle FIG. 5BIn the view, the strong backing material 540 is shown to include an indexing unit 542 configured to mate with a corresponding indexing feature mounted in the manufacturing allowance 554 of the wing 550 (which may correspond to the manufacturing allowance 204 of the preform 200 hardened into the wing 550 according to the above-described manufacturing process). In the illustrated embodiment, the indexing unit 542 is physically connected to the indexing feature, wherein the indexing unit 542 is shown to include a head 549 received within the indexing feature 210-1 (which is shown as a through hole). Although FIG. 5B Only one indexing unit 542 is shown, but each reinforcing backing 540 may include any suitable number of indexing units. Each indexing unit may be configured to engage with the indexing feature 210 of the wing 550, such as for initial alignment and / or maintaining alignment of the reinforcing backing with the wing. Like the indexing feature 210, the indexing unit 542 may adopt any suitable configuration and may include engagement devices (such as magnets) different from those used to achieve mechanical connection. The indexing unit may be configured to engage with multiple different indexing features 210 or indexing features whose positions may differ from one wing 550 to another, for example, so that the reinforcing backing 540 can be engaged with different winglets as needed.

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

[0078] like FIG. 5A As shown and more clearly in FIG. 5B As can be seen, during operation at various work stations 520, such as NDI station 524, the wing plate 550 is held suspended below the strong backing material 540 by a carrier 545 (e.g., an independently adjustable component, such as a telescopic carrier, also referred to herein as a spring (pogo)) including a vacuum connector 548, which applies a removable vacuum connector to the wing plate to secure the wing plate to the strong backing material 540. FIG. 5B The view shows four carriers 545, three of which are shown positioned with their vacuum connectors 548 abutting against the upper surface 574 of the wing 550, and one of which is shown in a shortened configuration such that its vacuum connectors 548 are spaced apart from the upper surface of the wing. Brief referenceFIG. 5A The diagram illustrates different numbers of carriers 545 for each of the three strong backing materials 540 that jointly support the wing 550, wherein the carriers are arranged linearly along the width of the wing. However, any number and / or configuration of carriers 545 can be used. The carriers 545 are aligned to contact the wing 550 at predetermined positions and heights on the wing 550. Once set to the desired length, the individual carriers are rigid. Thus, the alignment of the carriers 545, or more specifically, the alignment of the carriers 545 relative to each other and their length relative to the wing 550, can be arranged to apply forces transmitted through the wing 550 and to implement a desired profile 544 into the wing 550. Thus, the strong backing material 540 suspends the wing 550 below it while forcing the profile 544 onto the wing. This profile 544 can be the profile given to the wing by the laying mandrel 110 (e.g., as shown in the diagram). FIG. 1 The profile shown is 112), or a different profile required for a specific application. Thus, as the strong backing material 540 advances along the track 510 in the process direction 541, the profile 544 is implemented by holding the individual carriers 545 at the desired height (which forces the geometry at the flange 550 to correspond to the profile 544).

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

[0080] Although the shape of the wing 550 (including its profile and curvature) is determined during layup and curing, the implementation and adjustment of the profile may be desired after the wing is demolded. The implementation of the profile ensures that the wing 550 maintains the desired shape and does not exhibit an undesirable profile, such as sagging under its own weight. In some embodiments, the profile implemented by the reinforcing backing 540 and the carrier 545 facilitates the mounting of ribs and spars to the wing, for example, by ensuring proper alignment between the components and the portions of the wing to which they will be mounted. Specifically, the carrier 545 implements the chordal and spanwise profiles to desired tolerance levels. In one embodiment (not shown), the carrier 545 is movable relative to the reinforcing backing to a predefined position to implement the profile for various wing shapes. Furthermore, depending on any orientation preferred for the implementation of the profile (and / or other operations as the wing 550 advances through the assembly line 500), the “upper surface” 574 to which the carrier 545 is attached may be the outer surface of the wing 550 in a “right-side up” orientation relative to the strong backing material 540, or it may be the inverted inner surface of the wing.

[0081] During the discussion of assembly line 500 and the operations performed by the various workstations 520, reference will be made intermittently to the accompanying drawings (e.g., FIG. 6 to FIG. 10 The various flowcharts presented in the document illustrate the process according to... FIG. 5A to FIG. 5G The components and methods of operation are shown. For example, FIG. 6 This is a flowchart illustrating a method 800 for carrying a wing 550 in an exemplary embodiment. According to method 800, step 802 includes aligning a reinforcing backing 540 over the wing 550. In some embodiments, this includes driving the reinforcing backing 540 along a track 510 until the reinforcing backing is positioned over a desired and / or predefined lateral portion (such as a chordal portion) of the wing 550. In some embodiments, this includes driving multiple reinforcing backings 540 until they are each positioned over different desired and / or predefined lateral (e.g., chordal) portions of the wing 550. In one example, a reinforcing backing 540 may be moved along the track 510 until it is positioned over a different portion of the wing 550 from another reinforcing backing 540 that remains stationary. In some embodiments, aligning the reinforcing backing 540 is performed by or includes rotating the reinforcing backing 540 onto the wing 550. In some embodiments of this implementation, this transposition is accomplished by connecting the reinforcing backing 540 to one or more transposition features of the wing 550, such as by physically connecting the transposition unit 542 of the reinforcing backing 540 to the corresponding transposition feature 210 of the wing 550. Transposing the reinforcing backing 540 together with the wing 550 in this manner maintains proper alignment of the reinforcing backing and the wing, as well as subsequent actions throughout the method.

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

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

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

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

[0086] In some embodiments, a scan is performed to determine an initial wing profile. If the wing 550 is already in the desired (e.g., predetermined) profile initially, or across the entire wing, or in one or more portions thereof, then a change in profile may not be necessary. In some embodiments of such embodiments, adjusting the length of the individual springs 545 relative to the reinforcing backing 540 (i.e., making them longer or shorter) pushes and / or pulls the wing 550 into the desired profile. The adjustment of the length of the individual springs 545 is based at least in part on the determination of the degree to which the wing 550 is misaligned with the desired profile. That is, the length of some of the springs 545 may need to be adjusted, while the length of others may not need to be adjusted (e.g., only some portions of the wing 550 are misaligned with the predetermined profile). The vacuum coupling 548 of the springs 545 is precisely positioned relative to the upper surface 574 of the wing 550 to ensure that the profile implemented by the springs conforms to the desired profile when the springs are at the desired length.

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

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

[0089] The method can then continue, for example, advancing the wing 550 while implementing the profile (e.g., by moving the reinforcing backing material 540 along the track 510 in the process direction 541), and / or performing operations on the wing 550 while implementing the profile (e.g., at each work station 520). In embodiments that perform scanning, the method may include profile scanning during or after the operation, for example, to ensure that the wing 550 remains within the desired profile—or, in other words, that the wing does not become misaligned with the predetermined profile due to the operation.

[0090] Back FIG. 5A Workstations 520, arranged along track 510, perform operations on wingplate 550. These operations can be performed simultaneously (or during overlapping periods) or synchronously with one or more other workstations to perform different tasks at different portions of wingplate 550 (e.g., at the wing root 577, mid-length 578, wingtip 579, etc.). In this embodiment, NDI workstation 524 inspects wingplate 550 for out-of-tolerance conditions (e.g., internal voids, foreign matter or FOD, edge delamination or inconsistencies, etc.), cutting workstation 526 cuts the inlet into wingplate 550 (e.g., in manufacturing allowance 554), rib mounting workstation 528 mounts ribs to wingplate 550, and spars mounting workstation 530 mounts spars to wingplate 550.

[0091] In this embodiment, as will be explained in more detail below, the ribs are attached to the wingplate 550 during micro-pulsation advance. This can include multiple work stations operating simultaneously on various ribs, or multiple work stations operating on different ribs during the same time period. The wing spars are then attached while the wingplate 550 is held at the full-pulsation work station 520. However, according to an embodiment, the wing spars are attached before the ribs, or can be installed during full-pulsation or micro-pulsation. The ribs are attached to the wingplate 550 and the wing spars using a micro-pulsation or full-pulsation assembly. Alternatively, the wingplate 550 is lowered to a position above the subsequently attached ribs, and the wing spars are pulsed onto the wingplate 550.

[0092] In one implementation, the rib and spar installation process is performed by supplying the rib and spar sections from a parallel feeder line in a just-in-time (JIT) manner, such as by means of methods similar to those used in... FIG. 4The feed lines for the continuous rib feeder line 491-7 and the continuous spar feeder line 491-5 are shown in mode 480. The feeder lines are individually shown by different reference numerals 570 (e.g., 570-1, 570-2, etc.). FIG. 5A In terms of the materials or components provided, the cycle time on which the feeder lines provide the materials or components, etc., these feeder lines may be the same as, similar to, or different from the various feeder lines 490 shown in mode 480. In one embodiment, multiple spar sections may be connected end-to-end, for example, to form spars. In another embodiment, there are multiple rib mounting stations and one or more fastener sealing stations and multiple spar mounting stations. Another embodiment comprises each spar consisting of three sections spliced ​​together at the ends of the ribs.

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

[0094] As discussed in further detail in this article, while continuing through FIG. 5A After the work station 520 shown, the wing plate 550 (which can be an upper wing plate to which ribs and spars can be installed) enters the panel connection stage, as shown. FIG. 5F As shown in panel connection station 599, this panel connection stage attaches another wingplate (which may be a lower wingplate) to form a complete frame portion for the wing (e.g., a wing assembly). After wingplate 550 stops at panel connection station 599 for fastening, the panel connection stage operates independently (e.g., it operates on its own across the entire wing without other stations operating). In one embodiment, wingplate 550 remains paused at panel connection station 599 while other wingplates pulse through the work stations until the other wingplates have advanced at least their full length.

[0095] In the illustrated embodiment, feeder lines 570-1 to 570-6 at least partially correspond to feeder lines 491-7, 491-4, and 491-5. Feeder lines 570-1 to 570-6 supply resources and components to the various workstations 520 on a Just-In-Time (JIT) basis, and their operation is controlled and / or synchronized by controller 560 (or an additional controller 560) according to the desired cycle time. In one embodiment, feeder line 570-1 at least partially corresponds to inlet cap feeder line 490-5 and supplies a newly manufactured inlet cap to cut-off station 526. Feeder line 570-2 supplies fasteners to cut-off station 526. Feeder line 570-3 supplies fasteners to spar mounting station 530. Feeder line 570-4 supplies sealant to spar mounting station 530. Feeder line 570-5 provides fasteners to rib mounting station 528, and feeder line 570-6 provides sealant to rib mounting station 528. In another embodiment, additional / other feeder lines provide newly manufactured ribs, fasteners, and sealant to various work stations, such as spars and lower panels.

[0096] In one implementation, the upper wing plate advances through... FIG. 5A Workstation 520 is shown, followed by the lower wing. As briefly described above, the lower wing does not receive ribs or spars (i.e., because these components are already attached to the upper wing). It will become clear that cutting stations (such as cutting station 526) perform most of the work on the lower wing, while most of the work on the upper wing involves installing ribs and spars.

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

[0098] In this embodiment, each workstation in the workstation 520 of the assembly line 500 inserts, grips, engages, or aligns the rotation feature 210. In addition to (or instead of) physical (e.g., mechanical) connections, in some embodiments, rotation can be facilitated or occur together by reading RFID chips and / or other readable identification devices 126 (e.g., barcodes, etc.) on the wingplate. FIG. 5B An illustrative example of physical connection is shown, illustrating a portion of the wing 550 within the NDI station 524. Among the various structural components of the NDI station 524 is the upper NDI unit 602, which includes an upper frame 614. The upper frame 614 is shown to include an indexing unit 622. In a manner similar to that described above for the indexing unit 542 of the reinforcing backing 540, the indexing unit 622 of the NDI station 524 is physically connected to an indexing feature of the wing 550, specifically by means of a head 624 received in an indexing feature 210-2 located in the manufacturing allowance 554, wherein the indexing feature 210-2 is shown as a through-hole. Similarly, although... FIG. 5B Only one indexing unit 622 is shown, but each workstation 520 may include any suitable number of indexing units 622. Each indexing unit 622 may be configured to engage with an indexing feature of the wing 550, such as for initial alignment and / or maintaining alignment of the wing with the workstation. Like the indexing features, the indexing units 622 may employ any suitable configuration and may include connection devices (such as magnets) other than those used to achieve mechanical connection. The indexing units may be configured to engage with various different indexing features or different indexing features from one wing to another, for example, to enable the workstation to engage with different wings as needed.

