Contouring of the wire assembly fuselage section

Abstract

The invention relates to profile application of string assembled fuselage sections. A system and method for assembling sections of a fuselage (12) of an aircraft (10) is provided. The method includes pulsing a half-barrel section (24) of the fuselage (12) along a track (110) in a machining direction (199), determining a desired profile (361) of a portion of the half-barrel section (24) using an indexing feature (124) associated with the half-barrel section (24), and applying the desired profile (361) to the half-barrel section (24) using a component that applies an inner mold line (128) and a component that applies an outer mold line (126) when the profile of the half-barrel section (24) is outside of a tolerance from the desired profile (361).

Description

Technical Field

[0001] This invention relates to the field of manufacturing, and more particularly to the manufacturing of fuselage sections of aircraft. Background Technology

[0002] The frame defines the mechanical structure of an aircraft. A frame consists of multiple components that provide the desired structural characteristics. For example, a portion of the frame for an aircraft fuselage may include frames, skins, and stringers mechanically joined together according to design parameters (e.g., via co-bonding, co-curing, or fasteners). In current practice, frame components are fabricated and assembled in predetermined units on a factory floor. For example, an aircraft skin may be assembled at one unit and then transported to a new unit where the frame is fitted into the skin to form a full-section fuselage before being transported to the next unit.

[0003] While the manufacturing processes discussed above are reliable, delays can occur when work on specific parts of a component takes longer than expected. For example, if a particular section of the fuselage section requires more time than anticipated to install the frame, the entire section will remain in the unit until all delayed work is completed. The entire production system will be delayed until the full fuselage section is moved to the next unit. During these operations, heavy tooling is used to maintain the desired looseness / profile of the components at the unit.

[0004] 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.

[0005] The abstract of US2019 / 317482A1 states: "A stripping assembly for separating a workpiece from a manufacturing fixture has a horizontal beam assembly and a pair of vertical beam assemblies. The horizontal beam assembly includes a horizontal beam having a horizontal drive motor. Each vertical beam assembly includes a vertical beam operatively engaged with the horizontal drive motor and has a workpiece attachment assembly operatively engaged with the vertical drive motor. The workpiece attachment assembly has an attachment mechanism for attaching to a workpiece. The horizontal and vertical drive motors are operable in such a way that the vertical beams are moved away from each other along a horizontal drive axis, while the respective workpiece attachment assemblies are moved along a vertical drive axis, such that the attachment mechanism pulls the side of the workpiece away from the manufacturing fixture, while a central support of the horizontal beam maintains the crown of the workpiece in contact with the manufacturing fixture."

[0006] The abstract of US2019 / 084663A1 states: "Systems and methods for applying contours to aircraft parts are provided. One embodiment is a method for applying contours to aircraft parts. The method includes: removably attaching segmented ring details to aircraft skin details; attaching stringers to skin details to create a skin assembly; positioning the skin assembly at a support structure defining the contour; and securing a frame to the skin assembly to create a panel. The method also includes: removably mounting extender sections to the panel to complete the assembly of a support before removing the panel; transporting the panel while contouring the support; attaching the support to supports for other panels to form a barrel section of the aircraft fuselage while contouring the support; and removing the support from the barrel section after the barrel section has been formed."

[0007] The abstract of US2010 / 006202A1 states: "The present invention provides an apparatus and method for producing large-area fiber composite structural components, particularly for aircraft components, comprising: a predetermined forming element; a controllable laying device for laying at least one fabric sheet in a defined manner above or within the predetermined forming element; a controllable flipping device for flipping the predetermined forming element and the laying device in a defined manner relative to each other by a predetermined flipping angle; and a central control device connected to the laying device and the flipping device for controlling the laying device."

[0008] DE712525C refers to a clamping device used in the construction of aircraft shell parts. Summary of the Invention

[0009] The embodiments described herein provide assembly line techniques and systems that facilitate contouring of the fuselage's semi-cylinder sections during manufacturing. Specifically, a fixed arched component at the assembly line contacts and applies the desired cross-sectional contour to the semi-cylinder sections, which improves the operational performance of the semi-cylinder sections.

[0010] According to one aspect of this disclosure, a method for assembling a fuselage section of an aircraft, the method comprising:

[0011] The half-cylinder section of the machine body pulsates along the track in the processing direction;

[0012] The desired profile of a portion of the half-barrel section is determined using the rotation features associated with the half-barrel section; and

[0013] When the profile of the half-barrel section differs from the desired profile beyond the tolerance, the desired profile is applied to the half-barrel section using the component that applies the inner mold line and the component that applies the outer mold line.

[0014] Advantageously, the method is one in which applying the desired profile to the half-barrel section comprises: extending a plurality of wheels from a first arch to apply the inner mold line; and extending a plurality of wheels from a second arch to apply the outer mold line.

[0015] Preferably, the method is a method that further includes advancing the half-barrel section through the pressure zone in the processing direction to apply a contour.

[0016] Preferably, the method further includes: advancing the half-barrel section through the pre-compression zone in the processing direction before advancing through the compression zone.

[0017] Preferably, the method further includes: using non-destructive testing (NDI) to determine the initial profile of the half-barrel section.

[0018] Preferably, the method is a method that further includes determining the initial profile of the half-barrel section using non-destructive testing; and

[0019] The pressure zone is set to the gap and desired profile using a profile from NDI, the pressure zone being defined by the plurality of wheels from the first arch member that can extend along the inner mold line and the plurality of wheels from the second arch member that can extend along the outer mold line.

[0020] Preferably, the method is a method that further includes performing work on the half-barrel section within a workstation set along the track, while applying the desired profile.

[0021] Preferably, the method is one in which the work includes mounting the frame onto the half-barrel section while applying the desired profile.

[0022] Preferably, the method is one in which the work includes installing one or more of the door frame and window frame while applying the desired profile.

[0023] Preferably, the method is one in which the desired profile being applied is a cross-sectional profile.

[0024] Preferably, the method is a method in which applying the desired profile to the half-barrel section includes: positioning the wheel of the first arch member in contact with the inner mold line of the half-barrel section to apply the desired profile; and positioning the wheel of the second arch member in contact with the outer mold line of the half-barrel section to apply the desired profile.

[0025] Preferably, the method is a method that further includes retracting the wheel from the half-barrel section during a pause between pulses in the half-barrel section.

[0026] Preferably, the method further includes securing the half-barrel section to the track in such a manner that the recess of the half-barrel section faces the factory ground and the bearing edge of the half-barrel section contacts the track.

[0027] Preferably, the method is a method in which determining the desired profile using an indexing feature associated with the half-barrel section includes: mating a complementary feature at the indexing unit with the indexing feature; operating a controller to determine the desired profile associated with the mating; and based on the determination, extending the plurality of wheels from the first arch to apply the inner mold line, and extending the plurality of wheels from the second arch to apply the outer mold line.

[0028] A part of an aircraft, said part of the aircraft being assembled according to the method described above.

[0029] According to one aspect of this disclosure, a system for assembling a half-barrel section of a fuselage, the system comprising:

[0030] The track is configured to engage the opposing load-bearing edges of the half-barrel section;

[0031] A drive unit that moves the half-barrel section along the track; and

[0032] A first component, positioned to engage the inner mold line of the half-barrel section to apply a desired profile to the half-barrel section; and

[0033] A second component, which is positioned to engage the outer mold line of the half-barrel section to apply the desired profile of the half-barrel section.

[0034] Advantageously, the system is a system in which: the first component includes a first arch, the first arch further including a wheel extending from the first arch to apply the desired profile on the inner mold line; and the second component includes a second arch, the second arch further including a wheel extending from the second arch to apply the desired profile on the outer mold line.

[0035] Preferably, the system is a system in which the wheels of the first arch and the second arch are opposite each other to form a pressure zone, the pressure zone being operable to move the half-barrel section along the track.

[0036] Preferably, the system is a system in which: the shape of the first arched member is substantially complementary to the inner mold line of the half-cylinder section; and the shape of the second arched member is substantially complementary to the outer mold line of the half-cylinder section.

[0037] Preferably, the system is a system in which: a first portion of the wheel is circumferentially mounted around the first arched member; and a second portion of the wheel is circumferentially mounted around the second arched member.

[0038] Preferably, the system is a system in which the drive unit is operable to cause the half-barrel section of the machine body to pulsate synchronously along the track in the processing direction, while keeping the half-barrel section in such a way that the concave portion of the half-barrel section faces the factory ground and the bearing edge of the half-barrel section contacts the track.

[0039] Preferably, the system is a system in which the system is operable to pulsate the half-barrel section while the wheel engages the half-barrel section and applies the desired profile.

[0040] Preferably, the system further includes multiple supports that raise the track above the factory ground.

[0041] Preferably, the system is a system in which the track includes a plurality of rollers operable to move the half-barrel section along the track.

[0042] Preferably, the system is a system in which the first arched member is fixed and installed on the factory floor; and the second arched member is fixed and installed on the factory floor.

[0043] Preferably, the system is a system in which at least one of the first arch and the second arch is movable relative to the track.

[0044] Preferably, the system further includes a controller programmed to control the extension and descent of the wheel according to a desired profile stored in the controller.

[0045] Preferably, the system further includes a non-destructive inspection station operable to determine the circumferential radius of a portion of the half-barrel section during pauses between the micro-pulses along the track in the half-barrel section.

[0046] Preferably, the system further includes: a plurality of swing arms; a first portion pivotally mounted to the first arch and a second portion pivotally mounted to the second arch and opposite to the first portion; and a plurality of inlet rollers mounted to corresponding swing arms remote from the arch, the swing arms being biased to form a preload zone of the half-barrel section.

[0047] Preferably, the system is a system in which the bias of the pre-compression zone has sufficient force to pre-contour the half-barrel section before engaging the wheel.

[0048] According to one aspect of this disclosure, a method for assembling a half-barrel section of a fuselage includes:

[0049] The half-barrel section of the fuselage is fixed to the rail in such a way that the concave part of the half-barrel section faces the factory ground and the load-bearing edge of the half-barrel section contacts the rail.

[0050] This causes the half-barrel section to pulsate slightly along the track in the processing direction;

[0051] Inner and outer mold lines are applied to the segmented portions of the semi-cylinder section via arched members arranged along the track to define the desired profile of the semi-cylinder section; and

[0052] Work is performed on a portion of the half-barrel section, while applying both the inner and outer mold lines.

[0053] Advantageously, the method is one in which the work includes attaching at least one structural component to a half-cylinder section to maintain a desired profile, said at least one structural component including at least one of a frame, a window frame, and a door frame.

[0054] According to one aspect of this disclosure, a method for manufacturing an airframe includes:

[0055] The leading edge of the half-barrel section of the fuselage is transferred to the non-destructive testing station of the fuselage assembly system;

[0056] Determine the inner and outer mold lines of the leading edge portion of the half-barrel section;

[0057] The position of the first round arched component is constructed based on the inner mold line and the position of the second round arched component is constructed based on the outer mold line to form a pressure zone, which is operable to accommodate the leading edge portion between them;

[0058] The pressure zone formed by the wheels of the first and second wheel arches is operated to rotate the leading edge portion of the half-barrel section onto the wheel arches; and

[0059] The moving wheel relative to the first and second arched parts applies the desired profile to the leading edge portion of the half-barrel section.

[0060] According to one aspect of this disclosure, a fuselage assembly system includes:

[0061] The track is used to engage the load-bearing edge of the half-barrel section of the fuselage;

[0062] The first arched component has a shape that is complementary to the inner mold line of the half-barrel section;

[0063] The second arched component has a shape that complements the outer mold line of the half-barrel section;

[0064] A plurality of wheels, the plurality of wheels including a first portion of a wheel and a second portion of a wheel, the first portion of the wheel being disposed around a first arch and capable of extending relative to the first arch to engage an inner mold line, the second portion of the wheel being disposed around a second arch and capable of extending relative to the second arch to engage an outer mold line;

[0065] A non-destructive testing (NDI) station, said NDI station being capable of inspecting the half-barrel section; and

[0066] The controller is capable of:

[0067] The wheel is positioned relative to the leading edge of the half-barrel section using the detection data; and

[0068] Extend the wheel to apply the desired profile of the leading edge of the half-barrel section.

[0069] According to one aspect of this disclosure, a fuselage assembly method includes:

[0070] The micro-pulsation of the half-barrel section of the fuselage is dispersed through one or more stations along the track of the fuselage assembly system, the micro-pulsation being based on the rotational characteristics associated with the half-barrel section.

[0071] The half-barrel section was identified as being rotated to the placement point by at least one rotation feature;

[0072] Connect the travel station to the half-barrel section; and

[0073] Work is performed on the half-barrel section using the traveling station during one or more micro-pulse periods and the pauses between micro-pulse periods.

[0074] Advantageously, the method further includes: identifying the half-barrel section being rotated to the removal point via at least one rotation feature and disengaging the travel station from the half-barrel section.

[0075] According to one aspect of this disclosure, a fuselage assembly system includes:

[0076] The track is configured to engage the load-bearing edge of the half-cylinder section of the fuselage;

[0077] A drive unit capable of moving a half-barrel section along a track;

[0078] A transposition unit, operable to identify, via at least one transposition feature in the half-barrel section, that a relevant portion of the half-barrel section has been transpositioned to a placement point; and

[0079] A traveling station operable to connect to a half-barrel section, the traveling station operable to perform work on the half-barrel section during pauses between one or more micro-pulses and micro-pulses along the track.

