Method of assembling fuselages, assembly line system and device in the form of a loader

Abstract

This application relates to methods for assembling fuselages, assembly line systems, and loader-type equipment. Systems and methods for assembling aircraft fuselages are provided, particularly frame mounting stations for aircraft fuselage sections. One embodiment is a method for assembling an aircraft fuselage. The method includes transposing an arcuate section of the fuselage to a frame mounting station, feeding a frame into a recess defined by the arcuate section at the frame mounting station, placing the frame against the inner mold line (IML) of the arcuate section while it is within the recess, and securing the frame to the arcuate section.

Description

TECHNICAL FIELD

[0001] The present invention relates to the field of assembly, and more particularly, to the assembly of a fuselage. BACKGROUND

[0002] A fuselage defines the mechanical structure of an aircraft. The fuselage is made of a plurality of components that provide the required structural properties. For example, a portion of the fuselage for an aircraft fuselage can include frames, door surrounds, window frames and subassemblies, brackets, blankets, system elements, skins, and stringers, etc. that are mechanically coupled together (e.g., via co-bonding, co-curing, or fasteners) in accordance with design parameters. As currently practiced, the components of the fuselage are manufactured and assembled in predetermined cells on the factory floor. For example, skins of an aircraft can be assembled at a cell, which can then be transferred to a new cell where frames are installed into the skins to form a section of the fuselage.

[0003] While the above manufacturing processes are reliable, they encounter delays when work at a particular portion of a component is completed more slowly than expected. For example, if a particular portion of a fuselage section takes longer than expected to install a frame, the entire section remains at the cell until all work that has been delayed is completed. Alternatively, the work that has been delayed must later be completed in another work cell (i.e., in addition to the work already scheduled for that later work cell), which adds to the difficulty of manufacturing components in a timely and efficient manner.

[0004] Accordingly, it would be desirable to have a method and apparatus that addresses and overcomes at least some of the above problems, as well as other possible problems. SUMMARY

[0005] The embodiments described herein provide frame installation stations that facilitate pulsatile line assembly techniques and methods for manufacturing a fuselage section. After each pulse, a section of the fuselage is moved along the line assembly a particular length, i.e., less than the total length of the section, to allow certain processing operations to be performed at a particular location on the section of the fuselage. One or more frame installation stations are arranged at different locations of the line assembly to allow certain portions of the fuselage section to have frames installed onto the section. This assembly technique provides technical benefits by integrating the transport process into the assembly process and by reducing the amount of work that needs to be performed on the fuselage section each time a fuselage section is moved along the assembly line. In addition, the frame installation stations that facilitate the pulsatile line assembly techniques and methods for manufacturing a fuselage section can also be used for continuous line assembly that moves in a continuous rather than pulsatile manner.

[0006] One embodiment is a method for assembling an aircraft fuselage. The method includes indexing a bow section of the fuselage to a frame installation station, feeding one or more frames at the frame installation station into a recess defined by the bow section, placing the frame against an inner mold line (IML) of the bow section when the frame is within the recess, and securing the frame to the bow section. The bow section can take the form of a half barrel section of the fuselage, which can be joined with another half barrel section to form a complete barrel section, which can be joined with other barrel sections to form a composite fuselage of an aircraft.

[0007] Another embodiment is a non-transitory computer readable medium containing programming instructions operable when executed by a processor to perform a method for assembling an aircraft fuselage. The method includes indexing a bow section of the fuselage to a frame installation station, feeding one or more frames at the frame installation station into a recess defined by the bow section, placing the frame against an inner mold line (IML) of the bow section when the frame is within the recess, and securing the frame to the bow section.

[0008] Yet another embodiment is a system for assembling an aircraft fuselage. The system includes a section of the fuselage advanced to an indexing position, an indexing unit including complementary features that mate with features at the section, and a frame installation station disposed at the indexing unit. The frame installation station includes a loader that feeds a frame into a recess defined by the section, a tool that places the frame against an inner surface of the section when the frame is within the recess, and a fastening machine that attaches the frame to the section.

[0009] Another embodiment is an apparatus in the form of a loader for loading a frame onto a section of a fuselage. The apparatus includes a pinch roller disposed below a support edge of a bow section of the fuselage, the bow section of the fuselage being supported by rollers connected to struts and including a downward facing recess, and a motor that drives the pinch roller to advance the frame below the support edge and into the recess, for example through a gap between the struts.

[0010] The systems disclosed herein can utilize modular and redundant system equipment to form frame installation stations and other work stations of the system to allow for quick replacement in the event of a failure of one or more system equipment. The use of such modular and redundant system equipment allows the system to continue production while the failed system equipment is replaced with a properly functioning unit. The systems and apparatus disclosed herein can be designed to allow other work system equipment to perform the functions of the system equipment being replaced to help prevent slowing or stopping production while the failed system equipment is replaced.

[0011] Other illustrative implementations (e.g., methods and computer readable media related to the aforementioned implementations) can be described below. Features, benefits, and / or other aspects of the disclosure can be described in the following description and in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0012] Some implementations of the present disclosure are now described, by way of example only, and with reference to the accompanying drawings. The same reference numbers in different drawings identify the same elements or elements of the same type.

[0013] Figure 1 is a block diagram of a flowline assembly system including a frame installation station in an illustrative implementation.

[0014] Figure 2 is a flowchart illustrating a method for operating a line assembly system to install a frame in an illustrative implementation.

[0015] Figure 3 is a perspective view of a frame being fed under a half-barrel section of a fuselage prior to installation in an illustrative implementation.

[0016] Figure 4A is a side view of a frame being fed under a half-barrel section of a fuselage prior to installation in an illustrative implementation.

[0017] Figure 4B is a schematic of a fastening machine, for example, to install a frame by clamping the frame to a half-barrel section, by drilling holes, and by installing fasteners, shown in a first installation position.

[0018] Figure 4C is a schematic of the fastening machine of Figure 4B , showing the fastening machine moving with the half-barrel section to a second installation position as the half-barrel section and fastening machine move in a continuous, rather than pulsatile, manner.

[0019] Figure 4D is a schematic of the fastening machine of Figure 4B and Figure 4C , in a third installation position as the fastening machine and half-barrel section move.

[0020] Figure 4E is a schematic of the fastening machine after the fastening machine has transitioned back to a starting position to install a new frame to the half-barrel section.

[0021] Figure 5 is another perspective view of a frame being fed under a half-barrel section of a fuselage prior to installation in an illustrative implementation.

[0022] Figure 6 is an end view of a frame being fed under a half-barrel section of a fuselage prior to installation in an illustrative embodiment.

[0023] Figure 7 is a flowchart showing a method of acquiring datums for installing a frame in an illustrative embodiment.

[0024] Figure 8 is a flowchart showing another method for installing a frame in an illustrative embodiment.

[0025] Figure 9 is a flowchart depicting a method for acquiring a datum plane in an illustrative embodiment.

[0026] Figure 10 is an end view of a frame in an illustrative embodiment.

[0027] Figure 11 is a flowchart showing a method for operating a line assembly system to install a frame in an illustrative embodiment.

[0028] Figure 12 is a diagram depicting indexing of an assembly to a work station in an illustrative embodiment.

[0029] Figure 13A and Figure 13B is a flowchart showing another method for operating a line assembly system to install a frame in an illustrative embodiment.

[0030] Figure 14 is a flowchart showing another method for operating a line assembly system to install a frame in an illustrative embodiment.

[0031] Figure 15 is a flowchart of an aircraft production and service method in an illustrative embodiment.

[0032] Figure 16 is a block diagram of an aircraft in an illustrative embodiment.

[0033] Figure 17 is a perspective view of an aircraft in an illustrative embodiment. DETAILED DESCRIPTION

[0034] The accompanying drawings and the following description provide exemplary and non-limiting specific embodiments of the present disclosure, which relate to the manufacture of a bow section (also referred to as a half-barrel section) of an aircraft fuselage. It will be understood, therefore, that those skilled in the art will be able to design many arrangements that, although not explicitly described or shown herein, embody the principles of the disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of the disclosure, and are to be construed as being without limitation to such specifically recited examples and conditions. Thus, the present disclosure is not limited to the specific embodiments described below, but is defined by the claims and their equivalents.