[0099] In the illustrated embodiment, the indexing feature 210-1 of the wing 550 is shown as an indexing unit 542 connected to the reinforcing backing material 540, while the indexing feature 210-2 is shown as an indexing unit 622 connected to the NDI station 524. For illustrative purposes, this is intended to illustrate an example indexing configuration and not to suggest that all embodiments require indexing of the wing via physical connection with both the reinforcing backing material and the work station. In some embodiments, one or more work stations are indexed together with the reinforcing backing material supporting the wing, rather than directly with the wing. In some embodiments, one or more work stations are indexed together with the wing 550, rather than with the reinforcing backing material 540. In some embodiments, the work station is indexed together with both the wing and the reinforcing backing material. In any of these embodiments, the reinforcing backing material may also be indexed together with the wing.

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

[0101] In one embodiment, indexing is performed at least according to a wing plate 550 supported on a strong backing material 540 moving along a track 510, which includes a guide rail system located above a work station 520. The guide rail system may be coupled to a structure (such as a ceiling) or floor above the crane frame or work station (such as embedded in the floor, bolted to the floor, etc.) or may be coupled to another part of the factory. The wing plate 550 has been manufactured on a laying mandrel 110 according to the precise dimensions described above. Because the laying mandrel 110 has precisely accommodating surface features, and because the prefabricated part 200 for the wing plate 550 is laid on and conforms to these surface features, the wing plate 550 includes indexing features 210 precisely positioned within a manufacturing allowance 554. Therefore, once the wingplate 550 is indexed and suspended under the strong backing material 540 and pushed to the work station 520, the 3D position and rotation (including profile 544) of the wingplate 550 are transferred through indexing and precisely known at the work station 520. Thus, indexing eliminates the need for, for example, full scanning at each work station 520 via probes or robust optics. As needed, this information is provided to the work station 520 as part of the indexing, for example via information provided by an RFID chip. This allows a line to work sequentially on different parts of the aircraft (e.g., right and left wingplates, upper and lower wingplates) and even on different parts (e.g., wingplates) of different aircraft models. Therefore, the characteristics of the wingplate 550 within the range of the work station 520 are transferred to the work station as part of individual pulses or micro-pulses. Since the wingplate has more variation between pulse positions compared to the fuselage panels, the manufacturing allowance at the wingplate can include a large number of surface features to facilitate indexing.

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

[0103] The operation of workstation 520 is managed by a controller, which is typically located in... FIG. 5AThe controller 560 is designated as such. In one embodiment, the controller 560 determines the advance of the support material 540 along the track 510 (e.g., based on input from a technician) and uses this input to manage the operation of the work station according to instructions stored in the NC program. For example, the controller 560 may be implemented as custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

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

[0105] FIG. 5B This is a front view of the NDI station 524 in the exemplary embodiment (and as described above, corresponding to...). FIG. 5A The view arrow “5B” in the diagram shows the process of inspecting the wing 550, which is shown in cross section. FIG. 5B Examples of inspection techniques and systems that can be implemented, for instance, before the ribs and spars are mounted onto the wingplate. FIG. 5B A strong backing material 540 is depicted suspending the wing plate 550 below it. The NDI station 524 is set at the track 510 and inspects the wing plate 550 while it is suspended below the strong backing material 540.

[0106] FIG. 5BThe NDI station 524 shown includes an upper NDI unit 602 and a lower NDI unit 604. The upper NDI unit 602 includes a support 612 and a frame 614 that carries one or more NDI inspection heads 606 (shown as upper NDI inspection head 608), which are configured to move relative to the flange 550 and inspect its upper surface 574. The lower NDI unit 604 of the NDI station 524 is also shown including a frame 618 and a support 616 that carries additional NDI inspection heads 606 (shown as lower NDI inspection head 610) in a manner that allows the inspection heads to inspect the lower surface 576 of the flange 550. For simplicity, the NDI inspection head 606 is also referred to as an "inspection head," or simply a "head." The inspection heads 606 can be movable – that is, they can be configured to move relative to the upper NDI unit 602, the lower NDI unit 604, and / or the wing plate 550, or they can instead be stationary or fixed. For example, in the illustrated embodiment, the upper inspection head 608 is shown in the process of moving relative to the upper surface 574 of the wing plate 550 (e.g., by means of a track and / or drive or any suitable mechanism (not shown) of the upper NDI unit 602) via directional arrow 1002. Some or all of the lower inspection heads 610 can also be movable, in which case they can be independently movable, configured to move in an array-like manner, etc., or they can be stationary. Additional embodiments may include, except... FIG. 5BAny number or configuration of inspection heads other than those shown. Moving inspection heads can be used to perform surface inspections during pauses between forward or other movements of the wing 550 relative to the NDI station 524, such as by individually traversing different areas of the surface of the wing 550. Fixed inspection heads can be used to perform surface inspections as the wing 550 pulses or otherwise moves relative to the NDI station 524. For efficiency, the arrangement of the inspection head 606 relative to the NDI station 524 and / or the wing 550 as it advances through the work station 520 can be such that the inspection head is positioned at locations of interest, e.g., locations where out-of-tolerance conditions are more likely to be found, such as locations where previous wing inspections and / or analyses of the previous wing indicate that inspection is necessary or desired, and not positioned where inspection is less likely. Other arrangements of inspection heads may be used depending on the expectations or needs of a particular application. Some embodiments may include upper and lower inspection heads arranged in pairs on either side of the wing 550, such as to perform through-transmission inspection techniques. In some embodiments, an inspection head 606 is configured to inspect the entire surface or multiple surfaces of the wing 550. For example, in another embodiment, a fixed NDI inspection head is configured such that the inspection occurs during pulsation, and the inspection head is configured to cover the entire surface without head movement. This configuration can be used for both upper and lower surfaces and can be implemented with less complexity than systems utilizing a moving head. The inspection head 606 discussed herein may include an ultrasonic transducer that emits ultrasonic energy that penetrates the wing 550 to characterize the internal features of the wing. The operation of the inspection heads 606 (e.g., upper inspection head 608 and lower inspection head 610) is managed by a controller shown at 620, which operates an NC program to coordinate the movement of the inspection heads to facilitate scanning of the wing 550 in pulsating echo or transmission mode. Controller 620 may interface with and be different from controller 560. In some embodiments, controller 560 may provide the aforementioned functions of controller 620.

[0107] As described above, in the illustrated embodiment, the NDI station 524 is shown as being physically rotated to the wing plate 550 by means of the NDI station's rotation unit 622, the head 624 of which is received within the rotation feature 210-2 of the wing plate 550.

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

[0109] In another embodiment using the strong backing material 540, the position of the contacting strong backing material on the wing 550 (e.g., by means of the spring 545 and the vacuum connector 548) is checked via NDI before the wing is suspended under the strong backing material.

[0110] FIG. 7 This is a flowchart illustrating an implementation of a method for inspecting a wingplate designated as method 820. Method 820 is performed in a series of steps, including referencing FIG. 5B And in FIG. 1 to FIG. 4 and FIG. 5AThe components and structures shown describe the actions. Method 820 is shown to begin with step 822, which includes suspending the wing 550 below a shuttle device (such as a strong backing material 540). In one embodiment discussed above, suction is applied via a retractable vacuum coupler 548 to hold the wing 550 in place and apply a desired profile 544 to the wing 550. Specifically, the vacuum connection of the vacuum coupler 548, the inflexibility of the strong backing material 540, and the extensibility of the spring member 545 allow for profile application to the wing 550. The spring member 545 is removably coupled to the wing 550 to manipulate it into the desired profile.

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

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

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

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

[0115] In some embodiments, as described above, the position of the wingplate 550 relative to the NDI station 524 is monitored by transposing the wingplate to the NDI station, such as by means of various transposition features and / or RFID chips. In some embodiments, transposing the wingplate directly or via a strong backing material supporting the wingplate to the work station transmits information about the wingplate to an NDI station controller, which can then guide an NDI inspection of the wingplate based at least in part on that information. In some embodiments where the transposition feature is located within the wingplate's manufacturing allowance, the manufacturing allowance is typically not inspected.

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

[0117] As noted above, in some embodiments, an NDI inspection is performed as the wingplate is advanced past the NDI inspection head. This can be done regardless of how the wingplate is conveyed (e.g., via a strong backing or other means). FIG. 8 A method 840 for inspecting the wing plate 550 in an exemplary embodiment is further described. According to... FIG. 8 Step 842 includes receiving the wingplate 550 at the NDI station 524. Step 844 includes inspecting a portion of the wingplate 550 via the NDI station 524 during the wingplate's movement through the NDI station. The wingplate may be advanced intermittently or continuously through the NDI station, wherein inspection is performed during the wingplate's movement through the NDI station. Similar to method 820, in method 840, the NDI station may include movable and / or fixed NDI inspection heads. In one embodiment, the wingplate remains suspended below a strong backing material when it is at the NDI station. In another embodiment, the movable inspection head of the NDI station passes through different areas of the wingplate individually via the movable inspection head of the NDI station. In this way, inspection includes moving the inspection head relative to the wingplate while operating the inspection head array at the NDI station.

[0118] Back FIG. 5A The intermediate length portion 578 of the wing plate 550 is shown within the cutting station 526. Broadly speaking, the cutting station 526 is configured to remove material from the wing plate 550, for example, within the manufacturing allowance 554 or elsewhere. In some embodiments, the cutting station 526 cuts away one or more areas of the wing plate 550, for example, to install openings (such as entrances to be utilized in downstream workstations), such as to allow access to the internal volume between the wing plates after they have been joined together at a connecting station. While not essential for all embodiments, such entrances are typically installed in the lower wing plate, as opposed to the upper wing plate. This is in accordance with discussions related to padding operations (e.g., regarding...). FIG. 16A to FIG. 16C and FIG. 17A to FIG. 17CAs will become clear herein (as shown and described), in some embodiments, the lower wing plate is provided with multiple entrances that allow access to the compartments between adjacent ribs, for example, to facilitate the installation of pads by a robotic arm. Therefore, in such embodiments, the cutting station 526 can perform more operations on the lower wing plate than on the upper wing plate. In either case, the cutting station 526 can install an entrance cover and / or door into the wing plate 550, along with edge sealing, painting, and performing fastener drilling and installation (as applicable to the wing plate). In some embodiments, edge trimming for manufacturing allowances and entrance trimming are performed at different work stations.

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

[0120] FIG. 5C Corresponding to FIG. 5A The diagram shows a top view of assembly line 500, but with the reinforcing backing 540 shown as having been advanced along the process direction 541, such that the wing root 577 of the wingplate 550 is located within the rib mounting station 528. For simplicity, FIG. 5C Not shown in the middle FIG. 5A Some aspects (e.g., various feeder lines, etc.). FIG. 5D It shows the corresponding FIG. 5C A simplified side view of the view arrow "5D", where the view is omitted. FIG. 5C Some components are visible in the diagram to better illustrate the ongoing configuration / progress of the wing panel 550 to the wing assembly 600. As described above, rib mounting station 528 secures (in other words, temporarily and / or permanently mounts) rib 572. For ease of explanation, although rib 572 is generally more complex in configuration and appearance, rib 572 is shown in a simplified form in these views, as described in more detail below.