[0080] According to one aspect of this disclosure, a fuselage assembly method includes:

[0081] A portion of the half-cylinder section of the fuselage is micro-pulsated into a workstation placed along the track of the fuselage assembly system;

[0082] The half-barrel section is rotated relative to the work station using at least one indexing feature;

[0083] The components to be attached to the half-barrel section are placed near the half-barrel section;

[0084] Temporarily attach the component to the half-cylinder section;

[0085] Connect the travel station to the half-barrel section; and

[0086] During the pause between one or more subsequent micro-pulses along the track in the half-barrel section, the component is secured to the half-barrel section using the traveling station.

[0087] Advantageously, the method also includes identifying, via at least one indexing feature, that a relevant portion of the half-barrel section has been indexed to a removal point, which verifies that fastening is complete and disengages the travel station from the half-barrel.

[0088] According to one aspect of this disclosure, a fuselage assembly system includes:

[0089] The track is configured to engage the load-bearing edge of the half-cylinder section of the fuselage;

[0090] A drive unit capable of moving a half-barrel section along a track;

[0091] A transposition unit, operable to identify, via at least one transposition feature in the half-barrel section, that a relevant portion of the half-barrel section has been transpositioned to a placement point;

[0092] Workstation, operable for temporarily attaching components to the half-barrel section; and

[0093] The traveling station is operable to connect to the half-barrel section and is operable to fasten the component to the half-barrel section during a pause between one or more micro-pulses and micro-pulses along the track.

[0094] According to one aspect of this disclosure, an apparatus for applying a desired profile includes:

[0095] The first arched member further includes a wheel extending radially outward from the first arched member;

[0096] The second arched member, the second arched member further comprising a wheel extending radially inward from the second arched member; and

[0097] The wheel extending radially outward from the first arch and the wheel extending radially inward from the second arch serve as a pressure zone between the wheel extending radially outward from the first arch and the wheel extending radially inward from the second arch.

[0098] Advantageously, the device further includes an actuated positioning device that radially changes the position of the wheel relative to the corresponding arch member to change the pressure zone.

[0099] Preferably, the device further includes a complementary feature communicatively connected to each arched member, which cooperates with the indexing feature on the half-cylinder section.

[0100] Preferably, the device is one in which the pressure zone is adjusted to the desired profile of the half-barrel section according to instructions conveyed by the indexing feature to the complementary feature.

[0101] Preferably, the device is an apparatus in which the pressure zone is established to apply a desired profile to the half-barrel section within the field of view of the workstation and / or the arched member.

[0102] Preferably, the device is a device in which the arched member is connected to the work station.

[0103] Preferably, the device is one in which the first arched member further includes a wheel that extends radially inward from the first arched member to apply the desired profile along the inner mold line.

[0104] Preferably, the device is one in which the second arched member further includes a wheel extending radially inward from the second arched member to apply the desired profile along the outer mold line.

[0105] Other exemplary embodiments (e.g., methods and computer-readable media related to the foregoing embodiments) may be described below. The features, functions, and advantages already discussed may be implemented independently in various embodiments or may be combined in other embodiments, further details of which can be seen in the following description and figures. Attached Figure Description

[0106] Some embodiments of this disclosure will now be described by way of example and with reference to the accompanying drawings.

[0107] In all the accompanying drawings, the same reference numerals indicate the same element or the same type of element.

[0108] Figure 1 The aircraft is shown as being made from a half-tube section.

[0109] Figure 1A An example of a fuselage assembly system in an exemplary embodiment is shown.

[0110] Figure 2 This is a flowchart illustrating a method for operating the fuselage assembly system to apply inner and outer mold lines.

[0111] Figure 2A This is a flowchart illustrating a method for operating a fuselage assembly system to perform non-destructive inspection on a half-barrel section and to place the leading edge of the half-barrel section into a micro-pulsation system.

[0112] Figure 2B This is a flowchart illustrating a method for connecting a moving workstation to a half-barrel section.

[0113] Figure 2C This is a flowchart illustrating a method for performing work on a half-barrel section at a fixed workstation.

[0114] Figure 3 This is a perspective view of the half-cylinder section traveling through the fuselage assembly system in an exemplary embodiment.

[0115] Figure 4 , Figures 4A to 4C and Figure 5 This is a cross-sectional view of the pulley arch member with an applied profile in an exemplary embodiment.

[0116] Figure 6 This is a side view of the fixed arched member with the applied contour and the downstream station in an exemplary embodiment.

[0117] Figures 6A to 6C A flexible guide rail type fastener mounting device is described in an exemplary embodiment.

[0118] Figure 7 This is a flowchart of an exemplary embodiment of an aircraft production and service method.

[0119] Figure 8 This is a block diagram of an aircraft in an exemplary embodiment. Detailed Implementation

[0120] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. It will therefore be understood that those skilled in the art will be able to design various arrangements, although not expressly described or shown herein, that 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 conditions. Therefore, this disclosure is not limited to the specific embodiments or examples described below, but is limited by the claims and their equivalents.

[0121] The fuselage sections discussed in this article can be made of metal (e.g., aluminum) or composite materials. Composite parts (e.g., carbon fiber reinforced polymer (CFRP) parts) are initially laid out in multiple layers, which together are called preforms. The individual fibers within each layer of the preform are arranged 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, which cures to harden the preform into a composite part (e.g., for use in an 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 contain tackifiers or binders. Dry fibers are injected with resin before curing. For thermosetting resins, curing is a one-way process called hardening, while for thermoplastic resins, if reheated, the resin reaches a viscous form and can then be solidified into the desired shape. As used herein, the general term for the process of transforming a preform into its final hardened shape (i.e., transforming a preform into a composite part) is “hardening,” and this term encompasses the curing of thermosetting preforms and the molding / curing of thermoplastic preforms into their final desired shape.

[0122] Now refer to Figure 1 An exemplary diagram depicts an aircraft 10 that can realize an illustrative embodiment. In this exemplary example, the aircraft 10 has a right wing 15 and a left wing 16 attached to a fuselage 12. Each of the engines 14 is attached to the right wing 15 and the left wing 16 respectively. Known embodiments of aircraft have layouts with additional engines 14 and different engines. The fuselage 12 includes a tail section 18 and a nose section 38. Horizontal stabilizers 20, 21, and 23 are attached to the tail section 18 of the fuselage 12. The aircraft 10 is an example in which the fuselage 12 is largely formed by a plurality of semi-cylinder sections 24, which are manufactured in part in Figure 1AAs illustrated in the example. When attached together, the multiple half-tube sections 24 form the majority of the fuselage 12.

[0123] As described above, the fuselage 12 is made of multiple half-tube sections 24. The half-tube sections 24 are configured as upper half-tube sections 40 or lower half-tube sections 42, which are eventually combined to form the full tube section 44. Figure 1 Several barrel sections 44 are depicted, including: 44-1, 44-2, 44-3, 44-4, and 44-5. For completeness, barrel section 44-1 is made using upper barrel section 40-1 and lower barrel section 42-1; barrel section 44-2 is made using upper barrel section 40-2 and lower barrel section 42-2; barrel section 44-3 is made using upper barrel section 40-3 and lower barrel section 42-3; barrel section 44-4 is made using upper barrel section 40-4 and lower barrel section 42-4; and barrel section 44-5 is made using upper barrel section 40-5 and lower barrel section 42-5. Full barrel sections 44-1 and 44-2 correspond to view AA, while full barrel section 44-5 corresponds to view BB, and are sequentially fastened to the fuselage 12. The lower barrel section 42-3 is sometimes referred to as the wing box because wings 15 and 16 are attached to this section.

[0124] Unless otherwise specified, all of the aforementioned half-tube sections (e.g., upper half-tube section 40 and lower half-tube section 42) will be referred to as half-tube section 24. In some embodiments, half-tube section 24 includes hardened composite material skin parts or metal skin parts, such as those awaiting installation of window frames 145 and door frames 145-1 (view AA) and frame 146 (…). Figure 1 To enhance rigidity. One embodiment has a half-cylinder section 24 as a composite material skin part of an aircraft model and another half-cylinder section 24 as a metal skin part that proceeds sequentially along the assembly system 100.

[0125] Figure 1A A side block view of a fuselage assembly system 100 in an exemplary embodiment is shown. The fuselage assembly system 100 includes any system, device, or component operable to iteratively pulse one or more half-barrel sections 24 of the fuselage 12 along a track 110 by a distance less than their length. The fuselage assembly system 100 is also capable of performing work along an inner mold line (IML) 128 and / or an outer mold line (OML) 126 on the half-barrel sections 24, with the half-barrel sections 24 pausing between pulses. However, embodiments in which the half-barrel sections perform work while moving within the fuselage assembly system 100 will also be described. The inner mold line (IML) 128 and the outer mold line (OML) 126 are also illustrated in… Figure 1 On the half-barrel section 24.

[0126] A section gap 121 exists between the two half-barrel sections 24. The section gap 121 is sized to provide pauses during operation at stations 144, 144-1, during which workers can rest, perform maintenance, and conduct inspections. When the section gap 121 is opposite to stations 144, 144-1, it provides the benefit of these workers for rest and maintenance. The section gap 121 is typically set to the micro-pulsation 149 of the half-barrel section 24 and / or the frame spacing 147 (…). Figure 1 The length of the micropulsation 149 is less than the length of the half-barrel section 24 and can be as short as the frame spacing 147 or a fraction or multiple thereof. Therefore, in one embodiment, the section gap 121 is a multiple of the frame spacing 147, and as shown, the section gap 121 is equal to the frame spacing 147. The frame spacing 147 is generally the same distance between the individual window frames 145. In one embodiment, the section gap 121 is between two feet and twenty feet. Each half-barrel section 24 defines a recess 127 that surrounds one or more workstations 144, 144-1. Additional workstations providing different or the same function as workstations 144, 144-1 may also be placed within and / or outside the recess 127. The end effector 148 associated with workstations 144, 144-1 performs work on the half-barrel section 24. This work may include trimming, cutting, drilling, fastening, placing components (e.g., frame 146), and performing non-destructive testing (NDI) on the half-barrel section 24.

[0127] In this embodiment, each half-barrel section 24 is located via its bearing edge 122 in the processing direction 199 ( Figure 1A The half-barrel section 24 (marked as "processing direction 199") moves along track 110. Track 110 includes one or more guide rails 111, rollers 114, or other elements that facilitate movement (e.g., rolling or sliding) of the half-barrel section 24 along track 110. The half-barrel section 24 pulsates synchronously along track 110 in processing direction 199, while the shape of the half-barrel section 24 is applied (as further described herein) such that recess 127 faces the factory floor 150. The half-barrel section 24 configured as upper half-barrel section 40 moves along processing direction 199 in crown-up position 139. The half-barrel section 24 configured as lower half-barrel section 42 moves along processing direction 199 in keel-up position 137. In other embodiments, track 110 includes a drive unit 116 (e.g., chain drive, motorized trolley, powered roller, or other power system) capable of moving the half-barrel section 24 in processing direction 199.

[0128] In this embodiment, the track 110 includes supports 112 (e.g., a discrete series of supports) with rollers 114 disposed on them. The supports 112 are spaced apart by support gaps 123, which can be three feet or more, for example, four to six feet. In one embodiment, the supports 112 have a length 125 of four feet or more. Another embodiment may have supports 112 with a length 125 of six feet, eight feet, or more. The support gaps 123 and the support length 125 allow technicians easy access to or from under the track 110 or to workstations 144, 144-1 located below the bearing edge 122 of the half-barrel section 24. In one embodiment, the bearing edge 122 of the half-barrel section 24 directly contacts the rollers 114 of the track 110. Roller 114 physically supports the bearing edge 122 of the half-barrel section 24 and applies the desired outer mold line (OML) 126 and / or inner mold line (IML) 128 (e.g., within tolerances) to the half-barrel section 24. Track 110 also includes a motor 115 that drives the half-barrel section 24 (e.g., by rotating the roller or by pulling the half-barrel section 24).

[0129] In other embodiments, the bearing edge 122 is mounted on a guide rail 111, which rests on a roller 114. In still other embodiments, the bearing edge 122 is mounted on the roller 114. In one embodiment, the bearing edge 122 and the roller 114 slide along the guide rail 111. Arches 140 and 140-1 are fixed members to the ground 150. When referred to separately, arch 140 will be referred to as the second arch 140 or the outer arch 140, and arch 140-1 will be referred to as the first arch 140-1 or the inner arch.

[0130] Arches 140 and 140-1 are systems / components that apply OML 126 and / or IML 128 to the half-barrel section 24 while simultaneously allowing the half-barrel section 24 to advance (i.e., between OML 126 and IML 128). In this embodiment, one or more second arches 140 contact the OML 126 via wheels 142, while one or more inner arches 140-1 are disposed within recesses 127, causing the IML 128 to contact the wheels 142-1. Applying OML 126 and IML 128 includes pushing the half-barrel section 24 through the space between arches 140 and arches 140-1. Each arch 140 and 140-1 includes rigid fixing bodies 141 and 141-1. The corresponding arched members 140, 140-1 include wheels 142, 142-1, which are circumferentially mounted around and rotatably fixed to the bodies 141, 141-1. Wheels 142, 142-1 contact the half-barrel section 24 to physically apply OML 126 and IML 128 (which also produces the desired profile 361) onto the half-barrel section 24. Wheels 142, 142-1 are also operated to push the half-barrel section 24 along the arched members 140, 140-1, respectively.

