Composite wing panels and manufacturing methods

Abstract

This disclosure relates to composite wing panels and methods of manufacturing them. Wing panels having composite wing skin and longitudinal spars are produced on a moving production line. The wing panels are formed on a mandrel that moves along the production line through stations where a laminator lays the wing skin and a pick-and-place machine places longitudinal spars supplied by a longitudinal spars feeder onto the wing skin.

Description

Technical Field

[0001] This disclosure generally relates to the fabrication of composite structures, and more specifically to composite wing panels for aircraft and methods for fabricating such panels. Background Technology

[0002] The production of large composite structures (e.g., aircraft wings with spans of 100 feet or more) requires significant factory floor space. In mass production environments, such structures are typically fabricated and assembled in individual work cells within the factory floor, each dedicated to a specific task or process. For example, in the case of wing panels, a lay-up mandrel may be cleaned and prepared for use in the work cell, and then transferred to a different work cell elsewhere in the factory, where the composite wing skin is laid onto the mandrel using a laminator (e.g., an automated fiber lay-up (AFP) machine). Similarly, composite girders used to reinforce the wing skin are produced in separate units dedicated to composite lay-up, molding, inspection, and finishing operations. The girders are then transported to the wing skin location, where they are individually placed onto the wing skin, after which the resulting wing panels are transported to an autoclave, where they are cured for the desired curing time.

[0003] The abstract of EP3106280 states: "A composite structure fabrication system and method. The system includes a plurality of sheet carriers and an elongated forming mandrel, each of the plurality of sheet carriers being configured to support at least one layer segment, the elongated forming mandrel defining an elongated sheet forming surface, the elongated sheet forming surface being shaped to define a surface profile of a composite structure. The system also includes a carrier transfer device and a forming machine, the carrier transfer device being configured to selectively transport selected sheet carriers from a sheet feeding area to an intermediate position, the forming machine being configured to deform the selected sheet carriers and their respective layer segments over selected portions of the elongated sheet forming surface. The forming machine is further configured to separate the selected sheet carriers from their respective layer segments and return the selected sheet carriers to the carrier transfer device. The method includes a means of operating the system."

[0004] The abstract of WO2014 / 175799 states: "A method for manufacturing a torsion-resistant box-type skin composite structure mountable on a main substructure, the torsion-resistant box-type skin composite structure including skin components, reinforcing elements, and fastener elements for bonding the torsion-resistant box-type skin composite structure to the main substructure. The method includes the steps of: providing a molding tool; providing a skin layup on the molding tool; positioning the reinforcing layup and fastener layup to the skin layup to form an integral layup and co-curing the integral layup; and mounting connecting members to the reinforcing elements and fastener elements. This disclosure also relates to structures and data media storage programs suitable for performing the method using a data media storage program, as well as the production line itself."

[0005] While the described wing panel production method is reliable, it is not efficient. The need to move wing panel components between work cells and the delays experienced within a single cell increase process time and reduce throughput.

[0006] Therefore, a more efficient production method is needed that reduces process time by minimizing delays and transportation time, while making better use of factory floor space. Summary of the Invention

[0007] This disclosure generally relates to composite structures, and more specifically to the fabrication of composite aircraft structures, such as wing panels, on a production line.

[0008] According to one aspect, an apparatus for manufacturing composite wing panels is provided, the apparatus including a production line and a plurality of mandrels coupled to the production line. The apparatus also includes a production line drive configured to move the mandrels along the production line, and a plurality of stations along the production line. The stations are configured to perform work on the mandrels and include at least one wing skin lamination station. The apparatus also includes at least one laminator in the wing skin lamination station for laying composite wing skin on the mandrels. The apparatus further includes a controller coupled to the production line drive and configured to control the movement of the mandrels along the production line.

[0009] According to another aspect, a system for manufacturing composite wing panels is provided. The system includes a production line comprising multiple stations, each configured to produce a portion of a wing panel. The system also includes multiple mandrels on which the wing panels are produced. The mandrels are movable along the production line. The system further includes multiple feed lines, each configured to feed material to the stations. The system also includes a control system for the movement of the mandrels along the production line and for feeding material to the stations.

[0010] According to another aspect, a method for manufacturing composite wing panels for an aircraft is provided. The method includes moving multiple mandrels along a production line and laying composite wing skin on the mandrels at a lamination station along the production line. The method also includes placing composite longitudinal beams on the composite wing skin at a longitudinal beam placement station along the production line. The method further includes moving the mandrels along the production line through the lamination station and the longitudinal beam placement station according to the production cycle time for achieving a desired wing panel productivity.

[0011] According to another aspect, a method for manufacturing wing panels for an aircraft is provided. The method includes moving a mandrel along a production line through at least one lamination station and at least one longitudinal beam placement station. The method includes indexing the mandrel into the lamination station and laying composite wing skin onto the mandrel at the lamination station. The method further includes using the indexing of each mandrel to the lamination station to move the mandrel through the lamination station in sync with the laying of the composite wing skin. The method also includes indexing each mandrel into the longitudinal beam placement station and placing composite longitudinal beams onto the wing skin at the longitudinal beam placement station. The method further includes using the indexing of each mandrel to the longitudinal beam placement station to move the mandrel through the longitudinal beam placement station in sync with the placement of the composite longitudinal beams onto the wing skin.

[0012] According to another aspect, a method for manufacturing a wing panel of an aircraft is provided, the method comprising moving each of a plurality of mandrels along a production line and laying a composite wing skin on each mandrel respectively. The method includes fabricating a plurality of composite longitudinal beams on a longitudinal beam feed line and feeding the composite longitudinal beams from the longitudinal beam feed line to a longitudinal beam placement station. The method further includes placing the composite longitudinal beams on each composite wing skin at the longitudinal beam placement station. In one example, the method includes moving the mandrels along the production line through at least two longitudinal beam placement stations.

[0013] According to another aspect, a method for manufacturing aircraft wing skin is provided, the method comprising moving a laying mandrel along a production line, and as the laying mandrel moves along the production line, laying different sections of wing skin on each laying mandrel respectively using different laminators.

[0014] According to another aspect, a method for manufacturing wing panels of an aircraft is provided, the method comprising moving composite wing skins along a production line, and, as the wing skins move along the production line, placing composite longitudinal beam preforms on each wing skin at a longitudinal beam placement station along the production line.

[0015] According to another aspect, a method for manufacturing different wing panels of an aircraft is provided, the method comprising moving composite wing skins of different configurations along a production line and producing different sets of spar preforms on a spar feed line, wherein each of a plurality of sets of spar preforms is associated with one of the wing skins of different configurations. The method further comprises feeding the plurality of sets of spar preforms to a spar placement station along the production line such that the plurality of sets of spar preforms arrive at the spar placement station on time for placement on the associated wing skin, and at the spar placement station, finally placing each of the plurality of sets of spar preforms on the corresponding associated wing skin.

[0016] According to another aspect, a method for manufacturing different wing panels for an aircraft is provided, the method comprising moving different composite wing skins along a production line and producing spar preforms on a spar feed line. The method further comprises feeding the spar preforms individually to a spar placement station along the production line, such that individual spar preforms arrive at the spar placement station on time to be placed on the composite wing skin. The method also includes placing the spar preforms on the composite wing skin at the spar placement station.

[0017] According to another aspect, a method for manufacturing wing panels is provided, the method comprising moving composite wing skins along a production line and placing at least a first set of composite longitudinal beam preforms on each composite wing skin, wherein all composite longitudinal beam preforms in the first set are placed on the composite skins simultaneously.

[0018] According to another aspect, a method for manufacturing composite wing panels for an aircraft is provided. The method includes moving a plurality of mandrels along a production line including lamination stations through a plurality of stations. The method further includes laying composite wing skin onto the mandrels at the lamination stations and placing a shifting feature on each mandrel, the shifting feature shifting the mandrel to the lamination station.

[0019] According to another aspect, a method for manufacturing composite wing panels with multiple different configurations is provided. The method includes moving a laying mandrel along a production line through multiple stations and selecting the configuration of the composite wing panel to be manufactured. The method also includes manufacturing wing skin preforms by laying composite material on each mandrel based on the selected configuration, and placing composite longitudinal spars preforms on the wing skin preforms based on the selected configuration.

[0020] According to another aspect, a wing panel for an aircraft is provided, the wing panel comprising a pair of composite wing skins and a plurality of composite longitudinal spars located between and attached to the composite wing skins. The composite longitudinal spars include spar blades extending substantially parallel to each other.

[0021] One advantage of the disclosed manufacturing method is that it allows for more efficient fabrication of composite aircraft structures, such as composite wing panels. Another advantage is the reduction in the time required to fabricate composite wing panels. Yet another advantage is the ability to produce composite wing panels with improved consistency and quality. A further advantage is the reduction in the labor required for manufacturing composite wing panels. Another advantage is the more efficient use of available factory floor space. A further advantage of the disclosed manufacturing method is that it allows for the fabrication of composite aircraft structures (e.g., wing panels) with higher productivity and better consistency.

[0022] These features, functionalities, and advantages can be implemented independently in various examples of this disclosure, or in combination with other examples, where further details can be seen with reference to the following description and figures.

[0023] Please note that the term "mandrel" as used in this application refers to a mandrel on which parts (e.g., aircraft parts) can be placed. The term mandrel is used interchangeably with the term "layup mandrel," which refers to a surface on which parts, material layers, or combinations thereof can be positioned. For example, in the case of wing panels, this may involve a mandrel or layup mandrel on which the composite wing skin is laid using a laminator such as an automated fiber layup (AFP) machine. Attached Figure Description

[0024] The novel features of the characteristics considered as illustrative examples are set forth in the appended claims. However, the illustrative examples, preferred modes of use, further objects, and advantages will be best understood by referring to the following detailed description of the illustrative examples of this disclosure when read in conjunction with the accompanying drawings, wherein:

[0025] Figure 1 It is a 3D diagram of an aircraft.

[0026] Figure 2 yes Figure 1 The illustration shows a perspective view of the starboard wing of the aircraft, partially disassembled to reveal the internal components of the wing.

[0027] Figure 3 This is a schematic diagram of the wing panel, showing the placement of a typical longitudinal beam section.

[0028] Figure 4 This is a diagram and illustration of a production line for manufacturing composite wings.

[0029] Figure 5 yes Figure 4 A side view of a portion of the production line, showing a mandrel on a moving track.

[0030] Figure 6 yes Figure 5 The winning bid is " Figure 6 A diagram of the area marked "".

[0031] Figure 7 This is a block diagram and schematic illustration of a system for monitoring the movement of a mandrel along a production line.

[0032] Figure 8 It is a schematic side view of an AGV carrying a spindle.

[0033] Figure 9It is a schematic diagram of a part of the production line, which helps to explain the pulsation of the mandrel along the production line.

[0034] Figure 10 It is a diagram of the workstations on the production line, which helps to explain the technology of mounting devices on the mandrel.

[0035] Figure 11 This is a diagram showing a floor plan of the technology used across multiple workstations.

[0036] Figure 12 A perspective view of the mandrel with wing skin laid on it is shown, and the orientation of a longitudinal beam prefabricated component is shown. The positions of other longitudinal beam prefabricated components to be placed are indicated by dashed lines.

[0037] Figure 13 This is a partial plan view of a portion of the wing skin prefabrication laid on the mandrel, showing the manufacturing allowances and flash on the prefabrication.

[0038] Figure 14 Is with Figure 13 A similar illustration, but showing that the fringe has been removed.

[0039] Figure 15 Is with Figure 6 A similar illustration, but showing that the indexing feature has been added to the manufacturing allowance.

[0040] Figure 16 It is a diagram of a conceptual flowchart that helps explain how production takt times are assigned to processes along the production line.

[0041] Figure 17 It is a diagram illustrating the control and operation components along the workstations of the production line that performs operations before the wing panels harden.

[0042] Figure 18 It is a diagram of the workstation layout, showing how multiple laminators in the workstation lay different sections of the wing skin prefabrication.

[0043] Figure 19 yes Figure 18 The winning bid is " Figure 19 A diagram of the area marked "".

[0044] Figure 20 yes Figure 18 The winning bid is " Figure 20 A diagram of the area marked "".

[0045] Figure 21 It is a combination of block diagrams and schematic diagrams, showing how the laminators at different workstations lay different sections of the wing skin.

[0046] Figure 22The illustration shows how laminators at different workstations lay different sections of the wing skin prefabrication sheets.

[0047] Figure 23 This is a schematic diagram of a floor plan showing an example of a production line workstation layout.

[0048] Figure 24 is a schematic diagram of another example of a production line workstation layout.

[0049] Figure 25 is a schematic diagram of another example of a production line workstation layout.

[0050] Figure 26 This is a floor plan illustration of another example of a production line workstation layout.

[0051] Figure 27 It is a diagram illustrating an example of how the spindle is oriented when it makes a sharp turn along the production line.

[0052] Figure 28 This is a diagram illustrating another example of how the spindle orients itself when it makes a sharp turn along the production line.

[0053] Figure 29 yes Figure 4 The diagram shows the feed line of the longitudinal beam.

[0054] Figure 30 This is a diagram illustrating the combined block diagram and schematic diagram of the longitudinal beam feed line.

[0055] Figure 31 is Figure 29 A cross-sectional view along line 31-31 is shown.

[0056] Figure 32 is a cross-sectional view of the precast longitudinal beam.

[0057] Figures 33 to 40 This is a diagram illustrating how to fabricate precast longitudinal beams on a longitudinal beam feed line.

[0058] Figure 41 It is an illustration of a combination block diagram and schematic diagram, showing how to place the longitudinal beam sections on the wing skin at different work positions.

[0059] Figure 42 This is a schematic diagram of the wing skin, showing how the prefabricated longitudinal beams are placed in chordal order.

[0060] Figure 43 This is a schematic diagram of the wing skin, showing how the longitudinal beam prefabricated components are placed in spanwise order.

[0061] Figure 44It is a diagram and illustration showing how a set of precast longitudinal beams can be placed on the wing skin using a single pick-and-place machine.

[0062] Figure 45 It is an illustration of a combination block diagram and schematic diagram, showing how to place multiple sets of longitudinal beam segments on the wing skin in chordal order.

[0063] Figure 46 It is an illustration of a combination block diagram and schematic diagram, showing how to place multiple sets of longitudinal beam segments on the wing skin in spanwise order.

[0064] Figure 47 It is a diagram and illustration showing how to place all the longitudinal beam sections on the wing skin simultaneously.

[0065] Figure 48 It is an illustration of a partial cross-section of a portion of the mandrel on which the wing skin is laid, showing the edges of the precast longitudinal beam that has been placed on the wing skin.

[0066] Figure 49 and Figure 50 It is an illustration of a combination block diagram and schematic diagram, showing how a single pickup and placement machine continuously places multiple sets of longitudinal beam prefabricated components onto the wing skin in the chord direction.

[0067] Figure 51 yes Figure 49 The winning bid is " Figure 51 A diagram of the area marked "".