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

[0122] FIG. 5C The use of a moving station 552 (also referred to as a “follower”) is also illustrated, which is configured to engage with the wing plate 550 and the reinforcing backing 540 and perform work (such as trimming, fastening, applying sealant, etc.) by traveling across the wing plate 550, for example, along a moving station track 551 that can be removably mounted to the wing plate 550. While not required in all embodiments, the moving station 552 can perform work during pulsations (e.g., micro-pulsations), pauses (e.g., between micro-pulsations), or continuous movement of the wing plate 550 as the wing plate 550 advances through the assembly line 500. Depending on the design, the moving station 552 can “advance” (or “follow”) the wing plate 550 in multiple pulsations across multiple work stations 520 and can operate independently of other work stations on the assembly line 500. In this process, the position and size of the gaps (e.g., spacing) between the reinforcing backings 540 allow for the placement of the moving station track 551 and / or the moving station 552. In another embodiment, chute and other complementary elements are provided at the factory, such that the moving station 552 passes through or traverses these elements during the manufacturing process. The moving station 552 can travel along the return line (in... FIG. 5C (As shown at 547) Removed and fed, for example, in the opposite direction to process direction 541 (e.g., upstream of assembly line 500) to be installed on the next wing as needed. In another embodiment, one or more of the reinforcing backing materials 540 form a “smart bridge” by dynamically moving relative to the wing 550, so that the moving station 552 can enter the wing 550 to the maximum extent.

[0123] As mentioned above, FIG. 5DThis is a simplified side view of a portion of assembly line 500, showing a wing 550 with attachment ribs 572 conveyed along track 510 and simultaneously suspended below an assembly of three reinforcing backings 540. As briefly described above, one or more adapters 543 may facilitate the movement of the reinforcing backings 540 along track 510. Ribs 572 are attached to the lower surface 576 of the wing 550 at a suitable angle (indicated by angle θ). As will be explained below, in some embodiments, ribs 572 are vertically aligned and raised to the appropriate position for attachment to the lower surface 576 of the wing 550 (or more specifically, the upper wing). Thus, the wing can be suspended below the reinforcing backings at an angle corresponding to and / or facilitating the installation of the ribs at angle θ. This is in FIG. 5D As shown, the wingplate 550 is slightly inclined upward from the wing root portion 577 to the wing tip portion 579.

[0124] FIG. 5D Another view is also provided showing an exemplary configuration of the spring 545 and the vacuum connector 548. In the illustrated embodiment, the vacuum connector 548 is capable of angular deflection relative to the spring 545 and the reinforcing backing 540. Angular deflection can be facilitated by a common type of connection at the point where the vacuum connector 548 is connected to the spring 545 and / or at the point where the spring 545 is connected to the reinforcing backing 540. Angular deflection can adapt the connection with the wing 550 during changes in the wing profile to suspend the wing, etc., at a desired angle (as shown). Due to the angular flexibility of the vacuum connector, the wing can be suspended at any desired angle by adjusting the spring to the appropriate length. In another embodiment, the carrier 545, configured in a different manner, clamps the upper surface 574 of the wing 550 (e.g., via clamping, interference fit, etc.). As explained in detail above, a desired profile can be implemented by adjusting the spring 545 to a predetermined length, which corresponds to the desired vertical tilt angle of the profile at each of a plurality of chordal and spanwise positions.

[0125] As described above, several factors can determine the position of the spring member 545 and its corresponding vacuum connector 548 relative to the upper surface 574 of the wing 550, such as in shaping the wing 550. In some embodiments, one factor is the manner in which the ribs and spars are attached to the wing. For example, the spring member 545 and the vacuum connector 548 can be positioned such that the position of the vacuum connector 548 on the upper surface 574 is spaced apart from the corresponding position on the lower surface 576 of the wing that attaches the rib 572 to the wing (e.g., ...). FIG. 5D (See the view shown). For example, this can be done to allow the manufacture of an entry point to the rib 572 mounting area and can facilitate manual or automatic drilling and fastener installation to connect the rib to the wing plate.

[0126] exist FIG. 5DIn the diagram, one rib 572 is shown as a portion attached to the wing panel 550 within the rib mounting position 528. Other ribs 572, shown as portions attached to the wing panel 550 that have been advanced through the rib mounting position 528, are installed while these portions are within the rib mounting position 528. Although four are shown, in an actual wing assembly 600, the number of ribs 572 can and often is greater. FIG. 5D The winglets, ribs, spars, and other components shown in the accompanying drawings are for illustrative purposes only and are not necessarily drawn to scale or with contour lines. For example, rib 572 is shown in a simplified schematic form in this series of drawings. Later drawings (such as...) FIG. 11A to FIG. 11D and FIG. 17A to FIG. 17C The illustrative ribs are shown in more detail. The rib configuration or number of ribs 572 in the actual wing assembly 600 may differ from those depicted herein.

[0127] FIG. 5E (corresponding to) FIG. 5A and FIG. 5C The top view of assembly line 500 (as shown in the image) illustrates that the wing plate 550 has been conveyed by the reinforcing backing material 540 to the wing sparb mounting station 530, where the wing sparb 580 is attached (e.g., as part of a full-pulse process). In this embodiment, the wing sparb 580 is mounted after the rib 572, but in some embodiments, the rib 572 is mounted before the wing sparb 580. Furthermore, FIG. 5E The diagram shows individual spars (generally designated 580) assembled from multiple separate spar sections, each spar section designated 580-1 to 580-7 (however, unless otherwise specified, reference numeral 580 is used herein to refer to a spar, as well as a spar section or spar portion). The spar mounting station 530 can be accessed from one or more feeder lines 570 (representative feeder lines in...). FIG. 5E(As shown in the diagram) receiving pre-assembled spar 580, or individual spar segments or portions (e.g., 580-1 to 580-7) assembled at the spar installation station, or both. In embodiments where spar segments are provided to the spar installation station 530, the spar segments may be assembled to each other before being installed to the spar, for example to form a portion or the entire spar that will then be installed to the spar, and / or the spar segments may be installed to the spar as spar segments, thus forming a spar when they are installed separately. Additional components such as fasteners, sealants, etc., are also supplied to the spar installation station 530 to facilitate installation. After installation, the backing material 540 conveys the spar 550 back to the track 510, and the spar 550 is also conveyed to receive additional work. In the illustrated embodiment, the backing material 540 advances to the spar installation station 530 in any suitable manner (such as a redirection track (not shown) configured to allow movement along direction 1004 to the spar installation station 530). After installation, the reinforcing backing material can advance back to track 510 in direction 1006 via the same redirection track, for example, by advancing further along track 510 (e.g., toward the panel connection station), or be guided to another track, or advance along a track different from track 510. Another embodiment has a spar installation station 530 arranged along track 510, such that the advancement of the reinforcing backing material 540 in the process direction brings the spar into, through, and out of the station.

[0128] The illustrated configuration is an example of a configuration that allows selective bypassing of work stations 520, such as spar installation station 530. As described above, in some embodiments, the ribs and spars are attached only to the upper wing and not to the lower wing. In such embodiments, in configurations that allow selective bypassing of one or more work stations 520 (such as advancing the upper wing into spar installation station 530, but the lower wing being advanced through that station), efficiency in conveying and / or performing work on the wing can be achieved. In some such embodiments, the lower wing can instead be guided to work stations configured specifically for work on the lower wing rather than the upper wing, such as work stations that cut into the lower wing (e.g., work stations such as cutting station 526). In these embodiments, the attached spar and / or spar section is then fed to spar installation station 530 to attach to the next wing 550 traveling along track 510.

[0129] FIG. 5FAn example is illustrated in which, after work is completed at the spar installation station 530, the wing panel 550 has moved back to track 510 in direction 1006 and is ready to be advanced along track 541 (in a pulsed or continuous manner) in process direction 541 to another work station 520, shown as rib-to-spar attachment station 598 and panel connection station 599, where the lower wing panel can be connected to the upper wing panel already attached with ribs and spars. This operation allows the wing assembly 600 to await the installation of, for example, additional components and / or electrical and other systems.

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

[0131] According to the above text... FIG. 5A to FIG. 5FIt is apparent from the concepts, components, systems, and apparatus discussed that other embodiments of the assembly line 500 consistent with this disclosure may employ configurations different from those specifically illustrated and described. For example, some embodiments may use different sequences of operations connecting the wingplates, ribs, and spars to produce wing assemblies, and may therefore include some or all of the various workstations 520 in different sequences, or workstations other than those shown, or multiple workstations 520, or workstations that perform some or all of the functions of workstations 520 in addition to other tasks, etc. In some such embodiments, instead of separately mounting the spars and ribs to the wingplates (such as the upper wingplate) as in the embodiment shown in assembly line 500, the spars and ribs may instead be attached to each other to form a trapezoidal structure (where the spars act as "rails" of the ladder and the ribs form "runners"), and then this trapezoidal structure is mounted to the wingplate. Therefore, such implementations may include one or more workstations for assembling spars to ribs (from which ribs, spars, or spar portions and fasteners may be supplied) and one or more workstations for mounting rib and spar structures to wing plates and / or mounting rib and spar structures between the upper and lower wing plates. Similar to the illustrated implementation of assembly line 500, the various components and structures supplied to the aforementioned workstations may be configured for JIT delivery to the appropriate workstations.

[0132] Examples of this are in FIG. 5G The diagram shows an alternative configuration of the assembly line indicated as assembly line 500'. FIG. 5G Overall corresponding to FIG. 5C and FIG. 5E A top view of assembly line 500 is shown. However, although FIG. 5C and FIG. 5E The assembly line configuration shown includes rib mounting station 528 and spar mounting station 530 (rib 572 and spar 580 are individually and separately mounted to spar 550 at rib mounting station 528 and spar mounting station 530, respectively), but FIG. 5G The assembly line 500' shown is instead represented as comprising different workstations 520; specifically, a support structure assembly station 532 and a support structure installation station 534. The support structure assembly station 530 is located from one or more feeder lines 570 (representative feeder lines in...). FIG. 5G (As shown in the diagram) A rib 572 and a spar 580 are supplied, along with fastening and / or sealing components. For example, with... FIG. 4The feed lines corresponding to 491-6 and 491-7 shown can provide the wing beams and ribs to the support structure assembly station 532 on time and in the desired sequence for assembly into the trapezoidal support structure indicated at 588. The wing beam 580 can be pre-assembled or completed before being provided to the support structure assembly station 532, or it can be provided to the support structure assembly station as a separate wing beam section or portion (not shown separately) to be assembled with the rib 572 into the support structure 588.

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

[0134] The wing plate 550, equipped with the support structure 588 containing ribs 572 and spar 580, can advance to the panel connection station (such as...). FIG. 5F The panel connection station 599 shown allows another wing panel (such as a lower wing panel) to be installed onto the assembly. (The above refers to...) FIG. 5G The alternative configurations discussed may offer advantages over the configuration shown in assembly line 500, such as avoiding the lateral transfer of the wingplate relative to track 510 for spar installation (e.g.) FIG. 5E (as shown), or the efficiency achieved by mounting the ribs and spars together instead of separately.

[0135] Refer to 5A to FIG. 5G The various components of assembly line 500 presented in the text and described above, as well as the concepts and operations embodied therein, FIG. 9This is a flowchart illustrating a method 860 for manufacturing a wing via an assembly line such as assembly line 500, as an exemplary embodiment. In step 862, the wingplate 550 is suspended below a shuttle device (such as a reinforcing backing material 540) that implements a profile 544 onto the wingplate 550. For example, in one embodiment, a carrier 545 is secured to the wingplate 550 via a vacuum coupling 548 and positioned vertically to implement the profile. As described above, in some embodiments, suspending the wingplate 550 includes indexing the reinforcing backing material 540 together with the wingplate. Indexing can be a physical connection (e.g., physically attached or otherwise linked) between the reinforcing backing material 540 and one or more indexing features mounted in (e.g., within the manufacturing allowance of the wingplate 550). Additionally or alternatively, the transposition feature may include or incorporate a readable identification device (such as an RFID chip / tag or barcode), and transposition includes reading the identification device using a suitable reader (such as an RFID reader, scanner, or barcode reader, etc. (not shown)).

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

[0137] In step 866, structural components such as ribs 572 and spars 580 are installed into the wingplate 550 while contour 544 is being implemented (through a combination of the reinforcing backing 540, the carrier 545, and the vacuum connector). This may include co-joining and / or fastening ribs 572 and spars 580 to the wingplate 550 while the wingplate 550 remains suspended under the reinforcing backing 540. Alternatively, it may involve assembling ribs 572 and spars 580 into a support structure 588, and then installing the support structure to the wingplate 550 while the wingplate remains suspended under the reinforcing backing. In one embodiment, advancing the wingplate 550 includes pulsating the wingplate in the process direction (e.g., by full pulsation or micro-pulsation) and performing the installation of ribs 572 and spars 580 during pauses between pulsations. In another embodiment, advancing the wingplate 550 includes continuously moving the wingplate in the process direction and performing the installation of ribs 572 and spars 580 while the wingplate is continuously moving.