[0035] Traditional aerospace manufacturing processes typically utilize large, complex single processing cells with complex end effectors and large motion envelopes, which can result in poor job density (job density defined as the number of value added ("VA") touch points on the product in any case) and poor process equipment packing density (packing density defined as the number of people and equipment working on the product in parallel). Traditional setups can also require large queue areas and can result in large non-recurring (NR) as well as large recurring, flow, and footprint requirements. Thus, traditional aerospace manufacturing cell methods, which focus on a single process performed within a particular cell, can be considered to have certain disadvantages.

[0036] As described above, as currently practiced, specific components of the airframe are manufactured and assembled on the factory floor in these single processing cells. For example, a skin of an aircraft can be assembled at a processing cell, and then transferred to a new processing cell where, for example, a frame is installed to the skin to form a section of the fuselage. If a particular portion of the fuselage section takes longer than expected, the entire fuselage section remains in that particular processing cell until all of the necessary work that has been delayed is complete. Alternatively, the necessary work that has been delayed must be completed later in another processing cell (in addition to the work already scheduled for that processing cell), which increases the difficulty of manufacturing the components in a timely and efficient manner. Thus, this traditional aerospace manufacturing process is unable to establish a work flow that results in high productivity.

[0037] Some advantages of the present invention include synchronization of multiple different processing stations with the pulsed time or linear velocity of the design. Thus, as the assembly moves along the production line for processing at different processing stations to increase throughput, an appropriate production line velocity can be achieved. The disclosed system utilizes structural components that can achieve higher job density and processing equipment packaging density than traditional aircraft honeycomb stations. The system includes simplified frame reference fixed stations, described in more detail below, that are used to define a frame reference plane of a frame that is connected to the arc segments as they move linearly along the line assembly. The system employs a modular design with lean right-sized equipment to support production line mobility reliability and modular growth options. The modular design results in specific job zones that utilize purpose-built lean right-sized modular equipment designed to work in close proximity to other equipment and workers. The modular design of the disclosed system allows for quick change repair and maintenance built into the line assembly design. The system allows for referencing and indexing of frames, door surrounds, window surrounds, system fittings / brackets / subassemblies, and installation of blankets, NDI, and drill / edge trim. The system includes at least one processing station to remove manufacturing allowances to simplify further processing at upstream processing stations.

[0038] The frames can be made of metal or can be implemented as composite parts. Composite parts, such as carbon fiber reinforced polymer (CFRP) parts, are initially laid up in multiple layers, referred to as preforms. The individual fibers within each layer of a preform are aligned parallel to one another, but different layers can exhibit different fiber orientations in order to increase the strength of the resulting composite part along different dimensions. The preform can include a cured, viscous resin in order to harden the preform into a composite part. Carbon fibers that have been impregnated with uncured, thermoset or thermoplastic resin are referred to as "prepregs." Other types of carbon fibers include "dry fibers" that are not impregnated with thermoset resin but can include a tackifier or adhesive. Dry fibers can be impregnated with resin prior to curing. For thermoset resins, hardening is a one-way process referred to as curing, whereas for thermoplastic resins, they can reach a viscous form if re-heated. While the present embodiments disclose equipment, systems, and processing methods for manufacturing fuselage segments using composite parts, these same equipment, systems, and methods can also be used to manufacture metal segments of fuselages.

[0039] Current industry practice utilizes techniques that manufacture aircraft fuselages using quarter panels or single-piece barrel structures. The disclosed systems and processing methods are particularly useful in manufacturing the half-barrel sections of the fuselage because the half-barrel structure provides an optimized product design to achieve higher job density and processing equipment assembly density (because each station can have 3 or more job zones) and increase parallel processing. The greater number of job zones per station and the number of in-line stations that parallel process the half-barrel sections are advantageous and can improve productivity.

[0040] Figure 1 A block diagram of a flowline assembly system 100 that includes a frame installation station 140 in an illustrative embodiment. The flowline assembly system 100 includes any system, device, or component operable to repeatedly pulse a half-barrel section 120 of a fuselage along a track 110 a distance less than its length. The half-barrel section 120 is also referred to herein as a “section of a fuselage,” “section of the fuselage,” and “arch section,” and is identified by reference number 120. The flowline assembly system 100 is also capable of installing a frame on the half-barrel section 120 along an inner mold line (IML) 128 while the half-barrel section 120 is paused between pulses. The IML 128 defines an inner surface of the half-barrel section 120. While the flowline assembly system 100 is primarily disclosed in the form of a pulsed flowline assembly system, the same flowline assembly system can be implemented with certain modifications (disclosed in greater detail below) to form an assembly system that moves continuously on a flowline.

[0041] The half-barrel section 120 includes a portion of a fuselage, such as a section of a fuselage that is approximately forty feet long. In some embodiments, the half-barrel section 120 includes a hardened composite component or a metallic component, such as a section of an aircraft skin that is waiting to have a frame installed to enhance stiffness. The half-barrel section 120 includes an outer mold line (OML) 122 and an IML 128, and defines a recess 126 in which a frame 142 is aligned and installed. Figure 17 An aircraft manufactured from a plurality of half-barrel sections 120 is shown, the half-barrel sections 120 connected together to form a composite fuselage of the aircraft.

[0042] In this embodiment, the flowline assembly system 100 includes a track 110 along which the half-barrel section 120 is pulsed in a process direction (PD) 130. The flowline assembly system 100 also includes a frame installation station 140 that is operable to install a frame 142 on the half-barrel section 120 while the half-barrel section 120 is paused between pulses. Figure 1The semi-tubular segments 120 are moved along the tracks 110 on the "process direction 181. The tracks 110 include one or more tracks, rollers, or other elements that facilitate movement (e.g., rolling or sliding) of the semi-tubular segments 120 along the tracks 110. In further embodiments, the tracks 110 include chain drive devices mounted to a series of posts 114 (also referred to as "pogos") that advance in the process direction 181, motorized trolleys, powered or unpowered rollers 116, or other powered systems that are capable of moving the semi-tubular segments 120 in the process direction 181. As disclosed herein, even if one of the modular devices fails and needs to be replaced, the assembly line system will utilize redundant modular drive devices to support high line movement reliability and maintain movement of the assembly line system.

[0043] The assembly line system 100 also includes indexing units 130. Each indexing unit 130 is designed to physically couple with a feature 124 (e.g., a machined feature such as a hole or slot) in the semi-tubular segments 120. The features 124 are located at known positions along the semi-tubular segments 120 (e.g., along the arc and / or along the length of the semi-tubular segments 120), and in embodiments, each of the features 124 are separated by the same distance along the semi-tubular segments 120. In further embodiments, the spacing of the features in the manufacturing allowance varies along the length of the semi-tubular segments, as does the distance from the support edge 113 of the semi-tubular segment 120 that contacts the tracks 110. The shape, arrangement, and / or size of each feature 124 can be varied as needed to communicate a particular message to the frame installation station 140 when mated with a complementary feature. For example, placement of an indicator feature having a first shape in a first position can indicate that a first type of frame is desired to be installed, while placement of an indicator feature having a second shape in a second position can indicate that a second type of frame is desired to be installed. The 3D representation of the IML and / or OML layup of the portion of the semi-tubular segment that is within the field of view of the frame installation station 140 is known when the indexing unit 130 is mated with the indexing feature 124, as is the operation to be performed by the frame installation station 140. In further embodiments, the features 124 are arranged in a manufacturing allowance 129 of the semi-tubular segments 120 that is trimmed off prior to the semi-tubular segments 120 going into service. In further embodiments, the manufacturing allowance is in the form of windows 170 and doors 180 that will be cut off from the semi-tubular segments 120 by trimming after frame installation has occurred.