[0068] Figure 52 This is a side view illustration of the pickup machine, showing how to pick up the precast longitudinal beam.

[0069] Figure 53 This is a schematic diagram of the pickup and drop-off machine, partially cut open to show how the pickup arms are arranged in rows and columns.

[0070] Figure 54 It is a schematic diagram illustrating how all four wing panels of an aircraft wing are produced on the same production line.

[0071] Figure 55 It is a schematic diagram illustrating how wing panels with different constructions are produced on the same production line.

[0072] Figure 56 It is a combination of block diagrams and schematic diagrams illustrating how to identify the mandrel and associate it with different wing constructions.

[0073] Figure 57 This is a flowchart illustrating the process of manufacturing the wing panels of an aircraft.

[0074] Figure 58 This is a flowchart illustrating the process of manufacturing the wing panels of an aircraft.

[0075] Figure 59 This is a flowchart illustrating the process of manufacturing the wing panels of an aircraft.

[0076] Figure 60 This is a flowchart illustrating the process of manufacturing the wing panels of an aircraft.

[0077] Figure 61 This is a flowchart illustrating the process of manufacturing the wing panels of an aircraft.

[0078] Figure 62 This is a flowchart illustrating the process of manufacturing the wing panels of an aircraft.

[0079] Figure 63 This is a flowchart illustrating another method for manufacturing wing panels for aircraft.

[0080] Figure 64 This is a flowchart illustrating the process of manufacturing the wing panels of an aircraft.

[0081] Figure 65 This is a flowchart illustrating methods for manufacturing wing panels with different structures.

[0082] Figure 66 It is a flowchart illustrating the process of aircraft production and service.

[0083] Figure 67 It is a block diagram illustration of an aircraft. Detailed Implementation

[0084] The accompanying drawings and the following description provide specific illustrative examples of this disclosure. It should therefore be understood that those skilled in the art will be able to design various structures that, although not explicitly described or shown herein, implement 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. As a result, this disclosure is not limited to one or more of the specific examples described below, but is limited by the claims.

[0085] The wing panels described herein comprise one or more composite parts. Composite parts (e.g., carbon fiber reinforced polymer (CFRP) parts) are initially laid out in multiple layers, collectively referred to as preforms. Individual fibers within each layer of the preform are aligned parallel to each other, but different layers exhibit different fiber orientations to increase the strength of the resulting composite part along different dimensions. These parts are made from thermosetting resins, thermoplastic resins, or combinations of thermosetting and thermoplastic resins, sometimes referred to as hybrid material systems. In cases where the parts are made of thermosetting materials, the preform includes a viscous thermosetting resin that solidifies to irreversibly harden the preform into the composite part (e.g., for aircraft wings). Carbon fibers impregnated with uncured thermosetting or thermoplastic resins are referred to as “prepregs.” Other types of carbon fibers include “dry fibers” that are not impregnated with thermosetting resins but may contain tackifiers or adhesives. Dry fibers are infused with resin before hardening. For thermosetting resins, curing is a one-way process known as 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 the term encompasses both the hardening of thermosetting preforms and the molding / solidification of thermoplastic preforms into their final desired shape.

[0086] First refer to Figure 1 The aircraft 50 includes a fuselage 52, a pair of wings 54, and a tail 55. The tail 55 includes a pair of horizontal stabilizers 56 and a vertical stabilizer 58. A jet or other type of engine 60 is mounted on the wings 54. See also... Figure 2 and Figure 3 Each of the wings 54 includes a front spars 78 and a rear spars 80 extending from the inner end 62 to the outer end 64 of the wing 54. The spars 78 and 80 are connected together by ribs 82, which extend in the chord direction 66 and are spaced apart from each other in the spanwise direction 67. The spars 78, 80 and ribs 82 are sandwiched between and attached to the top wing panel and the bottom wing panel 75, which form the outer surface of the wing 54.

[0087] Each of the wing panels 75 comprises an upper wing panel 84 and a lower wing panel 85 respectively attached to spars 78, 80 and rib 82. Each of the upper wing panel 84 and the lower wing panel 85 comprises a wing skin 86 attached to a series of composite longitudinal spars 72. For ease of description, each of the upper wing panel 84 and the lower wing panel 85 (both port and starboard sides) may be referred to as wing panel 75 hereinafter. A series of compartments 83 are formed by the space defined by the ribs 82 on the sides, the spars 78, 80 in the longitudinal direction and the wing panels 75. The composite longitudinal spars 72 are spaced from the leading edge 68 to the trailing edge 70 of the wing 54 in the chord direction 66 and serve to transfer the loads on the wing skin 86 to the structure formed by the spars 78, 80 and rib 82.

[0088] As will be discussed below, the wing skin 86 is formed from a composite material (e.g., CFRP laid in wide strips with various fiber orientations) to provide the desired strength and flexibility. Composite longitudinal beams 72 are typically attached to the wing skin 86 via co-curing. Figure 3 As best shown, each of the composite longitudinal beams 72 may include a series of longitudinal beam segments 73 extending along the spanwise direction 67, these longitudinal beam segments being connected together by joints 76. Although Figure 3 Only three joints 76 are shown, but depending on the number of longitudinal beam sections 73 and / or the length L of the wing 54 or other factors, fewer or more joints 76 may be necessary or desirable.

[0089] Please note now. Figure 4 The figure broadly illustrates an automated moving production line 88 for producing the aforementioned type of wing panels 75, as well as other types of airfoil components (e.g., horizontal stabilizers 56 and vertical stabilizers 58, including stiffened composite wing skin). The wing panels 75 are laid and assembled onto multiple mandrels 90 ( Figure 5 On the production line 88, the mandrel 90 moves along a predetermined path 91 in the processing direction P through a series of stations 92-114, where value-added production work is carried out. Any number of mandrels 90 can be used, depending on the desired wing panel productivity. Mandrels 90 can be supplied from mandrel storage location 118 or can be returned to 120 and recycled after the wing panel 75 is demolded at station 106 140. In either case, the mandrel 90 is cleaned and prepared at 122 before being placed on the production line 88.

[0090] Any of various techniques can be used to move the mandrel 90 along a predetermined path 91 in the machining direction P through the workstation body 92-114. For example, refer to Figure 5 and Figure 6The spindle 90 can be placed on the moving track 89, which is controlled by the controller 162 discussed later. Figure 17 The mandrel 90 moves along a predetermined path 91 at a determined rate. As used herein, the terms “movement” and “motion” for mandrel 90 mean moving mandrel 90 continuously along production line 88, or incrementally in a pulsating or micro-pulsating manner, or any combination thereof. As will be discussed in more detail below, “pulsating” refers to an incremental or pulsating movement of a part such as wing panel 75 that is substantially equal to the length of that part. A micro-pulsation can be the rib spacing between ribs—a distance or a multiple or fraction thereof. Work can be performed during pauses during pulsating and / or micro-pulsating and / or during pulsating / micro-pulsating or any combination thereof. In some examples, mandrel 90 moves only forward 93 along production line 88; however, in other examples, mandrel 90 may pause and move backward 95 for a period of time before resuming its forward movement to allow certain types of work to be performed at the workstation. In the preceding examples, work such as lamination is performed as mandrel 90 moves, while laminators 124a-124d remain stationary. However, in other examples, laminators 124a-124d can move together with mandrel 90. Mandrel 90 can also be moved incrementally through any of stations 96-114 by pulsation or micro-pulsation.

[0091] Mandrel 90 is indexed to individual lamination stations 92-94 to inform stations 96-114 of the required looseness and lamination type (sheet orientation) of mandrel 90 within the purview of a specific lamination station 92-94. This information is conveyed by at least one indexing feature (e.g., slot, hole, pin, or some other element such as an RFID tag added to mandrel 90). In one example, mandrel 90 can be removably mounted at a predetermined position on a moving track 89 via indexing pin 152. In other examples, moving track 89 may include a conveyor belt (not shown), a self-propelled AGV (Automated Guided Vehicle), or a similar transport. In some examples, mandrel 90 is indexed to stations 96-114 and moves in a pulsating, micro-pulsating, or continuous manner. In other examples, multiple stations 96-114 are simultaneously indexed to mandrel 90 and work is performed on mandrel 90 simultaneously.

[0092] refer to Figure 7 In some examples, the need for physical rotation of the spindle 90 can be avoided by continuously monitoring the position of the spindle 90 using at least one position sensor 160 along the moving track 89. The sensor 160 (which may be non-contact) sends a signal to the controller 162 indicating the identifier and position of the spindle 90. (See reference...) Figure 8In other examples, instead of the moving track 89, the spindle can be transported by an AGV (Automated Guided Vehicle) 154 along a predetermined path 91, which is operated by a controller 162 via radio frequency communication 156.

[0093] In one example, the spindle 90 moves continuously in the machining direction P, while in other examples, the spindle 90 pulsates or moves in a micro-pulsating manner in the machining direction P. (Reference) Figure 9 When the incremental movement of the 90-axis is less than its length, it is called "micropulsation" 204, while when the movement of the 90-axis is equal to or greater than its length, it is called "full pulsation" 202. In the example of pulsation ( Figure 3 In this configuration, stations 92-114 can perform work on spindle 90 during pauses between micro-pulses 204, and multiple stations 92-114 can perform work on the same spindle 90 during the same pause between micro-pulses 202. Work can also be performed on spindle 90 during pulsations or micro-pulses, and during pauses between pulsations / micro-pulses, or during pauses between pulsations / micro-pulses and during pulsations / micro-pulses. In an example where spindle 90 moves continuously, stations 92-114 can perform operations as spindle 90 moves. In other examples, spindle 90 can move pulsatingly through some stations 92-114, but can move continuously through other stations 92-114.

[0094] In other examples, two separate versions can be implemented. The first version is the "driven" version, in which the machine or device performing the work is fixed at station 92-114 and performs the work on spindle 90, while spindle 90 moves through or past station 92-114. (Reference) Figure 10 In the second "hitchhiking" version, the working device 210 is physically connected to the spindle 90 206 and performs the work while both device 210 and spindle 90 move together until the point where device 210 disengages from spindle 90 208 is reached, then returns 212 to the beginning of station 92-114. For example... Figure 11 As shown, in some examples, device 210 can disengage from spindle 90 at downstream station 100 and travel with spindle 90 as it moves through multiple stations 92-100 before returning to an earlier station 92. Depending on the type of production process and the work being performed, both versions can be implemented simultaneously on the same spindle. Multiple stations among stations 92-114 operating in "drive" or "hitchhiking" mode can perform work on spindle 90 simultaneously. Typically, the work will be performed simultaneously on different parts of spindle 90.

[0095] Refer again Figure 4At one or more lamination stations 92, 94 (hereinafter sometimes referred to as lamination stations), wing skin 86 (hereinafter sometimes referred to as wing skin preform 86 before curing) is laid on mandrel 90. According to a lamination plan defining the number of layers and fiber orientation, composite material is laid on mandrel 90 by one or more laminators 124a-124d at each individual lamination station 92, 94. Each of the laminators 124a-124d may include, for example, an AFP (Automatic Fiber Placement) machine, which lays parallel bandwidths of fiber-reinforced plastic in the form of a belt or cut-slit belt referred to as a “bundle”. Composite material is supplied to the laminators 130a-130b located at lamination stations 92, 94 by composite material supply feeders 130a-130b respectively. The composite material is supplied to laminators 124a-124d, and at each of lamination stations 92 and 94, the composite material is laid on mandrel 90 at a rate that achieves the desired production cycle time. The aforementioned indexing feature may be placed on the laminate or formed in the laminate before curing.

[0096] As previously mentioned, in some examples, one or more laminators 124a-124d can be used to completely lay the wing skin prefabricated component 86 at a single lamination station 92, 94, while in other examples, laminators 124a-124d can be used to lay the wing skin prefabricated component 86 at multiple lamination stations 92, 94, wherein each lamination station lays sections 213, 214, 216 of the wing skin prefabricated component 86. Figure 21 In other examples, one or more laminators 124a-124b may lay sheets of wing skin preform 86 with one fiber orientation at a lamination station 92, while one or more laminators 124c-124d lay sheets of wing skin preform 86 with different fiber orientations at the next in-line lamination station 94. In those examples where sections 213, 214, 216 of the wing skin preform 86 are laid, these sections are joined together using lap joints, miter joints, or other types of joints formed during material laying. The individual sections 213, 214, 216 of the wing skin preform 86 laid at lamination stations 92, 94 are transferred to that station.

[0097] As the mandrel 90 moves past the corresponding lamination stations 92 and 94, laminators 124a-124d lay the composite material on the mandrel 90. In some examples, as will be discussed in more detail below, the mandrel 90 can be in a micro-pulsating manner (204). Figure 9The mandrel 90 moves incrementally through lamination stations 92 and 94, laying material onto the mandrel 90 between micro-pulses, while the mandrel 90 is briefly fixed. However, in other examples where the mandrel 90 moves continuously through lamination stations 92 and 94, the continuous movement of the mandrel 90 is synchronized with the movement of the laminators 124a-124d, thereby allowing the laminators 124a-124d to lay material continuously and uninterruptedly as the mandrel 90 moves.

[0098] After the wing skin preform 86 has been laid at lamination stations 92 and 94 in laminators 124a-124d, the mandrel 90 moves through one or more stations 96 and 98, where the composite longitudinal beam preform 72 is placed on the wing skin preform 86. Stations 96 and 98 may sometimes be referred to as longitudinal beam placement stations below. Figure 12 The diagram shows one of the longitudinal beam prefabricated components 74 placed on the wing skin prefabricated component laid on the mandrel 90. Any number of longitudinal beam prefabricated components 74 can be placed together or sequentially on the wing skin prefabricated component 86, as will be discussed in more detail below. Each of the two separate longitudinal beam placement stations 96, 98 includes one or more robotically operated pick-and-place machines (PNPs) 132a-132d, which place the composite longitudinal beam 72 or a segment thereof at a predetermined position on the wing skin prefabricated component 86 as the mandrel 90 moves through stations 96, 98. In some examples, one or more longitudinal beam prefabricated components 72 can also be placed manually.

[0099] As previously described, the mandrel 90 can move through stations 96, 98 in a micro-pulsating or continuous manner, wherein the operation and movement of PNP132a-132d are coordinated with the movement or pause of the mandrel 90 along the production line 88 (between micro-pulsations). Composite longitudinal beams 74 or their segments 73 are delivered to each station 96, 98 via corresponding associated longitudinal beam feed lines 134a, 134b, details of which will be discussed below. In some examples, segments 73 of the composite longitudinal beam 72, 4 feet or longer, can be placed as needed, and additional segments 73 can be spliced ​​together. Multiple segments 73 of the composite longitudinal beam 72 can also be placed in a batch. In some examples, all segments along the chordal direction 66 can be placed simultaneously, followed by the next batch of segments 73 along the spanwise direction 67, which are then spliced ​​with the previously placed segments. In other examples, all composite longitudinal beams 72 along the entire length of wing 54 can be placed at stations 96, 98 or in batches at the same stations 96, 98. Multiple batches of composite longitudinal beams 72 can be placed at each of stations 96, 98 to achieve the desired production cycle time for each station.