[0138] Although not in FIG. 9 As specifically shown, but in some embodiments, method 860 further includes additional operation stations 520 arranged along the process direction to perform various different operations, such as installing ribs and / or spars, connecting ribs and / or spars to each other and / or connecting them to wing plates, performing rework, inspecting wing plates, cutting / installing inlets, etc. In some embodiments, multiple operation stations 520 are provided to perform the same type of operation.

[0139] Method 860 can provide one or more technical advantages over the prior art, for example, because it enables the wing plate 550 or a portion thereof to remain transposed to various work stations 520 in the manufacturing environment, even when the wing plate is conveyed through multiple work stations 520 to receive jobs. That is, the wing plate 550 remains transposed to the strong backing material 540 during conveyance, which means that the work station 520 can quickly transpose itself to the strong backing material 540, the wing plate 550, or both. Furthermore, the technique of suspending the wing plate 550 under the strong backing material 540 allows for more and more ergonomic access and inspection of the wing plate 550 during the assembly process (e.g., performed by a technician).

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

[0141] Step 886 includes controlling the length of the spring members to implement the profile onto the wingplate while it is suspended below the strong backing material. The spring members can be adjusted independently. In one embodiment, the length of the spring members is controlled by setting them to a predetermined length, while in another embodiment, this includes operating actuators or air pressure to implement specific lengths on each spring member. When all spring members are set to their desired lengths, the wingplate remains aligned with the desired profile of the mounting rib, provided that the vacuum connectors of the respective spring members are correctly positioned for the specific wingplate.

[0142] As described above, in some embodiments, a scan is performed to determine an initial wing profile. If the wing is already in the desired profile, profile modification may not be necessary. In this case, the holding force applied by the individual springs may be less than the holding force if the springs actively modify the wing profile. Adjusting the length of the individual springs relative to the strong backing material (i.e., longer or shorter) to push and / or pull the wing to the desired profile is determined by the wing's design parameters. The position of the vacuum couplings of the springs is precisely positioned relative to the upper surface of the wing to ensure that the profile modified by the springs conforms to expectations when the springs are at the desired length.

[0143] As described above, various aspects of the assembly line 500 (or 500') for wing components are shown, including the operations that occur as the wingplate 550 advances through the various work stations 520 arranged along the assembly line.FIG. 5A to FIG. 5G In order to facilitate explanation, many systems, operations and components are shown in a simplified form and / or schematically (e.g., rib 572). FIG. 11A to FIG. 11D The installation of additional components onto the wing panel 550 during the production of the wing assembly 600 is illustrated in more detail. Specifically, FIG. 11A to FIG. 11D The installation of rib 572 to wingplate 550 at rib mounting station 528 is shown. In the illustrated embodiment, this wingplate is upper wingplate 550-1. Therefore, for convenience, wingplate 550 may be referred to as "upper wingplate 550-1" or simply "wingplate 550-1" in the following sections. The term "wing assembly" refers to the structure produced when wing components (such as wingplates, ribs, and / or spars) are assembled together. As described in more detail below, FIG. 11A This illustrates how rib 572 is moved to a position below upper wingplate 550-1 by means of a shuttle device, and FIG. 11B and FIG. 11C The rib is shown to be raised upward toward the lower surface of the upper wing for mounting to that lower surface. FIG. 11D The resulting wing assembly 600 is shown, wherein rib 572 is mounted to wingplate 550-1, and a pair of spars 580 are mounted at either end of rib 572.

[0144] FIG. 11A and FIG. 11B The view shown generally corresponds to FIG. 5C The view indicated by arrow "11" shows the wing 550-1 in a chordal section. As explained above, the wing 550-1 is suspended below the strong backing material 540 by means of a spring 545, which is connected to the upper surface 574 of the wing via a vacuum coupling 548. The wing 550-1 or at least FIG. 11A The section shown is located within the rib mounting station 528. As detailed in the discussion above, the flange 550-1 can be directly or via one or more of the supporting backing materials 540 to the work station 520. The flange 550-1 is shown having a plurality of longitudinal beams 640 mounted to its lower surface 576, which are shown to have a T-shaped cross-section. Although six longitudinal beams 640 are shown, more or fewer longitudinal beams may be used for specific upper flanges and / or ribs 572, and / or for specific locations along the spanwise length of the flange. In the assembly line (such as...) FIG. 5A to FIG. 5F Assembly line 500 (and / or shown) FIG. 5G In the context of the assembly line 500' shown, the longitudinal beam 640 may be installed at any point upstream of the rib mounting station 528 prior to rib mounting, or provided during the initial manufacturing of the upper flange from the precast component.

[0145] Although multiple rib configurations are possible and within the scope of this disclosure, FIG. 11A to FIG. 11DRib 572 is shown as an elongated solid structure including a web 646, which is reinforced (i.e., retains the profile) by a stiffener 648 (e.g., a beam or bracket that profiles the rib before it is secured to the flange 550). The top and bottom edges of rib 572 are shaped to follow the corresponding profile of the flange to which rib 572 will be mounted, and are provided with a plurality of openings or “rat holes” 650, the size of which is determined and positioned to accommodate, for example, a longitudinal beam 640, as well as cables and other structures (not shown) that can be mounted. For a similar purpose, web 646 also includes a plurality of access holes 652 positioned inwardly from the edge of the rib.

[0146] exist FIG. 11A In the middle, rib 572 is advanced into the position, and in one embodiment, it enters the rib mounting station 528 from a feeder line (denoted as 570), which may be a rib feeder line (such as rib feeder lines 491-7) that supplies rib 572 to the rib mounting station 528 in a just-in-time or JIT schedule. More specifically, in FIG. 11A In this configuration, rib 572 is kept vertically oriented while being conveyed via trolley 700 (e.g., a manually operated or automated trolley, autonomous guided vehicle (AGV), etc., propelled on a guide rail). As described above, rib 572 can be fed to trolley 700 via a timed feeder line and can move during pauses between pulses to enter rib mounting station 528. In the illustrated configuration, trolley 700 is propelled perpendicular to the process direction of wing plate 550. Trolley 700 is shown driven by wheels 702 (e.g., motorized wheels) on floor 710, but may alternatively be mounted on guide rails or tracks, etc. The wheels 702 drive chassis 708, which translates chassis 708 horizontally / laterally in direction 1008, thus conveying rib 572 to a position / location directly below wing plate 550. The trolley 700 may include indexing features (not shown) to facilitate indexing of the trolley relative to the rib mounting station 528 to ensure proper positioning of the shuttle relative to the rib mounting station before advancing to a position below the wing plate 550, and / or proper positioning of the shuttle (and therefore the rib) relative to the upper wing plate 550-1 when the shuttle is advanced to the appropriate position. This indexing feature may take the form of a cup cone of a cup cone indexing system, a hard stop, and / or other configurations. The chassis 708 holds one or more actuators 704, and supports 706 fixed to the actuators 704. The supports 706 are configured to support the ribs 572 in a vertical orientation. The actuators 704 (or other lifting devices) are configured to vertically drive the supports 706, such as to vertically lift the ribs 572 into contact with the lower surface 576 of the wing plate 550.

[0147] FIG. 11BThe rib 572 is shown after it has been driven vertically upward in direction 1010 to contact the lower surface 576 of the upper flange 550-1 (e.g., onto the rib area). It can now be seen more clearly that the size of the rat hole 650 provided along the upper edge of the rib 572 is determined and positioned to receive the longitudinal beam 640. The clearance between the rib 572 and the longitudinal beam 640 at the rat hole 650 can be greater than or less than the clearance shown in the figure. During attachment to the flange, the rib 572 is held in the desired orientation and position by the support 706. Although the term "installation" has been used in the preceding discussion in this disclosure, the term can include both temporary and permanent attachments. Therefore, when rib 572 first contacts the wing plate, the connection can be temporary (e.g., by clamping and / or nailing rib 572 into place) or permanent (such as by using temporary or permanent fasteners (e.g., via automated or manual drilling and fastener installation techniques, before and / or after removing trolley 700), or rib 572 can be permanently secured while aligning with the upper wing plate 550-1. In some embodiments (e.g., referenced below) FIG. 16A to FIG. 16C and FIG. 17A to FIG. 17C In the embodiments described further, after the rib 572 has been temporarily secured to the wing plate but before it is permanently installed to the wing plate, a shim may be installed to fill the gap between the rib and the wing plate interface. In either case, once connected to the upper wing plate 550-1, the coupling device holds the rib 572 in the desired position, so the trolley 700 can be removed.

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

[0149] FIG. 11C Corresponding to FIG. 11BThe view arrow 11C further illustrates the relationship between the trolley 700, rib 572, and upper wing plate 550-1. FIG. 11C Also illustrated in this embodiment, the upper flange 550-1, and specifically its lower surface 576, includes an alignment feature 584 configured to align with a complementary alignment feature 586 at the rib 572. The configuration of alignment features 584 and 586 can be any configuration that achieves alignment between the rib and the upper flange 550-1, such as a cup-cone configuration. Multiple corresponding indexing feature pairs may exist for each rib. Furthermore, in some embodiments, the alignment feature 584 is installed as an indexing feature 210 during the manufacture of the upper flange 550-1. These alignment features facilitate the alignment of the rib 572 before it is fastened to the upper flange 550-1. Thus, in one embodiment, lifting the rib 572 includes engaging the rib 572 with the alignment feature 584 at the flange 550. The rib 572 is delivered to the rib mounting station 528 in a just-in-time (JIT) manner as needed from the parallel assembly line / feeder line. In this way, different ribs are continuously generated in a pulsating environment as needed for placement in the wing assembly 600.

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

[0151] Based on the components and operations discussed above, FIG. 12This is a flowchart illustrating, in an exemplary embodiment, a method 900 for mounting ribs to an upper wingplate during the production of a wing assembly. The description of this method will refer to the components and concepts discussed above and shown in the accompanying drawings; however, the method is applicable to various setups. Step 902 includes suspending the upper wingplate 550-1 of the aircraft under a shuttle device (such as a reinforcing backing material 540). According to many of the methods described above, this step may include (and / or previously) demolding the upper wingplate 550-1 from a laying mandrel, transposing the upper wingplate to the reinforcing backing material 540, and / or coupling the wingplate to the reinforcing backing material (such as a vacuum coupling 548 via a spring member 545) to hold the upper wingplate while the profile is applied to it.

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

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

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

[0155] In step 908, rib 572 is positioned to contact the upper wingplate. As described above, this can be done by vertically lifting the rib, such as by using an actuator 704 of the drive trolley 700 to raise the rib 572 to contact the lower surface 576 of the upper wingplate 550-1. In some embodiments, this can be done by lowering the upper wingplate to contact the rib, such as by means of a spring 545 of a strong backing material 540. In some embodiments, a combination of lifting the rib and lowering the wingplate is performed to bring the components into contact. In some embodiments, positioning the rib 572 to contact the upper wingplate 550-1 includes engaging the rib with one or more indexing features of the wingplate (such as by means of... FIG. 11C The connection alignment features 584 and 586 are shown. This ensures the final precise alignment of rib 572 with upper flange 550-1.

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

[0157] In step 910, rib 572 is secured to upper wing 550-1 while the upper wing remains suspended under the reinforcing backing 540. As used herein, securing includes both temporarily holding the rib in place (e.g., by nailing, clamping, and / or other techniques) and permanent installation. In some embodiments, rib 572 is held in place prior to permanent installation, such as to allow for selective installation of gaskets into clearance (if any) at the rib-to-wing interface. In some embodiments, installation includes driving or otherwise passing mounting fasteners through upper wing 550-1 and rib 572. These operations may be performed via an end effector for mounting locking bolts or by other means. In some embodiments, to avoid hindering or interfering with the fastening operation, vacuum attachment is performed via a vacuum connector 548 located between or in between, but in any case, different from, the rib mounting locations. Therefore, in such an embodiment, the vacuum connector 528 is disposed on the wing 550 such that the position of the vacuum connector does not interfere with operations such as nail fastening and / or permanent fastener installation of the rib 572 performed by a technician or by automation.