[0044] In this implementation, each indexing unit 130 includes complementary features 134 for insertion into, holding, or otherwise cooperating with features 124. Indexing units 130 are placed in fixed, known positions relative to frame mounting station 140 and track 110. During assembly, a half-barrel segment 120 is pulsed a distance (e.g., a distance at least equal to the shortest distance between features 124), indexed to an indexing unit 130, and processed by frame mounting station 140. That is, a half-barrel segment 120 is pulsed to an indexing position. As long as features 124 in the half-barrel segment 120 and complementary features 134 in the indexing unit 130 match, the position of the half-barrel segment 120 is indexed to a known position in a coordinate space shared by track 110, indexing unit 130, and frame mounting station 140. Specifically, each indexing unit 130 is arranged at a known offset (O) from frame mounting station 140 (e.g., along three axes), which means that the act of indexing a half-barrel segment 120 to an indexing unit 130 results in a known position of the half-barrel segment 120 relative to frame mounting station 140. When the complementary features 134 cooperate with the indexing features, the IML and / or OML of the portion of the half-barrel segment within the view of station 140 and the operation to be performed by frame mounting station 140 are known. In one implementation, this knowledge comes from retrieving a prior scan of the half-barrel segment (or portion thereof) and aligning the scan with position information obtained from indexing unit 130. In another implementation, this knowledge is obtained by reading a radio frequency identifier (RFID) chip embedded in the half-barrel segment proximate to indexing unit 130. Indexing units 130 can also be provided at specific indexing stations.

[0045] In one implementation, indexing is performed at least according to the following description. A structure in the form of a half-barrel is carried on a track comprising a track system connected to a floor. The track is in a known position. The barrel segment has been manufactured on a layup mandrel according to precise dimensions, and this precise layup enables indexing features to be precisely positioned in the manufacturing tolerance of this barrel segment. Thus, once the half-barrel is positioned on a precisely positioned track (and possibly also additional inner mold line (IML) or outer mold line (OML) forcing tools provided upstream or downstream of the station), the 3D position and rotation of the barrel segment are precisely known when the indexing features are engaged, without the need for a full scan by probes or optical techniques at each station.

[0046] The relative stiffness of the barrel segment, whether relying on the demolding or otherwise formed, can help the half barrel segment maintain the desired profiling / IML / OML with precisely positioned rails and without any substantial shape defining tooling during pulsing assembly. In this arrangement, these features are precisely positioned in the barrel segment with respect to the profiling / IML / OML of the structure, and these precisely positioned rails help carry the half barrel segment from one station to another without distortion. Thus, the 3D position and orientation (e.g., including profiling / IML / OML) of the machine barrel segment is quickly and precisely characterized (i.e., indexed) after each pulse (or continuous movement) without the need to rescan the machine barrel segment each time. Again, the indexing process conveys the 3D characterization of the IML and / or OML profiling of the portion of the half barrel segment within view of the particular station, as well as which operation the station will perform. In some embodiments, the indexing indicates that no operation will be performed on the portion of the half barrel segment at the station.

[0047] Due to the precise indexing performed, the frame mounting station 140 knows exactly where the half barrel segments 120 are positioned relative to the half barrel segments 120 when they are locked into place by the indexing unit 130 at the frame mounting station 140, as well as which operation the frame mounting station will perform (e.g., by reference to the RFID determined during indexing). It is possible that no operation will be performed at a particular station, which enables maintenance to be performed at that station. The 3D position and orientation and / or profiling / IML / OML of the half barrel segment is then established or indexed into any numerical control (NC) programming or automation system used at that station. Thus, no setup time or scanning is required after each pulse (or continuous movement) of the half barrel segments 120. Furthermore, structures added to or removed from the half barrel segments 120 in existing stations can be added to any half barrel model or representation within the system 100 without the need to scan the half barrel segments for the changes.

[0048] Indexing of the half barrel section 120 of the fuselage can be performed by aligning the half barrel section 120 to the indexing unit 130. The frame mounting station 140 has a known relationship to the indexing unit 130, so this also indexes the half barrel section 120 to the frame mounting station 140. When the half barrel section 120 and the frame mounting station 140 are in the known relationship, the frame 142 loaded by the frame mounting station 140 is inherently indexed to the half barrel section 120 because the frame 142 itself is already in a known relationship to the frame mounting station 140. Thus, indexing an arcuate section of a fuselage, such as the half barrel section 120, can include mating a feature 124 located on the half barrel section 120 to a complementary feature 134 at the indexing unit 130, the indexing unit 130 having a known physical offset from the frame mounting station 140, such that the mating immediately results in the half barrel section 120 having a known position relative to the frame mounting station 140. This is because the complementary feature 134 at the indexing unit 130 is pre-positioned and sized to fit the half barrel section 120 in one particular and precisely determined position.

[0049] The frame mounting station 140 includes a loader 150 that feeds the frame 142 from a location outside the recess 126 into the recess 126 for alignment. The frame 142 is provided by a feeder line 191 that manufactures and supplies the frame just-in-time (JIT) to the frame mounting station 140 in the order and direction required for installation. Thus, the frame JIT arrival at the frame mounting station 140 includes the last portion of the feeder line for the frame.

[0050] The loader 150 includes a powered or gravity loading device for feeding the frame 142. In one embodiment, the feed frame 142 includes a longitudinal feed frame 142 under the arcuate section of the fuselage. The frame installation station 140 also includes an alignment tool 160 disposed within the recess 126 of the half barrel section 120. The alignment tool 160 is configured to align the frame 142 to a position along the IML 128 of the half barrel section 120. In one embodiment, the frame 142 is fed under the support edge 113 of the half barrel section 120 in an arcuate orientation that matches the arcuate IML of the half barrel section 120. This enables the frame 142 to be placed against the IML without needing to re-orient the frame. The alignment tool 160 can include a robotic arm, zero gravity arm, actuated device, or other machine. A fastening machine 144 (e.g., end effector, drill, automatic latching installation machine, etc.) installs the frame 142 by temporarily fastening the frame 142 into place or otherwise attaching the frame 142, and then installing fasteners 146 that permanently secure the frame 142 into place along the circumferential arc of the half barrel section 120 or any arc formed by the frame 142. It should be appreciated that the frame 142 need not be formed as a 180° arc to directly match the circumferential arc of the half barrel section 120, but can be formed as a smaller arc, such as a 60 or 90° arc, which can be spliced together to match a larger circumferential portion of the half barrel section 120. A frame splicing station 190 or apparatus for splicing frames together is described in more detail below.

[0051] It should be appreciated that more than one fastening machine 144 can be used on the frame installation station 140. Multiple fastening machines 144 with limited reach can operate in parallel with a worker positioned close to the fastening machines 144, while the inline assembly system 100 is pulsatingly or continuously feeding the half barrel sections 120 along the track 110. Thus, the work of the machines and the worker can be synchronized while the worker stands within the recess 126 of the half barrel section 120.

[0052] In one embodiment, the frame installation station 140 includes one of a plurality of stations disposed along the track 110 and spaced less than the length of the half barrel section 120, such as a “frame pitch,” which can for example equal the distance between frames. Figure 5Several frame spacing locations 397 are shown extending along the length of the arc segment 320. The operations performed by the other stations (also referred to as "processes") can include installing new components onto the half-barrel segment 120 via fasteners, removing material (e.g., drilling or trimming), adding material, etc. In one embodiment, each station performs one type of operation, such as but not necessarily limited to installing frames, installing door surrounds, installing window surrounds, installing ribs, cutting door holes, non-destructive inspection (NDI), sealing, and / or cutting window holes. In another embodiment, it can be desirable to install structures such as frames, door surrounds, and window frames onto the half-barrel prior to manufacturing the large cutout. This would allow the structure (the shell of the half-barrel) to be as rigid as possible during the holding / indexing / transferring process in order to better / more accurately index the process and / or components. As part of the installation process, these installed various components can be positioned and indexed relative to the half-barrel segment 120. For example, a cup-cone indexing system can be used to place the parts onto the half-barrel segment, and a hard stop indexing can be used to index the half-barrel segment 120 to another operation station.

[0053] In this embodiment, a frame splicing station 190 is also shown. The frame splicing station 190 splices adjacent frames together to form an integrated frame that occupies a larger circumferential portion of the half-barrel segment 120. For example, in an embodiment where the frames 142 form ninety degree arcs, the frame splicing station 190 performs a single splice to combine two frames 142 into a one hundred eighty degree frame. In an embodiment where the frames form sixty degree arcs, the frame splicing station 190 performs two splices to combine three frames at the same location along the length of the fuselage into a one hundred eighty degree frame. In one embodiment, the frame splicing station 190 applies fasteners and a splice plate that overlaps the two frames being spliced in order to structurally unite the frames. The joint can be made at the flange web of the frames and / or across one or more flanges of the frames.