[0100] After the uncured composite longitudinal beam 74 has been placed on the wing skin preform 86, the mandrel 90 passes through station 100, where a vacuum bagging operation and vacuum bag inspection are performed. The bagging operation includes applying a release liner, vent, vent, and caul to the mandrel body covering the green wing panel 75, and sealing the vacuum bag. In some examples, the vacuum bagging operation described above can be performed in more than one station 100 to achieve the desired production cycle for each station. In one example, the vacuum bagging operation uses a reusable caul / vacuum bag that travels with the mandrel 90 through the autoclave 145 to the demolding station 140, where it is removed and recycled back to station 100 after cleaning / repair.

[0101] Next, the mandrel 90 passes through a suitably sized autoclave 145 at station 102, where the wing panel 75 is hardened. The hardened wing panel 75 is then removed from the cleaning chamber 116 to station 104, where it is debagged. (Reference) Figures 13 to 15 After unpacking, the manufacturing allowance 137 on the wing panel 75 is a flash 135 ( Figure 13 ) was repaired, leaving a remaining manufacturing allowance of 139 ( Figure 14 When the wing panel 75 is on the spindle 90, one or more indexing features 141 and / or working commands 143 can be applied. Figure 15 Add to the remaining manufacturing allowance 139. Indexing feature 141 allows mandrel 90 to be identified and located within each station. Work instruction 143 informs the station what work to perform on mandrel 90. Adding indexing feature 141 before demolding allows the wing panel 75 to be positioned in downstream stations 106-114 using the accuracy of the mandrel.

[0102] The indexing feature 141 and / or work instruction 143 may also be added to the remaining manufacturing allowance 139 after demolding during subsequent manufacturing processes. The indexing feature 141 may be in the form of a hole, slot, pin, RFID, or other feature. The indexing feature 141 may also be in the form of an entry port (not shown) in the wing panel 75 to help notify specific downstream stations 106-114 of the identification of the wing panel 75 (model, upper or lower wing panel, left or right wing) and the specific work to be performed on the wing panel 75 at that station. The work instruction 143 may be a printed mark, barcode, RFID, or other form. The indexing feature 141 may be detected visually or using an automated inspection device (not shown) at any station.

[0103] After unpacking, wing panel 75 moves through station 106, where it is demolded 140 (removed from mandrel 90) and can be placed on a portable fixture (not shown), allowing it to be transported to station 108, where wing panel 75 is cleaned 142. Cleaning wing panel 75 removes dust / debris generated by trimming / drilling and other fabrication work. Next, wing panel 75 undergoes non-destructive testing (NDI) at station 110, after which it moves through station 111, where any inconsistencies or out-of-tolerance issues are corrected before fabrication work begins. After inspection and rework, wing panel 75 is transported to station 112, where it is trimmed, fastener holes are drilled, and additional features, such as indexing feature 41, can be added.

[0104] Trimming wing panel 75 while it is on mandrel 90 allows for the accurate positioning of trimmer / cutter (not shown) using mandrel 90, which is used to add indexing feature 141 to wing panel 75. The final trimming edge 147 of wing panel 75 is established after the indexing feature 141 is no longer needed as a means of identifying a specific wing panel 75 at each station 104-114. Figure 14 , Figure 15 The mandrel 90 may have cutouts (not shown) on its surface, which are filled with a potting compound to form potting areas (not shown) within the mandrel 90. These potting areas allow for overshooting and / or the addition of indexing features for cutting / dressing cutters / end mills / drills, thereby preventing damage to the mandrel 90 and / or the cutter / end mill / drill.

[0105] After finishing and adding part indexing features 141, the mandrel 90 is demolded from the wing panel 75. As previously described, after demolding, the mandrel 90 is cleaned / washed at 122 and the potting compound is restored. The mandrel 90 is then returned to the cleaning chamber 116 at 120, where it is reused. The completed wing panel 75 can then be transported to station 114, where it is painted and cured for the desired curing time at 148. At this point, the wing panel 75 is ready to be assembled with the other components of the wing 54 at station 150.

[0106] Workstations 92-114 are each designed to perform their work within specific time periods. For example, the workload assigned to workstations 92-114 can be customized so that each of them can perform pulsations 202 and / or micro-pulsations 204 on the wing skin prefabricated component 86 or the longitudinal beam prefabricated component 74. Figure 9The work is performed during a unified pause between multiple stations 92-114 (e.g., a pause shared / synchronized across multiple stations 92-114 at production line 88). In one example, the integer of pauses that are equal and synchronously performed across wing skin preforms 86 or longitudinal beam preforms 74 is equal to the hardening time of the preform. In other examples, pauses are synchronous for stations 92-114 working on the same part, but not shared between different types of parts. In some examples, a larger pause is an integer multiple of a smaller pause. In other examples, some parts of production line 88 run continuously, while others are pulsating. Stations 92-114 share a common production cycle time. To achieve a common production cycle time, more or fewer stations 92-114 can be used.

[0107] All operations discussed above are performed according to the production cycle time of the longitudinal beam prefabricated component 74 and the wing skin prefabricated component 86. Forcing production cycle times across multiple stations 92-114 allows operations between stations 92-114 to be coordinated and synchronized according to a common schedule. In one example, each station 92-114 performs a certain amount of work based on the time span of the autoclave heating cycle, which is the process requiring the longest time span to complete compared to the processes performed by other stations 92-100 and 104-114. In other words, the autoclave heating cycle is the process along production line 88 that limits productivity because it requires the longest time span to complete. If it is determined that the production cycle time of a particular station 92-114 is too long to meet the desired part productivity, additional stations can be added such that the sum of the production cycle times of the additional stations is equal to or slightly less than the autoclave heating cycle time.

[0108] Autoclave processing can be performed sequentially or in multiples of each other. For example, two or more multiples of wing panels 75 can be processed simultaneously. Thus, in one example, the amount of time spent during the pauses of wing skin preforms 86 or longitudinal beam preforms 74 at each station 92-114 is equal to the expected hardening time of preforms 74, 86 at autoclave 145 (or equal to a period of time divisible by the hardening time). As previously mentioned, the processing time is the sum of the production cycle time before autoclave and the pulsation / micro-pulsation, which is approximately equal to the autoclave processing time. This allows various components to move synchronously, continuously, or pulsatingly across multiple stations 92-114, consistent with the hardening process performed at autoclave 145. Subdividing the fabrication of a structure into parts or substructures for machining and assembly allows for the parallel machining and assembly of parts or substructures, increasing the overall throughput and fabrication speed of larger structures. Parts / substructures are “bits” that can be processed in parallel with other “bits” and delivered downstream in just-in-time (JIT) to serial stations so that they can be integrated into larger structures (e.g., wing panels 75) in a later curing or pre-curing manner.

[0109] In other examples, parts or substructures (e.g., longitudinal beam prefabricated parts 74) used as inputs to stations 92-114 of production line 88 are delivered by feed line 134 in a pulsed movement and JIT manner, with feed line 134 supplying parts or substructures directly to stations 92-114. The JIT pulsed movement of parts to stations 92-114 reduces the amount of space required for factory storage and the amount of space required for the passageways transporting materials from storage to stations 92-114. JIT delivery of parts also allows feed line 134 to have efficient production cycle times for JIT delivery to downstream stations 92-114. The pulsed movement of feed line 134 to each station 92-114 may or may not have the same production cycle time as the station 92-114 to which the parts are fed. In some examples, parts or substructures (e.g., longitudinal beam prefabricated parts) supplied by a single production line are slightly different from each other, and a specific type of part or substructure required at a certain point in time is supplied in a JIT manner.

[0110] Figure 16The diagram illustrates how the process of manufacturing wing 54 on production line 88 is synchronized based on the production takt times of various assembly processes, sub-assembly lines, and feed lines for JIT delivery. As previously mentioned, the production takt time reflects the production speed required to match the expected demand level. The production takt time can be calculated for all processes and tasks required to manufacture wing panels 75 on production line 88. Using the production takt time system, the parts and subassemblies of wing 54 move along production line 88 as efficiently as possible, and the work of manufacturing and assembling them is primarily value-added work. The throughput of production line 88 helps to establish a production takt time of 92-114 per station so that production line 88 meets the required expected productivity. Furthermore, the use of the production takt time system facilitates the identification of bottlenecks and non-value-added work, allowing these inefficiencies to be reduced or eliminated through appropriate modifications to the production processes and / or equipment.

[0111] Now for reference Figure 4 and Figure 16 Both, Figure 16 An example is illustrated along the process flow of production line 88, where one or more stations 92-114 act as feed lines to feed parts to downstream lines including one or more stations 92-114. For example, from the upstream feed line to... Figure 4 Parts are supplied to the wing assembly line 159 at workstation 150. The upstream feed lines include a wing panel assembly line 166, a rib feed line 180, and a spars feed line 186, each with a corresponding production cycle time selected for just-in-time (JIT) delivery of ribs 82, wing panels 75, and spars 78, 80 to the wing assembly line 159. Similarly, composite wing skin prefabrication prefabrication prefabrication prefabrication prefabrication prefabrication prefabrication prefabrication line 164, including upstream lamination stations 92, 94, for laying the wing skin prefabrication ... Material feed lines 170 and 172 feed composite materials to wing skin prefabrication line 164 and longitudinal beam prefabrication line 174, respectively. As previously mentioned, wing skin prefabrication line 164 and longitudinal beam prefabrication line 174 supply wing skin prefabrication parts 86 and longitudinal beam prefabrication parts 74 to wing panel assembly line 168 according to the production cycle time allowed for wing panel assembly line 166 to supply wing panels to wing assembly line 159 at JIT.

[0112] Rib layup is just-in-time (JIT) supplied from rib layup and forming line 178 to rib feed line 180, which then JIT-receives material via layup material feed line 176. In some examples, the rib 82 supplied by rib feed line 180 may not be made of aluminum or other metal, and the material supplied by material feed line 176 may be aluminum or other metal, rather than a composite material. Similarly, layup material feed line 182 supplies material to sparse layup and forming line 184 according to the production cycle time allowed for sparse feed line 186 to supply spars 78, 80 to wing assembly line 159. Other parts or subassemblies may be JIT-supplied to wing assembly line 159. For example, miscellaneous materials may be fed at 188, fasteners at 190, and sealant at 192. Additionally, hatch covers may be fed by feed line 196. Trimming operations resulting in finishing may be performed, and the material is removed at 194. Wing 54 has been fully assembled at wing assembly line 159 and delivered at 198 during full pulse for engagement with fuselage 52.

[0113] Processes performed at stations along any of the aforementioned feed lines can be executed simultaneously as parts move along the feed line in a pulsating, micro-pulsating, or continuous manner. Each feed line may share a common production takt time, which may or may not be equal to the line it is currently feeding. The throughput of the assembly line and feed lines helps establish the production takt time for each station on the assembly line and feed line required to meet the desired throughput. The production takt time of the feed line stations is designed to accommodate JIT delivery at the stations at the end of the feed line with the desired throughput.

[0114] Each feed line station and assembly line feed line has at least two inputs and one output. For example, mandrel 90, along with wing skin prefabrication layup 86 and composite material 126 from composite material feeder 130b, is input to station 94, and the resulting laminate on mandrel 90 is output from lamination station 92. Typically, the main inputs and outputs coincide with the station, and the feed line output arriving at that station is received from a third party. The latter structure is applied to stations in main production line 88 and stations in feed lines 130, 134. The inputs to a station can be arranged on both sides or more of the station.

[0115] Now pay attention Figure 17The diagram broadly illustrates the components of the control system 200, which controls and operates various components of the production line 88 prior to the hardening of the wing panel 75. Specifically, the control system 200 is configured to control the pulsating movement of the mandrel 90 along the production line 88, and the pulsating feeding of parts from the feed line to the workstations. The previously discussed controller 162 controls and coordinates the operation of the components of the production line 88 and is responsible for synchronizing the work according to the production cycle time, which is calculated to maximize efficiency and produce the complete wing panel at a desired productivity. The controller 162 synchronizes the operation of the fabrication equipment and processes according to the production cycle times of various processes, sub-assembly lines, and feed lines so that JIT delivery to upstream workstations 92-114 to the upstream assembly line is achieved.

[0116] As previously mentioned, the selected production cycle time results in productivity matching the desired output level. The production cycle time can be calculated by controller 162 for all processes and tasks desired in the production of wing panels 75 on production line 88. Using a micro-pulsating, pulsating, or continuous moving-line production cycle system, the parts and components of wing panels 75 move as efficiently as possible along production line 88 under the control of controller 162, and the work performed is essentially all value-added work. The throughput of the assembly line and feeder lines helps establish the production cycle time for each station on the assembly line and feeder lines to meet the productivity requirements. Controller 162 controls production line driver 205, which drives moving track 89, and thus drives drive spindle 90 or other platforms assembled with parts or sub-components in a continuous, micro-pulsating, or full-pulsating manner. Controller 162 also controls the operation of AGV 154, the use of which is optional. In some examples, the spindle 90 may be moved along various sections of the production line 88 via a combination of AGV 154 and production line drive 205 (e.g., conveyor, power roller, and / or chain / belt drive (not shown)). In other examples, the spindle 90 may be moved along the production line 88 via AGV 154 alone, or via production line drive 205 alone, or some combination thereof. The controller 162 includes one or more programming computers and / or processors, along with associated memory and programming instructions (all not shown).

[0117] Other components of production line 88, which form part of workstations 22-114 (e.g., autoclave 145 and vacuum control / vacuum inspection device 203), are also controlled by controller 162. Although PNPs 132a, 132b and laminators 124a, 124b may have local control, their operation is synchronized and / or controlled by controller 162. Similarly, the operation of components of the beam feeders 134a, 134b and composite material feeders 130a, 130b is also controlled and synchronized by controller 162.

[0118] Figure 18Showing something similar to Figure 4 The details of lamination station 97 at stations 92 and 94 shown are illustrated, where individual laminators lay different sections of the wing skin preform 86. For example, multiple laminators 124a, 124b, and 124c at lamination station 97 can lay composite material 126 on different sections 213, 214, and 216 of the wing skin preform 86. Each laminator 124a, 124b, and 124c receives composite material 12, which can be in the form of composite tape or bundle. Laminators 124a, 124b, and 124c are assigned to sections 213, 214, and 216 of the sheet 215, respectively, laying strips 221 of composite material within sections 213, 214, and 216. In some examples, laminators 124a, 124b, and 124c can be substantially the same type, while in other examples, they can be different types with different capabilities. For example, one or more laminators 124-124c may have only 3 degrees of freedom, while the others may have 6 degrees of freedom. Therefore, at lamination station 97, specialized laminators 124a-124c can be used to lay specific sections 213, 214, and 216, while lower-cost standard laminators 124a-124c can be used to lay other sections of sheet 215, such as sections 213, 214, and 216. In some examples, such as... Figure 20 As shown, the side-by-side strips 221 of adjacent sections 214 and 216 form a joint 223, which can be a butt joint or a lap joint. In other examples, such as Figure 19 As shown, any one of the strips 221 laid by different laminators 124a, 124b, and 124c can be spliced ​​together 225 by butt joints, overlap joints, or miter joints.