[0158] Steps 904 (translating the rib), 908 (positioning the rib to contact the wingplate), and 910 (attaching the rib to the wingplate) are performed while the wingplate 550 is suspended and / or while keeping the rib 572 vertical and upright. One or more steps, or all steps, of method 900 are performed at the rib mounting station. Method 900 or a series of steps thereof can be performed repeatedly to mount multiple ribs 572 onto the same wingplate 550.

[0159] Method 900 offers technological advantages over existing systems and techniques because it enables the implementation of a profile on the winglet 550 and the rapid installation of the rib 572 into the winglet while maintaining the implemented profile. By keeping the rib vertically oriented throughout the installation process, Method 900 can save labor and increase efficiency in the factory shop and / or assembly line.

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

[0161] Mounting the ribs and spars to the wingplate and to each other can include any suitable technique, including those disclosed herein. Some embodiments of method 900 continue, such as connecting the lower wingplate to the ribs and spars already mounted to the upper wingplate. See below for reference. FIG. 16A to FIG. 16C A more detailed explanation of one way to perform this operation is provided. FIG. 16A to FIG. 16C This illustrates one method of installing shims during the assembly of wing components.

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

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

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

[0165] Furthermore, in some embodiments, the spar 580 (or spar portion) is connected to the rib 572 before the rib is fixed to the wing plate (such as the upper wing plate 550-1) to create a trapezoidal structure with horizontal openings (such as the support structure 588). FIG. 5G The wing assembly is then mounted in the best visible position, and the upper and lower wing panels 550 are then installed onto the horizontally open trapezoidal structure. FIG. 14 This is a flowchart illustrating another method 940 for assembling a wing assembly in such an embodiment. This embodiment includes connecting a sparsor 580 to a rib 572 in step 942. Then, in step 944, an upper wingplate 550 is connected to one side of the spars 580 and rib 572 or support structure 588. This process may involve suspending the upper wingplate 550-1 under a shuttle device (such as a strong backing material in other example methods) and raising the support structure 588 of the connected ribs and spars in place to secure it to the upper wingplate. In some such embodiments, all ribs and spars are fastened together before being connected to the upper wingplate; in other such embodiments, additional ribs and / or spars or spar sections are attached to the wing assembly after the support structure 588 is connected to the upper wingplate. In step 946, the lower wingplate is finally connected to the opposite side of the support structure 588 of the connected spars 580 and rib 572 to complete the wing assembly.

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

[0167] FIG. 15This is a flowchart illustrating aspects of multiple operations performed simultaneously or concurrently on a wingplate in an exemplary embodiment, and shows a method 960 for assembling a wing or wing assembly (such as by attaching ribs and spars to the upper wingplate). Step 962 includes suspending the upper wingplate 550-1 of the aircraft below a shuttle device (such as a strong backing material (e.g., strong backing material 540)). Step 964 includes attaching one or more ribs 572 and one or more spars 580 (or portions of spars 580) to the upper wingplate 550 simultaneously or at least concurrently on a work station 520 located at the upper wingplate while the upper wingplate remains suspended. Step 966 includes pulsating the upper wingplate through the work station 520 in the process direction. In some embodiments, an additional work station 520 also performs operations on the wingplate during these operations, including installing inlets (at the cutting station), attaching ribs to spars (at the rib-to-spar attachment station), etc. In another embodiment, the work station installs the ribs and spars during pauses between pulsations of the upper wingplate. In yet another embodiment, the method further includes securing the lower wingplate to the ribs and spars mounted to the upper wingplate.

[0168] Various aspects of wing assemblies (such as mounting ribs and spars to the wingplate) may involve installing shims between the wingplate and one or more ribs and / or spars, for example, where any gap between the individual components exceeds a specific dimension (such as a shim tolerance threshold). This can occur, for example, after the ribs and spars have been clamped and / or nailed into place, but after the ribs and spars have already... FIG. 5A Before fastening the components together in assembly line 500, shims are installed. Once the components have been positioned and nailed / clamped into place, shims are filled into the gaps between the various components (e.g., between ribs and upper or lower wingplates, between spars and upper or lower wingplates, between ribs and spars, etc.).

[0169] FIG. 16A and FIG. 16B This is an illustrative embodiment illustrating the automated installation of gaskets between the ribs and the wing plates (specifically, by means of an end effector of a robotic arm that can be detachably connected to the reinforcements of the respective ribs). More detailed and as... FIG. 16A and FIG. 16B As shown, the wing assembly 600 is suspended below a strong backing material (not shown) by means of a length-adjustable spring 545, which includes a vacuum connector 548 connected to the upper surface 574 of the wing plate 550 of the wing assembly. FIG. 16A An embodiment of the wing assembly 600 is shown, comprising a wingplate 550 in the form of an upper wingplate (indicated by 550-1), while FIG. 16BAn embodiment is shown in which the wing assembly 600 also includes a second wing 550 in the form of a lower wing (indicated by 550-2). The wing assembly 600 is shown as having a plurality of ribs 572 fixed to the lower surface 576 of the upper wing 550-1.

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

[0171] Although other configurations are possible, FIG. 16AIn this design, the robotic arm 750 is shown as an actuator 760 and a kinematic chain of a rigid body 762 extending from a carriage 764. The carriage 764 is in turn mounted on a reinforcement 648 of the rib 572. The reinforcement 648 is also referred to herein as a "support". In some embodiments, such as as described above, the support 648 is mounted to the rib 572 before the rib is mounted to the wing plate 550 to serve as a reinforcement, i.e., to stabilize the rib and / or to implement a desired (e.g., flat) profile to the rib. Thus, in some embodiments, the support 648 serves both as a reinforcement and as a connection point for the robotic arm. In other embodiments, the support 648 may additionally or alternatively serve as a general connection point for a machine or device for moving or otherwise manipulating the rib during manufacturing and / or assembly operations. In some embodiments, the support is removably attached, for example, using bolts or other similar fasteners. As further detailed below, the connection between the slide 764 of the robotic arm 750 and the support 648 of the rib 572 is a removable connection, allowing the robotic arm to be connected to and disconnected from the support via the slide 764 detachably mounted on the support. Furthermore, in the illustrated embodiment, the connection allows the slide 764 to move independently along the length of the support, such as to facilitate the robotic arm's access along the length of the rib 572 to the gap and / or shim position 758 (e.g., unrestricted shim position 758).

[0172] The robotic arm 750 can be moved (e.g., repositioned) from one support to another (such as by detaching from the first support and then attaching to the second support) to operate at different locations along the wing assembly 600. FIG. 16A In the illustrated embodiment, this is accomplished by means of a trolley 770. The trolley 770 includes a set of wheels 772 mounted and configured to support a trolley body 774 relative to a surface (such as a floor surface). One or more wheels 772 may be motorically or otherwise driven. The trolley body 774, in turn, supports a telescopic lift 776 configured to engage and raise or lower a carriage 764. Thus, the trolley 770 is configured to position the carriage 764 for engagement with a bracket 648, or to move the carriage to a position where it can be engaged with a bracket of a second rib after separation from the bracket of the first rib 572, such as by a combination of raising or lowering the lift 776 and moving the trolley body relative to the floor surface (and / or rib 572) by means of the wheels 722.

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

[0174] FIG. 16A A shim feeder line, schematically represented by 780, is also shown, configured in the illustrated embodiment to supply shims 756 (such as unrestricted shims 756) for mounting by a robotic arm 750. In some embodiments, the shim feeder line 780 is configured to dynamically manufacture shims 756 (such as unrestricted shims 756) for mounting, based on input received from an end effector 752, such as in response to signals or communications provided by an operator and / or controller 778, which is configured to measure or otherwise evaluate various gaps encountered during analysis.

[0175] Therefore, it can be seen that an example operation for automated shim installation of a wing assembly can be performed by evaluating individual locations in a series of locations within the wing assembly (such as, for example, individual locations in a series of locations where previous analysis indicated the presence (or potential presence) of shim location 758) or the overall arrangement of individual joints in joints between connected components. In one example, the carriage 764 of the robotic arm 750 is sequentially coupled to a bracket 648 mounted to each of a plurality of ribs 572 of the wingplate 550 to perform detection and analysis of individual gaps and / or shim installation for each shim location 758 in a space defined by one or two adjacent ribs 572. This space is also referred to as a compartment 790. As described above, in such an example, the carriage 764 can move along the bracket 648 to allow inspection and / or installation of the entire length of the rib 572 or at least the sides of the rib (or ribs), which define a compartment for installing the robotic arm 750. FIG. 16A In the illustrated embodiment, five ribs 572 (also indicated as 572-1, 572-2, 572-3, 572-4, and 572-5, respectively) are shown mounted to the upper wing 550-1, thereby forming six compartments 790 (which are individually indicated only as 790-1, 790-2, 790-3, 790-4, 790-5, and 790-6). A carriage 764 is shown as a bracket 648 coupled to rib 572-4, thereby allowing the end effector 752 of the robotic arm 750 to inspect and / or not only mount shims 756 (such as unrestricted shims 756) to the side of rib 572-4 where the bracket 648 is mounted, but also to the side of the next adjacent rib (i.e., rib 572-3) and any other accessible location within compartment 790-4. Therefore, by connecting the carriage 764 of the robotic arm 750 to the brackets 648 of each rib 572, shim mounting can be performed in each compartment 790-1, 790-2, etc. In compartments where there is no bracket 648 to which the carriage 764 can be connected (such as...) FIG. 16B In compartments 790-6, gap inspection and / or shim installation can be performed by moving the robotic arm 750 using a trolley body 774 and a telescopic lift 776. In other embodiments, additional supports can be installed to allow the robotic arm 750, mounted solely by means of the supports, to perform inspection and / or shim installation. Different wing assemblies may have more or fewer ribs (and correspondingly more or fewer compartments). In some embodiments, the robotic arm 750 is engaged with the support 648 of the rib 572 before the rib 572 is placed against the wingplate.

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

[0177] exist FIG. 5A As described above, wing assembly 600 is shown to also include lower wingplate 550-2. Furthermore, telescopic lift 776 is shown extending through inlet 792 in lower wingplate 550-2 to access support 648, such as to attach carriage 764 to (or detach from) the support. Inlet 792 may already be located at upstream work station 520 (such as...). FIG. 16A The robot arm 750 (including carriage 764) is installed at the cutting station 526 shown. The inlet 792 is sized to allow insertion and subsequent removal of the robot arm 750. To minimize the size of the inlet 792, the robot arm 750 may be extended, folded, or otherwise aligned to have a configuration with a minimum cross-section for insertion and withdrawal through the inlet. Alternatively, the robot arm 750 may be specifically designed and / or configured to match a predetermined inlet size. The lower wing 550-2 is shown to include a plurality of inlets 792, one inlet per compartment, to allow the robot arm 750 to be inserted and then engaged to perform inspection and / or shim installation in the respective compartments. In one embodiment, when the robot arm 750 is positioned within a compartment, the robot arm inspects and / or shims fill the sides of two ribs defining the compartment, which reduces the number of times the robot arm 750 needs to be aligned with the inlet 792 for inspection or removal.

[0178] In some implementations... FIG. 16B and FIG. 16A The sequential operation is described in two phases, where the first phase is executed (e.g., ... FIG. 16B As shown, a shim 756 (such as an unrestricted shim 756) (e.g., an upper shim) is installed to a shim position 758 (such as an unrestricted shim position 758) between the rib 572 and the lower surface of the upper wingplate 550-1. Then, the lower wingplate 550-2 is installed to the wing assembly 600, and then a shim (e.g., a lower shim) is installed to a shim position 758 (such as an unrestricted shim position 758) between the rib 572 and the upper surface 574 of the lower wingplate 550-2.FIG. 16A (As shown). In other words, in this embodiment, the lower wing 550-2 is installed after the upper gasket is installed. In other embodiments, FIG. 16B and FIG. 16A Alternative operations are described—for example, FIG. 16B This can represent the first stage of the above sequential operations, while FIG. 16C This can refer to the operation of installing the lower wingplate 550-2 onto the wing assembly 600 before installing any (upper or lower) shims 756 (such as unrestricted shims 756). In either case, the robotic arm 750 can move compartment by compartment along the length of the wing assembly by means of a trolley 770 to perform shim installation in each compartment. As described above, in some embodiments, multiple robotic arms are deployed to simultaneously perform shim position detection and / or analysis and / or shim installation in more than one compartment.