[0054] The operation of the frame installation station 140 and / or other stations is managed by a controller 112. In one embodiment, the controller 112 determines the progress of the half-barrel segment 120 along the track 110 (e.g., based on input from a technician, according to an automated process, such as input from a camera or a physical sensor, such as a linear or rotary actuator), and uses that input to manage the operation of the frame installation station 140 according to instructions stored in a numerical control (NC) program. The controller 112 can be implemented as, for example, custom circuitry, a hardware processor executing sequential standard operating program instructions, or some combination thereof.

[0055] In further embodiments, similar to Figure 1The illustrated system and stations are for wrap-around installation of windows or doors. In such embodiments, wrap-around elements entering the work stations at the end of the feeder line are aligned for IML installation, OML installation, and / or passage through a half barrel section housing. Fasteners and similar components are fed into the work stations in a manner similar to Figure 1 the feeder line for the frame in the middle is fed into the work station at the end of the feeder line.

[0056] In all of the stations, there will be multiple work zones within and adjacent to the stations so that efficient parallel processing can be performed by people, equipment, and / or both in close proximity to each other. This is a component of the drive for single purpose simplicity, limited functionality, and machine motion of the equipment. It is a safety design issue for the operator, and it is a productivity, maintainable, modular design concept unique to aerospace applications. Conventional aerospace processing using large, complex single processing cells with complex end deflectors and large motion envelopes typically results in poor work and processing assembly density.

[0057] Reference will be made to Figure 2 discuss illustrative details of the operation of the line assembly system 100. For this embodiment, it is assumed that one or more half barrel sections 120 have been placed sequentially on the track 110 and are ready to receive a frame for installation.

[0058] The gap between adjacent half barrel sections in-line is an operational management lever for increasing available monthly time (ATV) and supporting line mobility reliability requirements. As a result of this continuous flow line design, new operational management and maintenance strategies can be pursued.

[0059] Figure 2 is a flowchart illustrating a method 200 for operating a line assembly system to install a frame in an illustrative embodiment. Reference is made to Figure 1 the line assembly system 100 of FIG. 1 to describe the steps of the method 200, but those skilled in the art will appreciate that the method 200 can be performed in other ways. The steps of the flowchart described herein are not all inclusive and can include other steps not shown. The steps described herein can also be performed in alternative orders. Furthermore, although the steps are described herein with respect to half barrel sections, they can be applied to any suitable arcuate segment of a fuselage, such as a full barrel section, a quarter barrel section, or other segment size.

[0060] Generally, the workpiece is divided into product lengths, and the process operation is 5% to 10% of the product length, which is true for both pulsed and continuously moving assembly line systems 100. In the case of a continuously moving line, the length product moves during an equal pulsed time. In step 202, the bow section of the fuselage is pulsed along the track 110 in the process direction 181 less than the length of the bow section. In step 202, the half barrel section 120 is pulsed along the track 110 in the process direction 181 (e.g., along the length of the track 110) less than the length of the half barrel section 120, or even its entire length. The half barrel section 120 is pulsed to incrementally expose new portions of the half barrel section 120 for receiving work from the frame installation station 140. The distance traveled in the pulse can equal, for example, the distance between frame positions (i.e., the frame pitch) at the half barrel section 120. Of course, other pulse lengths are possible. In implementations where the track 110 is driven, this includes driving one or more elements of the track to move the half barrel section in the process direction 181. Generally, redundant drives can be placed along the length of the track 110, which will be integrated in the entire indexing and movement system. In further implementations, this includes operating an autonomous guided vehicle (AGV), or operating a powered cart mounted to the track 110, in order to pulse the half barrel section 120 along the track 110 to the desired position. In implementations where additional sections of the fuselage are disposed on the track 110, the additional sections are also pulsed or continuously moved less than the length of the half barrel section 120 in synchronization with the pulse of the half barrel section 120 shown. Figure 1 The half barrel section 120 is pulsed or continuously moved less than the length of the half barrel section 120 in synchronization with the pulse of the half barrel section 120 shown.

[0061] In step 204, the bow section is indexed to the frame installation station. In step 204, the half barrel section 120 is indexed to the track 110. In one implementation, this includes mating the feature 124 in the half barrel section 120 with a complementary feature 134 that is fixed relative to the track 110 at a known offset of the frame installation station 140 at the track 110. For example, a pin disposed at the track 110 can be inserted into a hole that has been machined into the half barrel section 120 at a predetermined interval. In further implementations, any suitable indexing technique and system can be used to arrange the half barrel section 120 in the desired relationship with the frame installation station 140. After the half barrel section 120 has been indexed, the position of the half barrel section 120 relative to the frame installation station 140 is known (i.e., because the offset from the indexing unit 130 to the frame installation station 140 is known). Thus, work can be performed at a desired level of precision (e.g., within a fraction of an inch) even for very large structures. In implementations where multiple sections of the fuselage are traveling along the track 110 simultaneously, the indexing of the half barrel section 120 can be performed synchronously.

[0062] The indexing of the frame 142 at step 204 will likely include hard machining surface references both circumferentially and forward / backward. It is composed of common reference surfaces for multiple sections. This means that a simple fixture in the frame installation station 140 for indexing frames in the production line can position all frames 142 in the sections within the production line. This structure can provide manufacturing simplification and can result in significant reductions in machining and costs. In a traditional aerospace fixed cell manufacturing system, a larger tool including a fixture for each frame is typically required, or 2) duplicate machining and capital costs can be incurred due to the need to put in hole positioning features to position the frame 142 relative to the half barrel section 120. This simple standard work reference and indexing used herein can help reduce non-recurring and recurring costs for both the suppliers that manufacture the frames 142 or other components and the line operators and suppliers that manufacture the skin / stringer half barrel sections 120.

[0063] In step 206, the frame is fed at the frame installation station into the recess defined by the arcuate section. In step 206, the loader 150 feeds the frame 142 at the frame installation station 140 into the recess 126 defined by the half barrel section 120. In embodiments in which the half barrel section 120 travels on overhead rails, this includes the loader 150 feeding the frame below the edge of the half barrel section 120 that contacts the rails 110 and / or below the rails 110 (e.g., below their edges). For example, this can include pushing the frame through a feeder nip below the arcuate section. Because the frame 142 is curved to match the profile of the IML 128, the frame 142 presents a profile many feet long (e.g., matching the desired IML radius of the half barrel section 120), even though the frame itself has a cross section only a few inches wide. To be able to load frames of these dimensions, in one embodiment, the loader 150 rotates the frame 142 as it feeds the frame 142 so that the frame is curved below the longitudinal edge of the half barrel section 120 as it is fed (as shown). Figures 3 to 5

[0064] ​In step 208, the frame is placed against the inner mold line of the arcuate segment while the frame is in the recess. In step 208, based on the indexing in step 202, the alignment tool 160 places the frame 142 against the IML 128 of the half-tube segment 120 while the frame 142 is in the recess. In one embodiment, this includes the alignment tool 160 lifting, rotating, and pressing the frame 142 against the IML 128 via a zero-gravity arm or robotic arm, or even via a manual process. That is, the frame 142 is clamped to the outer skin forming the half-tube segment 120 when the frame 142 is aligned. This arrangement is based on the indexing in step 202, as the indexing conveys a representation of the position of the half-tube segment 120 along the track 110, and depending on the embodiment can further indicate the loft of the half-tube segment 120 and / or the characteristics of the IML 128.