[0119] The joints 225 in the different layers of the laminate are offset from each other, causing them to be misaligned across the entire thickness of the laminate. Laminators 124a, 124b, 124c can lay composite material 126 on sections 213, 214, 216 in any order. In some examples, two or more of laminators 124a, 124b, 124c can lay composite material 126 on the same sections 213, 214, 216 before returning to apply it to the assigned sections 213, 214, 216. Although in Figure 15 The intermediate presses 124a, 124b, and 124c are positioned on one side of the mandrel 90, but they can be positioned anywhere around the mandrel 90.

[0120] Now pay attention Figure 21 This illustrates an alternative method for laying the wing skin prefabricated component 86. Figure 4 and Figure 18In the previously discussed example shown, the laminator 124 at each of lamination stations 94, 96 can lay the entire wing skin preform 86. However, in Figure 21 In the example shown, one or more laminators 124a-124c located at different stations 92a-92c can lay different sections 213, 214, 216 of a specific wing skin prefabricated component 86. Furthermore, multiple laminators 124b, 124d at station 92b can lay different portions 218, 220 of section 214 of the wing skin prefabricated component 86, which is laid at that station. Therefore, it can be seen that different laminators lay different portions of the wing skin sections.

[0121] Now for reference Figure 22 In some examples, laminators 124a, 124b, and 124c, located at different stations 92a, 92b, and 92c, can simultaneously apply composite materials to the wing skin preform 86 to improve lamination efficiency. For example, as... Figure 22 As shown, wing skin preform 86a is transferred from station 92a to station 92b. At station 92b, laminator 124b begins laying composite material on the leading edge section 217b, while at station 92a, laminator 124a is laying composite material on the trailing edge section 217a of wing skin preform 86a. In this example, laminator 124b has already completed laying a complete layer 215a on wing skin preform 86b and is not idle; rather, it begins laying composite material on wing skin preform 86a when it enters station 92b. Similarly, wing skin preform 86b can be seen being transferred from station 92b to station 92c. In this example, the entire lamination 215a has been laid on the wing skin preform 86b before it begins to enter station 92c. Instead of waiting until the wing skin preform 86b is fully inside station 92c, the laminator 124c station 92c begins laying the next lamination 215b as the leading edge of the wing skin preform 86b begins to enter station 92c. Therefore, stations 92b and 92c can work simultaneously on the same wing skin preform 86b. Depending on the width of stations 92a, 92b, and 92c and the distance between them, stations 92a, 92b, and 92c may also work simultaneously on the same wing skin preform 86b.

[0122] Various geometric structures for workstation 92 are possible to better utilize factory floor space and / or customize production line 88 to best suit a specific factory layout. For example, workstation 92 can be arranged along... Figure 23 The U-shaped path 241 shown in Figure 24, or the zigzag path 243 shown in Figure 24, or the circular "runway" path 245 shown in Figure 25 are arranged as shown in Figure 25. Figures 20 to 22 The path layout shown concentrates workstations 92, thus reducing shop floor requirements compared to a more linear path layout. Additional workstations 92 can be added as needed to increase production capacity and / or work density. Alternatively, depending on the application, one or more workstations 92 can be deactivated as needed. Figure 23 In the example shown, the mandrel 90 moves along the direction of arrow 255 from the loading area 227 at the start 231 of the production line 88 through any number of stations 92 to the unloading area 229 at the end 233 of the production line 88. The mandrel 90 is loaded onto the track 89 within the loading area 227 and can be removed from the track 89 in the unloading area 229, after which it can be repaired and recycled back to the loading area 227. In each of these production line layout examples, the mandrel 90 is rotated to each station 92 before the wing skin prefabricated component 86 is laid on it.

[0123] Similarly, in the example of the zigzag path 243 shown in Figure 24, production line 88 also has a loading area 227 at the beginning 231 of production line 88, where the mandrel 90 is loaded, and an unloading area 229 at the end 233 of production line 88, where the mandrel 90 is unloaded. Figure 22 In the illustrated annular path configuration 245, the loading area 227 and the unloading area 229 can be located anywhere around the production line 88. Furthermore, the loading and unloading of mandrels 90 can be performed at the same station 92. For example, when a mandrel 90 enters one of the stations 92, the mandrel 90 with a complete wing skin preform 86 can be removed from the track 89, and another mandrel 90 can be loaded at 227 into the position on the track 89, ready for laminating another wing skin preform 86.

[0124] In the example shown in Figure 25, the circular path construction 245 is rectangular; however, it can have any other regular or irregular shape, such as an ellipse, depending on the application. The multiple stations 92 in the example of Figure 25 can each have a... Figure 18 The example shown consists of two or more similar laminators 124. The lamination operations at different stations 92 are coordinated in such a way that each station 92 lays out the wing skin preform 86 and the joints in the layers are staggered throughout the laminate.

[0125] In one example, all stations 92 in Figure 25 contain one or more laminators 124, and the wing skin preform 86 is fully laid after the mandrel 90 completes its movement through station 92 along a circular path. In other examples, the mandrel 90 may need to move through all stations 92 multiple times to fully complete the wing skin preform 86. In other examples (e.g., Figure 20 and Figure 21 (As shown in the examples), after the mandrel has moved through all stations 92, it can move backward through station 92 to laminate additional sheets at station 92 to fully complete the wing skin preform 86. In other examples, the mandrel 90 may need to move back and forth multiple times along the production line path to complete the wing skin preform 86. Multiple mandrels 90 carrying different types of wing skin preforms 86 can move simultaneously along the production line 88; for example, any of the four possible versions of the wing skin preform 86 includes the top and bottom wing skin preforms 86 of the port and / or starboard wing 54. Furthermore, any of these four versions of the wing skin preform 86 can be in any manufacturing state as they move along the circular runway path.

[0126] In the configuration of runway path 245, mandrels 90 are placed on production line 88 at loading area 227 and cycle through the various stations 92 until they are removed at unloading area 229. In other examples, mandrels 90 may be loaded and unloaded in a single area; in other words, mandrels 90 may be removed at an area along production line 88 and replaced by another mandrel 90 at the same area. Multiple mandrels 90 may move along runway path 245 simultaneously. Furthermore, as will become apparent below, mandrels 90 may move back and forth through any one of the stations 92 and move back and forth through another of the stations 92.

[0127] exist Figures 23 to 2 In each example shown in 5, the steering 239 is relatively smooth rather than sharp, so as the mandrels pass through the steering 239, the orientation of the mandrels remains aligned with their direction of travel (machining direction P). However, in some examples, the steering 239 may be relatively sharp, for example, Figure 26 The 90-degree turn is shown. In this case, the spindle can be pivoted 90 degrees at turn 239. Figure 26 In the example shown, spindle 90 can be mounted on track 89 for pivoting movement 247 about pivot point 253. As spindle 90 moves from left to right along the horizontal segment 257 of production line 88 and reaches a sharp turn 239, it is pivoted 247 about pivot point 253 on track 89, thereby maintaining spindle 90 aligned with the machining direction P, and thus maintaining wing panel 86 aligned with the machining direction P. In those examples where AGV 154 is used to move spindle 90 along production line 88, any necessary turn 239 or reorientation of other spindle 90 can be achieved by manipulating AGV 154.

[0128] In some applications, arranging production line 88 in a way that optimizes factory floor space and / or manpower utilization may be necessary or desirable. Therefore, refer to Figure 27In another example, production line 88 includes two production line segments 275a and 275b arranged side-by-side and generally parallel to each other. Production line segments 275a and 275b may be spaced apart by a distance 279, which allows for the sharing of equipment and / or manpower between the two segments 275a and 275b. Each of the production line segments 275a and 275b may contain any number of individual workstations 92, where work such as wing skin lamination can be performed.

[0129] The mandrel 90 is placed on the production line 88 at loading station 227 and moves from left to right along the upper production line segment 275a. When the mandrel 90 reaches the end of production line segment 275a, it shifts laterally 269 (downward as shown) to production line segment 275b. The mandrel 90 can be moved laterally 269 manually or using an automated device (not shown) or a combination thereof. The mandrel 90 then moves 255 from right to left on production line segment 275b until it reaches unloading area 229, where it is unloaded, cleaned, and prepared as needed, before looping 235 back to loading area 227. In other examples, loading and unloading of the mandrel 90 can be performed in a single (same) area. Then, in other examples, the mandrel 90 moves 255 times along production line segment 275a and then production line segment 275b before leaving. Figure 27 The production line 88 shown can be used to produce wings for a specific model of aircraft or all wing panels 75 for multiple models of the same aircraft or different aircraft. For example, the individual upper wing panels 84L-1 and lower wing panels 85L-1 of the left wing of an aircraft, and the upper wing panels 84R-1 and lower wing panels 85R-1 of the right wing, can be produced as a set 271 on a set of spindles 90. Similarly, wing panels 84L-2, 85L-2, 84R-2, and 85R-2 of the left and right wings 54 of different models of aircraft can be produced on different sets of spindles 90 on the same production line 88.

[0130] Optionally, one or more offline holding areas 285 may be provided anywhere along production line 88, for example at the end of production line segment 275a, where any number of mandrels 90 may be unloaded and temporarily held for reasons such as maintenance, establishing a desired production cycle, or inspection. Mandrel storage area 118 may be located near loading area 227 to allow mandrels 90 to be stored until needed on production line 88. Figure 27 The production line layout shown is particularly effective in utilizing factory floor space because the two production line sections 275a and 275b can be spaced close to each other if needed. The close spacing between the two production line sections 275a and 275b also facilitates manpower sharing between the two sections. As mentioned above, Figure 27The production line layout shown is also well-suited for mass production of wing panels with different constructions and / or different wing panels for different aircraft models.

[0131] Figure 28 An example of a sawtooth production line structure is shown, which combines... Figure 27 The production line shifting concept shown avoids the need for negotiation or rotation of the mandrel 90 around the turning point of production line 88. In this example, production line 88 is arranged as a series of adjacent segments 275 that are generally parallel to each other. Each segment 275 may contain any number of stations 92. The mandrel 90 moves 255 from the mandrel loading area 227 through all segments 275 to the mandrel unloading area 229, where they are transported and recycled 235 back to the loading area 227. When the mandrel 90 reaches the end of a segment 275, it shifts laterally 269 to an adjacent segment 275, where it moves 255 along production line 88 until it reaches the end of a segment 275, and then it shifts laterally 269 again to the next adjacent segment 275. Thus, the mandrel 90 moves back and forth along segments 275 until the wing panel 75 is completed and removed from the mandrel 90 at the unloading area 229.

[0132] As described above, the movement of production line 88 can be reversed, causing mandrel 90 to move backward. For example, once the wing skin preform 86 has been processed in one or more stations 92, mandrel 90 can be moved backward for additional processing or returned to loading area 227. Moving mandrel 90 backward to a previous station 92 is desirable because the previous station 92 contains specialized equipment and / or is otherwise better suited to perform specific lamination operations. The ability to position loading area 227 and unloading area 229 at any point along production line 88 allows for greater processing flexibility and can increase work density while reducing shop floor space requirements.

[0133] Figure 29 and Figure 30 It shows Figure 4 and Figure 41 Examples of beam feed lines 134a and 134b are shown. In this example, beam feed lines 134a and 134b each include a lamination station 222, which lays and trims flat loads 224 of fiber-reinforced material (e.g., uncured CFRP). These flat loads 224 may additionally receive layers of fluorinated ethylene propylene (e.g., FEP), insulating sheets (e.g., glass fiber sheets electrically insulating carbon fibers from aluminum components), etc.

[0134] Flattened feed 224 is formed into longitudinal beam preforms 74 on mandrel 226 via forming station 228. After forming, the longitudinal beam preforms 74 are placed on pallet 230, which advances 261 along track 232 (e.g., a power conveyor or other component). Track 232 can be linear or can be arranged in a ring 265 layout, with one or more longitudinal beam preforms 74 entering track 232 and leaving when laying and forming are complete (e.g., after preforms continue to be laid during one or more passes through ring 265). Thus, longitudinal beam preforms 74 are laid and formed layer by layer according to a predefined ply plan. Other layouts of track 232 are possible. In one example, multiple lamination stations 222 are followed by multiple forming stations 228, each aligned along track 232.

[0135] Within track 232, mandrel 226 can cycle through the same lamination station 222 multiple times before leaving track 232, followed by the same forming station 228. Depending on the design, pallet 230 stores a single longitudinal beam preform 74 or a group or set 272 of longitudinal beam preforms 74. Longitudinal beam preforms 74 can be fed in sets 272 to the longitudinal beam placement stations 96, 98 where they are to be placed. However, in some applications, it may be necessary or desirable to JIT feed longitudinal beam preforms individually, sequentially or in subsets. An automated longitudinal beam placement machine (e.g., PNP 132) picks up longitudinal beam preforms 74 individually, in sets, or in subsets from pallet 230 and places them onto the wing skin preform 86. As will be discussed in further detail below, in one example, PNP 132 picks up and places a single longitudinal beam prefabricated piece 74 at a time, while in other examples, PNP 132 picks up and places a batch or set 272 of longitudinal beam prefabricated pieces 74 onto the wing skin prefabricated piece 86 each time. In some examples, the placement of the longitudinal beam prefabricated pieces 74 can be performed manually or manually with machine assistance. The longitudinal beam feed lines 134a and 134b are each configured such that smaller structures or “positions” are processed in parallel and delivered by JIT to the serially arranged stations discussed above, for later curing or pre-curing and integration into the wing panel 75 along with other “positions” (if applicable).

[0136] Figure 31 illustrates this. Figure 29 and Figure 30An example of a lamination station 222 is shown. In this example, the lamination station 222 includes a plurality of heads 236, each head 236 dispensing bundles of material to form multilayer sheet flatbeds 224. The heads 236 are mounted to a frame 238 and move along the frame 238 to a desired location for laying the material. The frame 238 provides structural strength to the lamination station 222 while also enabling the heads 236 to move. A conveyor belt 240 moves the flatbeds 224 (in and out of the sheet direction) relative to the heads 236 via a belt 242, enabling each head 236 to lay the flatbeds 224, each flatbed comprising multilayer fiber-reinforced material of any desired combination of fiber orientations (e.g., + / - 45°, 0°, 90°).