[0131] In other embodiments, the work density (as exemplified by the number of stations 144, 144-1 provided along the half-barrel section 24) is significantly higher than that of other embodiments. Figure 1A The situation is illustrated below. For clarity, the number and complexity of workstations 144, 144-1 have been reduced and simplified. That is, as the number of workstations 144, 144-1 per track 110 length increases, the workload performed per square foot of factory floor space on the half-barrel section 24 increases. The workload density is also significantly higher than in existing assembly systems, thereby significantly improving efficiency and reducing the size of the assembly system 100. In another embodiment, the arches 140, 140-1 are movable and capable of traveling parallel to track 110. The arches 140, 140-1 are capable of self-propelled or moving on the track (e.g., Figure 3 As shown in the figure, the track consists of two parallel track sections 110-1 and 110-2.

[0132] The fuselage assembly system 100 also includes indexing units 130. Each indexing unit 130 is designed to be physically or communicatively coupled to an indexing feature 124 (e.g., an RFID chip), an additional feature (e.g., a pin), or a machining feature (e.g., a hole or slot in the half-barrel section 24). Another embodiment has a scanner for the indexing units 130 as scanning indexing features 124 (particularly devices that can be scanned, such as RFID chips). The indexing features 124 are placed at known precise locations along the half-barrel section 24, and in one embodiment, each indexing feature 124 is spaced equidistantly along the half-barrel section 24. In other embodiments, the indexing features 124 are placed at various spacings and conform to various shapes and sizes. In other embodiments, the indexing features 124 are arranged linearly or non-linearly, depending on the construction of the individual sensing unit used to sense a particular indexing feature 124. The linear or non-linear arrangement of the indexing features 124 includes varying or constant spacing between features. In some other embodiments, the indexing feature 124 is provided in the manufacturing allowance 129 of the half-barrel section 24, which is trimmed off at a point before the half-barrel section 24 is completed. In such embodiments, the system 100 is programmed to precisely stop the pulsation or micro-pulsation of the half-barrel section 24 when the indexing feature 124 is within the operating field of view of the corresponding indexing unit 130.

[0133] In other embodiments, certain indexing units 130 include complementary features 134 for insertion, gripping, or otherwise adapting to the mechanical properties of indexing features 124 to facilitate hard stops when indexing features 124 and complementary features 134 engage. Indexing units 130 are positioned in a fixed, known location relative to tracks 110 or stations 144, 144-1. During assembly, the half-barrel section 24 is pulsed at least equal to the distance of the shortest micro-pulse 149, for example, the frame spacing 147. That is, the half-barrel section 24 is pulsed to indexing units 130. Whenever the indexing feature 124 in the half-barrel section 24 engages with the complementary feature 134 in the indexing unit 130, the position of the half-barrel section 24 is indexed to a known location in the coordinate space shared by tracks 110, indexing units 130 and / or stations 144, 144-1 and recess 127. Specifically, each indexing unit 130 is positioned at a known offset from stations 144, 144-1 (e.g., along three axes). This means that the action of indexing the half-barrel section 24 to the indexing unit 130 ensures that the positions of the half-barrel sections 24, OML 126, and / or IML 128 within the fields of view 113, 113-1, 113-2 of each of stations 144, 144-1 and / or arches 140, 140-1 are known to stations 144, 144-1 or arches 140, 140-1 at the end of each micro-pulse 149. Furthermore, the action of indexing the half-barrel section 24 to the indexing unit 130 ensures that the positions of the half-barrel section 24, OML 126, and / or IML 128 within the fields of view 113, 113-1, 113-2 of each of the arches 140, 140-1 are known at the end of each micro-pulse 149. The arches 140, 140-1 apply the desired OML 126 and / or IML 128 to the half-barrel section 24 and produce a profile 361 (e.g., ...) at the arches 140, 140-1 and / or stations 144, 144-1. Figure 3 (As shown), this occurs simultaneously with the transposition and can continue to do so before and / or after the transposition.

[0134] The indexing mechanism transfers details of the semi-cylinder section 24 within the fields of view 113-1 and 113-2 of the arched members 140 and 140-1, respectively. This information is used to set the positions of wheels 142 and 142-1 relative to the arched members 140 and 140-1, respectively, using connectors 433 and 434 and connectors 433-1 and 434-1. The radius of the semi-cylinder section 24 is 363 ( Figure 3(As shown) can vary between one half-barrel section 24 and the next half-barrel section 24. In one embodiment, the half-barrel section 24 is a model with a specific radius 363, while the next half-barrel section 24 will require a different radius 363. Another embodiment includes a half-barrel section 24 with a non-constant or tapered radius 363 as a half-barrel section 24 that generates micro-pulsations 149 in the machining direction 199. The non-constant or tapered half-barrel section 24 will have unequal radii 363 and a second radius 363-1. The desired profile 361 of the half-barrel section 24 is transferred from the indexing feature 124 to the arches 140, 140-1 via complementary feature 134 and indexing unit 130. The wheels 142, 142-1 are adjusted relative to the arches 140, 140-1 to a suitable radius 363 for the half-barrel section 24, respectively. Variations between models include different radii 363 for the half-barrel section 24. Wheels 142, 142-1 are positioned relative to arches 140, 140-1 such that profiles 361 can be applied to the half-barrel sections 24 within the views 113-1, 113-2 of arches 140, 140-1 for specific radii 363. The leading edge 170 of the half-barrel section 24 engages with wheels 142, 142-1 during micro-pulsations 149. Profiles 361 are applied to the half-barrel sections 24 by wheels 142, 142-1 until the trailing edge passes through wheels 142, 142-1.

[0135] Fields of view 113-1, 113-2 are the widths of the work performed by the arched members 140, 140-1 on the half-barrel section 24 during pauses or pulses. In other words, fields of view 113-1, 113-2 are the lengths of the half-barrel section 24 within the working range of the arched members 140, 140-1 during pauses or micro-pulsations 149. The illustrated arched members 140, 140-1 are larger than the fields of view 113-1, 113-2 of the longitudinal portion 422 compared to actual practice. The lengths of the fields of view 113-1, 113-2 of the arched members 140, 140-1 are generally closer to the length of the micro-pulsation 149. The fields of view 113-1, 113-2 of the arched members 140, 140-1 may or may not overlap.

[0136] As will be readily understood, in the preceding section describing horizons 113-1 and 113-2, at any given time, only a small longitudinal portion of the half-barrel section 24 engages with arches 140, 140-1 and wheels 142, 142-1. The effect of arches 140, 140-1 on the half-barrel section 24 will be felt in the half-barrel section 24 upstream and downstream of arches 140, 140-1. Therefore, in some embodiments, a segment 195 in the half-barrel section 24 that is longer than horizon 113-1 or horizon 113-2 is held in the desired profile 361. The addition of frames 146 and frames 145, 145-1 is also operated to apply the desired profile 361 downstream of arches 140, 140-1. As an example and for illustration only, arch members 140, 140-1 are operated to apply a desired profile 361 on each side of the arch members 140, 140-1 for the length of one or both frame spacings 147.

[0137] In one embodiment, indexing is performed at least as described below. A structure in the form of a half-barrel section 24 is carried on a bearing edge 122 on a track 110, which includes a set of supports 112 (e.g., longitudinal connectors) fixed to a ground 150. The half-barrel section 24 is fabricated on a laying mandrel according to precise dimensions. This precise laying allows the indexing feature 124 to be precisely positioned within the manufacturing allowance 129 of the half-barrel section 24. Thus, once the half-barrel section 24 is precisely positioned on the supports 112, arches 140, 140-1 apply OML 126 and / or IML 128 to the half-barrel section 24. When the indexing feature 124 is engaged, OML 126 and / or IML 128 are precisely known, eliminating the need for a complete scan via probe or optical technology at each station 144, 144-144 after each micropulse 149.

[0138] The relative stiffness of the half-barrel section 24, formed by demolding or otherwise, helps maintain a reasonable proximity to the desired OML 126 and / or IML 128 (e.g., desired profile 361) without requiring any shape-defining tools to be mounted or secured to the half-barrel section 24 during micro-pulsation 149. Shape-defining tools would require additional stations (e.g., similar to station 144) for mounting the shape-defining tools on the half-barrel section 24, and another additional station for removing the shape-defining tools. In this example, instances of the shape-defining tools would be mounted on the ends of the half-barrel section 24, and one or more additional instances would be mounted somewhere between the ends. The shape-defining tools would, to some extent, impede access to the half-barrel section 24 until it is removed. Furthermore, the addition and removal of the shape-defining tools can be considered as non-value-added work relative to the half-barrel section 24.

[0139] In the embodiments disclosed herein, the indexing feature 124 is precisely positioned within the half-barrel section 24 in relation to the OML 126 and / or IML 128, and the precisely positioned guide features of the track 110 (e.g., guide rail 111 and roller 114) and the arches 140, 140-1 facilitate the transfer of the half-barrel section 24 from station 144 to station 144-1 without deformation. Therefore, when indexed after each micro-pulse 149, the 3D position and orientation (such as the OML 126 and / or IML 128 of the half-barrel section 24) are quickly and accurately determined without requiring rescanning and recalibrating of the half-barrel section 24 after each movement.

[0140] Continuing, frame 146, window frame 145, and door frame 145-1 are installed into half-tube section 24 to reinforce it before removing the window and / or door installation manufacturing allowance 135, resulting in a trimmed edge 135-1. In the example shown, station 144 installs frame 146 into half-tube section 24. Station 144-1 secures window frame 145 into half-tube section 24. Traveling station 144-2 is attached at placement point 144-3 and travels with half-tube section 24, performing work during and / or between micro-pulsations 149. Traveling station 144-2 travels with half-tube section 24 and separates manufacturing allowance 135 from half-tube section 24 after installing window frame 145, door frame 145-1, and frame 146.

[0141] Other implementations of workstation 144 are as follows: Figure 6 As shown in the diagram. Specifically, travel stations 144-4 and 144-5 include... Figure 6A and Figure 6C The flexible guide rail type fastener mounting device is shown. Traveling stations 144-2 travel alongside the half-tube section 24 like a "hitchhiker," then return to placement point 144-3 to reconnect and continue work on the half-tube section 24. One embodiment may have multiple traveling stations 144-2 that travel alongside the half-tube section 24 at any given time. Furthermore, before removing the window or door manufacturing allowance 135, frames 146 and window frames 145 and door frames 145-1 are added to reinforce the half-tube section 24, after which the window and / or door manufacturing allowance 135 is removed. Although only stations 144 and 144-1 are shown, more stations are possible.

[0142] Because precise indexing is performed, technicians at each station 144, 144-1 can accurately know their position or the location of their tools (such as end effector 148) relative to the positioning of the half-barrel section 24. The half-barrel section 24 remains in place mechanically or otherwise during indexing. The OML 126 or IML 128 of the half-barrel section 24 is then established or indexed to any CNC programming or automation system used at stations 144, 144-1. Therefore, no time setting or scanning is required after each pulse of the half-barrel section 24. Furthermore, structures added to (e.g., frame 146, frame 145) or removed from (manufacturing allowance 135) the half-barrel section 24 in previous stations 144, 144-1 can be added to any half-barrel section 24 model or representation within system 100 without scanning changes to the half-barrel section 24.

[0143] That is, the indexing of the half-barrel section 24 can be performed by aligning it with the indexing unit 130. Stations 144, 144-1 have a known relationship with the indexing unit 130, thus also indexing the half-barrel section 24 to stations 144, 144-1. When the two are in a known relationship, tools such as end effectors 148 at stations 144, 144-1 are in a known relationship with the OML 126 and IML 128 of the half-barrel section 24. Therefore, indexing the half-barrel section 24 may include mates the indexing feature 124 at the half-barrel section 24 with the complementary feature 134 at the indexing unit 130, which has a known physical offset from stations 144, 144-1. This is because the complementary feature 134 at the indexing unit 130 is pre-positioned and its size is designed to fit the indexing feature 124, while the half-barrel section 24 is in a specific and precisely determined position.

[0144] In one embodiment, complementary feature 134 is coupled to indexing feature 124 at indexing unit 130 to convey the type of the half-barrel section 24 and the range of work to be performed on the half-barrel section 24 within the field of view 113 of stations 144, 144-1, and 144-2. Field of view 113 is the width of the work performed on the half-barrel section 24 at stations 144, 144-1. Field of view 113 extends in the longitudinal portion 422 of the half-barrel section 24. The type of the half-barrel section 24 conveys to stations 144, 144-1, and 144-2 the information that feed lines 136-1 and 136-2 need to provide to stations 144, 144-1 just-in-time (JIT) respectively. Feed line 136-1 provides frame 146, fasteners, sealant, etc., to station 144 JIT. Feeder line 136-2 supplies window frames 145, fasteners, sealants, etc. to workstation 144-1JIT.

[0145] In another embodiment, complementary feature 134 mates with indexing feature 124 at indexing unit 130 to transmit OML 126 and IML 128 data to arch members 140, 140-1. This information helps arch members 140, 140-1 apply the desired OML 126 and / or IML 128 to the half-barrel section 24 using wheel 142. Arch members 140, 140-1 may be additional components at workstations 144, 144-1 in addition to being standalone components. Generally, arch members 140, 140-1 are no longer needed after the installation of frames 146, window frames 145, and door frames 145-1, as these are also operated to apply OML 126 and IML 126 to the half-barrel section 24.