[0065] In step 210, the frame is secured to the arcuate segment. In step 210, the fastening machine 144 secures the frame 142 to the half-tube segment 120. In one approach, securing the frame is performed during a pause between pulses of the arcuate segment in the process direction 181 (e.g., by the frame pitch). In one embodiment, the frame 142 is positioned along the IML 128 by feeding the frame 142 under the support edge 113 of the half-tube segment 120 in an orientation that matches the IML 128 of the half-tube segment 120. This approach further includes connecting the frame 142 with the alignment tool 160 to facilitate placing the frame against the IML. In one embodiment, this step includes the fastening machine 144 clamping the frame 142 to the IML 128, drilling holes through the IML 128 and the frame 142, and installing fasteners. Steps 206 through 210 can be repeated as needed until all of the frames have been installed along a portion of the length of the half-tube segment 120. Then, the operations can proceed to steps 202 and 204, followed by again repeating steps 206 through 210. These operations can continue until the half-tube segment 120 has received frames along its length (e.g., after having been moved a distance at least equal to its length).

[0066] Method 200 provides technical benefits over prior art techniques, as it enables the implementation of line-based assembly techniques on large structures such as aircraft fuselages. Because this technique moves the large structure in small increments (e.g., 2 to 8 feet, frame pitch (i.e., the distance between frame installation stations), etc.), it also reduces the amount of work to be done in each job interval, which reduces the risk of delays and the potential length of such delays.

[0067] Figure 3is a perspective view of the frame 350 being fed under the longitudinal edge of the barrel section 320 of the fuselage prior to installation in an illustrative embodiment. Although not shown, in certain embodiments, stringers and / or ribs can be installed onto all or a portion of the barrel section 320, where the stringers are not co-cured with the barrel section.

[0068] The barrel section 320 defines a recess 326, and has IML 328, and moves along rollers 314 of the column 312 at the track 310. The barrel section 320 also includes indexing features 322, also referred to herein as machined features 322, in the form of holes that index to indexing units 330 on either side thereof. Other types of features are also possible. During the campaign, the barrel section 320 is moved along the track 310 to expose a new longitudinal portion to one or more stations. During each pulse, the barrel section 320 is advanced a distance (which is less than the length of the barrel section, and can be equal to the length of a longitudinal portion thereof). The machined features 322 within the barrel section 320 are separated by a spacing I that is less than P. However, in further embodiments, the machined features 322 are separated by more than P. Moreover, although the machined features 322 are shown to be linearly aligned and similarly shaped, in further embodiments, the machined features 322 need not be so. After each pulse ends, the machined features 322 cooperate with the indexing units 330, and the frame is installed.

[0069] In this embodiment, the frame installation station 340 comprises a fixed arcuate half-ring structure 345 (or a half-ring that is movable relative to the station 340) on which the half-tube segment 320 travels during pulsing. The frame installation station 340 installs frames at the longitudinal portion of the half-tube segment that is within the frame installation station’s view at the track. The movement of the half-tube segment 320 exposes a new longitudinal portion of the inner mold line (IML) of the fuselage to the machines disposed along the fixed half-ring structure 345. After the half-tube segment 320 is paused, it is clamped for frame installation. In one embodiment, the physical engagement formed between the indexing unit 330 at the track 310 and the half-tube segment 320 causes the half-tube segment 320 to resist the applied force. This enables the frame installation station 340 to perform a single-up assembly (OUA) process, in which a single alignment machine 420 is pressed against the half-tube segment 320. That is, the force applied by the alignment machine 420 is transmitted to the indexing unit through the physical engagement / connection between the half-tube segment 320 and the indexing unit. Because the indexing unit is fixed relative to the fixed half-ring structure 345, the force is borne without movement of the half-tube segment 320. This enables the clamping force between the half-tube segment 320 and the machine to reach the required level as the machine works. Furthermore, the clamping load from the over-up assembly (OUA) operation can be transmitted through the IML or OML reinforcement structure (e.g., via the fixed half-ring structure 345) as needed. During operation, the frame 350 is loaded underneath the half-tube segment 320 and enters the recess 326 through the gap G before the frame 350 is aligned with and installed at the frame installation location 360.

[0070] Downstream of the frame installation station 340, additional stations can perform work on the half-tube segment 320, such as by installing surrounds for doors and windows, or closing the doors and windows. These stations can even be located only the frame spacing away from the frame installation station 340, or a different distance.

[0071] Furthermore, in some embodiments, window cut-outs are performed downstream in the same half-tube segment after frame installation or during frame installation, such as by a cut-out station 370 disposed downstream of the frame installation station 340. The cut-out station 370 cuts out windows 372 or doors at predetermined locations, and can operate during the same pause as the frame installation station 340. Thus, Figure 3 The arrangement of stations in the line assembly system 100 enables multiple stations to work on different portions of the half-tube segment 120 within their station’s view during the same pause (regardless of whether the line assembly system 100 is pulsed or continuous in-line).

[0072] In one embodiment, a cut-off station 370, disposed downstream of the frame installation station, cuts off material from the longitudinal portion of the frame previously received from the frame installation station 340 after the half-tube section 320 of the fuselage is advanced through the frame installation station 340, and the longitudinal portion enters the field of view of the cut-off station. In another embodiment, the cut-off station 370 cuts off material from a second longitudinal portion while the frame installation station 340 installs a first longitudinal portion.

[0073] Using the above techniques, multiple operations can be performed on one pulsed half-tube section at the pitch of one frame (or any pitch less than half the length of the half-tube fuselage section). In further embodiments, the operations of non-destructive imaging (NDI) frame installation, window surround installation, shearing and final trim, and edge sealing can be performed serially during the same pause on the same half-tube section.

[0074] The advantage of using multiple workstations and multiple production lines is that the components, standards, consumables, tools, etc. used in the workstations are compatible. Scrap from previous numbers of pulsed lengths can be more easily handled and removed from the system 100. Thus, due to the integrated material flow of inputs and outputs with the integrated system, production rates can be increased, which can result in reduced per unit repeat costs and reduced capital costs to produce a given number of units per month. The integrated flow in the assembly line system can enable the production line to be efficiently worked due to the work processes being synchronized to be repetitive standard workstations.

[0075] Figure 4A is a side view of the frame 350 fed under the half-tube section of the fuselage prior to installation in the illustrative embodiment, and corresponds to the view arrow 4 of Figure 3 Although each frame is shown here as having a longitudinal length L and occupying a 180 degree arc of the IML, in further embodiments, the frames can occupy any suitable arc and then can be spliced together into a complete ring.

[0076] In one embodiment, the frames 350 do not extend to the extent of the manufacturing allowance to the support edge 329. That is, there is a gap of height H between the bottom of the frame 350 and the support edge 329. This arrangement provides additional clearance that facilitates movement along the track 310 and subsequent installation of splice plates between the half-tube sections of the fuselage. The frames 350 can be connected subsequently by a stub frame (not shown) or other components. In one embodiment, the frames 350 remain recessed into the arcuate periphery of the half-tube sections of the fuselage, they are installed into the half-tube sections of the fuselage, and occupy less than 180 degrees of circumference. In yet another embodiment, the frames 350 are installed full length, and then cut to the required length after installation to accommodate splice plate installation or other operations.

[0077] The longitudinal length of the frame 350 during the installation process is rotated 90 degrees from the length of the half barrel section 320 during the installation process. Figure 4A A device 400 in the form of a loader 410 including a motor 412 is also shown. The motor 412 drives pinch rollers 414 that form a feeder nip 415 to move the frame 350 under the half barrel section 320 and into the recess 326 while also rotating the frame 350 about the center point C. Specifically, the frame 350 is pushed under the longitudinal edge 329 of the barrel section 320 by the feeder nip 415 created by the powered pinch rollers 414. The frame 350 is oriented to be placed within the half barrel section 320.

[0078] Briefly, the loader 410 includes pinch rollers 414 disposed under / at the support edge 329 of the arcuate section (e.g., the half barrel section 320) of the machine body that is supported by rollers 314 connected to uprights 312 (e.g., struts). In further embodiments, the pinch rollers 414 are attached to the support edge 329 of the machine body section and roll along a continuous track mounted to the uprights 312, creating a “roller skate” at the arcuate section (e.g., the half barrel section 320). The arcuate section includes a downward facing recess 326. The motor 412 drives the pinch rollers 414 to advance the frame 350 under the support edge 329 and into the recess 326 via a gap (G) between the struts (e.g., columns 312). Figure 3 The pinch rollers 414 form a feeder nip 415 for driving the frame 350 into the recess 326 of the half barrel section 320. The pinch rollers 414 drive the frame 350 in a direction perpendicular to the process direction 181 of the arcuate section (e.g., the half barrel section 320) of the machine body, and the pinch rollers 414 feed the frame 350 to the alignment machine 420 of the frame installation station 340.