[0137] Please now note Figure 32, which illustrates an example of a longitudinal beam prefabricated member 74 (sometimes also referred to as an inverted T-shaped blade longitudinal beam). The longitudinal beam prefabricated member 74 includes a blade 244 and a base 246, the base 246 being formed by two L-shaped members 248 joined together and engaging with a bottom cover 256. Each L-shaped member 248 includes a blade portion 250 and a flange portion 252. The blade portions 250 are joined back-to-back, and the flange portion 252 engages with the bottom cover 256. A noodle 260 is installed in a gap 258 between the rounded edge of the L-shaped member 248 and the bottom cover 256. The angle at which the flange portion 252 is inclined relative to the base portion 250 causes the blade 244 to be inclined relative to the base 246 at a desired angle. As will become apparent in the following description, the angle 254 of blade 244 relative to base 246 facilitates the placement of the longitudinal beam preform 74 on a corrugated surface, such as the corrugated 278 wing skin preform 86, and can also increase the stiffness of the longitudinal beam preform 74 depending on the application. More specifically, to facilitate the batch placement of longitudinal beams, the angle 254 of blade 244 is chosen such that blades 244 are approximately parallel to each other. The parallel orientation of the blades allows them to be picked up in batches or in multiples and is easier to place on common equipment such as PNP aircraft 132.

[0138] Figures 33 to 40 An example of a method for manufacturing the longitudinal beam preform 74 at the aforementioned forming station 228 is shown. In this example, the longitudinal beam preform 74 is... Figure 27 The inverted T-shape shown has blade 244 inclined relative to base 246. From Figure 33 Initially, mandrels 226a and 226b are mounted on tool base 262 at forming station 228. Figure 34 In the process, the PNP machine (not shown) places one or more flat loads 224 on each mandrel 226a, 226b. Next, as... Figure 35 As shown, the flat charge 224 is formed downwards onto the surfaces of the mandrels 226a and 226b. (Reference) Figure 36One or more additional flattened elements 224c, 224d are placed on mandrels 226a, 226b, thereby covering the previously formed flattened elements 224a, 224b. These additional flattened elements 224c, 224d are formed in the same manner, resulting in the formation of a first preform 264 and a second preform 266, which form the L-shaped section or component 248 of the longitudinal beam preform 74 (FIG. 32).

[0139] refer to Figure 37 The spindles 226a and 226b, together with the first preform 264 and the second preform 266, rotate 268 90° clockwise and counterclockwise, respectively. Next, as... Figure 38 As shown, mandrels 226a and 226b are pulled together by 273, thereby forcing the blade portions 250 of the first preform 264 and the second preform 266 into face-to-face contact. (Reference) Figure 39 The spring-loaded element 260 is placed in the gap 258 between the two L-shaped sections or components 248a and 248b. Then, as... Figure 40 As shown, the bottom cover 256 is placed on the flange portion 252, covering the spring member 260, thereby completing the fabrication of the longitudinal beam preform 74. At this time, the mandrels 226a and 226b are removed, allowing the longitudinal beam preform 74 to be removed from the forming station 228 and placed in the tray 230 on one of the longitudinal beam feed lines 134. Figure 4 , Figure 29 , Figure 30 ).

[0140] Please note now. Figure 41 , Figure 41 An example is illustrated of a method for placing a segment 73 of a longitudinal beam prefabricated component 74 onto a wing skin 86 at a single station 96, thereby using multiple placement machines to place the segment 73. In this example, multiple PNPs 132a-132h are located on opposite sides of a moving track 89 at station 96. PNPs 132a-132h receive the longitudinal beam segment 73 from separately associated longitudinal beam feed lines 134a-134h in a JIT configuration. Each of the PNPs 132a-132h places one of the longitudinal beam segments 73, such that the entire longitudinal beam prefabricated component 74 extending along the entire length of the wing skin 86 is placed simultaneously, thereby improving production efficiency. Furthermore, by using two sets of PNPs 132a, 132c, 132e, 132g and 132b, 132d, 132f, 132h to place the sections 73 of the longitudinal beam prefabricated components 74, two full-length longitudinal beam prefabricated components 74 can be placed simultaneously or sequentially on the wing skin 86, thereby further improving production efficiency. The additional longitudinal beam prefabricated components 74 are placed on the wing skin 86 in this manner, moving along the chord direction 66 of the wing skin 86 until all longitudinal beam prefabricated components 74 have been placed.

[0141] The placement position of the longitudinal beam section 73 can be controlled by the controller 162, which controls the operation of PNP 132a-132h. Figure 17 The position of the wing skin preform 86 is determined. The position is shifted to the mandrel 90, so the controller 162 "knows" where to instruct PNPs 132a-132h to place the longitudinal beam segments 73 on the wing skin preform 86. This "knowledge" used by the controller 162 includes relative positional information achieved through the shifting. The mandrel 90 is shifted to the PNP station 96 and the wing skin preform 86 is shifted to the mandrel 90, therefore the controller 162 knows the position of the wing skin preform 86 in space at the PNP station 96, and thus knows the position for placing the longitudinal beam segments 73 on each wing skin preform 86. In other words, the mandrel 90, the composite wing skin prefabricated component 86, and the composite longitudinal beam prefabricated component 74 are rotated relative to each other, such that the composite wing skin prefabricated component 86 is laid at the rotated position on the mandrel 90, and the composite longitudinal beam prefabricated component 74 is placed at the rotated position on the composite wing skin prefabricated component 86. When the longitudinal beam sections 73 are placed, they are connected together by joints 76 suitable for the application, such as butt joints, lap joints, or miter joints, to name a few.

[0142] refer to Figure 42 The segments 73 of the longitudinal beam prefabricated component 74 can be placed continuously on the wing skin prefabricated component 86 in a chordal direction or sequence 66. The segments 73 can be placed in such a way that they begin at any point along the span of the wing skin 86. For example, the segments 73 of the longitudinal beam prefabricated component 74 can be placed simultaneously in the chordal direction 66, for example, setting both the inner end 62 and the outer end 64 of the wing skin 86 during a pause.

[0143] refer to Figure 43 The segments 73 of the precast longitudinal beam 74 can be placed consecutively in a spanwise sequence 67, and joints 76 can then be added to connect the segments 73. In some examples, the segments 73 of the precast longitudinal beam 74 can be placed in any predetermined order. For example, some longitudinal beam segments 73 can be placed in a spanwise sequence 67, while other longitudinal beam segments 73 are placed in a chordwise sequence 66. Figure 37 In the example shown, the longitudinal beam segments 73 are connected together via joints 76 as they are placed.

[0144] Now pay attention Figure 44This illustrates another method for placing the longitudinal beam prefabricated component 74 onto the wing skin prefabricated component 86. In this example, an entire set or group or “batch” 272 of the longitudinal beam prefabricated components 74 is placed onto the wing skin prefabricated component 86 in a single placement operation. Each set 272 of the longitudinal beam prefabricated components 74 may include longitudinal beam segments 73 that are spliced ​​together after they are placed, or they may include full-length longitudinal beam prefabricated components 74 spanning the entire length of the wing 54. In some examples, all the longitudinal beam prefabricated components 74 of the wing panel 75 may be placed onto the wing skin prefabricated component 86 as a single batch. A single batch may include longitudinal beam segments 73 or may include full-length longitudinal beam prefabricated components 74, or any combination of longitudinal beam segments 73 and longitudinal beam prefabricated components 74.

[0145] The longitudinal beam prefabricated parts 74 are supplied to the longitudinal beam platform area 270 by the longitudinal beam feed line 134, where they are held, for example, in a tray (not shown) ready to be picked up and placed. The PNP machine 132 at station 96 simultaneously picks up all the longitudinal beam prefabricated parts 74 in the assembly 272. The PNP machine 132 transfers the assembly 272 of longitudinal beam prefabricated parts 74 to the position of the mandrel 90 and places them as a group on the wing skin prefabricated part 86 by the controller 162. Figure 17 The wing skin prefabricated components 86 are positioned at the designated locations. The positions of the longitudinal beam prefabricated components 74 relative to each other can be pre-arranged for rotation placement in the longitudinal beam bench area 270. As will be discussed in more detail below, the longitudinal beam prefabricated components 74 have specially constructed physical features, such as parallel longitudinal beam blades 244 (Figure 32), which allows them to be picked up in batches rather than requiring them to be picked up individually.

[0146] Figure 45 The above reference shows Figure 44 The method of explanation involves a set of 272 longitudinal beam prefabricated members 74 placed on the wing skin 86 at the outer end 64. In this example, the set of 272 longitudinal beam prefabricated members 74 spans the entire width of the wing skin 86 in the chord direction 66. In other examples, the set 272 may span only a portion of the width of the wing skin 86. Figure 46 As shown, the precast longitudinal beams 74 of multiple sets 272a and 272b can be placed end-to-end in the spanwise direction 67 and joined together by joints 76. In other examples, such as Figure 47 As shown, all 276 longitudinal beam prefabricated pieces 74 of the entire wing panel 75 are placed on the wing skin prefabricated piece 86 as a single assembly 272.

[0147] Now for reference Figures 48 to 51The wing skin preform 86 typically has a curvature of 278 in the chord direction 66, which can vary along the span of the wing. Although not shown in the figure, the wing skin preform 86 may also have a curvature of 278 in the spanwise direction 67. Figure 12 The curvature on the surface is 278. For example... Figure 48 As shown, the inverted T-shaped longitudinal beam preform 74 discussed above can be placed individually or in groups on the wing skin preform 86 by one or more PNPs 132. During placement, the longitudinal beam preform 74 is rotated and aligned with the wing skin preform 86 and the mandrel 90. When placed, the base 246 of the longitudinal beam preform 74 follows the curvature 278 of the wing skin preform 86, while the blades 244 all extend in the same direction parallel to each other. The parallel orientation of the blades 244 allows the PNP 132 to pick up and place the longitudinal beam preform 74 without adjusting the angular orientation of each longitudinal beam preform 74 to match the curvature 278. The parallel longitudinal beam blades 244 allow for easier picking and holding by the PNP 132, and easier separation from the longitudinal beam preform 74 when they are placed in batches on the wing skin preform 86.

[0148] Figures 49 to 53 The PNP 132 is shown with multiple linearly aligned vertically movable arms 280 (see [link]). Figure 53 Attached to the bottom of arm 280 is a clamp 282 capable of gripping and carrying the longitudinal beam precast component 74. Figure 51 In one example shown, the clamp 282 includes a pair of spaced-apart, opposing carrier members 277 between which the longitudinal beam preform 74 can be gripped. Each carrier member 277 is generally L-shaped in cross-section and includes a grid of internal channels 283 terminating at an opening 281 facing the blade 244 and a base 246 of the longitudinal beam preform 74. The internal channels 283 are coupled to a suitable vacuum source (not shown) that selectively evacuates the internal channels 283 to create a vacuum at the opening 281, which pulls the blade 244 and / or flange portion 252 against the carrier members 277, enabling the carrier members 277 to grip, pick up, and then place the longitudinal beam preform 74 at an indexed position on the wing skin preform 86. In the illustrated example, the carrying member 277 extends along the entire length of the longitudinal beam precast 74; however, in other examples, the carrying member 277 may include segments spaced apart along the length of the longitudinal beam precast 74. A variety of other types of mechanical and pneumatic clamps can be used to clamp the blades 244 and / or flange portions 252 of the longitudinal beam precast 74.

[0149] During the placement process, PNP 132 is moved to a position ( Figure 49In this position, arm 280 is above and aligned with the blades 244 of the longitudinal beam preform 74. Arm 280 then moves downwards, and the gripper 282 blades grasp the longitudinal beam preform 74 through the blades 244 and / or base 246, allowing the longitudinal beam preform 74 to be picked up and transported to the indexed placement position covering the wing skin preform 86. Arm 280 and / or PNP 132 move downwards, placing the longitudinal beam preform 74 onto the wing skin 86. Gripper 282 then releases the blades 244, allowing PNP 132 to move back to the starting position in preparation for picking up another longitudinal beam preform 74.

[0150] exist Figure 51 In the example shown, releasing the longitudinal beam preform 74 during placement is achieved by releasing the vacuum holding the preform 74 on the carrier member 277. In some applications, it may also be desirable to apply positive pressure at the opening 281 in the carrier member 277, which forces the longitudinal beam preform 74 to release from the clamp 282. In practice, the clamp 282 is a releasable coupling that uses negative pressure or vacuum to clamp the longitudinal beam preform 74 and uses positive pressure to release and push it away. There is no need to adjust the angular orientation of the arm 280 to compensate for the curvature 278 of the wing skin preform 86. Figure 48 This is because the curvature compensation of 278 is "built-in" into the design of the longitudinal beam precast 74. The blades of the longitudinal beam precast 74 remain parallel to each other during the pick-up and placement sequence.

[0151] In the example just described, PNP 132 picks up and places a single longitudinal beam prefabricated member 74. However, multiple PNPs 132 can be used to pick up and place multiple longitudinal beam prefabricated members 74 sequentially or simultaneously, wherein the multiple PNPs 132 are of the type having multiple clamps 282 with clamping blades 244 along their length. In other examples, such as Figure 53 As shown, one or more PNP132 may have an array of arms 280 and clamps 282 arranged in rows 284 and columns 286, capable of simultaneously picking up and placing a set of longitudinal beam preforms 74. In this example, each row 284 of the clamps 282 picks up a blade from the blade 244 and / or base 246 of one of the longitudinal beam preforms 74.

[0152] Now for reference Figure 54 As previously combined Figure 1 and Figure 2As mentioned, each wing 54 includes an upper wing panel 84 and a lower wing panel 85. Therefore, a pair of wings (port and starboard sides) comprises four wing panels 75a-75d, which are constructed differently from each other in shape and / or profile, or have other functional differences. All four wing panels 75a-75d can be produced sequentially on the same production line 88 in any desired order. More than one type of wing panel 75 can also be produced on the same production line 88 and arranged in series. This is achieved through controller 162 (…). Figure 17 The controller 162 achieves the indexing of the mandrel 90, thereby achieving the indexing of the wing panel 75 of that model. In other words, the controller 162 "knows" which model of wing panel 75 to manufacture on each mandrel 90 and instructs each station what work needs to be performed on that mandrel 90 for the specific model to be produced on that particular mandrel 90. In other examples, indexing can be achieved using other techniques (e.g., any of the techniques discussed previously). For example, the mandrel 90 may have an indexing feature 141 ( Figure 15 The transposition feature 141 identifies the type of wing panels 75a-75d and the work to be performed on the wing panels 75a-75d.

[0153] like Figure 54 As shown, the four wing skins 86a-86d are laid on four different spindles 90a-90d. The spindles 90a-90d each have a profile that matches the wing panel 75. Figure 54 (Not shown in the diagram), whose central axes 90a-90d form part of the wing panel 75. In the example shown, wing skins 86a and 86b respectively form the starboard wing 54 ( Figure 1 The wing skins 86a and 86d form part of the upper and lower wing panels 75 of the port wing 54. Although the wing skins 86a-86d are shown as being produced in groups and continuously on production line 88, they can be produced in other sequences or mixed with other types of wing panels 75. Thus, for example, the production of wing panels 84 of one aircraft can be mixed with the production of wing panels 84 of another aircraft.