[0179] FIG. 16A The rib 572 of the carriage 764 on which the robotic arm 750 is mounted is depicted (specifically, as shown in the image). FIG. 16A The view shown is of rib 572-4, and therefore corresponds to FIG. 16A The view arrow is 16C. However, FIG. 16C The component shown is applicable to any rib 572 in the illustrated embodiment. For clarity, FIG. 16C Only the slide 764 of the robot arm is shown in the view, and components of the strong backing material (e.g., springs and vacuum couplings) are also not shown in this view. FIG. 16C A view is provided illustrating an example configuration of a bracket or reinforcement 648, shown mounted against the web 646 of rib 572. More specifically, bracket 648 is shown mates with an indexing feature (generally shown as indexing feature 794) at rib 572. The indexing feature facilitates alignment of bracket 648 with rib 572 during mounting and can take any suitable form, such as through holes in web 646 configured to receive fasteners such as bolts. FIG. 16C The bracket 648 is also illustrated, including a rack 796 with teeth 798, to which a carriage 764 is clamped or otherwise removably attached. The carriage 764 is configured to translate back and forth along the bracket 648 in a controlled and indexable manner using the teeth 798 (e.g., via a drive mechanism engaging the teeth, such as a pinion, worm gear, etc.). Therefore, based on the position of the bracket 648 (or relative to the bracket 648) and the position of the carriage 764 along the bracket 648, the position of the robot arm can be indexed relative to a rib (such as the rib to which the carriage of the robot arm is attached). While not necessary in all embodiments, FIG. 16C The support 648 is also shown to include a centering feature 654 that can facilitate rotation (such as by being able to determine the position of the carriage relative to a known reference point more quickly).

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

[0181] FIG. 16C A representative pair of spars 580, mounted at either end of rib 572 to upper wing plate 550-1, is also shown. Spars 580 are illustrated in a simplified form and therefore not shown as including, for example, specialized upper and lower cover shapes that facilitate fastener attachment to the wing plate. Teeth 798 are shown extending sufficiently toward the end of bracket 648, which in this embodiment is connected to the rib 572 to which it is mounted, to allow the carriage 764 to move sufficiently close to the spars so that clearance assessment and / or shim installation by a robotic arm can be performed at the joint between the spar and the wing plate and / or at the joint between the spar and the rib. In another embodiment, bracket 648 facilitates rail mounting of collar and / or nut mounts. This may be particularly advantageous when the lower wing plate has already been installed and access is only possible through an inlet. Furthermore, although rib 572 and wing plate 550 are not shown to precise scale or dimensions, FIG. 17A to FIG. 17C Multiple gaps are shown between rib 572 and the lower surface 576 of upper flange 550-1, such as at representative gasket location 758.

[0182] As described above, in some embodiments, the robotic arm 750 performs operations other than gasket installation, such as gap detection and / or inspection to facilitate the identification of gasket positions 758 (e.g., unrestricted gasket positions 758). In some embodiments, the robotic arm performs additional operations, including sealing, sealant inspection, fastener installation, collar or nut installation on fasteners, collar or nut installation inspection, etc. The robotic arm 750 may perform such operations via selecting interchangeable end effectors 752 (e.g., the end effector can be changed, such as via inlet 792, while the carriage 764 of the robotic arm 750 is coupled to the support 648), or by utilizing a multi-functional end effector 752, or by utilizing multiple robotic arms 750 (each robotic arm can be mounted and remain in the appropriate position on the support; in some cases, more than one such robotic arm is coupled to the support). The robotic arm 750 may be operated automatically or remotely via a floor-based controller that enables a technician to operate the robotic arm (e.g., via remote control). After the robotic arm 750 has completed its work, it can be reattached to the trolley 770 and removed.

[0183] FIG. 17A This is a perspective view of robotic arms 750, each robotic arm 750 operating to inspect clearances in a compartment 790 located between two ribs 572 and defined on one side by a spar 580 of the example wing assembly 600, to install shims 756 (such as unrestricted shims 756) in shim positions 758 (such as unrestricted shim positions 758), to install sealants or collars / nuts, etc. In the embodiments depicted in these figures, a technician sets up, operates, and maintains the robotic arm 750 after the robotic arm's carriage 764 is placed on a support 648 via a trolley (not shown). For simplicity, the following discussion assumes that in each of these figures, the robotic arm 750 operates within the same compartment 790 between the same two ribs 572 (numbered 572-1 and 572-2, respectively). FIG. 17B In this process, a robotic arm 750 is mounted on a bracket 648 that abuts rib 572-1, and operates its end effector 752 to inspect the position of rib 572 abutting against the upper wing plate 550, particularly the position of rib 572-2 between itself and the surface of the wing plate 550 for which it abuts. Based on this inspection, the robotic arm 750 selectively installs shims 756 (such as unrestricted shims 756) at shim positions 758 (such as unrestricted shim positions 758) within the compartment. FIG. 17A In the middle, the slide 764 of the robotic arm 750 is in FIG. 17C Compared to the previous position, the slide 764 of the robotic arm 750 has advanced along the support 648 to a position closer to the end of the support, and is shown using its end effector 752 to inspect a position near the bottom of rib 572-2. FIG. 18 In this embodiment, the robotic arm 750 uses its end effector 752 to place a shim (not shown) at shim position 758 above the support 648, wherein rib 572-1 is secured to the upper wing plate 550. With the shim in place, fasteners can be installed through the upper wing plate 550 and rib 572-1 to secure the wing plate to the rib, or at least a portion thereof located on the shim, where the shim is in place. In some embodiments, the shim is secured in place by means of one or more fasteners; in some embodiments, the shim is held in place by friction engagement instead of friction, since the rib is fastened to the wing plate.

[0184] Considering the aforementioned components and concepts, FIG. 16A to FIG. 17CThis is a flowchart illustrating, in an exemplary embodiment, a method 920 for manipulating a robotic arm (such as robotic arm 750) to perform a task related to the wing assembly (e.g., in wing assembly 600). Step 922 includes mounting a bracket 648 to a rib 572. In some embodiments, this is done before the rib is held or placed against the wingplate 550, such as after the rib is demolded and during (or after) other preparation of the rib for mounting to the wingplate. In some embodiments, this is done after the rib is held or placed against the wingplate. Mounting the bracket 648 can be facilitated by aligning the bracket with indexing features of the rib 572 (e.g., complementary cup-cone features, through holes for receiving bolts, etc.). Once mounted, the bracket 648 implements a desired profile (such as a flat profile) onto the rib 572. In some embodiments, the bracket is removably mounted.

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

[0186] Once connected, in step 926, the robotic arm 750 is operated to install one or more shims between the rib and the wing at the rib-wing interface (i.e., when the robotic arm is connected to the support 648 via the carriage 764). As described above, this may include moving the robotic arm 750 along the length of the support 648 (e.g., by driving the carriage 764) to align the robotic arm 750 with the shim positions at the rib, and / or moving the robotic arm within the range of the additional shim positions.

[0187] In some embodiments of method 920, a robotic arm is operated via a suitably configured end effector to inspect the rib-to-winglet interface, such as detecting, inspecting, and / or measuring gaps between components. In some such embodiments, the results of the measurements are transmitted, for example, to a technician or controller to determine whether a particular gap exceeds a padding tolerance threshold (which may indicate an out-of-tolerance condition) and is therefore considered a padding location (to which the pad is installed). In some such embodiments, the results of the measurements are used to select a suitable pad to be installed (e.g., by size, dimension, taper, or other characteristics) to correct for out-of-tolerance conditions.

[0188] Gaskets 756 (such as unrestricted gaskets 756) can be supplied via a gasket feeder line in any suitable manner. For example, selectable gaskets (e.g., those with different tapers and / or sizes, etc.) can be stored in a bin accessible to the robotic arm. In some embodiments, new gaskets are dynamically manufactured, or pre-manufactured gaskets are adjusted (e.g., trimmed) (e.g., based on gap checks and / or measurements), and then conveyed for insertion into gasket positions 758 and provided on time for placement.

[0189] After the shim 756 is installed, the method may further include retracting the robotic arm 750 and moving the carriage 764 along the support 648 to a new position for further shim installation and / or other operations. Once the shim 756 has been installed into a shim position 758 accessible from the support 648 (such as an unrestricted shim position 758), the carriage 764 can be detached from the support and moved to a new position (such as moving to a support on another rib). In some embodiments, this is facilitated by a wheeled trolley equipped with a telescopic lift. In some embodiments, this involves removing the robotic arm 750 through an inlet gap (such as located in the lower wingplates 550-2).

[0190] Such as about FIG. 19As can be understood from the above description, method 900 can be used in wing assemblies 600 that include a variety of components and configurations. For example, although described in the context of an embodiment where a rib is held against a wingplate, the method can be repeatedly used in wing assemblies that include multiple ribs held against a wingplate. In other words, once steps 922, 924, and 926 are performed to install a shim at a shim location between a first rib and a wingplate, these steps can be repeated to install a shim at a shim location between a second rib and a wingplate. Method 900 can also be used in wing assemblies 600 in which multiple ribs 572 are held at their upper edges against a wingplate (such as an upper wingplate 550-1), and another wingplate (such as a lower wingplate 550-2) is held against the opposite (or lower) edge of a rib. In such a configuration, the lower wingplate 550-2 can be added to the wing assembly before or during the shim installation operation. In one example, the method includes first performing steps 922, 924, and 926 at the upper shim location between the rib and the upper wingplate, then adding the lower wingplate to the wing assembly, and then performing steps 922, 924, and 926 at the lower shim location between the rib and the lower wingplate. As described above, after the shim is installed between the rib and the wingplate, the rib can be fastened (e.g., mounted) to the wingplate. In another example, the method includes performing shim installation at both the upper and lower shim locations, for example in a configuration where the lower wingplate has already been placed. In any of these examples, the method includes repositioning the robotic arm, for example, to couple the carriage to a support of a different rib by moving (e.g., retracting and inserting) the robotic arm through an access gap in the wingplate (such as in the lower wingplate).

[0191] Turn now FIG. 1 The illustration depicts an exemplary aircraft 1200 in which exemplary embodiments of wing panels and / or wing assemblies produced according to aspects of this disclosure can be implemented. In other words, aircraft 1200 is an example of an aircraft that can be formed using composite parts, wing panels, and / or wing assemblies produced according to one or more of the following aspects: FIG. 2A and FIG. 2B as well as FIG. 4 The illustrated manufacturing method is shown. FIG. 5A to FIG. 5F Illustrative pattern shown; FIG. 11A to FIG. 11D The exemplary assembly line 500 is shown. FIG. 16A to FIG. 16C The illustrated rib and spar mounting techniques are shown. FIG. 17A to FIG. 17C and FIG. 20The illustrated shim mounting technique; one or more of the methods shown in the remaining figures; and / or any of the foregoing items. In this illustrated example, the aircraft 1200 has wings 1202 attached to and extending to either side of the fuselage 1204. The aircraft 1200 includes engines 1206 attached to the respective wings 1202. Located at the rear end of the fuselage 1204 is a tail section 1208, which includes a pair of opposing horizontal stabilizers 1210 and vertical stabilizers 1212. The wings 1202 are formed by upper wingplates 550 and lower wingplates (not shown) joined together, wherein assemblies of ribs and spars (not shown) at least partially form their internal structure.