[0079] The frame 350 that has entered the recess 326 is acquired by an alignment machine 420 that operates an actuator 422 to drive the frame into position. In further embodiments, loaders 410 are disposed on either side of the half-tube segment 320 and each loader rotates and moves a frame into the recess 326. However, in further embodiments, the alignment is performed manually. In such embodiments, the loader on the left side 399 of the half-tube segment 320 provides for mounting frames on the right side and the loader 410 on the right side 398 of the half-tube segment 320 provides for mounting frames on the left side 399. In another embodiment, the frames are held in place with temporary fasteners and a "drill and fill" installation is facilitated. The fastening machine 430 installs the frame 350, for example, by clamping the frame to the IML 328, by drilling, and by installing fasteners 146. In further embodiments, the frame 350 for one frame installation station 340 can be installed on the left side while the frame 350 for another frame installation station, for example, downstream of the upstream station, can be installed on the right side and engaged to the left side frame. This technique can be used to engage frames that occupy less than a one hundred eighty degree arc, for example, a ninety degree arc or a sixty degree arc. A certain amount of permanent fasteners with the above-described multiple synchronizers can fasten the frame 350 or frame portions to the half-tube segment 320 within a dispensing pulse time or interval time for a continuous moving line. If a continuous in-line assembly system is used, the various processing equipment and support tools / devices must move with the continuously moving half-tube segment. Once the frame 350 is secured to the half-tube segment 320, the equipment pulses back to the starting installation point for the next frame installation or other processes as described below.

[0080] Figures 4B to 4E Mechanisms and processing sequences are shown that allow the frame installation station 340 to function as a continuous moving in-line assembly system. In this embodiment, the half-tube segment 320 moves continuously from one installation location to another installation location rather than in a pulsed manner.

[0081] In this embodiment, each fastening machine 430 is movably mounted to the arcuate half-ring structure 345 of the frame installation station 340 to allow each machine 430 to move along the arc of the half-ring structure 345. This frame installation system 340 includes a linear motion actuator 450 that allows each machine 430 to move simultaneously with the half-tube segment 320 in a linear process direction. In Figure 4BIn the middle, the process direction is indicated by arrow 181. The linear motion actuator 450 comprises a track 480 on which the machine 430 is movably mounted and which supports the machine 430 when it is moved in the process direction 181. A drive unit 470 is connected to the track 480 and provides the drive to move the machine 430 in a linear fashion. This drive unit 470 also allows the linear actuator 450 to be moved along the track 460 mounted to the half ring structure 345. This track can be arcuate to match the arcuate half ring structure 345 or can have a different configuration depending on the manner in which the machine 430 is secured for movement along the half ring structure 345. In addition, it will be appreciated that the manner in which the track 460 is coupled to the half ring structure 345 can vary depending on the structure of the frame mounting station 340.

[0082] In Figure 4B In the middle, the process direction is indicated by arrow 181. The linear motion actuator 450 comprises a track 480 on which the machine 430 is movably mounted and which supports the machine 430 when it is moved in the process direction 181. A drive unit 470 is connected to the track 480 and provides the drive to move the machine 430 in a linear fashion. This drive unit 470 also allows the linear actuator 450 to be moved along the track 460 mounted to the half ring structure 345. This track can be arcuate to match the arcuate half ring structure 345 or can have a different configuration depending on the manner in which the machine 430 is secured for movement along the half ring structure 345. In addition, it will be appreciated that the manner in which the track 460 is coupled to the half ring structure 345 can vary depending on the structure of the frame mounting station 340. Figure 4B In the middle, the process direction is indicated by arrow 181. The linear motion actuator 450 comprises a track 480 on which the machine 430 is movably mounted and which supports the machine 430 when it is moved in the process direction 181. A drive unit 470 is connected to the track 480 and provides the drive to move the machine 430 in a linear fashion. This drive unit 470 also allows the linear actuator 450 to be moved along the track 460 mounted to the half ring structure 345. This track can be arcuate to match the arcuate half ring structure 345 or can have a different configuration depending on the manner in which the machine 430 is secured for movement along the half ring structure 345. In addition, it will be appreciated that the manner in which the track 460 is coupled to the half ring structure 345 can vary depending on the structure of the frame mounting station 340. Figure 4B In the middle, the process direction is indicated by arrow 181. The linear motion actuator 450 comprises a track 480 on which the machine 430 is movably mounted and which supports the machine 430 when it is moved in the process direction 181. A drive unit 470 is connected to the track 480 and provides the drive to move the machine 430 in a linear fashion. This drive unit 470 also allows the linear actuator 450 to be moved along the track 460 mounted to the half ring structure 345. This track can be arcuate to match the arcuate half ring structure 345 or can have a different configuration depending on the manner in which the machine 430 is secured for movement along the half ring structure 345. In addition, it will be appreciated that the manner in which the track 460 is coupled to the half ring structure 345 can vary depending on the structure of the frame mounting station 340.

[0083] Figure 4C In the middle, the process direction is indicated by arrow 181. The linear motion actuator 450 comprises a track 480 on which the machine 430 is movably mounted and which supports the machine 430 when it is moved in the process direction 181. A drive unit 470 is connected to the track 480 and provides the drive to move the machine 430 in a linear fashion. This drive unit 470 also allows the linear actuator 450 to be moved along the track 460 mounted to the half ring structure 345. This track can be arcuate to match the arcuate half ring structure 345 or can have a different configuration depending on the manner in which the machine 430 is secured for movement along the half ring structure 345. In addition, it will be appreciated that the manner in which the track 460 is coupled to the half ring structure 345 can vary depending on the structure of the frame mounting station 340.

[0084] Figure 4DThe fastening machine 430 is shown further moved to a third mounting position. Here, the fastening machine 430 is again moved simultaneously with the half barrel segment 320. Also, the fastening machine 430 has again moved along the arc of the frame 350 to a new mounting position at which a new fastener 146 will be installed. The drive unit 470 simultaneously moves the fastening machine 430 and the linear motion actuator 450 along the arc length of the frame 350 to this new mounting position. While the disclosed embodiment utilizes three mounting positions, it should be understood that more or less mounting positions can be implemented during the fastening process. As Figure 4D shown, when the fastening machine 430 is in its extended position, the new frame 350 is moved to an initial starting position by movement of the half barrel segment 320.

[0085] In Figure 4E the fastening machine 430 has moved back to the initial first mounting position where it will initially engage the new frame 350. The same sequence of installing fasteners at different mounting positions along the frame 350 and half barrel segment 320 is repeated.

[0086] It should be understood that the linear motion actuator 450 disclosed above is merely one mechanism that can be implemented to move the fastening machine 430 with the half barrel segment 320 in a continuous motion, in-line assembly system. Additionally, other equipment (such as the alignment machine 420 of the system 300) can need to be moved with the half barrel segment. Such equipment can also be connected to the actuation device to allow the piece of equipment to move from an initial processing position through a work stroke and then back to the initial processing position to repeat a particular work process.

[0087] Figure 5 is another perspective view of the frame 350 being fed under the half barrel segment 320 of the fuselage in the illustrative embodiment prior to installation. According to Figure 5The fastening machines 512, 522 arranged along the combination of the inner half ring structure 530 and the inner half ring structure 520 and the outer half ring 510 operate together to facilitate clamping and installation of the frame 350. In this embodiment, the OML fastening machines 512 are also visible, as is one of the set of IML fastening machines 522 that are movably mounted to the inner half ring structure 520, 530. The IML and OML fastening machines 512, 522 operate in tandem to perform installation of the frame 350. The clamping machines 512, 522 can be mounted to rails or other mechanisms that enable each clamping machine 512, 522, 530 and the outer half ring structure 510 to move each fastening machine 512, 522 along a defined arc. It will be appreciated that more than one fastening machine 512, 522 can be associated with each half ring structure 510, 520, 530. In further embodiments, more than one frame installation station can be used. For example, multiple stations can be used in series along the length of the half barrel section 320 to install frames that occupy a 90 degree arc. Figure 5 Also shown is a frame spacing location 397 along the length of the half barrel section 320.