[0146] The operation of tracks 110, stations 144, 144-1, arches 140, 140-1, and / or other components is managed by controller 160. In one embodiment, controller 160 determines the advance of the half-barrel section 24 along track 110 based on an automated process, such as input from a camera or physical sensors (e.g., linear or rotary actuators), based on input from a technician or automated sensing via indexing feature 124. Controller 160 instructs connectors 433, 433-1, 434, 434-1 to reach lengths 437, 437-1 (e.g., ...) based on indexing information transmitted to arches 140, 140-1. Figure 4 (As shown). Reference Figure 4 The controller 160 positions the wheels 142, 142-1 to form a pressure zone 420 at a desired radius of 363. Initially, the pressure zone 420 is set with a gap 421-1 so that the leading edge 170 initially passes between the wheels 142, 142-1. The controller 160 then instructs the connectors 433, 433-1, 434, 434-1 to form the pressure zone 420 with the gap 421. The controller 160 uses this input to manage the operation of various components according to instructions stored in a digital control (NC) program. For example, the controller 160 may be implemented as a custom circuit, a hardware processor that executes programmed instructions, or some combination thereof.

[0147] The process using arched parts 140, 140-1 is used to apply profile 361 to the half-barrel section 24 within the view 113 of adjacent stations 144, 144-1 during pauses between micro-pulses 149. This allows the half-barrel section 24 to be momentarily forced into profile 361 within stations 144, 144-1 when profile 361 exceeds tolerances.

[0148] Illustrative details of the operation of the fuselage assembly system 100 will be provided in reference to Figure 2The following discussion will be conducted. For this embodiment, it is assumed that the half-tube section 24 of the fuselage (e.g., a half-tube section, a third-tube section, or any suitable circumferential portion) has had its bearing edge 122 trimmed onto a laying mandrel prior to demolding. These sections have been demolded and are awaiting assembly work, such as trimming, frame installation, inspection, or other activities.

[0149] Figure 2 This is a flowchart illustrating a method of operating the fuselage assembly system 100 in an exemplary embodiment. (See reference...) Figure 1A The steps of method 200 are described in the fuselage assembly system 100, but those skilled in the art will understand that method 200 can be performed in other systems. The steps in the flowcharts described herein are not all included and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0150] In step 202, the half-barrel section 24 of the machine body is fixed to the track 110 such that the recess 127 of the half-barrel section 24 faces the ground 150 and the bearing edge 122 of the half-barrel section 24 directly contacts the track 110. For the upper half-barrel section 40, the half-barrel section 24 moves along the processing direction 199 at the crown-up position 139. For the lower half-barrel section 42, the half-barrel section 24 moves along the processing direction 199 at the keel-up position 137. In other words, the half-barrel section 24 forms a semi-cylinder or an inverted "U" shape, with the keel located at the apex of the "U". At each apex end of the inverted "U" and the recess 127, the bearing edge 122 is held / supported by the rollers 114 of the track 110 and directly contacts these rollers 114. In one embodiment, securing the half-barrel section 24 to the track 110 includes placing the half-barrel section 24 on the track 110 in such a way that the bearing edge 122 is held in place by the roller 114.

[0151] In step 204, the half-barrel section 24 is pulsed (e.g., synchronously) along the track 110 in the processing direction 199. In one embodiment, pulsating the half-barrel section 24 includes micro-pulsating the half-barrel section 24 by a distance less than the length of the half-barrel section 24. In other embodiments, the half-barrel section 24 is micro-pulsated at a frame spacing 147 (i.e., the distance between frames 146 to be placed in the half-barrel section 24), although any suitable pulsation distance can be used, including multiples or fractions of the frame spacing 147. During pulsation, the half-barrel section 24 may roll over wheels 142, 142-1 mounted to the arches 140, 140-1, and these wheels 142, 142-1 contact the half-barrel section 24 during and / or after movement of the half-barrel section 24 to apply the desired profile 361.

[0152] However, pulsations shorter than the length of the half-barrel section 24 are also referred to as “micro-pulsations.” As used herein, a micro-pulsation can be any suitable distance, including multiples of the frame spacing 147. In one embodiment, a gap of at least two feet is left between the half-barrel sections 24 during a pulsation. This allows a technician to exit between the half-barrel sections 24 when the section gap 121 coincides with workstations 144, 144-1. In other embodiments, the support 112 is high enough to allow a technician to walk or take cover beneath the track 110.

[0153] In step 206, the arched members 140, 140-1 defining cross-sections OML 126 and IML 128 apply these cross-sections to the half-barrel section 24. Application includes pushing the half-barrel section 24 into profile 361. In this embodiment, because the wheels 142, 142-1 are in a known position relative to the body 141 of the arched members 140, 140-1, and because the wheels 142, 142-1 contact the half-barrel section 24, the wheels 142, 142-1 hold the half-barrel section 24 in place and physically apply the OML 126 and IML 128 as desired. In other embodiments, if the half-barrel section 24 is outside profile 361, the wheels 142, 142-1 only contact the half-barrel section 24 and are used to apply the OML 126 and IML 128 to the half-barrel section 24. In some other embodiments, wheels 142, 142-1 maintain contact with the half-barrel section 24 between micro-pulses, or retract from the half-barrel section 24 via connectors 433, 433-1, 434, and 434-1. Connectors 433, 434 and 433-1, 434-1 extendably attach wheels 142-1, 142 to arches 140 and 140-1, respectively.

[0154] In step 208, work is performed on the half-barrel section 24 while applying cross-sections OML 126 and IML 128. In an embodiment where the half-barrel section 24 is pulsated, work is performed during pauses between micro-pulses 149, while the wheels 142, 142-1 of the arches 140, 140-1 are forced into contact with the half-barrel section 24. In an embodiment where the half-barrel section 24 moves continuously, work is performed as the half-barrel section 24 moves in the machining direction 199. Work is performed by stations 144, 144-1 via end effector 148 and may include cutting, drilling, and finishing (e.g., final edge finishing). Another embodiment has machining equipment attached to the half-barrel section 24 (e.g., those associated with traveling station 144-2) to work on the half-barrel section 24 as it continues in the machining direction 199. When the work is completed and the tool returns to attachment point 144-3 in the continuous movement line as described above, the processing equipment (not shown) is separated from the half-barrel section 24. For example, this processing may include non-destructive testing (NDI) equipment, placement, fastening, etc., as described above. In embodiments where the half-barrel section 24 is micro-pulsated 149, after the pause is completed, the work proceeds to step 204 and the half-barrel section 24 is micro-pulsated again 149 to receive additional work.

[0155] Method 200 offers a technical advantage by applying contour 361 directly to large moving parts (e.g., half-barrel section 24) without requiring fixtures or other components to be attached to these parts. Installing fixtures to apply OML 126 and IML 128 is a non-value-added task that increases the workload and time of the manufacturing process. The arches 140, 140-1 and wheels 142, 142-1 provide flexibility in the manufacturing process because OML 126 and IML 128 are applied without restricting access to portions of the half-barrel section 24 within the field of view of stations 144, 144-1. Therefore, as the half-barrel section 24 advances through stations 144, 144-1, there is no accompanying contour forming process to further restrict access to the half-barrel section 24. This allows for precise work execution without access barriers as the half-barrel section 24 micro-pulses 149 through stations 144, 144-1. Furthermore, because multiple workstations 144, 144-1 can be located within the recess 127 of the half-barrel section 24, a large number of different types of work (e.g., drilling, finishing, sealing, painting, inspection, etc.) can be performed simultaneously across various parts of the half-barrel section 24 within the field of view of workstations 144, 144-1. This increases the assembly speed and work density on the factory floor 150. Moreover, method 200 is able to convert the transport time of the half-barrel section 24 into added-value time for work performed on the half-barrel section 24, particularly during NDI inspection or finishing to remove manufacturing allowances 129, 135 and / or bearing edges 122.

[0156] The field of view 113 is the width of the work performed by stations 144 and 144-1 on the half-barrel section 24 during pauses or pulses. In other words, the field of view 113 is the length of the half-barrel section 24 within the working range of stations 144 and 144-1 during pauses or pulses. Stations 144 and 144-1 are illustrated as having a larger field of view 113 relative to the longitudinal portion 422 than in practice. The length of the field of view 113 of stations 144 and 144-1 is generally closer to the length of the micro-pulse 149. The fields of view 113 of stations 144 and 144-1 do not overlap.

[0157] Figure 2A This is a flowchart illustrating a method of operating the fuselage assembly system 100 in an exemplary embodiment. (See reference) Figure 1A and Figures 3 to 5 The steps of method 220 are described in the fuselage assembly system 100, but those skilled in the art will understand that method 220 can be performed in other systems. The steps in the flowcharts described herein are not all included and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0158] The half-barrel section 24 of the machine body is fixed to the track 110 such that the recess 127 of the half-barrel section 24 faces the ground 150 and the bearing edge 122 of the half-barrel section 24 directly contacts the track 110. The half-barrel section 24 for the upper half-barrel section 40 moves in the processing direction 199 at the crown-up position 139. Each indexing unit 130 is designed to be physically or communicatively connected to the indexing feature 124 (e.g., an RFID chip), additional features (e.g., a pin), or machining features (e.g., a hole or slot in the half-barrel section 24). In another embodiment, a scanner having scanning indexing features 124 (in particular, a scannable device, e.g., an RFID chip) serves as the indexing unit 130 to control the movement of the half-barrel section 24 via input to a controller 160, which in turn controls the operation of the drive unit 116. Each indexing unit 130 includes a complementary feature 134 for inserting, gripping, or otherwise adapting to the indexing feature 124 to enable hard stop upon mating.

[0159] The indexing is performed at least according to the following instructions. The half-barrel section 24 is carried at the bearing edge 122 on a track 110, which includes a set of supports 112 (e.g., longitudinal connectors) fixed to the ground 150. The half-barrel section 24 is fabricated on a laying mandrel according to precise dimensions. This precise laying allows the indexing feature 124 to be precisely positioned within the manufacturing allowance 129 of the half-barrel section 24.

[0160] In step 222, the half-cylinder section 24 is transposed to be configured as NDI stations 371, 371-1 (e.g. Figure 6 The workstation shown is similar to workstation 144. In step 224, within the field of view 113-3 of NDI stations 371 and 371-1, the radius 363-2 of the half-barrel section 24 is measured along the circumferential direction 370, while micro-pulsations pass through NDI stations 371 and 371-1 (as shown). Figure 4(As shown). In step 226, NDI station 371, 371-1 information related to the radius 363-2 for creating profile 361 is transmitted to arch members 140, 140-1 via controller 160 for use within the field of view 113-1, 113-2 of arch members 140, 140-1. In step 228, the rotation of the half-barrel section 24 to the arch members 140, 140-1 is completed. In step 230, the wheels 142, 142-1 are positioned relative to the arch members 140, 140-1 with the initially set gap 421-1 and radius 363-3 to form pressure zone 420. Step 232 shows the leading edge 170 being micro-pulsated through pressure zone 420. In step 234, pressure zone 420 is set with gap 421 to apply profile 361 on half-barrel section 24. As shown in step 236, when within the field of view 113-3 of NDI stations 371, 371-1, using measurement data for the same half-barrel section 24, profile 361 is applied to the half-barrel section 24 within the field of view 113-1, 113-2 of arched members 140, 140-1, while simultaneously causing the half-barrel section 24 to micro-pulse through pressure zone 420. Field of view 113-3 is the width of the work performed by NDI stations 371, 371-1 on the half-barrel section 24 during pauses or during pulsations between pauses.

[0161] Figure 2B This is a flowchart illustrating a method 240 for operating the fuselage assembly system 100 in an exemplary embodiment. (See also...) Figure 1A and Figures 6 to 6C The steps of method 240 are described using the fuselage assembly system 100 as an example, but those skilled in the art will understand that method 240 can be performed in other systems. The steps in the flowchart described herein are not all included and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0162] In step 242, the micro-pulsation 149 of the half-tube section 24 is moved to placement point 144-3. Stations 144 and 144-1 install the frame 146 into the half-tube section 24. Station 144-1 fastens the window frame 145 into the half-tube section 24.

[0163] In step 246, travel station 144-2 is attached at placement point 144-3 and travels along with the half-tube section 24, performing work during pauses between micro-pulsations 149 and / or micro-pulsations 149. Travel station 144-2 travels along with the half-tube section 24 and separates the manufacturing allowance 135 from the half-tube section 24 after the window frame 145 and frame 146 are installed. Another embodiment has stations 144, 144-1 for positioning the frame and / or window frame onto the half-tube section 24. Then, as part of step 246, travel stations 144-4 and 144-5 are also connected to the half-tube section 24.