[0192] FIG. 20 These are block diagrams illustrating the various components and systems (or stages) discussed herein in exemplary embodiments. Specifically, FIG. 20A plant 1300 is depicted, comprising a first assembly line 1310 located in a cleanroom environment indicated by 1312 and a second assembly line 1314 located in a non-cleanroom environment 1316. A boundary (e.g., one or more walls or enclosures) indicated by 1318 separates the cleanroom 1312 and non-cleanroom 1316 environments. At layup 1320, a displacement feature (such as displacement feature 210) is integrated into a laminate 1322 (such as preform 200) for a wingplate. The laminate 1322 is cured in an autoclave 1324 to form a composite part 1326. According to embodiments herein, the composite part 1326 is a wingplate (e.g., wingplate 550), more specifically an upper wingplate, but the plant 1300 may be configured to manufacture, process, and otherwise operate on composite parts in the form of other aircraft components besides wingplates. Composite part 1326 is then transferred to assembly line 1314, which, in the illustrated embodiment, is shown as a system and stages that advance composite part 1326 in the process direction 1328 through various systems and stages specific to those suitable for the upper flange. For example, at assembly line 1314, trimming stage 1330 removes excess material and / or installs additional indexing features into composite part 1326. At demolding stage 1332, composite part 1326 is demolded (e.g., removed from the laying mandrel), after which a profile is implemented onto composite part 1326 via profile implementation 1334, wherein composite part 1326 is secured to shuttle device 1336 (such as one or more strong backing materials 540), which includes carrier element 1338 (e.g., an adjustable-length spring element 545 including vacuum coupling 548). As the composite part advances along assembly line 1314, shuttle device 1336 applies the contour to composite part 1326, such as via carrier 1338. As composite part 1326 advances past rib mount 1340 and spar mount 1342, ribs and spars are mounted onto composite part 1326. As needed, inspection of the rib and spar assemblies and shim installation are performed by robotic arm 1344. The lower wingplate 1346 is then attached to form a wing assembly (e.g., wing assembly 600). The various systems and stages described with respect to plant 1300 can be combined or adopted in the form of the various workstations 520 described above. Furthermore, for simplicity, not all of the aforementioned workstations 520 are... FIG. 20 Specifically, it is shown that although assembly line 1314 may include stations such as one or more NDI stations 524, cutting stations 526, etc. The above text regarding... FIG. 4 Other operations described can be combined with or employ the methods shown in Mode 480 and FIG. 21 The feeder line, laying line, or assembly line shown are in one or more forms; for example, trimming 1330 and demolding 1332 can be performed in demolding operations 490-11.

[0193] Follow us now FIG. 22 This example broadly illustrates control components of a production system that performs lamination and / or ultrasound examinations (e.g., continuously) in an exemplary embodiment. Controller 1400 coordinates and controls the operation of laminator 1420 and the movement of one or more mobile platforms 1470 along a movement line 1460 having a powertrain 1462. Controller 1400 may include a processor 1410 coupled to a memory 1412 storing a program 1414. In one example, mobile platforms 1470 are driven along a movement line 1460 continuously driven by a powertrain 1462 controlled by controller 1400. In this example, mobile platforms 1470 include a utility connection 1472, which may include an electrical, pneumatic, and / or hydraulic quick-disconnect device connecting mobile platforms 1470 to a utility 1440 from an external source. In other examples, as previously described, the mobile platform 2470 may include, for example, spindles and / or other tools, parts, supplies, etc., on an automated transport vehicle (such as an automated guided vehicle (AGV)) including onboard utilities and a GPS / autonomous navigation system 1474. In another example, a laser tracker 1450 is used to control the movement of the mobile platform 1470. A position and / or motion sensor 1430, coupled to the controller 1400, is used to determine the position of the mobile platform 1470 and the powertrain 1462.

[0194] Example A view depicting an assembly line 1500 (e.g., a continuous assembly line) in an exemplary embodiment is shown in terms of a series of work areas 1502 arranged along a moving line and configured to perform various operations. The work areas include a work area for tool preparation 1510, which involves cleaning a tool 1504 (e.g., laying a mandrel 110), applying a coating and / or potting compound to the tool 1504, or servicing the tool 1504, after which the tool 1504 is conveyed on a platform 1506 to an additional work area 1502. The additional work area includes a work area for material application 1520 (e.g., where lamination operations are performed) to form a preform 1522 (such as preform 200). The preform 1522 can then be conveyed via the assembly line 1500 to downstream work areas, which include a work area for shrinkage 1530, a work area for compaction 1540, and a work area for molding 1550. Shrinkage and / or compaction of the preform 1522 may include vacuum compaction performed via vacuum bag 1532. Molded preform 1522 may be performed via pre-curing molding and / or via a combination of molding between tool 1504 and pad 1542.

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

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

[0197] FIG. 23

[0198] In the following examples, additional processes, systems, and methods are described in the context of manufacturing and assembling systems for aircraft wings.

[0199] Referring more specifically to the accompanying drawings, embodiments of this disclosure can be implemented as follows: FIG. 24 The aircraft manufacturing and maintenance methods shown in 1600 and such FIG. 24 The description is given within the context of the aircraft 1602 shown. During pre-production, method 1600 may include the specification and design 1604 of the aircraft 1602 and the procurement of materials 1606. During production, the manufacturing of components and sub-assemblies of the aircraft 1602 and system integration 1610 may be performed. Subsequently, the aircraft 1602 may undergo certification and delivery 1612 for entry into service 1614. When in use by the customer, routine maintenance and upkeep 1616 (which may also include modifications, reconfigurations, refurbishments, etc.) are scheduled for the aircraft 1602. The apparatus and methods specifically implemented herein may be employed during any one or more suitable stages of production and use as described in method 1600 (e.g., specification and design 1604, material procurement 1606, component and sub-assembly manufacturing 1608, system integration 1610, certification and delivery 1612, commissioning 1614, maintenance and servicing 1616) and / or any suitable component of aircraft 1602 (e.g., frame 1618, system 1620, interior 1622, propulsion system 1624, electrical system 1626, hydraulic system 1628, environment 1630).

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

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

[0202] As mentioned above, the apparatus and methods specifically implemented herein can be used during any one or more of the production and maintenance phases described in method 1600. For example, components or sub-assemblies corresponding to component and sub-assembly manufacturing 1608 can be made or manufactured in a manner similar to that of components or sub-assemblies produced when aircraft 1602 is put into service. Moreover, during sub-assembly manufacturing 1608 and system integration 1610, one or more apparatus embodiments, method embodiments, or combinations thereof can be utilized, for example, by significantly accelerating the assembly of aircraft 1602 or reducing the cost of the aircraft. Similarly, when aircraft 1602 is put into service (e.g., and without limitation, during maintenance and servicing 1616), one or more apparatus embodiments, method embodiments, or combinations thereof can be utilized. Therefore, this disclosure can be used for any stage or any combination thereof discussed herein (such as specifications and design 1604, material procurement 1606, component and sub-component manufacturing 1608, system integration 1610, certification and delivery 1612, commissioning 1614, maintenance and servicing 1616) and / or any suitable component of the aircraft 1602 (e.g., frame 1618, system 1620, interior 1622, propulsion system 1624, electrical system 1626, hydraulic system 1628 and / or environment 1630).

[0203] In one embodiment, the part comprises a portion of a frame 1618 and is manufactured during component and subassembly manufacturing 1608. The part can then be assembled into the aircraft during system integration 1610 and utilized during commissioning 1614 until wear renders it unusable. Then, during maintenance and upkeep 1616, the part can be discarded and replaced with a newly manufactured part. The inventive components and methods can be utilized throughout component and subassembly manufacturing 1608 to produce new parts.

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

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

[0206] 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 following claims.

[0207] This document also provides the following examples, which should not be confused with the appended claims, which define the scope of protection and relate to the following:

[0208] 1. A method for assembling an airfoil (920), the method comprising the following steps:

[0209] - Connect (924) the robotic arm (750) to a support (648), the support (648) being attached to a rib (572) held against a wing plate (550); and

[0210] - While the robotic arm is being attached to the bracket, the robotic arm is operated (926) to install one or more gaskets (756) between the rib and the wing plate.

[0211] 2. The method according to Example 1, the method further includes the step of: mounting the bracket (648) to the rib (572).

[0212] 3. The method according to Example 1 or 2, the method further comprising the step of: holding the rib (572) against the wing plate (550).

[0213] 4. The method according to Example 2 or 3, wherein the step of mounting the bracket (648) to the rib (572) is performed prior to the step of holding the rib (572) against the wing plate (550).

[0214] 5. The method according to Example 2 or 3, wherein the step of mounting the bracket (648) to the rib (572) is performed after the step of holding the rib (572) against the wing plate (550).

[0215] 6. The method according to any one of Examples 2 to 5, wherein the step of mounting the bracket (648) to the rib (572) comprises: aligning the bracket with the rotation feature (794) at the rib.

[0216] 7. The method according to any one of Examples 2 to 6, wherein the bracket (648) is detachably mounted to the rib (572).

[0217] 8. The method according to any one of Examples 1 to 7, wherein the support (648) applies the desired profile to the rib (572).

[0218] 9. The method according to any one of Examples 1 to 8, the method further comprising the step of: rotating the position of the robotic arm (750) relative to the support (648).

[0219] 10. The method according to any one of Examples 1 to 9, wherein the robotic arm (750) is detachably coupled to the support (648).

[0220] 11. The method according to Example 10, the method further comprising the step of: after operating (926) the robotic arm to install one or more pads (756), disengaging the robotic arm (750) from the support (648).

[0221] 12. The method according to Example 11, the method further comprising the steps of: repeatedly engaging (924) the robotic arm (750) for each of the plurality of ribs (572) held against the wing plate (550), and manipulating (926) the robotic arm to install one or more pads (756).

[0222] 13. The method according to any one of Examples 1 to 12, the method further comprising the step of: driving the robotic arm (750) along the bracket (648) to align the robotic arm with the pad position (758) along the rib to the wingplate interface.

[0223] 14. The method according to any one of Examples 1 to 13, the method further comprising the step of: inspecting the rib-to-wingplate interface.

[0224] 15. The method according to Example 14, wherein the step of inspecting the rib-to-wingplate interface is performed by operating (926) the robotic arm (750).

[0225] 16. The method according to Example 14 or 15, wherein the step of inspecting the rib-to-wingplate interface is performed by identifying the position (758) of the pad (756) via the end effector (752) of the robotic arm (750).

[0226] 17. The method according to any one of Examples 14 to 16, the method further comprising the step of: determining whether the gap between the rib and the flange interface is greater than a padding tolerance threshold.

[0227] 18. The method according to Example 17, the method further comprising the step of selecting a gasket (756) based on the size of a gap greater than the filling tolerance threshold.

[0228] 19. The method according to Example 17 or 18, the method further comprising the step of: manufacturing a gasket (756) based on the size of a gap greater than the filling tolerance threshold.

[0229] 20. The method according to any one of the foregoing examples, the method further comprising the step of delivering the pad (756) to the robotic arm (750) via a feeder line (780).

[0230] 21. The method according to any one of the foregoing examples, the method further comprising the step of fastening the rib (572) to the wing plate (550).

[0231] 22. The method according to Example 21, wherein the step of fastening the rib (572) to the wing plate (550) is performed after operating (926) the robotic arm (750) to install one or more pads (756).

[0232] 23. The method according to Example 22, wherein the step of fastening the rib (572) to the wing plate (550) is performed after operating (926) the robotic arm (750) to install all of the shims in the one or more shims (756).

[0233] 24. The method according to any one of the foregoing examples, wherein the wing plate (550) is an upper wing plate (550-1) held against the upper edge of the rib (572), and wherein the method further comprises the step of holding a lower wing plate (550-2) against the lower edge of the rib (572) after operating (926) the robotic arm (750) to install one or more pads (756) between the rib and the upper wing plate.

[0234] 25. The method according to Example 24, the method further comprising the step of: while the robotic arm is coupled to the bracket (648), manipulating (926) the robotic arm (750) to install one or more gaskets (756) between the rib (572) and the lower wing plate (550-2).

[0235] 26. A portion of an aircraft assembled according to any one of the foregoing examples.