[0154] Figure 55 This illustrates how wing panels 75 with different shapes for different applications can be produced on the same production line 88. For example, wing panels 75e-75g with different shapes suitable for different aircraft wings can be manufactured separately on mandrels 90e-90g traveling along the same production line 88. Wing panels 75h that form part of a horizontal stabilizer 56 or a vertical stabilizer 58 can be manufactured on mandrel 90e and produced together with wing panels for the same or different aircraft.

[0155] In order to produce different wing panels 75 for the same or different aircraft on the same production line 88, it may be necessary to identify and / or track the unique mandrel 90 for each type of wing panel 75. Figure 56 A configuration is shown for identifying the individual mandrels 90 to assemble the correct wing skin prefabricated component 86 and longitudinal spars prefabricated component 74 onto the correct mandrel 90 traveling along the production line 88. The mandrel 90 may be provided with a suitable form of marking 306 that uniquely identifies the mandrel 90. In one example, marking 306 may include a barcode 290 that can be read by an optical or other type of barcode reader 296.

[0156] In another example, marker 306 may include an RFID (Radio Frequency Identification) tag 292 read by a suitable RFID reader 294. In some examples, manufacturing allowance 137 (on the mandrel 90 or the wing skin prefabricated component 86 already laid on the mandrel 90) Figure 15 It may also include a shifting feature 141 that transmits shifting information to one or more workstations. This shifting information can be connected to the workstation via a suitable connection device, such as a reader, for example, readers 294, 296. The shifting information is removed when the manufacturing allowance is no longer needed and is removed, provided that the shifting information has already been placed on the allowance of the wing skin preform 86.

[0157] In any of the scenarios described above, the read information is delivered to controller 162, which may include one or more processors (not shown) and suitable software for processing the information and associating mandrel 90 with wing configuration 300 stored in memory 298. Based on the wing configuration 300 associated with a particular mandrel 90, controller 162 instructs production line equipment (e.g., laminators 124 and PNP 132) 302 to produce the corresponding wing panel 75 using the associated mandrel 90. The aforementioned indexing feature can also be used to track “positions” supplied to stations to be incorporated into wing skin preforms 86, or as part of work performed at downstream stations, such as bagging and post-curing operations.

[0158] Now pay attention Figure 57This diagram broadly illustrates the steps of a method for manufacturing wing panels 75 on production line 88. At 308, multiple mandrels 90 move along production line 88 in the processing direction P. The mandrels 90 can move continuously or incrementally along production line 88 in a pulsating or micro-pulsating manner. At 310, composite wing skin 86 is laid on the mandrels 90 along production line 88 at lamination station 92. Composite wing skin 86 can be laid on mandrels 90 as they move in a pulsating, micro-pulsating, or continuous manner, or during pauses between pulsations or micro-pulsations. At 312, composite longitudinal beams are placed on the composite wing skin at longitudinal beam placement station 96 along the production line. At 313, the mandrels 90 are moved along production line 88 through lamination station 92 and longitudinal beam placement station 96, according to the production cycle time resulting in the desired productivity of wing panels 75.

[0159] Figure 58 A method for manufacturing wing panels is broadly illustrated. Starting at 314, a mandrel 90 moves along production line 88 through at least one lamination station and one spar placement station. However, in some examples, the mandrel 90 moves through more than two stations. At 315, each mandrel 90 is rotated to the lamination station. At 316, as the mandrel 90 moves through the lamination station, the composite wing skin 86 is laid on the mandrel 90 at the lamination station. At 318, the mandrel movement through the lamination station is synchronized with the laying of the composite wing skin using the rotation from each mandrel to the lamination station. At 320, each mandrel 90 is rotated to the spar placement station. At 322, a composite spar 74 is placed on the composite wing skin at any spar placement station. At 325, the mandrel movement through the spar placement station is synchronized with the placement of the composite spar on the wing skin using the rotation from each mandrel to the spar placement station.

[0160] Now for reference Figure 59 Another method of manufacturing the wing panel 75 begins at 324, where multiple mandrels 90 move along production line 88. At 326, the composite wing skin 86 is laid on the multiple mandrels 90. At 328, multiple composite longitudinal beams 74 are fabricated on the longitudinal beam feed line 134. At 329, each mandrel 90 moves along production line 88 through the longitudinal beam placement station. At 330, the composite longitudinal beam 74 is fed from the longitudinal beam feed line 134 to the longitudinal beam placement station. At 332, as the mandrels 90 move through the longitudinal beam placement station, the composite longitudinal beam 74 is placed on the wing skin 86 at the longitudinal beam placement station.

[0161] Figure 60The steps of a method for manufacturing an aircraft wing skin 86 are broadly illustrated. Starting at 334, a laying mandrel 90 moves along a production line 88. At 336, as the laying mandrel 90 moves along the production line 88, different sections 213, 214, and 216 of the wing skin 86 are laid onto each laying mandrel 90 using different laminators 124.

[0162] refer to Figure 61 A method for manufacturing wing panels 75 begins at 338, wherein composite wing skin 86 moves along production line 88. At 340, as the wing skin 86 moves along production line 88, longitudinal beam preforms 74 are placed on the individual wing skins 86 at a longitudinal beam placement station.

[0163] Now for reference Figure 62 Another method of manufacturing the wing panel 75 begins at 341, where composite wing skin 86 of different constructions moves along production line 88. As previously combined... Figure 27 and Figure 28 The composite wing skin 86 discussed can move back and forth along one segment 257 of production line 88 and another segment 263 of production line 88. At 343, girders preforms of different sets 272 are produced on the girder feed line, each of the sets 72 of girders preforms being associated with one of the wing skins 86 of different configurations. At 357, the girders preforms in their sets 272 are fed to the girder placement station along production line 88, such that each of the girders preform sets arrives at the girder placement station on time for placement on the associated wing skin. The feeding of the sets 272 of girders preforms can be performed sequentially, such that they arrive in the order in which they will be placed; however, other sequences are also possible. Furthermore, while feeding the girders preforms in sets 272 may be efficient in some applications, in other applications it may be necessary or desirable to feed them individually, either sequentially or in subsets, using a JIT method. At position 358, each of the precast longitudinal beams in assembly 272 is placed on its respective associated wing skin at the longitudinal beam placement station.

[0164] Figure 63 The steps of another method for manufacturing the wing panel 75 are shown extensively. At 342, the composite wing skin 86 is laid. At 344, at least the composite longitudinal beam preforms 74 of the first assembly 272 are placed on each of the composite wing skins 86. All the composite longitudinal beam preforms 74 of the first assembly 272 are placed on the composite wing skin 86 simultaneously.

[0165] Figure 64The basic steps of a method for manufacturing wing panels are illustrated. At 345, multiple mandrels 90 move along production line 88 through multiple stations, including a lamination station. At 347, wing skin is laid onto the mandrels 90 at the lamination station. At 349, an indexing feature is placed on the mandrels 90. At 351, the indexing feature is used to index the mandrels to the stations, allowing pre-selected work to be performed on the mandrels at each station.

[0166] Figure 65 A method for manufacturing composite wing panels 75 with multiple different configurations is illustrated. Starting at 346, a lay-up mandrel 90 moves along production line 88 through multiple stations 92-98. At 348, the configuration of the wing panel 75 to be manufactured is selected. At 350, wing skin 86 is manufactured by laying composite material onto each mandrel 90 based on the selected configuration. At 352, composite longitudinal spars preforms 74 are placed on the wing skin 86 based on the selected configuration.

[0167] The examples disclosed herein can be used in a variety of potential applications, particularly in the transportation industry, including, for example, aerospace, marine, automotive applications, and other applications utilizing composite skins reinforced with composite stiffeners. Therefore, reference is now made to... Figure 66 and Figure 67 Examples of this disclosure can be found in, for example, Figure 66 The aircraft manufacturing and service method 400 shown and such Figure 67 Used in the context of the aircraft 402 shown. The aircraft applications disclosed in the examples may include various airfoil type structures, such as wings and stabilizers. During pre-production, the exemplary method 400 may include the specification and design 404 of the aircraft 402 and material procurement 406. During production, the manufacturing 408 of components and sub-assemblies of the aircraft 402 and system integration 410 occur. Thereafter, the aircraft 402 can be certified and delivered 412 for service 414. During customer service, the aircraft 402 is scheduled for routine maintenance and upkeep 416, which may also include modifications, remodeling, refurbishment, etc.

[0168] Each process of Method 400 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 suppliers, subcontractors, and vendors; and an operator may be an airline, leasing company, military entity, service provider, etc.

[0169] like Figure 67As shown, an aircraft 402 produced by exemplary method 400 may include a frame 418, multiple systems 420, and an interior 422. The frame 418 includes wings and stabilizers 424, each wing and stabilizer including a composite wing skin 426 reinforced using composite longitudinal beams 428. Examples of advanced systems 420 include one or more of a propulsion system 430, an electrical system 432, a hydraulic system 434, and an environmental system 436. 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 marine and automotive industries.

[0170] The systems and methods implemented herein may be employed during any or more stages of the aircraft manufacturing and servicing method 400. For example, a component or sub-assembly corresponding to production process 408 may be made or manufactured in a manner similar to that of components and sub-assemblies produced during the servicing of aircraft 402. Furthermore, one or more apparatus examples, method examples, or combinations thereof may be utilized during production processes 408 and 410, for example, by significantly accelerating the assembly of aircraft 402 or reducing its cost. Similarly, one or more apparatus examples, method examples, or combinations thereof may be used during the servicing of aircraft 402, for example, but not limited to, repair and maintenance 416.

[0171] As used in this article, when used with a list of items, the phrase "at least one" means that different combinations of one or more of the listed items can be used, and it is possible that only one of the individual items in the list is needed. For example, "at least one of items A, B, and C" can include, but is not limited to, items A, A and B, or item B. This example could also include items A, B, and C, or items B and C. Items can be specific objects, things, or categories. In other words, any combination of items in the list and at least one of many items can be used, but not all items in the list are required.

[0172] The descriptions of the various illustrative examples are presented for purposes of illustration and description and are not intended to exhaustively list or limit the examples of the disclosed form. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different illustrative examples may offer different advantages compared to other illustrative examples. The selection and description of one or more examples are intended to best explain the principles and practical applications of the examples and to enable others skilled in the art to understand the disclosure of various examples with various modifications suitable for the particular use considered.

[0173] This document also provides the following examples, which relate to aspects of this disclosure:

[0174] The first example includes an apparatus for manufacturing composite wing panels, the apparatus comprising:

[0175] Production line;

[0176] Multiple mandrels, wherein the multiple mandrels are connected to the production line;

[0177] A production line driver configured to move the mandrel along the production line;

[0178] Multiple workstations along the production line, the multiple workstations being used to perform work on the mandrel, the multiple workstations including at least one wing skin lamination workstation;

[0179] At least one laminator, wherein the at least one laminator is used in the at least one wing skin lamination station to lay composite wing skin on the mandrel; and

[0180] A controller, which is connected to the production line drive and configured to control the movement of the mandrel along the production line.

[0181] In an embodiment according to the first example, the plurality of workstations include a plurality of lamination workstations, each lamination workstation being configured to lay at least a section of wing skin on each of the mandrels.

[0182] In an embodiment according to the first example, the at least one wing skin lamination station includes a plurality of laminators, each laminator being configured to lay at least a section of composite wing skin onto each of the mandrels.

[0183] In an embodiment according to the first example, the plurality of workstations includes at least one longitudinal beam placement workstation configured to place a composite longitudinal beam on the composite wing skin.

[0184] In an embodiment according to the first example, the at least one longitudinal beam placement station includes at least one automatic pick-and-place machine configured to pick up a section of the composite longitudinal beam and place it on the composite wing skin.

[0185] In an embodiment according to the first example, the plurality of workstations include a plurality of longitudinal beam placement workstations, each longitudinal beam placement workstation being configured to place a composite longitudinal beam on the composite wing skin.

[0186] In an embodiment according to the first example, the apparatus further includes a plurality of longitudinal beam feed lines, each longitudinal beam feed line being configured to produce composite longitudinal beams and feed the composite longitudinal beams to one of the longitudinal beam placement stations.

[0187] In an embodiment according to the first example, the controller is configured to synchronize the work performed on each of the mandrels with the movement of the mandrels along the production line.

[0188] In an embodiment according to the first example, the controller is configured to use the production cycle time that produces the desired wing panel productivity to synchronize the work performed on each of the mandrels with the movement of the mandrels along the production line.

[0189] In an embodiment according to the first example, the apparatus further includes a plurality of feed lines that move in sync with the movement of the mandrel along the production line and are configured to supply material to at least some workstations according to the production cycle time that produces the desired wing panel productivity.

[0190] In an embodiment according to the first example, each of the feed lines is configured to supply the material to the at least some of the workstations on time.

[0191] The second example includes a system for manufacturing composite wing panels, the system comprising:

[0192] The production line includes multiple workstations;

[0193] Multiple mandrels, on which the wing panel is produced, the mandrels being movable along the production line through the workstation;

[0194] Multiple feed lines, each configured to feed parts to at least certain stations; and

[0195] A control system configured to control the mandrel to move pulsatingly along the production line and to pulsatingly feed the parts from the feed line to the workstation; and

[0196] Each workstation is configured to produce a part of the composite wing panel.

[0197] In an embodiment according to the second example, the control system includes a controller configured to control the pulsating movement and the pulsating feed based on the production cycle time that produces the desired wing panel productivity.

[0198] In an embodiment according to the second example, the control system includes a controller configured to synchronize the pulsating movement of the mandrel with the pulsating feed of the part.

[0199] In an embodiment according to the second example, the workstation includes:

[0200] At least one lamination station, the at least one lamination station being configured to lay composite wing skin onto the mandrel, and

[0201] At least one longitudinal beam placement station is configured to place a composite longitudinal beam on the composite wing skin.

[0202] In an implementation according to the second example, each of the mandrels includes a work instruction that defines the work to be performed on the mandrel at each of the workstations.

[0203] In an embodiment according to the second example, the control system includes at least one position sensor in each of the workstations, the at least one position sensor being configured to sense the position of the mandrel at the workstation.

[0204] A third example includes a method for manufacturing a composite wing panel for an aircraft, the method comprising:

[0205] This causes multiple mandrels to move along the production line;

[0206] At the lamination station along the production line, the composite wing skin is laid onto the mandrel;

[0207] At the longitudinal beam placement station along the production line, the composite longitudinal beam is placed on the composite wing skin; and

[0208] Based on the production cycle time for generating the desired wing panel productivity, the mandrel is moved along the production line through the lamination station and the longitudinal beam placement station.

[0209] In the implementation according to the third example, moving the mandrel through multiple workstations is performed by continuously moving the mandrel along the production line.

[0210] In the implementation according to the third example, moving the mandrel through the lamination station and through the longitudinal beam placement station is performed incrementally.

[0211] In an embodiment according to the third example, incrementally moving the mandrel includes pulsating the mandrel along the production line.