[0164] Workstations 144 and 144-1 temporarily fasten frame 146, window frame 145, and / or door frame 145-1 to the half-tube section 24. One implementation of this temporary fastening involves intermittently installing final fasteners within workstations 144 and 144-1 to secure frame 146, window frame 145, and / or door frame 145-1 into place. Intermittent fastening includes tightening every 10 or 20 fasteners or some other type of spacing, using production-grade fasteners. Another implementation of this temporary fastening involves intermittently installing temporary fasteners within workstations 144 and 144-1 to secure frame 146, window frame 145, and / or door frame 145-1 into place. Intermittent fastening includes tightening every 10 or 20 fasteners or some other type of spacing, using Cleco-type fasteners. Traveling workstations 144-4 and 144-5 include... Figure 6A and Figure 6C The illustrated flexible guide rail type fastener installation device. Traveling stations 144-4 and 144-5 are vacuum-attached to the half-tube section 24 and fasten the frame 146 and / or window frame 145 and / or door frame 145-1 to the half-tube section 24. As part of step 248, traveling stations 144-4 and 144-5 travel with the half-tube section 24 as the half-tube section 24 experiences micro-pulsations 149 and / or pauses, and may even perform fastener installation while passing through stations 144, 144-1. Traveling station 144-2 travels with the half-tube section 24 like a "hitchhiker" and separates the manufacturing allowance 135 from the half-tube section 24, also as part of step 248.

[0165] As part of step 250, travel stations 144-2, 144-4, and 144-5 disengage from the half-barrel section 24 after fastener installation or adjustment is completed. Then, travel stations 144-2, 144-4, and 144-5 return to placement points 144-3, 144-6, and 144-5 respectively (e.g., ...). Figure 6(As shown). In one embodiment, the traveling stations 144-2, 144-4, and 144-5 travel back to the placement points 144-3 and 144-6 by their own power and onboard track structure.

[0166] Now for reference Figure 6A , Figure 6B and Figure 6C Retractable wheels (not shown) are arranged along first flexible guide rails 636, 636-1, 636-2 and second flexible guide rails 638, 638-1, 638-2, as well as carriers 46, 46-1, 46-2. In tracked configuration, travel stations 144-2, 144-4, and 144-5 travel by their own power from one connection point on the half-barrel section 24 to another connection point on the half-barrel section 24, and then reconnect. As part of step 252, another configuration has 144-2, travel stations 144-4, and 144-5 traveling by their own power back to placement points 144-3 and 144-6. One embodiment may have multiple travel stations 144-2, 144-4, and 144-5 that travel with the half-barrel section 24 at any given time.

[0167] In addition, before removing the window or door manufacturing allowance 135, add frame 146 and window frame 145 and door frame 145-1 to reinforce the half-cylinder section 24, and then remove the window or door manufacturing allowance 135.

[0168] Figure 2C This is a flowchart illustrating a method of operating the fuselage assembly system 100 in an exemplary embodiment. (See reference...) Figure 1A and Figure 6 , Figure 6A and Figure 6C The steps of method 260 are described in the fuselage assembly system 100, but those skilled in the art will understand that method 260 can be performed in other systems. The steps in the flowcharts described herein are not all included and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0169] In step 262, the semi-tube section 24 is micro-pulsated 149 into stations 144 and 144-1. In step 264, during the micro-pulsation 149, the semi-tube section 24 is rotated to stations 144 and 144-1. As part of step 266, stations 144 and 144-1 position the frame 146, window frame 145, and / or door frame 145-1 onto the semi-tube section 24. Then, as part of step 268, stations 144 and 144-1 temporarily fasten the frame 146, window frame 145, and / or door frame 145-1 to the semi-tube section 24. The implementation of temporary fastening includes intermittently installing final fasteners within stations 144 and 144-1 to secure the frame 146, window frame 145, and door frame 145-1 into place. Intermittent fastening involves tightening with fasteners at intervals of 10 or 20 other types of spacing, using production-grade fasteners. Another embodiment of temporary fastening involves intermittently installing temporary fasteners at stations 144, 144-1 to secure frame 146, window frame 145, and / or door frame 145-1 into place. Intermittent fastening involves tightening with fasteners at intervals of 10 or 20 other types of spacing, using Cleco-type fasteners. Traveling stations 144-4 and 144-5 are then connected to the half-tube section 24. As part of step 270, as the half-tube section 24 advances through at least one micro-pulse 149, traveling stations 144-4 and 144-5 fasten frame 146, window frame 145, and / or door frame 145-1 to the half-tube section 24.

[0170] Workstations 144 and 144-1 temporarily fasten frame 146, window frame 145, or door frame 145-1 to the half-cylinder section 24. Traveling workstations 144-4 and 144-5 include... Figure 6A , Figure 6B and Figure 6C The flexible guide rail type fastener installation device is shown. Traveling stations 144-2, 144-4, and 144-5 are vacuum-attached to the half-tube section 24, and secure the frame 146 and / or window frame 145 and / or door frame 145-1 to the half-tube section 24. As part of step 248, traveling stations 144-2, 144-4, and 144-5 travel with the half-tube section 24 as the half-tube section 24 micro-pulses 149 and / or pauses, and even include performing fastener installation while possibly passing through stations 144, 144-1. Traveling station 144-2 travels with the half-tube section 24 like a "hitchhiker," separating the manufacturing allowance 135 from the half-tube section 24, also as part of step 248.

[0171] Traveling stations 144-2, 144-4, and 144-5 are disengaged from the half-barrel section 24 after the fasteners are installed or repaired.

[0172] Then, travel stations 144-2, 144-4, and 144-5 return to placement points 144-3 and 144-6, respectively. One embodiment allows travel stations 144-2, 144-4, and 144-5 to travel back to placement points 144-3 and 144-6 using their own power and onboard tracked configuration. Retractable wheels (not shown) are arranged along first flexible guide rails 636, 636-1, 636-2 and second flexible guide rails 638, 638-1, 638-2, as well as carriers 646, 646-1, 646-2. When in tracked configuration, travel stations 144-2, 144-4, and 144-5 travel under their own power from one connection point on the half-barrel section 24 to another connection point on the half-barrel section 24, and then reconnect. As part of step 252, another configuration includes 144-2, travel stations 144-4, and travel stations 144-5 that travel back to placement points 144-3 and 144-6 under their own power. One embodiment may have multiple travel stations 144-2, 144-4, and 144-5 that travel with the half-tube section 24 at any given time. Furthermore, before removing the window or door manufacturing allowance 135, frames 146 and window frames 145 and door frames 145-1 are added to reinforce the half-tube section 24, and then the window or door manufacturing allowance 135 is removed. Although only travel stations 144-2, 144-4, and 144-5 are shown, more travel stations are possible.

[0173] Figure 3 This is a perspective view of a half-barrel section 24 of the fuselage traveling through the fuselage assembly system 100 in an exemplary embodiment. In this embodiment, the half-barrel section 24 includes a recess 127. The track 110 includes a plurality of supports 112 (e.g., longitudinal connectors), each support including a roller 114 fixed in the processing direction 199 and driving the half-barrel section 24.

[0174] Figure 3The diagram also depicts a factory floor 150 and inner and outer arched members 140-1 fixed to it. For clarity, workstations 144 and 144-1 are omitted from this drawing. To reiterate, the inner and outer arched members 140-1 and 140-1 can be attached to workstations 144 and 144-1 as attachments or as independent components. The inner arched member 140-1 is sized to contact the IML 128 of the half-barrel section 24 using wheels 142-1. The inner arched member 140-1 includes a base 342 fixed at the factory floor 150. The inner arched member 140-1 also includes wheels 142-1. Each wheel 142-1 is rotatably fixed to the base 342, and the wheels 142-1 are distributed circumferentially along the base 342. When contact with IML 128 is required, wheel 142-1 contacts IML 128 to push half-barrel section 24 into desired profile 361. In some embodiments, when a portion of half-barrel section 24 is not in profile 361, only a subset of wheels 142-1 engages with half-barrel section 24.

[0175] In another embodiment, in the area / location where high-precision 3D positioning and contour 361 control are desired, several sets of wheels 142-1 (e.g., pairs of complementary wheels at circumferential positions along the fixed arch 140-1) can be positioned to contact the half-barrel section 24. Multiple arches 140-1 with accompanying wheels 142-1 are sequentially located along the half-barrel section 24 in stations 144, 144-1 to apply the contour 361 more precisely. When the half-barrel section 24 has the contour 361, it then has the desired OML 126 and IML 128. In another embodiment, the arches 140-1 with wheels 142-1 are included in at least one station 144, 144-1. In another embodiment, when workstations 144, 144-1 have arch-like structures for accommodating fabrication within workstations 144, 144-1 (e.g., arch-like frames 146 for holding drill holes or for fastener mounting equipment for mounting frame 146 or window frame 145 and door frame 145-1), wheels 142-1 are added to arch-like structures to apply contour 361 within workstations 144, 144-1.

[0176] In contrast, in areas where a less precise contour structure is desired, each arch 140-1 uses only one or two sets of wheels 142-1, and only one arch 140-1 is employed. Another embodiment uses only arches 140-1 with wheels 142-1, without OML arches like arch 140, and the wheels 142 are used only to maintain the desired contour 361 in contact with the IML 128. For example, while maintaining the desired shape for mounting frame 146, the half-tube section 24 is held less rigidly so that frame 146, window frame 145, or door frame 145-1 can be easily fastened to the half-tube section 24 without gaskets.

[0177] In yet another embodiment, the wheels 142-1 are positioned such that they do not contact the IML 128 of the half-barrel section 24 unless the half-barrel section 24 is outside the contour 361. Furthermore, one embodiment includes contacting the wheels 142-1 with the half-barrel section 24 as it moves in the machining direction 199, during pauses between pulses, or during micro-pulses 149 or pulses, or during the duration of continuous movement, and not at other times.

[0178] The outer arch 140 is sized to engage the OML 126 of the half-barrel section 24. The outer arch 140 includes a base 352 fixed at a location on the factory floor 150. The outer arch 140 also includes wheels 142. Each wheel 142 is rotatably fixed to the outer arch 140, and the wheels 142 are distributed circumferentially along the outer arch 140. Upon contact with the OML 126, the wheels 142 engage the OML 126 to push the half-barrel section 24 into the desired cross-sectional profile 361. In some embodiments, when a portion of the half-barrel section 24 is not in the profile 361, only a subset of the wheels 142 engages with the half-barrel section 24.

[0179] In another embodiment, in areas / locations where high-precision 3D positioning and contour 361 control are desired, several sets of wheels 142 (e.g., pairs of wheels 142 at circumferential positions along the fixed arch 140) can be positioned to contact the half-barrel section 24. In areas requiring more precise contour 361 control, wheels 142 and / or 142-1 can be positioned along the arch 140 and arch 140-1, while in other areas requiring lower precision, wheels 142 or 142-1 can be omitted, respectively. Multiple arches 140 with accompanying wheels 142 are sequentially positioned along the half-barrel section 24 in stations 144, 144-1 to apply contour 361 more precisely. In another embodiment, an outer arch 140 with wheels 142 is included in at least one station 144, 144-1. In yet another embodiment, stations 144, 144-1 have arch-like structures adapted for manufacturing within stations 144, 144-1. In this embodiment, arch members 140, 140-1 hold drilled holes or fastener mounting devices for mounting frame 146 or window frame 145 and door frame 145-1. Wheels 142-1 are added to arch members 140-1 to apply profile 361 within stations 144, 144-1. In contrast, in areas where a less precise profile structure is desired, only one or two sets of wheels 142-1 and one outer arch member 140 are used per outer arch member 140. Another embodiment uses only the outer arch member 140 with wheels 142, without using the IML arch member 140-1 and wheels 142-1, to maintain only the desired profile 361 in contact with OML 126. For example, while maintaining the desired shape for mounting frame 146, the half-tube section 24 is held less rigidly so that frame 146, window frame 145 or door frame 145-1 can be easily fastened to half-tube section 24 without gaskets.

[0180] In yet another embodiment, wheels 142, 142-1 are positioned such that they do not contact the OML 126 and / or IML 128 of the half-barrel section 24, unless the half-barrel section 24 is outside the contour 361. Furthermore, one embodiment includes positioning wheels 142, 142-1 to contact the half-barrel section 24 as the half-barrel section 24 moves in the processing direction 199, during pauses between pulses, or during micro-pulses 149 or pulses, or during the duration of continuous movement, and not at other times.

[0181] about Figure 3 The fixed arched component 140-1 discussed is implemented as a stand-alone device in some embodiments and integrated with respect to workstations 144, 144-1 in other embodiments.

[0182] Figure 4 Based on Figure 3 4B-4B view Figure 4A Previous steps and Figure 4B The illustrations for the previous two steps. In Figure 4 In this embodiment, the pressure zone 420 is set with a gap 421-1 to allow the leading edge 170 to initially pass between wheels 142-1 and 142. The leading edge 170 has not yet passed between wheels 142-1 and 142. If the half-barrel section 24 has a radius 363-2, then the gap 421-1 is wider than the gap 421 to allow the leading edge 170 to initially pass between wheels 142-1 and 142. In this embodiment, the radius 363-2 is smaller than the radius 363. If the radius of the half-barrel section 24 is an uncorrected radius 363-2, then the gap 421-1 is wider than the gap 421 to allow the leading edge 170 to initially pass between wheels 142-1 and 142. In the illustrated embodiment, the radius 363-2 is smaller than the radius 363. Wheel 142-1 is also set with a radius 363-3, which is smaller than either radius 363 or radius 363-2. By setting wheels 142-1 and 142 with a gap of 421-1 and a radius of 363-3, wheel 142-1 is prevented from impacting wheels 142-1 and 142 with the leading edge 170, thus preventing the micro-pulsations of the half-barrel section 24 from being blocked by the leading edge 170 impacting wheels 142-1 and 142. Impact can hinder micro-pulsations. In different embodiments, when the radius 363-2 is greater than the radius 363, wheel 142-1 is also set with a radius 363-3. The radius 363-3 will be set to a radius of 363. In another embodiment, the radius 363-3 is greater than 363 at some locations and less than 363 at others in the circumferential 370 position relative to the arched members 140-1 and 140. On the circumferential 370, wheels 142-1 and 142 are positioned with an appropriate radius 363-3 and a pressure zone 420 with a gap 421-1 that is complementary to the radius 363-2.