[0088] Figure 5 The illustrated system shows how the use of modular equipment (e.g. fastening machines 522) and the use of two inner half ring structures 520, 530 can maintain the flow of an inline assembly system in the event of failure of one of the fastening machines 522. For example, if the fastening machine 522 shown on the half ring structure 520 fails, another fastening machine 522 (not shown) located on the second half ring structure 530 can be programmed to perform the fastening process that would normally be performed by the failed fastening machine 522 located on the half ring structure 520. This feature allows a failed fastening machine 522 on the half ring structure 520 to be quickly replaced by another work cell without stopping or slowing the manufacturing.

[0089] Figure 6 is an end view of a frame 350 being fed under the arcuate section of the fuselage (including the half barrel section 320) prior to installation in an illustrative embodiment, and corresponds to Figure 5view plane (i.e., the face perpendicular to the page). (For example, by interacting with and mating to such index features installed into the manufacturing overhang 610 at the arcuate segments). The half-tube segment 320 includes a frame ridge 692 onto which the frame 350 will be installed. The frame 350 will be installed along the length of the half-tube segment 320 at the frame spacing location 397. A hard stop 694 establishes a plane in alignment with the frame reference plane 690 at the frame installation station 340. The frame 350 is pushed against the frame ridge 692 and the hard stop 694 to ensure alignment, and then the frame 350 is clamped into place and installed. The frame reference plane 690 is established by three or more points along the surface defined by the index features discussed in the Figure 10

[0090] In this embodiment, after the half-tube segment 320 of the machine body is pulsed / propelled into the page along the track 310 in the process direction 181, one or more index features (e.g., machined features 322) at the half-tube segment engage in contact with the index unit 330, which indexes the half-tube segment 320 to the frame installation station 340. Next, the frame reference plane 690 of the frame 350 is defined by physically mating the frame 350, the loader 410, and / or a portion of the fastening machine 430 to the surface defined by the index features. The index features can include pins or D / A holes, and the frame, loader, or machine can include pins that mate with at least three D / A holes (or a shape that defines a plane) to define the frame reference plane 690. For example, in an embodiment where the index features include pins, the frame 350 includes determinant assembly (D / A) holes that are slotted over the pins to obtain the reference plane. Thus, the positions of the pins and D / A holes can be reversed, such that the frame 350 is positioned by the fastening machine 430 with reference to the frame reference plane 690. In further embodiments, the D / A holes are used to temporarily secure the frame 350 into place prior to drilling and filling installation.

[0091] ​The baseline method will use a surface reference located on the frame 350. Specifically, the surface reference can be formed by a tool or machined reference surface as part of the frame manufacturing. In one particular embodiment of an inline assembly system, the surface reference can be a flat web portion of the frame 350 that is a fixed tool surface located in the first frame installation station. If the first installation station cannot complete all fastenings, then the next frame installation station will not have a fixed tool to position the frame. The next frame installation station will have additional fasteners to fully fasten the frame to the half barrel section. Another reference on the frame can be a trimmed edge on the frame that will be positioned by a tool surface on the tool fixture and will be either a longitudinal cut-off manufacturing allowance (end of section of part) or offset from the start point of the half barrel section. This method standardizes all frames for each section in the row. This simplifies the manufacturing of the frame and the fuselage skin stringer half barrel sections and makes it easier to automate the positioning of the frame to the fixture instead of positioning the D / A holes placed in the fuselage half barrel section and frame.

[0092] As used herein, the frame reference surface 690 includes a plane of the frame 350 (e.g., established by lidar, visual inspection, physical contact, etc.) or a surface along the IML of the half barrel section 320 that is contacted by the frame 350 after the frame 350 has been attached. The frame reference surface 690 for the frame 350 is obtained through the physical connection between the components of the frame installation station 340 and the half barrel section 320. In one embodiment, the frame reference surface 690 that facilitates installation of the frame 350 is obtained by aligning one or more matrix assembly (D / A) holes 652 (or surfaces) at the frame 350 with corresponding pins 650 or surfaces of the half barrel section 320. Thus, the frame reference surface 690 is based on one or more indexing features at the half barrel section 320. In one embodiment, a surface of the frame (e.g., a web or flange of the frame) is held against the D / A holes or other features in order to obtain the frame reference surface 690.

[0093] In one embodiment, the machined feature 322 is used to establish a frame reference surface 690 aligned with the web or flange of the frame (e.g., based on a lidar analysis). In another embodiment, a mechanical stop is used to establish the reference surface. That is, the frame web or flange can be brought to rest against a hard stop 694. In this embodiment, the frame reference surface 690 is coplanar with the web or flange of the frame, as the web or flange falls within a single plane. This system enhances the ease of positioning the frame relative to the fuselage. In this arrangement, the half barrel section of the fuselage is pulsed, the part is engaged, the frame is passed under the bearing edge of the section of the fuselage, and the frame reference surface 690 is positioned relative to the part. In one embodiment, this occurs automatically when the feature is engaged at the station, as the frame reference surface 690 can or can not be a moving component. The coplanar portion of the frame 350 is placed against the frame reference surface 690, and then the frame is fastened into place (e.g., by installation of a latch or other component).

[0094] Any suitable combination of these techniques can be used in order to obtain the frame reference surface 690 for indexing the frame relative to the half barrel section 320. There can be some variation in the frame or frame orientation that needs to be slightly different in each frame installation station 340. Thus, there can be slight variations in the half barrel section 320, in the frame installation station 340, and / or in the frame or intercostal to be installed. This information can be communicated through the indexing feature located in the manufacturing allowance 129 of the half barrel section 320. The frame installation station 340 is then alerted to the variation at the start of the pause, which facilitates the acquisition of the frame reference surface 690 described above.

[0095] In addition, this process or similar processes can also be used for other additional structures, such as surrounds for windows and doors, clips, antennas, etc. These structures can also be passed under the fuselage section as needed for installation on the IML of the fuselage section.

[0096] Figure 6 Further variations of the subject matter are also depicted, in which the indexing unit 330 includes a feature (e.g., a cup) that cooperates with a feature 642 (e.g., a frame landing feature in one embodiment, a pre-installed stringer in embodiments in which the indexing unit 330 is disposed at the IML of the half barrel section 320) that has a backing 644 that defines the frame reference surface 690. Using the variations described herein, the reference surface can be defined along the IML or OML of the half barrel section 320. In addition, features on one or both sides can be used to establish the relative position of the frame reference surface 690 relative to the feature, even when the feature is not within the frame reference surface. Thus, the feature can be integral with a parallel plane of the frame reference surface, or intersecting with the frame reference surface. In addition, Figure 6 Features 640 are shown placed on the loader 410 for connection with the pin 620 and to define the frame reference surface 690.

[0097] Figure 6 Also depicted is a fastening machine 430 that includes a feature (e.g., cup 660) that cooperates with pin 662 to define a frame reference surface 690. Fastening machine 430 acquires frame reference surface 690 by either holding frame 350 in contact with the indexing feature or by holding its own feature (e.g., cup 660) in contact with the indexing feature.

[0098] As described above, fastening machine 430 also attaches / secures the frame to the arc segment based on frame reference surface 690 (e.g., by placing a web or flange of frame 350 in contact with frame reference surface 690).

[0099] Further, Figure 6 Depicted is a braking machine 630 that includes an actuator 632 that drives a pin stop 634 that stops pin 620 and defines a frame reference surface 690 (e.g., along its front or back surface). Pin stop 634 receives half barrel segment 320. Frame 350 is placed against pin stop 634 to determine frame reference surface 690, and then frame 350 is indexed / positioned relative to half barrel segment 320. Thus, pin stop 634 holds contact with one or more features at half barrel segment 320 to acquire frame reference surface 690. In further embodiments, a laser, ultrasonic sensor, etc. establishes frame reference surface 690 for frame 350. For example, in one embodiment, the process includes identifying a planar region by the above-described techniques, or detecting a constellation of features that define a planar region to use as a reference surface. Further, D / A holes can be used to align with the reference surface or flange edge or web face as desired.