[0212] In the embodiment according to the third example, the laying of the wing skin and the placement of the longitudinal beams are performed between the pulses during the pulse.

[0213] In an embodiment according to the third example, laying the composite wing skin onto the mandrel at the lamination station includes laying different sections of the composite wing skin separately at the lamination station using a separate laminator.

[0214] In the embodiment according to the third example, the composite wing skin is laid in a single lamination station along the production line.

[0215] In the embodiment according to the third example, the placement of the composite longitudinal beam on the composite wing skin is carried out at a separate longitudinal beam placement station along the production line.

[0216] In an embodiment according to the third example, placing the composite longitudinal beam on the composite wing skin includes using multiple placement machines to place sections of the composite longitudinal beam on the composite wing skin.

[0217] In an implementation according to the third example, the method further includes:

[0218] The composite longitudinal beam is produced along the longitudinal beam feed line, and

[0219] The composite longitudinal beam is fed from the longitudinal beam feed line to the longitudinal beam placement station on time.

[0220] In an embodiment according to the third example, the method includes rotating the mandrel to the lamination station and the longitudinal beam placement station, such that the composite wing skin is laid on the mandrel at the rotated position and the composite longitudinal beam is placed on the composite wing skin at the rotated position.

[0221] In an implementation according to the third example, the transposition includes:

[0222] Place at least one transposition feature on at least one of the mandrel and the composite wing skin, and

[0223] The transposition feature is detected.

[0224] A fourth embodiment of this disclosure includes a composite wing panel manufactured by a method according to any embodiment of the third example.

[0225] The fifth example includes a method for manufacturing a wing panel of an aircraft, the method comprising:

[0226] The mandrel is moved along the production line through at least one lamination station and at least one longitudinal beam placement station;

[0227] The mandrel is rotated to the lamination station;

[0228] At the lamination station, the composite wing skin is laid onto the mandrel;

[0229] The mandrel is moved synchronously through the lamination station and the composite wing skin is laid using the mandrel's rotation to the lamination station;

[0230] The mandrel is rotated to the longitudinal beam placement position;

[0231] At the longitudinal beam placement station, the composite longitudinal beams are respectively placed onto the composite wing skin; and

[0232] The mandrel is moved through the longitudinal beam placement station and the composite longitudinal beam is placed on the composite wing skin by means of the mandrel's rotation to the longitudinal beam placement station.

[0233] In the implementation according to the fifth example, moving the mandrel through the lamination station and through the longitudinal beam placement station is performed based on the production cycle time that results in achieving the desired wing panel productivity.

[0234] In an implementation according to the fifth example, the method further includes:

[0235] The mandrel is moved along the production line into the autoclave, and

[0236] The composite wing skin and the composite longitudinal beam are cured in the autoclave for a curing period.

[0237] The production cycle time is not greater than the curing period.

[0238] In an embodiment according to the fifth example, shifting the mandrel to the lamination station and shifting the mandrel to the longitudinal beam placement station includes placing a shifting feature on the mandrel.

[0239] In an embodiment according to the fifth example, laying the composite wing skin includes:

[0240] At the lamination station, a laminator is used to lay the composite material onto one of the mandrels.

[0241] As the mandrel enters the lamination station, the laminator is connected to the mandrel at the lamination station.

[0242] As the laminator lays the composite material onto the mandrel, the laminator and mandrel move together through the lamination station, and

[0243] After the laminator has completed the laying of the composite material, the laminator is detached from the mandrel.

[0244] In an implementation according to the fifth example, the method further includes:

[0245] Connect the device to one of the mandrels;

[0246] The mandrel and the device are moved along the production line through multiple workstations;

[0247] The device is used to perform work on the composite wing skin on the mandrel; and

[0248] After the mandrel has moved through the plurality of workstations, the device is detached from the mandrel.

[0249] In an implementation according to the fifth example, the method further includes:

[0250] The transposition feature is placed on at least one of the mandrel and the composite wing skin.

[0251] The mandrel is rotated using the rotation feature at the lamination station and the longitudinal beam placement station.

[0252] The sixth example includes a wing panel manufactured by a method according to any embodiment of the fifth example.

[0253] The seventh example includes a method for manufacturing a wing panel of an aircraft, the method comprising:

[0254] This causes multiple mandrels to move along the production line;

[0255] The composite wing skin is laid on the multiple mandrels respectively;

[0256] Multiple composite longitudinal beams are fabricated on the longitudinal beam feeding line;

[0257] The plurality of mandrels are moved along the production line and placed at the workstation via the longitudinal beams;

[0258] The composite longitudinal beam is fed from the longitudinal beam feed line to the longitudinal beam placement station; and

[0259] The composite longitudinal beam is placed on the composite wing skin at the longitudinal beam placement station.

[0260] In an implementation according to the seventh example, the method further includes:

[0261] The assembly of composite longitudinal beams fabricated on the longitudinal beam feed line is associated with the composite wing skin, and

[0262] Specifically, the composite longitudinal beams are fed to the longitudinal beam placement station so that the assembly of composite longitudinal beams is fed to the longitudinal beam placement station for timely placement onto the composite wing skin.

[0263] In the implementation according to the seventh example, wherein:

[0264] Fabricating the plurality of composite longitudinal beams includes forming blades on the composite longitudinal beams, and

[0265] Placing the composite longitudinal beam includes placing the composite longitudinal beam in a manner that makes the blades substantially parallel.

[0266] In an implementation according to the seventh example, the method further includes:

[0267] The mandrel is moved synchronously through the longitudinal beam placement station and the composite longitudinal beam is fed from the longitudinal beam feed line to the longitudinal beam placement station.

[0268] In an implementation according to the seventh example, the synchronization includes:

[0269] A production cycle time is selected to move the mandrel through the longitudinal beam placement station and feed the composite longitudinal beam from the longitudinal beam feed line to the longitudinal beam placement station, wherein the production cycle time is selected to produce the desired wing panel productivity, and

[0270] The production cycle time is used to move the mandrel through the longitudinal beam placement station and to feed the composite longitudinal beam.

[0271] In an embodiment according to the seventh example, the method includes moving the mandrel in a micro-pulsating manner through the longitudinal beam placement station.

[0272] In an embodiment according to the seventh example, the placement of the composite longitudinal beam on the wing skin is performed between the micropulsations.

[0273] In an implementation according to the seventh example, the method further includes:

[0274] The mandrel is moved along the production line through at least two longitudinal beams to a placement station;

[0275] As the mandrel moves through each of the at least two longitudinal beam placement stations, the composite longitudinal beam is placed on the composite wing skin; and

[0276] The composite longitudinal beam is fed to each of the at least two longitudinal beam placement stations.

[0277] In an embodiment according to the seventh example, placing the composite longitudinal beam includes placing sections of the composite longitudinal beam on the composite wing skin and splicing the sections together.

[0278] In the implementation according to the seventh example, the placement of the composite longitudinal beam is performed using a pick-and-place machine.

[0279] The eighth example includes a wing panel manufactured by a method according to any embodiment of the seventh example.

[0280] The ninth example includes a method for manufacturing wing skin of an aircraft, the method comprising:

[0281] To move the laying mandrel along the production line; and

[0282] As the laying mandrel moves along the production line, different sections of the wing skin are laid onto the laying mandrel using different laminators.

[0283] In an embodiment according to the ninth example, the production line includes multiple workstations, and different sections of the wing skin are laid on different workstations respectively.

[0284] In an embodiment according to the ninth example, the production line includes multiple workstations, and the different sections of the wing skin are laid at one of the workstations.

[0285] In the embodiment according to the ninth example, different laminators lay different portions of the wing skin sections.

[0286] In an embodiment according to the ninth example, moving the laying mandrel includes continuously moving the laying mandrel along the production line.

[0287] In the embodiment according to the ninth example, the movement of the laying mandrel is performed in a micro-pulsating manner, and the laying of the different segments is performed between the micro-pulsations.

[0288] In the implementation according to the ninth example, the movement of the laying mandrel is performed based on a production cycle time selected to generate the desired wing panel productivity.

[0289] The tenth example includes the wing skin of an aircraft manufactured according to any embodiment of the method of the ninth example.

[0290] The eleventh example includes a method for manufacturing a wing panel of an aircraft, the method comprising:

[0291] Moving the composite wing skin along the production line; and

[0292] As the composite wing skin moves along the production line, at the longitudinal beam placement station along the production line, the longitudinal beam preform is placed on the composite wing skin.

[0293] In an embodiment according to the eleventh example, placing the longitudinal beam preforms includes simultaneously placing all the longitudinal beam preforms on the composite wing skin at a longitudinal beam placement station along the production line.

[0294] In an embodiment according to the eleventh example, placing the longitudinal beam preform includes placing a portion of the longitudinal beam preform onto the composite wing skin at a plurality of longitudinal beam placement stations along the production line.

[0295] In an embodiment according to the eleventh example, placing the longitudinal beam preform includes placing sections of the longitudinal beam preform onto the composite wing skin at a plurality of longitudinal beam placement stations along the production line.

[0296] In the embodiment according to the eleventh example, each of the longitudinal beam preforms has a blade, and placing the longitudinal beam preforms includes placing the longitudinal beam preforms in such a manner that the blades are substantially parallel to each other.

[0297] In an embodiment according to the eleventh example, each of the longitudinal beam preforms has a blade, and placing the longitudinal beam preforms includes simultaneously placing a plurality of longitudinal beam preforms on each of the composite wing skin.

[0298] In an embodiment according to the eleventh example, placing the longitudinal beam preform includes: continuously placing the longitudinal beam preform on the composite wing skin in the chordal direction of the composite wing skin.

[0299] In an embodiment according to the eleventh example, placing the longitudinal beam preform includes: continuously placing the longitudinal beam preform on the composite wing skin in the spanwise direction of the wing skin.

[0300] In an embodiment according to the eleventh example, placing the longitudinal beam preform on the composite wing skin includes: placing multiple sets of longitudinal beam preforms on the composite wing skin at multiple longitudinal beam placement stations along the production line.

[0301] In an embodiment according to the eleventh example, placing the longitudinal beam preforms includes: using a pick-and-place machine to place different longitudinal beam preforms onto the composite wing skin.

[0302] In one embodiment according to the eleventh embodiment, the method further includes:

[0303] Production of precast longitudinal beams on the longitudinal beam feeding line; and

[0304] The precast longitudinal beam is fed from the longitudinal beam feed line to the longitudinal beam placement station.

[0305] In the embodiment according to the eleventh example, the feeding of the longitudinal beam prefabricated component is performed in a manner that ensures the longitudinal beam prefabricated component arrives at the longitudinal beam placement station on time.

[0306] In the embodiment according to the eleventh example, the placement of the longitudinal beam preform on the composite wing skin is performed based on the production cycle time selected to generate the desired wing panel productivity.

[0307] In the embodiment according to the eleventh example, the placement of the longitudinal beam prefabricated component on the composite wing skin is carried out in a series of micro-pulses on the production line.

[0308] In the embodiment according to the eleventh example, moving the composite wing skin includes moving the composite wing skin in a micro-pulsating manner through the longitudinal beam placement station, and

[0309] The placement of the longitudinal beam prefabricated component onto the composite wing skin is performed between the micro-pulsations.

[0310] In the embodiment according to the eleventh example, the movement of the composite wing skin is performed continuously, such that as the composite wing skin moves continuously through the longitudinal beam placement station, the longitudinal beam prefabricated component is placed on the composite wing skin.

[0311] In the embodiment according to the eleventh example, at the longitudinal beam placement station, a pick-and-place machine is used to place the longitudinal beam prefabricated component onto the composite wing skin.

[0312] The twelfth example includes a wing panel of an aircraft manufactured according to any embodiment of the method of the eleventh example.

[0313] The thirteenth embodiment includes a method for manufacturing different wing panels of an aircraft, the method comprising:

[0314] To move different composite wing skins along the production line;

[0315] Multiple sets of longitudinal beam preforms are produced on a longitudinal beam feed line, wherein each of the multiple sets of longitudinal beam preforms is associated with one of different composite wing skins.

[0316] The plurality of assemblies of the longitudinal beam prefabricated components are fed along the production line to the longitudinal beam placement station, such that the plurality of assemblies of the longitudinal beam prefabricated components arrive at the longitudinal beam placement station on time to be placed on the composite wing skin; and

[0317] At the longitudinal beam placement station, the plurality of prefabricated longitudinal beam components are placed on the composite wing skin.

[0318] In an embodiment according to the thirteenth example, feeding the plurality of sets of precast longitudinal beams includes: sequentially feeding the plurality of sets of precast longitudinal beams along the longitudinal beam feed line in a preselected order, such that the plurality of sets of precast longitudinal beams arrive at the longitudinal beam placement station in the preselected order.

[0319] In an embodiment according to the thirteenth example, the plurality of sets of feeding the longitudinal beam prefabricated components include: feeding the longitudinal beam prefabricated components in segments, and placing the plurality of sets of the longitudinal beam prefabricated components includes placing the segments on the composite wing skin and splicing the segments together.

[0320] In an embodiment according to the thirteenth example, placing the plurality of sets of longitudinal beam prefabricated components includes placing the longitudinal beam prefabricated components individually in each of the plurality of sets.

[0321] In an embodiment according to the thirteenth example, placing the plurality of sets of longitudinal beam prefabricated components includes simultaneously placing all longitudinal beam prefabricated components in each of the plurality of sets.

[0322] In an embodiment according to the thirteenth example, producing the plurality of sets of longitudinal beam preforms includes forming blades on the longitudinal beam preforms, and placing the plurality of sets of longitudinal beam preforms includes placing the longitudinal beam preforms in the set of longitudinal beam preforms in such a manner that the blades on the longitudinal beam preforms in each of the plurality of sets of longitudinal beam preforms are substantially parallel to each other.

[0323] The fourteenth embodiment includes a method for manufacturing different wing panels for an aircraft, the method comprising:

[0324] To move different composite wing skins along the production line;

[0325] Precast longitudinal beam components are produced on the longitudinal beam feeding line;

[0326] The longitudinal beam prefabricated components are individually fed to the longitudinal beam placement station along the production line, ensuring that each prefabricated component arrives at the placement station on time to be placed on the composite wing skin; and

[0327] The prefabricated longitudinal beam is placed on the composite wing skin at the longitudinal beam placement station.

[0328] In an embodiment according to the fourteenth example, feeding the longitudinal beam prefabricated component includes feeding the longitudinal beam prefabricated component sequentially along the longitudinal beam feed line in a preselected order, such that the longitudinal beam prefabricated component arrives at the longitudinal beam placement station in the preselected order.

[0329] In an embodiment according to the fourteenth example, placing the longitudinal beam prefabricated component includes simultaneously placing a plurality of longitudinal beam prefabricated components on each of the composite wing skin.