[0183] Arched components 140 and 140-1 are located after nondestructive testing (NDI) stations 371 and 371-1 (e.g.) Figure 6(As shown). NDI stations 371 and 371-1 measure the radius 363-2 of the half-barrel section circumferentially 370 during each micro-pulse 149. The half-barrel section 24 is micro-pulsed through NDI stations 371 and 371-1. NDI station 371 performs an external NDI check on the half-barrel section 24, while NDI station 371-1 performs an internal NDI check on the half-barrel section 24. The radius 363-2 is measured on the half-barrel section 24 circumferentially 370 as the half-barrel section 24 passes through NDI stations 371 and 371-1 in a micro-pulse 149 or continuously. This radius measurement can be performed optically, mechanically, or otherwise suitable. This measurement information establishes the radius 363-2 of the half-barrel section 24 circumferentially 370 within the field of view 113-3 of NDI stations 371 and 371-1. When the same measuring portion of the half-barrel section 24 is within the field of view 113-2 and 113-1 of the arched members 140 and 140-1 respectively, the measurement information for the field of view 113-3 of the half-barrel section 24 is transmitted via the controller 160 for use. This measurement information is used to set the radius 363-3 and the pressure zone 420 with the gap 421-1.

[0184] Figure 4A yes Figure 4B A diagram illustrating the steps preceding the previous steps. Figure 4A In this configuration, a gap 421-1 is used to set the pressure zone 420 so that the leading edge 170 initially passes between wheels 142-1 and 142. If the radius of the half-barrel section 24 is an uncorrected radius 363-2, then the gap 421-1 is wider than the gap 421 to allow the leading edge 170 to initially pass between wheels 142-1 and 142. In the illustrated embodiment, the radius 363-2 is smaller than the radius 363. In another embodiment, the radius 363-2 is greater than 363. Wheel 142-1 is also set to a radius 363-3 smaller than either radius 363 or radius 363-2. Setting wheels 142-1 and 142 with a gap 421-1 and setting wheel 142-1 with a radius 363-3 prevents the leading edge 170 from impacting either wheel 142-1 or 142, so that the micro-pulsations of the half-barrel section 24 are not blocked by the leading edge 170 impacting wheels 142-1 and 142. The impact can impede the micro-pulsation. Then, the half-barrel section 24 is pulsated, causing the leading edge 170 to pass through the pressure zone 420.

[0185] Then, controller 160 instructs connectors 433, 433-1, 434, 434-1 to form a pressure zone 420 with gap 421, as shown. Figure 4BAs shown. Forming the pressure zone 420 with gap 421 is the first step in establishing the profile 361 in the half-barrel section 24. The pressure zone 420 is positioned after indexing to facilitate the sliding of the leading edge 170 of the half-barrel section 24 into the pressure zone 420 during micro-pulsation 149. If desired, wheels 142-1 and 142 apply the profile 361 to the half-barrel section 24 by pushing the half-barrel section 24 toward its corresponding arches 140, 140-1 as the half-barrel section 24 advances in the machining direction 199. The application of the profile 361 occurs after the leading edge 170 passes through the pressure zone 420, with the pressure zone 420 set with gap 421 (after the gap 421 is set at gap 421-1).

[0186] Figure 4B These are cross-sectional views of wheels 142-1 and 142 located on the inner arched member 140-1 and the outer arched member 140, respectively. Figure 4B-4B It applied Figure 3 The outline in 361. Figure 4B In the diagram, wheel 142-1 is shown contacting IML 128, while wheel 142 is shown contacting OML 126. A pressure zone 420 is formed between wheel 142-1 and wheel 142. As the half-barrel section 24 advances through the pressure zone 420 in the machining direction 199, wheel 142 rotates counterclockwise 410. As the half-barrel section 24 advances through the pressure zone 420 in the machining direction 199, wheel 142-1 rotates clockwise 410-1. In one embodiment, the gap 421 between wheel 142-1 and OML 142 is too large for forming the pressure zone 420. In other embodiments, wheel 142-1 and wheel 142 together form the pressure zone 420, which forces the longitudinal portion 422 of the half-barrel section 24 ( Figure 1A A desired profile 361 is formed between them. When the plurality of wheels 142-1, 142 are aligned circumferentially along the inner arch 140-1 and outer arch 140, the pressure zone 420 applies the cross-sectional profile 361 along the entire IML 128 and / or OML 126 of the half-barrel section 24. Wheels 142-1 and 142 are held on the shaft 430 by wheel mounts 380, 382, ​​respectively. Wheel mounts 380, 382 are attached to arches 140-1 and 140 via connectors 433, 434 and connectors 433-1, 434-1, respectively. Connectors 433, 434 and connectors 433-1, 434-1 are extendable and retractable relative to arches 140-1 and 140 in directions of length 437, 437-1, respectively. Wheels 142-1 and 142 move relative to arched member 140-1 and arched member 140 via connectors 433 and 434 and connectors 433-1 and 434-1, respectively.

[0187] Connectors 433, 434 and connectors 433-1, 434-1 are hydraulic, electric, mechanical actuators and / or other suitable actuators. Mechanical actuators are screw jacks or similar devices. Wheels 142-1 and 142 move relative to arches 140, 140-1 via connectors 433-1, 434-1 and connectors 433, 434, respectively, and, based on information transmitted to arches 140, 140-1 via indexing from the half-barrel section 24, place pressure zone 420 at a position where contour 361 needs to be applied within the field of view 113-1, 113-2 of arches 140, 140-1. Based on the indexing information transmitted to arches 140, 140-1, controller 160 instructs connectors 433, 433-1, 434, 434-1 to reach lengths 437, 437-1. The controller 160 positions the wheels 142, 142-1 to form a pressure zone 420 at a desired radius 363. This process using the arched elements 140, 140-1 is used to apply profile 361 to the half-barrel section 24 within the view 113 of adjacent stations 144, 144-1 during micro-pulsations 149 or during pauses between micro-pulsations 149. This allows for temporary forced entry of the half-barrel section 24 into profile 361 within stations 144, 144-1 when profile 361 is outside tolerance.

[0188] Figure 4C An example is illustrated by applying profile 361 in a half-barrel section 24 having a radius of 363-1. Radius 363-1 is smaller than radius 363. Connectors 433, 434 and connectors 433-1, 434-1 are extendable and retractable relative to arches 140, 140-1 in directions of length 437, 437-1, respectively. Wheels 142, 142-1 are movable relative to arches 140, 140-1 via connectors 433, 434 and connectors 433-1, 434-1, respectively. Connectors 433, 434 and connectors 433-1, 434-1 are hydraulic, electric, and / or mechanical actuators. The mechanical actuator is a screw jack or similar device. Wheels 142 and 142-1 move relative to arches 140 and 140-1 via connectors 433-1, 434-1 and connectors 433 and 434 respectively, and place pressure zone 420 at a position where contour 361 needs to be applied within the field of view 113-1 and 113-2 of arches 140 and 140-1.

[0189] The application of profile 361 is based on information transmitted via indexing from the half-barrel section 24 to the arch members 140, 140-1. Based on the indexing information transmitted to the arch members 140, 140-1, the controller 160 instructs the connectors 433, 433-1, 434, 434-1 to reach lengths 437, 437-1. The controller 160 positions the wheels 142, 142-1 to form a pressure zone 420 at the desired radius 363-1. Initially, the pressure zone 420 is set with a gap 421-1 so that the leading edge 170 initially passes between the wheels 142, 142-1. Then the controller 160 instructs the connectors 433, 433-1, 434, 434-1 to form the pressure zone 420 with a gap 421. Forming the pressure zone 420 with a gap 421 is the first step in establishing profile 361 in the half-barrel section 24. When the pressure zone 420 is positioned after the indexing, the leading edge 170 of the half-barrel section 24 slides into the pressure zone 420 during micro-pulsation 149, and if necessary, the wheels 142-1 and 142 apply profile 361 to the half-barrel section 24 by pushing the half-barrel section 24 toward its respective arch 140, 140-1.

[0190] Figure 5 This is a cross-sectional view of the wheels 142-1 and 142 on the inner arched component 140-1 and the outer arched component 140. Figure 5-5 , its in Figure 3 Contour 361 is applied. Wheel mounts 380-1 and 382-1 are used to hold wheels 142-1 and 142 on shaft 430, respectively. Wheel mounts 380-1 and 382-1 are reinforced by entry rollers 520 and 520-1 disposed on swing arms 510 and 510-1, which pivot about shaft 512 upstream of pressure zone 420 and are biased toward half-barrel section 24 by a default force F. Entry roller 520 is separated by gap G and held in place by the default amount of force F. However, entry roller 520 is capable of pivoting 530 on swing arm 510 about shaft 512. Because swing arm 510 is biased to return to its default position relative to shaft 512, swing arm 510 pushes / forces entry roller 520 into contact with half-barrel section 24. This means that if a new half-barrel section 24 is about to enter between arches 140, 140-1 but is not fully aligned, the entry roller 520 can pre-profile the half-barrel section 24 more progressively into profile 361 via the pre-pressing zone 531 compared to using only the pressing zone 420. The pre-pressing zone 531 helps to bring the leading edge 170 of the half-barrel section 24 into the pressing zone 420 as part of the precursor profile forming device, avoiding a stop in the processing direction 199 due to the leading edge 170 hitting 142-1 or 142 of the half-barrel section 24, which is substantially outside the profile 361. The leading edge 170 is pre-profiled via the pre-pressing zone 531 as a precursor placed into the profile 361 by the pressing zone 420.

[0191] Figure 6 This is a side view illustrating an example embodiment of system 100, which includes fixed arches 140-1, 140 applying contour 361 and downstream stations 144, 144-1. In this embodiment, the half-cylinder section 24 of the fuselage 12 is supported along a support column 112, which is mounted to the factory ground 150. The inner arches 140-1 and the outer arches 140 define contour 361 (as shown in the image). Figure 3 (As shown) is applied to the half-barrel section 24, which advances along the processing direction 199 and extends through multiple stations 144, 144-1. During pauses between micro-pulses 149, or during continuous movement, end effectors 148 at stations 144, 144-1 perform work on the half-barrel section 24 to assemble a complete half-barrel section (e.g., 40) for connection with another half-barrel section (e.g., 42). In one embodiment, end effector 148 operates to install frame 146 or door frame 145-1 and / or window frame 145, which reinforces the half-barrel section 24 and reduces or eliminates the need for additional arching.

[0192] Traveling stations 144-4 and 144-5 are attached to station 144 and travel with the half-barrel section 24 while performing work during and / or during pauses in micro-pulsations 149. In one example, traveling stations 144-4 and 144-5 are a flexible track type system. Traveling station 144-4 includes a flexible track for mounting fasteners on the mounting frame 146. Traveling station 144-5 is a flexible track for mounting fasteners on the window frame 145. When placed, traveling stations 144-4 and 144-5 drill fastener holes and install fasteners to attach the frame 146 and the window frame 145.

[0193] Looking back Figure 1A After the window frame 145 and frame 146 are installed, the travel station 144-2 separates the manufacturing allowance 135 from the half-barrel section 24. For example, travel stations 144-4, 144-5 travel with the half-barrel section 24 like "hitchhikers" to the removal point 152, then return to the placement point 144-6, and are loaded / unloaded via a robot or other system for reattachment, and further work is carried out on another part of the half-barrel section 24 or the next half-barrel section to pulsate along the track 110. One embodiment may have multiple travel stations 144-4, 144-5 that travel with the half-barrel section 24 at any given time.

[0194] Figure 6AThis is a more detailed illustration of the travel station 144-5 connected to the half-tube section 24. The flexible guide system 622 includes a plurality of attachment vacuum cups 660, which are releasably secured to the half-tube section 24 at spaced intervals along the length of the first flexible guide 636 and the second flexible guide 638. A vacuum source 644 is connected to the vacuum cups 660 via a hose (not shown) to provide attachment force. One vacuum source 644 serves the vacuum cup 660 on the first flexible guide 636, while another vacuum source 644 serves the vacuum cup 660 on the second flexible guide 638. The locations of the two vacuum sources 644 are shown, but one may be sufficient. The second flexible guide 638 is preferably parallel to and spaced apart from the first flexible guide 636. The first and second flexible guides 636 are located outside the periphery of the window frame fastener location 662. Although multiple fastener mounting positions 662 are shown, the actual number of fastener mounting positions 662 can vary. Other suitable attachment components can also be used, such as magnets coupled to the internal ferromagnetic surface. The first flexible guide rail 636 and the second flexible guide rail 638 are connected by spacers 640 and 642. When vacuum-coupled or magnetically coupled, the first flexible guide rail 636 and the second flexible guide rail 638 are drawn into a shape complementary to the half-barrel section 24. The travel station 144-5 is mounted on the half-barrel section 24, for example, in station 144-1.