[0236] 27. A non-transitory computer-readable medium comprising programming instructions that, when executed by a processor, enable the execution of a method (920) for assembling a wing, the method comprising the following steps:

[0237] - Connect (924) the robotic arm (750) to a support (648), the support (648) being attached to a rib (572) held against a wing plate (550); and

[0238] - While the robot arm is being attached to the support, the robot arm is operated (926) to install one or more gaskets (756) between the rib and the wing plate.

[0239] 28. The medium according to Example 27, wherein the method (920) further includes the step of mounting the bracket (648) to the rib (572).

[0240] 29. The medium according to Example 27 or 28, wherein the method (920) further includes the step of holding the rib (572) against the wing plate (550).

[0241] 30. The medium according to Example 29, wherein the step of mounting the bracket (648) to the rib (572) is performed prior to the step of holding the rib against the wing plate (550).

[0242] 31. The medium according to Example 29, wherein mounting the bracket (648) to the rib (572) is performed after the step of holding the rib against the wing plate (550).

[0243] 32. The medium according to any one of Examples 28 to 31, wherein the step of mounting the bracket (648) to the rib (572) includes: aligning the bracket with the rotation feature (794) at the rib.

[0244] 33. The medium according to any one of Examples 28 to 32, wherein the support (648) is detachably mounted to the rib (572).

[0245] 34. The medium according to any one of Examples 27 to 33, wherein the support (648) implements the desired profile onto the rib (572).

[0246] 35. The medium according to any one of Examples 27 to 34, wherein the method (920) further comprises the step of: rotating the position of the robotic arm (750) relative to the support (648).

[0247] 36. The medium according to any one of Examples 27 to 35, wherein the robotic arm (750) is detachably coupled to the support (648).

[0248] 37. The medium according to Example 36, wherein the method (920) further includes the step of: after operating (926) the robotic arm to install one or more pads (756), disengaging the robotic arm (750) from the support (648).

[0249] 38. The medium according to Example 37, wherein the method (920) further comprises the steps of: repeatedly engaging (924) the robotic arm (750) for each of the plurality of ribs (572) held against the wing plate (550), and operating (926) the robotic arm to install one or more pads (756).

[0250] 39. The medium according to any one of Examples 27 to 38, wherein the method (920) further comprises the step of driving the robotic arm (750) along the support (648) to align the robotic arm with the pad position (758) along the rib to the wingplate interface.

[0251] 40. The medium according to any one of Examples 27 to 39, wherein the method (920) further includes the step of inspecting the rib-to-wing interface.

[0252] 41. The medium according to Example 40, wherein the step of inspecting the rib-to-wingplate interface is performed by operating (926) the robotic arm (750).

[0253] 42. The medium according to Example 40 or 41, wherein the step of inspecting the rib-to-wingplate interface is performed by identifying the position (758) of the pad (756) via the end effector (752) of the robotic arm (750).

[0254] 43. The medium according to any one of Examples 40 to 42, wherein the method (920) further includes the step of determining whether the gap between the rib and the flange interface is greater than the padding tolerance threshold.

[0255] 44. The medium according to Example 43, wherein the method (920) further includes the step of selecting a gasket (756) based on the size of a gap greater than the filling tolerance threshold.

[0256] 45. The medium according to Example 43 or 44, wherein the method (920) further includes the step of: manufacturing a gasket (756) based on the size of a gap greater than the filling tolerance threshold.

[0257] 46. ​​The medium according to any one of Examples 27 to 45, wherein the method (920) further comprises the step of delivering the pad (756) to the robotic arm (750) via a feeder line (780).

[0258] 47. The medium according to any one of Examples 27 to 46, wherein the method (920) further comprises the step of fastening the rib (572) to the wing plate (550).

[0259] 48. The medium according to any one of Examples 27 to 47, wherein the step of fastening the rib (572) to the wing plate (550) is performed after operating (926) the robotic arm (750) to install one or more pads (756).

[0260] 49. The medium according to Example 48, wherein the step of fastening the rib (572) to the wing plate (550) is performed after operating (926) the robotic arm (750) to install all of the gaskets in the one or more gaskets (756).

[0261] 50. The medium according to any one of Examples 27 to 49, wherein the wing plate (550) is an upper wing plate (550-1) held against the upper edge of the rib (572), and wherein the method further comprises the step of holding a lower wing plate (550-2) against the lower edge of the rib after operating (926) the robotic arm (750) to install one or more pads (756) between the rib and the upper wing plate.

[0262] 51. The medium according to Example 50, wherein the method (920) further comprises the step of: while the robot arm is coupled to the bracket (648), operating (926) the robot arm (750) to install one or more gaskets (756) between the rib (572) and the lower wing plate (550-2).

[0263] 52. A part of an aircraft assembled according to a method (920) defined by instructions stored on a computer-readable medium of any of Examples 27 to 51.

[0264] 53. A system for assembling an airfoil, the system comprising:

[0265] - Carriage (764), said carriage being connected to rib (572); and

[0266] - A robotic arm (750) extending from the carriage and operable to perform work at the interface between the rib and the wing plate (550).

[0267] 54. The system according to Example 53, wherein the carriage (764) is coupled to the bracket (648), the bracket is mounted to the rib (572), and the rib is held against the wing plate (550).

[0268] 55. The system according to Example 53 or 54, wherein the robotic arm (750) is operable for mounting a pad (756) at the interface.

[0269] 56. The system according to any one of Examples 53 to 55, wherein the operation is selected from the group consisting of: inspection, padding, and fastener installation.

[0270] 57. The system according to any one of Examples 53 to 56, wherein the robotic arm (750) includes an end effector (752) that inspects the rib (572) to identify the position (758) of the pad (756).

[0271] 58. The system according to any one of Examples 53 to 57, wherein the carriage (764) is operable to drive the robotic arm (750) along the support (648) to align the robotic arm with the interface located between the rib (572) and the wing plate (550).

[0272] 59. The system according to any one of Examples 53 to 58, wherein the robotic arm (750) includes an end effector (752) configured to mount the pad (756).

[0273] 60. The system according to any one of Examples 53 to 59, wherein the robotic arm (750) includes an end effector (752) configured to install fasteners.

[0274] 61. The system according to any one of Examples 53 to 60, wherein the robotic arm (750) includes an end effector (752) configured to inspect the interface.

[0275] 62. The system according to any one of Examples 53 to 61, wherein the carriage (764) is configured to drive the robotic arm (750) along the support (648) via a rack and pinion system.

[0276] 63. The system according to any one of Examples 53 to 62, the system further comprising: a lift (776) configured to control the vertical position of the carriage (776) when the carriage is separated from the support (648).

[0277] 64. The system according to Example 63 further includes a wheeled trolley (770) that supports the elevator (776) and is operable to move the elevator relative to the floor surface.

[0278] 65. The system according to any one of Examples 53 to 64, the system further comprising: a feeder line (780) configured to manufacture and / or deliver a pad (756) for mounting by the robotic arm (750) at the interface.

[0279] 66. Use the system of any one of Examples 53 to 65 to manufacture a part of an aircraft.

[0280] 67. An apparatus for assembling an aircraft wing, the apparatus comprising:

[0281] - A robotic arm (750), the dimensions of which are designed to be positioned at the interface between the rib (572) and the wing plate (550), the robotic arm comprising:

[0282] - An end effector (752) that performs a task on the interface, the task being selected from the group consisting of: inspecting the interface, installing a gasket (756) at the interface, and installing a fastener at the interface.

[0283] 68. The apparatus according to Example 67, wherein the robotic arm (750) is mounted to a carriage (764) that travels along a support (648) mounted to the rib (572).

[0284] 69. The apparatus according to Example 67 or 68, wherein the robotic arm (750) is disposed within a compartment (790) between ribs (572).

[0285] 70. Use the apparatus of any one of Examples 67 to 69 to manufacture a part of an aircraft.

Claims

1. A method for assembling an aircraft wing, the method comprising the following steps: - A reinforcement is mounted to a rib of the wing, the reinforcement implementing a desired profile onto the rib; - The robotic arm is provided with a single support by connecting it to the rib of the wing via the reinforcement on the rib; as well as - While the robotic arm is being attached to the reinforcement, the robotic arm is operated to install one or more spacers between the rib and the wing plate.

2. The method according to claim 1, wherein: The reinforcement is detachably mounted to the rib, and / or The step of installing the reinforcement to the rib includes aligning the reinforcement with the rotation feature at the rib.

3. The method according to claim 1, further comprising the following steps: The rib is held in place by the wing plate.

4. The method according to claim 2 or 3, wherein: The step of installing the reinforcement to the rib is performed before the step of holding the rib against the wing plate, or The step of installing the reinforcement to the rib is performed after the step of holding the rib against the wing plate.

5. The method according to claim 1, further comprising the following steps: Rotate the position of the robotic arm relative to the reinforcement, and / or The robot arm is driven along the reinforcement to align the robot arm with the pad position along the rib to the wingplate interface.

6. The method according to claim 1, wherein, The robotic arm is detachably connected to the reinforcement.

7. The method according to claim 6, further comprising the following step: After the step of operating the robotic arm to install one or more pads, the robotic arm is separated from the reinforcement.

8. The method according to claim 6, wherein the method comprises the following steps: The robotic arm is repeatedly engaged with each of the multiple ribs held against the wing plate, and the robotic arm is operated to install one or more pads.

9. The method according to claim 1, further comprising the following steps: The interface between the rib and the wing plate is inspected.

10. The method according to claim 9, wherein, The step of inspecting the rib-to-wingplate interface is performed by manipulating the robotic arm, and / or The step of inspecting the rib-to-wingplate interface is performed by identifying the position of the pad via the end effector of the robotic arm, and / or The method further includes the following step: determining whether the gap at the interface between the rib and the wing plate is greater than the padding tolerance threshold.

11. The method according to claim 10, further comprising the step of: Gaskets are selected based on the size of gaps larger than the filling tolerance threshold, and / or The gasket is manufactured based on the size of the gap, which is greater than the filling tolerance threshold.

12. The method according to claim 1, further comprising the following steps: The rib is fastened to the wing plate.

13. The method according to claim 12, wherein, The step of fastening the rib to the wing plate is performed after operating the robotic arm to install one or more pads.

14. The method according to claim 12, wherein, The step of fastening the rib to the wing plate is performed after the robotic arm is operated to install all of the shims in the one or more shims.

15. The method according to claim 1, wherein, The wing plate is an upper wing plate held against the upper edge of the rib, and the method further includes the steps of: after manipulating the robotic arm to install one or more shims between the rib and the upper wing plate, holding the lower wing plate against the lower edge of the rib, and The method further includes the step of: while the robot arm is attached to the reinforcement, operating the robot arm to install one or more spacers between the rib and the lower wing plate.

16. A system for assembling an airfoil, the system comprising: - A carriage, the carriage being coupled to a reinforcement on a rib and the carriage being solely supported by the reinforcement, wherein the reinforcement is removably attached to the rib and configured to implement a desired profile onto the rib; and - A robotic arm extending from the carriage and configured to inspect the gap at the interface between the rib and the wing plate, wherein the carriage is configured as the sole support for the robotic arm.

17. The system according to claim 16, wherein, The rib is held in place by abutting against the wing plate.

18. The system according to claim 17, wherein: The carriage is operable to drive the robotic arm along the reinforcement to align the robotic arm with the interface located between the rib and the wing plate, and / or The carriage is configured to drive the robot arm along the reinforcement via a rack and pinion system.

19. The system according to claim 16 or 17, wherein, The robotic arm is operable to install a pad at the interface.

20. The system of claim 19, further comprising: A feeder line configured to manufacture and / or deliver pads for mounting by the robotic arm at the interface.

21. The system according to claim 16 or 17, wherein: The robotic arm includes an end effector that inspects the rib to identify the position of the pad, and / or The robotic arm includes an end effector configured to mount the pad, and / or The robotic arm includes an end effector configured to install fasteners, and / or The robotic arm includes an end effector configured to inspect the interface.

22. The system according to claim 16 or 17, further comprising: An elevator configured to control the vertical position of the carriage when the carriage is separated from the reinforcing member.

23. The system of claim 22, further comprising: A wheeled trolley that supports the lift and is operable to move the lift relative to the floor surface.

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