[0330] In an embodiment according to the fourteenth example, feeding the longitudinal beam preform includes: sequentially feeding the longitudinal beam preform such that the longitudinal beam preform forms a plurality of sets of the longitudinal beam preforms respectively associated with different wing skins, and

[0331] Placing the longitudinal beam prefabricated component on the composite wing skin includes: placing the longitudinal beam prefabricated component on the wing skin of the assembly.

[0332] In an embodiment according to the fourteenth example, producing the longitudinal beam preform includes forming blades on the longitudinal beam preform, and

[0333] Placing the longitudinal beam precast component includes placing the longitudinal beam precast component in such a manner that the blades on the longitudinal beam precast component are substantially parallel to each other.

[0334] The fifteenth example includes a method for manufacturing a wing panel, the method comprising:

[0335] Moving the composite wing skin along the production line; and

[0336] At least a first set of composite longitudinal beam prefabricated components are placed on the composite wing skin, wherein all composite longitudinal beam prefabricated components in the first set of the composite wing skin are placed on the composite skin simultaneously.

[0337] In the embodiment according to the fifteenth example, placing the first set of composite longitudinal beam prefabricated components onto the composite wing skin is performed using a pick-and-place machine.

[0338] In an implementation according to the fifteenth example, the method further includes:

[0339] At least a second set of composite longitudinal beam prefabricated components are placed on the composite wing skin, wherein the composite longitudinal beam prefabricated components in the second set are simultaneously placed on the composite wing skin.

[0340] In the embodiment according to the fifteenth example, the placement of the first set of composite longitudinal beam prefabricated components and the placement of the second set of composite longitudinal beam prefabricated components are each performed using a pick-and-place machine.

[0341] In an embodiment according to the fifteenth example, each of the composite longitudinal beam prefabricated members has a base configured to match the profile of the composite wing skin, and wherein:

[0342] Placing the at least first set of composite longitudinal beam prefabricated components includes: picking up each of the composite longitudinal beams and placing the base of the composite longitudinal beam prefabricated component against the composite wing skin.

[0343] In an embodiment according to the fifteenth example, each of the composite longitudinal beam preforms includes a blade, and picking up each of the composite longitudinal beam preforms includes grasping the blade and using the blade to place the base onto the composite wing skin.

[0344] In an embodiment according to the fifteenth example, the placement of the first set of composite longitudinal beam prefabricated components is performed as the composite wing skin moves along the production line.

[0345] The sixteenth example includes a method for manufacturing a composite wing panel for an aircraft, the method comprising:

[0346] Multiple mandrels are moved along a production line, including a lamination station, through multiple stations;

[0347] At the lamination station, the composite wing skin is laid onto the mandrel; and

[0348] The indexing feature is placed on the mandrel, and the indexing feature indexes the mandrel to the lamination station.

[0349] In one embodiment according to the sixteenth embodiment, the method further includes:

[0350] The work instructions are placed on the composite wing skin, and

[0351] At a station downstream of the lamination station, work is performed on the composite wing skin using work instructions.

[0352] The seventeenth example includes a method for manufacturing multiple composite wing panels of different configurations, the method comprising:

[0353] This allows the laying mandrel to move along the production line through multiple stations;

[0354] Choose the construction of the composite wing panel to be manufactured;

[0355] Based on the aforementioned construction, wing skin preforms are manufactured by laying the composite material onto the laying mandrel; and

[0356] Based on the selection of the aforementioned configuration, the composite longitudinal beam preform is placed on the wing skin preform.

[0357] The eighteenth example includes a wing panel of an aircraft, the wing panel comprising:

[0358] A pair of composite wing skins; and

[0359] Multiple composite longitudinal beams are located between and attached to the composite wing skin, the composite longitudinal beams comprising longitudinal beam blades extending substantially parallel to each other.

[0360] In an embodiment according to the eighteenth example, the composite wing skin has a length in the spanwise direction of the wing panel, and the composite longitudinal beam substantially extends the length of the composite wing skin.

[0361] In an embodiment according to the eighteenth example, the composite wing skin has a width in the chordal direction of the wing panel, and the composite longitudinal beam substantially extends the width of the composite wing skin.

[0362] In an embodiment according to the eighteenth example, the composite wing skin has a length in the spanwise direction of the wing panel, and at least some of the composite longitudinal beams include multiple segments spliced ​​together and extending in the spanwise direction of the wing panel.

[0363] In an embodiment according to the eighteenth example, at least some of the composite longitudinal beams include multiple segments spliced ​​together and extending in the spanwise direction of the wing panel.

[0364] In an embodiment according to the eighteenth example, the composite wing skin includes a profile, and the composite longitudinal beam includes a base and blades conforming to the profile, wherein the blades extend substantially parallel to each other.

[0365] 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 appended claims.

Claims

1. An apparatus (210) for manufacturing composite wing panels, the apparatus (210) comprising: Production line (88); Multiple mandrels (90) are connected to the production line; A production line driver (205) is configured to move the spindle (90) along the production line (88); Along the production line (88) are multiple stations (92-114) for performing work on the mandrel (90), the multiple stations (92-114) including at least one wing skin lamination station (92-94). At least one laminator (124a-124d) in at least one wing skin lamination station (92-94) for laying the composite wing skin onto the mandrel (90); and A controller (162) is coupled to the production line driver (205) and configured to control the movement of the mandrel along the production line.

2. The apparatus according to claim 1, wherein, The plurality of workstations (92-114) include a plurality of lamination workstations (92-94), each lamination workstation (92-94) being configured to lay at least a section of wing skin on each of the mandrels (90); and / or wherein, The at least one wing skin lamination station (92-94) includes multiple laminators (124a-124d), each laminator (124a-124d) being configured to lay at least a section of composite wing skin on each of the mandrels (90).

3. The apparatus according to claim 1 or 2, wherein, The plurality of workstations (92-114) include at least one longitudinal beam placement workstation (96, 98), wherein each of the at least one longitudinal beam placement workstation (96, 98) is configured to place a composite longitudinal beam on the composite wing skin.

4. The apparatus according to claim 3, wherein: The at least one longitudinal beam placement station (96, 98) includes at least one automatic pick-and-place machine (132), which is configured to pick up a section of the composite longitudinal beam and place it on the composite wing skin; or, The apparatus also includes multiple longitudinal beam feed lines (134a, 134b), each of which is configured to produce composite longitudinal beams and feed the composite longitudinal beams to one of the longitudinal beam placement stations.

5. The apparatus according to claim 1 or 2, wherein, The controller is configured to synchronize the work performed on each of the mandrels (90) with the movement of the mandrels (90) along the production line (88).

6. The apparatus according to claim 5, wherein, The synchronous use generates the production cycle time for the desired wing panel productivity.

7. The apparatus according to claim 5, wherein, The apparatus also includes multiple feed lines that move synchronously with the mandrel along the production line and are configured to supply material to at least some workstations according to the production cycle time that produces the desired wing panel productivity.

8. The apparatus according to claim 7, wherein, Each of the feed lines is configured to supply the material to the at least some of the workstations on time.

9. A system for manufacturing composite wing panels, the system comprising: - The apparatus according to any one of claims 1 to 8; - Multiple feed lines, each of which is configured to feed parts to at least some workstations; as well as - A control system (200) configured to control the pulsating movement of the mandrel along the production line and the pulsating feeding of the parts from the feed line to the workstation, and Each workstation is configured to produce a part of the composite wing panel.

10. The system according to claim 9, wherein, The control system includes a controller configured to control the pulsating movement and the pulsating feed based on the production cycle time that produces the desired wing panel productivity. and / or The control system includes a controller configured to synchronize the pulsating movement of the mandrel with the pulsating feed of the part; and / or Each of the mandrels includes a work instruction that defines the work to be performed on the mandrel at each of the workstations; and / or The control system includes at least one position sensor in each of the workstations, the at least one position sensor being configured to sense the position of the mandrel at the workstation.

11. A method for manufacturing wing skin and / or composite wing panels for an aircraft, the method comprising the following steps: Move multiple spindles along the production line (308); At the lamination station along the production line, the composite wing skin is laid on the mandrel (310). At the longitudinal beam placement station along the production line, the composite longitudinal beam is placed on the composite wing skin (312); and Based on the production cycle time for generating the desired wing panel productivity, the mandrel is moved along the production line through the lamination station and the longitudinal beam placement station (313).

12. The method according to claim 11, wherein, The step of moving the mandrel through multiple workstations is performed by continuously moving the mandrel along the production line; and / or in: - Moving the mandrel through the lamination station and through the longitudinal beam placement station is performed incrementally; and / or - The step of laying the composite wing skin onto the mandrel at the lamination station includes: laying different sections of the composite wing skin separately at the lamination station using a separate laminator; and / or - The step of laying the composite wing skin is performed in separate lamination stations along the production line; and / or - The step of placing the composite longitudinal beam onto the composite wing skin is performed at a separate longitudinal beam placement station along the production line; and / or - The step of placing the composite longitudinal beam on the composite wing skin includes: using multiple placement machines to place sections of the composite longitudinal beam on the composite wing skin.

13. The method according to claim 12, wherein, The step of incrementally moving the mandrel includes pulsating the mandrel along the production line.

14. The method according to claim 13, wherein, The steps of laying the wing skin and placing the longitudinal beams are performed between the pulses during the pulse.

15. The method according to claim 12, wherein, The method further includes: The composite longitudinal beam is produced along the longitudinal beam feed line and fed from the longitudinal beam feed line to the longitudinal beam placement station on time.

16. The method according to any one of claims 11 to 15, the method comprising indexing the mandrel (315, 320) to the lamination station and the longitudinal beam placement station, such that the composite wing skin is laid at the indexed position on the mandrel, and the composite longitudinal beam is placed at the indexed position on the composite wing skin; and / or in, The transposition step includes: placing at least one transposition feature on at least one of the mandrel and the composite wing skin, and detecting the transposition feature.

17. The method of claim 16, wherein the method comprises the following steps: The step of using the mandrel to move the mandrel through the lamination station is synchronized with the step of laying the composite wing skin (318). The step of moving the mandrel through the longitudinal beam placement station using the mandrel will be synchronized with the step of placing the composite longitudinal beam onto the composite wing skin (325).

18. The method according to any one of claims 11 to 15, further comprising the step of: - Move the mandrel along the production line into the autoclave, and - The composite wing skin and the composite longitudinal beam are cured in the autoclave for a curing period, wherein the production cycle time is not greater than the curing period; And / or, the method further includes the following steps: - Connect the device to one of the mandrels; - Move the mandrel and the device along the production line through multiple workstations; - Performing work on the composite wing skin on the mandrel using the device; and - Disconnect the device from the mandrel after the mandrel has moved through the plurality of workstations; And / or, wherein the step of laying the composite wing skin includes: - At the lamination station, a laminator is used to lay the composite material onto one of the mandrels; - As the mandrel enters the lamination station, the laminator is connected to the mandrel at the lamination station; - As the laminator lays the composite material onto the mandrel, the laminator and mandrel are moved together through the lamination station; and - After the laminator has completed the laying of the composite material, the laminator is detached from the mandrel.

19. The method according to any one of claims 11 to 15, further comprising the step of: - Fabricate multiple composite longitudinal beams on the longitudinal beam feeding line; - Move the plurality of mandrels along the production line through the longitudinal beams to the placement station; as well as - The composite longitudinal beam is fed from the longitudinal beam feed line to the longitudinal beam placement station. The step of fabricating the plurality of composite longitudinal beams includes forming blades on the composite longitudinal beams, and the step of placing the composite longitudinal beams includes placing the composite longitudinal beams in a manner that makes the blades substantially parallel. And / or, the method further includes the following steps: - The step of moving the mandrel through the longitudinal beam placement station is synchronized with the step of feeding the composite longitudinal beam from the longitudinal beam feed line to the longitudinal beam placement station.

20. The method of claim 19, further comprising the step of: Multiple sets of composite longitudinal beams fabricated on the longitudinal beam feed line are associated with the composite wing skin, and wherein the feeding of the composite longitudinal beams is performed such that the multiple sets of composite longitudinal beams are fed to the longitudinal beam placement station for timely placement on the composite wing skin.

21. The method of claim 19, wherein, The synchronization steps include: - Feeding the composite longitudinal beam from the longitudinal beam feed line to the longitudinal beam placement station, and - The steps of moving the mandrel through the longitudinal beam placement station and feeding the composite longitudinal beam are performed according to the production cycle time.

22. The method according to any one of claims 11 to 15, further comprising the step of: - Move the mandrel along the production line through at least two longitudinal beams to a placement station; - As the mandrel moves through each of the at least two longitudinal beam placement stations, the composite longitudinal beam is placed on the composite wing skin; and - Feed the composite longitudinal beam to each of the at least two longitudinal beam placement stations. And / or, wherein the step of placing the composite longitudinal beam includes placing a section of the composite longitudinal beam on the composite wing skin and splicing the sections together; And / or, wherein the step of placing the composite longitudinal beam is performed using a pick-and-place machine; And / or, wherein each of the composite longitudinal beam preforms has a base configured to match the profile of the composite wing skin, and wherein placing at least a first set of composite longitudinal beam preforms comprises: picking up each of the composite longitudinal beams and placing the base of the composite longitudinal beam preform against the composite wing skin.

23. The method according to any one of claims 11 to 15, wherein, The longitudinal beam is a prefabricated longitudinal beam component.

24. The method of claim 23, wherein, The steps for placing the precast longitudinal beams include the following: - At the longitudinal beam placement station along the production line, all longitudinal beam prefabricated components are simultaneously placed on the composite wing skin; or - At multiple longitudinal beam placement stations along the production line, a portion of the prefabricated longitudinal beam is placed on the composite wing skin; or - At multiple longitudinal beam placement stations along the production line, sections of the precast longitudinal beams are placed on the composite wing skin.

25. The method according to claim 24, wherein, The step of placing the longitudinal beam prefabricated component includes: continuously placing the longitudinal beam prefabricated component on the composite wing skin in the chord direction or the spanwise direction of the composite wing skin.

26. The method according to any one of claims 11 to 15, wherein, The longitudinal beam is a collection of longitudinal beams or longitudinal beam prefabricated components on a longitudinal beam feed line, wherein each of the collections of longitudinal beam prefabricated components is associated with one of different composite wing skins, and wherein the method further includes the step of feeding the collections of longitudinal beam prefabricated components to a longitudinal beam placement station along the production line, such that the collections of longitudinal beam prefabricated components arrive at the longitudinal beam placement station on time to be placed on the composite wing skin.

27. The method of claim 26, wherein: - The step of feeding the plurality of sets of precast longitudinal beam components includes: sequentially feeding the plurality of sets of precast longitudinal beam components along the longitudinal beam feed line in a preselected order, such that the plurality of sets of precast longitudinal beam components arrive at the longitudinal beam placement station in the preselected order; or - The step of placing the plurality of sets of longitudinal beam prefabricated components includes: placing the longitudinal beam prefabricated component in each set of the plurality of sets individually or placing all the longitudinal beam prefabricated components in each set of the plurality of sets simultaneously.

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