[0195] Drilling tool 650 and fastener installation tool 648 are located in carrier 646. Carrier 646 is movably coupled to first flexible guide rail 636 and second flexible guide rail 638. The movable coupling includes a rack and pinion system or a similar system not shown. Lateral alignment 654 allows drilling tool 650 and fastener installation tool 648 to move laterally across carrier 646 relative to the first and second flexible guide rails 636 and 638. A lateral helical jack system is shown, but other actuation systems are also possible. Fastener feeder 652 feeds fasteners to fastener installation tool 648 for drive to fastener installation position 662 created by drilling tool 650 in half-barrel section 24. Another embodiment releases vacuum cup 660 from half-barrel section 24 and then returns manually or automatically to placement point 144-6.

[0196] Figure 6BAn example is shown of a travel station 144-2 connected to the half-barrel section 24. The flexible guide system 622-1 includes a plurality of attachment vacuum cups 660-1, which are releasably secured to the half-barrel section 24 at spaced intervals along the length of a first flexible guide 636-1 and a second flexible guide 638-1. A vacuum source 644-1 is connected to the vacuum cups 660-1 via a hose (not shown) to provide attachment force. One vacuum source 644-1 serves the vacuum cups 660-1 on the first flexible guide 636-1, while the other vacuum source 644-1 serves the vacuum cups 660-1 on the second flexible guide 638-1. The locations of two vacuum sources 644-1 are shown, but one may be sufficient. The second flexible guide 638-1 is preferably parallel to and spaced apart from the first flexible guide 636-1. The first flexible guide rail 636-1 and the second flexible guide rail 638-1 are located outside the periphery of the window frame fastener positions 662. Although multiple fastener mounting positions 662 are shown, the actual number of fastener mounting positions 662 can vary. Other suitable attachment components can also be used, such as magnets attached to the internal ferromagnetic surface. The first flexible guide rail 636-1 and the second flexible guide rail 638-1 are connected by spacers 640-1 and 642-1. When vacuum-connected or magnetically connected, the first flexible guide rail 636 and the second flexible guide rail 638-1 are drawn to the half-tube section 24 into a shape complementary to the half-tube section 24. The travel station 144-2 is mounted on the half-tube section 24, for example, in station 144-1.

[0197] Coarse dressing tool 650-1 and fine dressing tool 648-1 are located in carrier 646-1. Carrier 646-1 is movably coupled to first flexible guide rail 636-1 and second flexible guide rail 638-1. The movable coupling includes a rack and pinion system or a similar system not shown. Lateral alignment 654-1 allows the coarse dressing tool 650-1 and fine dressing tool 648-1 to move laterally across carrier 646-1 relative to the first and second flexible guide rails 636-1. A lateral screw jack system is shown, but other drive systems may also be used here. Guiding system 652-1 guides the coarse dressing tool 650-1 and fine dressing tool 648-1. Coarse dressing tool 650-1 provides the first pass of the dresser to separate the manufacturing allowance 135 from the half-barrel section 24. Fine dressing tool 648-1 creates the final dressing line 664 within tolerance. The final trimming line 664 is within the perimeter formed by the fastener mounting position 662, and forms a cut of manufacturing allowance 135 when completed. The coarse trimming tool 650-1 and the fine trimming tool 648-1 are shown initially trimming in direction 670. Then, the coarse trimming tool 650-1 and the fine trimming tool 648-1 advance along directions 672, 674, and 676. In other embodiments, the coarse trimming tool 650-1 and the fine trimming tool 648-1 advance along directions 670, 672, 674, and 676 in any combination of directions 670, 672, 674, and 676. In yet another embodiment, the coarse trimming tool 650-1 and the fine trimming tool 648-1 advance in directions opposite to those 670, 672, 674, and 676. In one embodiment, the vacuum cup 660-1 is released from the half-cylinder section 24 and then manually or automatically returns to the placement point 144-3.

[0198] Figure 6CAn example is shown of a travel station 144-4 connected to the half-barrel section 24. The flexible guide system 622-2 includes a plurality of attachment vacuum cups 660-2, which are releasably secured to the half-barrel section 24 at spaced intervals along the length of a first flexible guide 636-2 and a second flexible guide 638-2. A vacuum source 644-2 is connected to the vacuum cups 660-2 via hoses to provide attachment force. One vacuum source 644-2 serves the vacuum cups 660-2 on the first flexible guide 636-2, while the other vacuum source 644-2 serves the vacuum cups 660-2 on the second flexible guide 638-2. The locations of the two vacuum sources 644-2 are shown, but one may be sufficient. The second flexible guide 638-2 is preferably parallel to and spaced apart from the first flexible guide 636-2. The first flexible guide rail 636-2 and the second flexible guide rail 638-2 are positioned substantially parallel to the fastener positions 668 of the frame 146. One embodiment has a first flexible guide rail 636-2 on one side of the fastener positions 668 and a second flexible guide rail 638-2 on the opposite side of the fastener positions 668. Although multiple fastener mounting positions 668 are shown, the actual number of fastener mounting positions 668 can vary. Other suitable attachment components can also be used, such as magnets attached to an internal ferromagnetic surface. The first flexible guide rail 636-2 and the second flexible guide rail 638-2 are connected by spacers 640-2 and 642-2. When vacuum-coupled or magnetically coupled, the first flexible guide rail 636-2 and the second flexible guide rail 638-2 are drawn to the half-barrel section 24 into a shape complementary to the half-barrel section 24. A travel station 144-4 is mounted on the half-barrel section 24 in station 144.

[0199] Drilling tool 650-2 and fastener installation tool 648-2 are located in carrier 646-2. Carrier 646-2 is movably coupled to first flexible guide rail 636-2 and second flexible guide rail 638-2. The movable coupling includes a rack and pinion system or a similar system not shown. Lateral alignment 654-2 allows drilling tool 650-2 and fastener installation tool 648-2 to move laterally across carrier 646-2 relative to the first and second flexible guide rails 636-2. Lateral helical jack system 658 is shown, but other actuation systems are also possible herein. Fastener feeder 652-2 feeds fasteners to fastener installation tool 648-2 to drive them into fastener installation positions 668 created by drilling tool 650-2 in half-barrel section 24. During fastener installation, the carrier 646-2 moves along a circumferential direction 675 on the first flexible guide rail 636-2 and the second flexible guide rail 638-2. The circumferential direction 675 is parallel to the frame 146.

[0200] One embodiment has a first flexible guide rail 636-2 and a second flexible guide rail 638-2 extending from the bearing edge 122 to the bearing edge 122 along a circumferential direction 675 across the crown-up position 139 or keel-up position 137 of the half-barrel section 24. In this embodiment, there is more than one spacer 640-2 and spacer 642-2. This embodiment has spacers 640-2 or 642-2 arranged along a circumferential direction 675 at several positions, including at least near each bearing edge 122 and near the crown-up position 139 or keel-up position 137 of the half-barrel section 24. One embodiment has a tracked travel station 144-4. Retractable wheels 680 are arranged along the first flexible guide rail 636-2, the second flexible guide rail 638-2, and the carrier 646-2. Tracked travel stations 144-4 are positioned on the half-barrel section 24, and fasteners are then installed to attach the frame 146 to the half-barrel section 24. Wheels 680 are then deployed, and vacuum cups 660-2 are released from the half-barrel section 24. Travel stations 144-4 then slowly move along the half-barrel section 24 on the wheels 680 toward placement point 144-6. A controller 160 guides the travel stations 144-4 slowly along the half-barrel section 24. Alternatively, the vacuum cups 660-2 of travel stations 144-2, 144-4, and 144-5 are released from the half-barrel section 24, and then travel stations 144-2, 144-4, and 144-5 are returned to placement point 144-6, either manually or automatically.

[0201] Example

[0202] In the following examples, additional processes, systems, and methods are described in the context of an airframe assembly system.

[0203] For more specific details, please refer to the accompanying drawings, as shown in... Figure 7 Method 700 and shown Figure 8 Embodiments of this disclosure are described in the context of aircraft manufacturing and servicing in the aircraft 702 described herein. In one embodiment, aircraft 702 is associated with... Figure 1The aircraft 702 is identical to the aircraft 10. During pre-production, method 700 may include the specification and design 704 of the aircraft 702 and the procurement of materials 706. During production, the manufacturing of components and sub-assemblies of the aircraft 702 and system integration 710 occur. Thereafter, the aircraft 702 can be certified and delivered 712 for service 714. When used by the customer, the aircraft 702 is scheduled for routine maintenance and upkeep 716 (this may also include modifications, remodeling, refurbishment, etc.). The apparatus and methods implemented herein may be used during any or more suitable phases of production and service described in method 700 (e.g., specifications and design 704, material procurement 706, component and sub-component manufacturing 708, system integration 710, certification and delivery 712, service 714, repair and maintenance 716) and / or any suitable component of aircraft 702 (e.g., frame 718, system 720, interior 722, propulsion system 724, electrical system 726, hydraulic system 728, environmental system 730).

[0204] Each process of Method 700 may be performed or executed by a systems integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a systems integrator may include, but is not limited to, any number of aircraft manufacturers and major systems subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service provider, etc.

[0205] like Figure 8 As shown, the aircraft 702 produced by method 700 may include a frame 718 having multiple systems 720 and an interior 722. Examples of systems 720 include one or more of a propulsion system 724, an electrical system 726, a hydraulic system 728, and an environmental system 730. Any number of other systems may be included. Although an aerospace example is shown, the principles of this disclosure can be applied to other industries, such as the automotive industry.

[0206] As mentioned above, the apparatus and methods implemented herein may be employed during any or more phases of the production and service described in method 700. For example, a component or sub-component corresponding to component and sub-component manufacturing 708 may be made or manufactured in a manner similar to that of a component or sub-component produced when the aircraft 702 is in use. Furthermore, one or more apparatus embodiments, method embodiments, or combinations thereof may be utilized during component and sub-component manufacturing 708 and system integration 710, for example, to significantly accelerate the assembly of the aircraft 702 or reduce its cost. Similarly, one or more apparatus embodiments, method embodiments, or combinations thereof may be utilized when the aircraft 702 is in use (e.g., but not limited to, during maintenance and repair 716). Therefore, this disclosure can be used at any stage discussed herein, or in any combination thereof, such as specifications and design 704, material procurement 706, component and sub-component manufacturing 708, system integration 710, certification and delivery 712, service 714, repair and maintenance 716 and / or any suitable component of aircraft 702 (e.g., frame 718, system 720, interior 722, propulsion system 724, electrical system 726, hydraulic system 728 and / or environmental system 730).

[0207] In one embodiment, the part comprises a portion of a frame 718 and is manufactured during component and subassembly manufacturing 708. The part can then be assembled into the aircraft in system integration 710 and used in service 714 until wear renders it unusable. Then, in repair and maintenance 716, the part can be discarded and replaced with a newly manufactured part. The components and methods of the present invention can be utilized throughout component and subassembly manufacturing 708 to manufacture new parts.

[0208] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein can be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination thereof. For example, an element can be implemented as dedicated hardware. A dedicated hardware element can be referred to as a “processor,” a “controller,” or some similar term. When provided by a processor, functionality can be provided by a single dedicated processor, a single shared processor, or multiple individual processors, some of which may share the functionality. Furthermore, the explicit use of the terms “processor” or “controller” should not be construed as referring specifically to hardware capable of executing software, and may implicitly include, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic, or certain other physical hardware components or modules.

[0209] Furthermore, control elements can be implemented as instructions executable by a processor or computer to perform element functions. Some examples of instructions are software, program code, and firmware. Instructions are operational when executed by a processor to instruct the processor to perform element functions. Instructions can be stored on processor-readable storage devices. 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.

[0210] While specific embodiments have been described herein, the scope of this disclosure is not limited to these specific embodiments. The scope of this disclosure is defined by the claims and any equivalents thereof.

[0211] Furthermore, this disclosure includes the following listed provisions, which define exemplary embodiments of this disclosure:

[0212] 1. A method for assembling a fuselage (12) segment of an aircraft (10), the method comprising:

[0213] The half-barrel section (24) of the machine body (12) is pulsated along the track (110) in the processing direction (199);

[0214] The desired profile (361) of a portion of the half-barrel section (24) is determined using the indexing feature (124) associated with the half-barrel section (24); and

[0215] When the profile of the half barrel section (24) differs from the desired profile (361) by a margin outside the tolerance, the desired profile (361) is applied to the half barrel section (24) using the component that applies the inner mold line (128) and the component that applies the outer mold line (126).

[0216] 2. The method according to Clause 1, wherein applying the desired profile (361) to the half-barrel section (24) comprises:

[0217] Multiple wheels (142-1) extend from the first arched member (140-1) to apply the inner mold line (128); and

[0218] Multiple wheels (142) extend from the second arch (140) to apply the outer mold line (126).

[0219] 3. The method according to clause 1 or 2, further comprising:

[0220] The half-barrel section (24) is advanced through the pressure zone (420) in the processing direction (199) to apply the contour.

[0221] 4. The method according to Clause 3, further comprising:

[0222] Before advancing through the pressure zone (420), the half-barrel section (24) is advanced through the pre-pressure zone (531) in the processing direction (199).

[0223] 5. The method according to any one of clauses 1 to 4, wherein the method further comprises:

[0224] The initial profile of the half-barrel section (24) was determined using non-destructive testing.

[0225] 6. The method according to any one of clauses 2 to 5, wherein the method further comprises:

[0226] The initial profile of the half-barrel section (24) was determined using non-destructive testing; and

[0227] The initial profile is used to set the pressure zone (420) to the gap (421-1) and the desired profile (361), the pressure zone (420) being defined by the plurality of wheels (142-1) from the first arch (140-1) that can extend along the inner mold line (128) and the plurality of wheels (142) from the second arch (140) that can extend along the outer mold line (126).

[0228] 7. The method according to any one of clauses 1 to 6, wherein the method further comprises:

[0229] The work is performed on the half-barrel section (24) within the workstation (144, 144-1) set along the track (110), while the desired profile (361) is applied.

[0230] 8. The method according to Clause 7, wherein the steps of performing the work include mounting the frame (146) onto the half-barrel section (24) while applying the desired profile (361).

[0231] 9. The method according to Clause 7 or 8, wherein the steps of performing the work include installing one or more of the door frame (145-1) and the window frame (145) while applying the desired profile (361).

[0232] 10. The method according to any one of clauses 1 to 9, wherein the applied desired profile (361) is a cross-sectional profile.

[0233] 11. The method according to any one of clauses 2 to 10, wherein applying the desired profile (361) to the half-barrel section (24) comprises:

[0234] The wheel (142-1) of the first arched member (140-1) is positioned to contact the inner mold line (128) of the half-barrel section (24) to apply the desired profile (361); and

[0235] The wheel (142) of the second arch (140) is positioned to contact the outer mold line (126) of the half barrel section (24) to apply the desired profile (361).

[0236] 12. The method according to any one of clauses 2 to 11, the method further comprising: retracting the wheel (142, 142-1) from the half-barrel section (24) during a pause between pulses of the half-barrel section (24).

[0237] 13. The method according to any one of clauses 1 to 12, the method further comprising: fixing the half-barrel section (24) to the track (110) such that the recess (127) of the half-barrel section (24) faces the factory ground (150) and the bearing edge (122) of the half-barrel section (24) contacts the track (110).

[0238] 14. The method according to any one of clauses 1 to 13, wherein determining the desired profile (361) using the rotation feature (124) associated with the half-barrel section (24) comprises:

[0239] The complementary feature (134) at the transposition unit (130) is matched with the transposition feature (124); and

[0240] The operation controller (160) determines the desired profile (361) associated with the mating; and

[0241] Based on the determination, the plurality of wheels (142-1) are extended from the first arch (140-1) to apply the inner mold line (128), and the plurality of wheels (142) are extended from the second arch (140) to apply the outer mold line (126).

[0242] 15. A portion of an aircraft (10) assembled according to any one of clauses 1 to 14.

[0243] 16. A system (100) for assembling a half-barrel section (24) of a fuselage (12), the system (100) comprising:

[0244] Track (110), said track (110) is configured to engage the opposing bearing edges (122) of said half barrel section (24);

[0245] A drive unit (116) that moves the half-barrel section (24) along the track (110); and

[0246] A first component, the first component being oriented to engage the inner mold line (128) of the half-barrel section (24) to apply a desired profile (361) to the half-barrel section (24); and

[0247] A second component, which is positioned to engage the outer mold line (126) of the half-barrel section (24) to apply the desired profile (361) of the half-barrel section (24).

[0248] 17. The system (100) pursuant to Clause 16, wherein:

[0249] The first component includes a first arch (140-1), which further includes a wheel (142-1) extending from the first arch (140-1) to apply the desired profile (361) on the inner mold line (128); and

[0250] The second component includes a second arch (140), which further includes a wheel (142) extending from the second arch (140) to apply the desired profile (361) on the outer mold line (126).

[0251] 18. The system (100) according to Clause 17, wherein the wheel (142-1) of the first arch (140-1) and the wheel (142) of the second arch (140) are opposite each other to form a pressure zone (420), the pressure zone (420) being operable to move the half-barrel section (24) along the track (110).

[0252] 19. The system (100) described in Clause 17 or 18, wherein:

[0253] The shape of the first arched member (140-1) is substantially complementary to the inner mold line (128) of the half-barrel section (24); and

[0254] The shape of the second arched member (140) is substantially complementary to the outer mold line (126) of the half-cylinder section (24).

[0255] 20. The system (100) according to any one of clauses 17 to 19, wherein:

[0256] The first portion of the wheel (142-1) is circumferentially mounted around the first arched member (140-1); and

[0257] The second portion of the wheel (142) is circumferentially mounted around the second arched member (140).

[0258] 21. The system (100) according to any one of clauses 16 to 20, wherein the drive unit (116) is operable to synchronously pulsate the half-barrel section (24) of the machine body (12) in the processing direction (199) along the track (110), while holding the half-barrel section (24) in such a way that the recess (127) of the half-barrel section (24) faces the factory ground (150) and the bearing edge (122) of the half-barrel section (24) contacts the track (110).

[0259] 22. The system (100) according to Clause 21, wherein the system is operable to pulsate the half-barrel section (24) while the wheels (142, 142-1) engage the half-barrel section (24) and apply the desired profile (361).

[0260] 23. The system (100) according to any one of clauses 16 to 22, the system (100) further comprising a plurality of supports (112) that raise the track (110) above the factory ground (150).

[0261] 24. The system (100) according to any one of clauses 16 to 23, wherein the track (110) includes a plurality of rollers (114) operable to move the half-barrel section (24) along the track (110).

[0262] 25. The system (100) according to any one of clauses 17 to 24, wherein:

[0263] The first arched member (140-1) is fixed and installed on the factory floor (150); and

[0264] The second arched member (140) is fixed and installed on the factory floor (150).

[0265] 26. The system (100) according to any one of clauses 17 to 25, wherein at least one of the first arch (140-1) and the second arch (140) is movable relative to the track (110).

[0266] 27. The system (100) according to any one of clauses 17 to 26, the system (100) further comprising a controller (160) programmed to control the corresponding extension and retraction of the wheels (142-1, 142) according to a desired profile (361) stored in the controller (160).

[0267] 28. The system (100) according to any one of Clauses 16 to 27, the system (100) further comprising a non-destructive inspection station operable to determine the circumferential radius (363) of a portion of the half-barrel section (24) during pauses between the micropulses (149) along the track (110) of the half-barrel section (24).

[0268] 29. The system (100) according to any one of clauses 17 to 28, said system (100) further comprising:

[0269] Multiple swing arms (510, 510-1), a first portion pivotally mounted to the first arch (140-1), and a second portion pivotally mounted to the second arch (140) and opposite to the first portion; and

[0270] Multiple entry rollers (520, 520-1) are mounted to corresponding swing arms (510, 510-1) away from the arch (140, 140-1), and the swing arms (510, 510-1) are biased to form a pre-compression zone (531) of the half-barrel section (24).

[0271] 30. The system (100) according to Clause 29, wherein the bias of the pre-compression zone (531) has sufficient force to pre-contour the half-barrel section (24) before engaging the wheels (142, 142-1).

[0272] 31. An apparatus for applying a desired profile to a semi-cylinder section of an aircraft fuselage, the apparatus comprising:

[0273] The first arched member (140-1) further includes a wheel (142-1) extending radially outward from the first arched member (140-1);

[0274] A second arched member (140), the second arched member (140) further comprising a wheel (142) extending radially inward from the second arched member (140); and

[0275] The wheel (142-1) and the wheel (142) are used for the pressure zone (420) between the wheel (142-1) and the wheel (142).

[0276] 32. The apparatus according to clause 31, further comprising:

[0277] An actuated positioning device that radially changes the position of the wheels (142, 142-1) relative to the corresponding arched members (140, 140-1) to change the pressure zone (420).

[0278] 33. The apparatus according to clause 31 or 32, further comprising:

[0279] Complementary feature (134), which is communicatively connected to each arch member (140, 140-1) and cooperates with the indexing feature (124) on the half barrel section (24).

[0280] 34. The apparatus according to any one of clauses 31 to 33, wherein the apparatus is configured to:

[0281] According to the instructions conveyed by the transposition feature (124) to the complementary feature (134), the pressure zone (420) is adjusted to the desired profile (361) of the half barrel section (24).

[0282] 35. The apparatus according to any one of clauses 31 to 34, wherein:

[0283] The pressure zone (420) is established to apply a desired profile (361) on the half-barrel section (24) within the field of view (113, 113-1, 113-2) of the workstation (144, 144-1) and / or the arch (140, 140-1).

[0284] 36. The apparatus according to any one of clauses 31 to 35, wherein:

[0285] The arched components (140, 140-1) are connected to the workstations (144, 144-1).

[0286] 37. The apparatus according to any one of clauses 31 to 36, wherein:

[0287] The first arch (140-1) also includes a wheel (142-1) that extends radially inward from the first arch (140-1) to apply the desired profile (361) on the inner mold line (128).

[0288] 38. The apparatus according to any one of clauses 31 to 37, wherein:

[0289] The second arch (140) also includes a wheel (142) that extends radially inward from the second arch (140) to apply the desired profile (361) on the outer mold line (126).

Claims

1. A method for assembling a fuselage (12) section of an aircraft (10), the method comprising the steps of: The half-barrel section (24) of the machine body (12) is pulsated along the track (110) in the processing direction (199); The desired profile (361) of a portion of the half-barrel section (24) is determined using the indexing feature (124) associated with the half-barrel section (24); and When the profile of the half barrel section (24) differs from the desired profile (361) by a margin outside the tolerance, the desired profile (361) is applied to the half barrel section (24) using the component that applies the inner mold line (128) and the component that applies the outer mold line (126).

2. The method of claim 1, wherein, The step of applying the desired profile (361) to the half-barrel section (24) includes the following steps: Multiple wheels (142-1) extend from the first arched member (140-1) to apply the inner mold line (128); and Multiple wheels (142) extend from the second arch (140) to apply the outer mold line (126).

3. The method according to claim 1 or 2, further comprising the following step: The half-barrel section (24) is advanced through the pressure zone (420) in the processing direction (199) to apply the contour.

4. The method according to claim 3, further comprising the following step: Before advancing through the pressure zone (420), the half-barrel section (24) is advanced through the pre-pressure zone (531) in the processing direction (199).

5. The method according to claim 1 or 2, further comprising the following step: The initial profile of the half-barrel section (24) was determined using non-destructive testing.

6. The method according to claim 2, further comprising the following step: The initial profile of the half-barrel section (24) was determined using non-destructive testing; as well as The initial profile is used to set the pressure zone (420) to the gap (421-1) and the desired profile (361), the pressure zone (420) being defined by the plurality of wheels (142-1) from the first arch (140-1) that can extend along the inner mold line (128) and the plurality of wheels (142) from the second arch (140) that can extend along the outer mold line (126).

7. The method according to claim 1 or 2, further comprising the following step: Within the workstations (144, 144-1) set along the track (110), work is performed on the half-barrel section (24) while the desired profile (361) is applied.

8. The method of claim 7, wherein, The steps of performing the work include mounting the frame (146) onto the half-barrel section (24) while applying the desired profile (361).

9. The method of claim 7, wherein, The steps of performing the work include installing one or more of the door frame (145-1) and window frame (145) while applying the desired profile (361).

10. A system (100) for assembling a half-barrel section (24) of a fuselage (12), the system (100) comprising: Track (110), said track (110) is configured to engage the opposing bearing edges (122) of said half barrel section (24); A drive unit (116) moves the half-barrel section (24) along the track (110); as well as A first component, which is positioned to engage the inner mold line (128) of the half-barrel section (24) to apply the desired profile (361) of the half-barrel section (24); as well as A second component, which is positioned to engage the outer mold line (126) of the half-barrel section (24) to apply the desired profile (361) of the half-barrel section (24).

11. The system (100) according to claim 10, wherein: The first component includes a first arch (140-1), which further includes a wheel (142-1) extending from the first arch (140-1) to apply the desired profile (361) on the inner mold line (128); and The second component includes a second arch (140), which further includes a wheel (142) extending from the second arch (140) to apply the desired profile (361) on the outer mold line (126).

12. The system (100) of claim 11, wherein, The wheels (142-1) of the first arch (140-1) and the wheels (142) of the second arch (140) are opposite each other to form a pressure zone (420), which is operable to move the half-barrel section (24) along the track (110).

13. The system (100) according to claim 11 or 12, wherein: The shape of the first arched member (140-1) is substantially complementary to the inner mold line (128) of the half-barrel section (24); and The shape of the second arched member (140) is substantially complementary to the outer mold line (126) of the half-cylinder section (24).

14. The system (100) according to claim 11 or 12, wherein: The first portion of the wheel (142-1) is circumferentially mounted around the first arched member (140-1); and The second portion of the wheel (142) is circumferentially mounted around the second arched member (140).

15. The system (100) according to claim 11 or 12, wherein The drive unit (116) is operable to cause the half-barrel section (24) of the machine body (12) to pulsate synchronously along the track (110) in the processing direction (199), while keeping the half-barrel section (24) in such a way that the recess (127) of the half-barrel section (24) faces the factory ground (150) and the bearing edge (122) of the half-barrel section (24) contacts the track (110).

16. The system (100) of claim 15, wherein, The system is operable to pulsate the half-barrel section (24) while the wheels (142, 142-1) engage the half-barrel section (24) and apply the desired profile (361).

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