[0100] Various components of frame installation station 340 can also be used to establish a reference surface. For example, frame installation station 340 can include a fixture and / or sensor for establishing a reference surface that is accurate when the half barrel segment of the fuselage is engaged to the track at the end of each pulse. Such a fixture can be an arcuate structure that is complementary to the surface of the frame (e.g., frame web or flange) or to the frame (e.g., along the span of the frame).

[0101] In another embodiment, a plane is established within the frame installation station 340. The plane coincides with the frame pitch location 397 on the half barrel segment. Next, the frame reference is matched to the plane to determine the frame alignment relative to the half barrel segment at the frame pitch location 397. The frame is then installed onto the half barrel segment. Thus, the process includes aligning the frame reference to the plane located at the frame pitch location 397 of the half barrel segment. The plane is established relative to the frame pitch location 397 of the half barrel segment. This is how the frame is properly installed in the design location relative to the half barrel segment. The plane is used to ensure the frame is aligned and positioned relative to the half barrel segment at the frame pitch location 397. The frame pitch location 397 and the plane within the frame installation station 340 align the frame with the frame pitch.

[0102] Figure 7 is a flowchart depicting a method 700 of installing a frame in an illustrative embodiment. Step 702 includes moving an arcuate segment of a machine body including a frame ridge 692 in a process direction 181 until a frame pitch location 397 is within a field of view of a frame installation station. Step 704 includes feeding a frame into a recess defined by the arcuate segment. Step 706 includes performing a hoop alignment of the frame within the recess that positions the frame circumferentially within the frame ridge 692. Step 708 includes identifying a reference at a frame reference surface. Step 708 includes identifying a reference at a frame reference surface that establishes a plane within the frame installation station based on a matching of the reference to the frame pitch location. In one embodiment, the reference at the frame is selected from the group consisting of: a flange edge, a flange hole edge, a flange hole centerline, and a web surface. In one embodiment, identifying the reference at the frame includes holding a fastening machine 430 in contact with the reference. In another embodiment, acquiring the reference at the frame includes holding a loader feeding the frame in contact with the reference. In yet another embodiment, the reference includes a pin, and establishing the plane includes inserting a determinant assembly (D / A) hole at the frame on the pin. Identifying the reference establishes a plane within the frame installation station based on a matching of the reference to the frame pitch location 397. In one embodiment, establishing the plane includes holding a hard stop 694 in contact with the reference at the frame installation station, and holding the frame in contact with the hard stop 694. Step 710 includes aligning the plane with the frame reference surface 690 and the frame ridge 692 within the frame installation station. Step 712 includes attaching the frame to the frame ridge 692 when the plane is aligned with the frame reference surface. Connecting the frame to the arcuate segment includes installing a fastener through the frame and the arcuate segment.

[0103] Figure 8is a flowchart showing another method 800 for installing a frame in illustrative embodiments. Step 802 includes placing a manufacturing allowance 129 that defines a lower boundary of an arcuate segment (e.g., half-tube segment 120) of a fuselage in contact with a track 110. This provides a support surface for traversing the roller system. Step 802 can include lowering the arcuate segment onto a series of supports (e.g., columns 312) after the arcuate segment has been demolded from a layup mandrel.

[0104] Step 804 includes conveying the arcuate segment through the manufacturing allowance 129 in a process direction 181 along the track 110. This can include drive rollers at the track 110, sliding the arcuate segment 120 along the track, etc. Because the manufacturing allowance 129 bears the load of the arcuate segment, if the lower edge of the manufacturing allowance 129 becomes worn or uneven during conveyance, no problem is created because the manufacturing allowance will be cut away before the arcuate segment is assembled into a full-tube segment.

[0105] Step 806 includes indexing the arcuate segment to a frame installation station. This step can be performed by any of the indexing techniques and systems described above. In step 808, a frame is fed into contact with an inner mold line (IML) of the arcuate segment at the frame installation station below the manufacturing allowance. In embodiments where the track includes supports spaced a predetermined distance apart in the process direction 181, feeding the frame includes feeding the frame between the supports, as shown in Figure 3 In further embodiments, feeding the frame includes simultaneously moving and rotating a drive pinch roller 414 of the frame. In yet further embodiments, feeding the frame can include moving the frame from outside the left side of the arcuate segment to inside the right side of the arcuate segment, feeding the frame through the track (e.g., under the track or across the track), or rotating the frame.

[0106] Step 810 includes securing the frame to the arcuate segment. As described above, this can be accomplished by installing fasteners through the frame and the arcuate segment.

[0107] Method 800 provides a technical benefit by enabling the frame to be quickly loaded into a position for securing to a fuselage segment without the need to lift or reorient the fuselage segment as it is advanced in the process direction 181. This saves time and allows the conveyance time to be used to increase the value of the portions of the fuselage.

[0108] Figure 9is a flowchart depicting a method for acquiring a datum plane 690 in illustrative embodiments. Step 902 includes pulsing a barrel section of a fuselage in a process direction 181. Step 904 includes engaging an index feature at the barrel section. Step 906 includes passing a frame under the barrel section. Step 908 includes positioning a datum plane 690 relative to the index feature. This can occur automatically when the index part is engaged in the frame mounting station, as the frame datum plane 690 need not be a moving part, and the index part can or can not be within the datum plane. In step 910, a coplanar portion of the frame is placed against the datum plane 690. In step 910, a coplanar portion of the frame is placed against the frame datum plane 690, and the frame is secured in place (e.g., a thumbtack is secured in place, secured by a fastener, etc.). Either side of the frame web, the flange edge, and / or the D / A hole can be used as the coplanar entity. For example, the frame mounting station can have a datum plane 690 established by three pins that align with the D / A holes at the frame.

[0109] Similar to method 800, method 900 provides technical benefits by enabling the frame to be quickly loaded into a position for securing to a section of a fuselage without the need to lift or re-orient the section of the fuselage as it advances in the process direction 181. This saves time and makes the transfer time valuable for increasing the value of the fuselage section.

[0110] Figure 10 is an end view of a frame in illustrative embodiments, and corresponds to Figure 6 view arrow 10. As Figure 10 shown, the frame 350 is secured to a barrel section 320 of a fuselage. To perform a controlled placement in the direction indicated by arrow 181, a datum plane 1060 can be acquired by bringing portions of the frame 350 into coplanar alignment with hard stops 694, based on laser projection and alignment of the portions, etc. In this embodiment, the portions include an outer flange edge 1010, a boundary of a D / A hole 1050, a rear portion 1020 of the frame 350, a front portion of the frame 350, another D / A hole 1050, a face 1030, and an inner flange edge 1040. Any face, leading edge, trailing edge, or centerline of these portions can be used to establish the frame datum plane, as can any three points defined by these portions. Thus, various arrangements can be used at the frame to align with the frame positioner datum plane. One of the frame datum planes can be used to align with a plane at a particular frame spacing position 397 relative to the frame mounting station at one frame spacing position 397 and another datum for another frame spacing position 397, etc. The datum planes are established by Figure 10An arc is established by indicating at least three points as shown by at least one dashed line. The at least three points in the arc establish a frame plane aligned with the plane at frame spacing position 397 within the frame installation station. In another embodiment, the three points used to establish the reference plane 690 are on the same web surface, or along the same flange, or the same edge of three holes, or three center points, or center lines, or two aligned holes. The positions of these points can be sensed using a laser or hard stop. The hard stop can contact or engage with the flange edge, aligned frame holes, frame web, etc., at three locations.

[0111] Figure 11 This is a flowchart illustrating a method 1100 for using an operating line assembly system to install a frame in an illustrative embodiment. Step 1102 includes pulsating an arcuate section of the machine body along a track in the process direction 181, thereby presenting a longitudinal portion of the arcuate section to a workstation at the track. Step 1104 includes transferring a three-dimensional (3D) representation of the longitudinal portion to the workstation during pauses between pulsations of the arcuate section. The transfer of the 3D representation can be achieved by reading the rotational features of the arcuate section (or its longitudinal portion) in the form of an RFID chip at the arcuate section (e.g., ...). Figure 12 The 3D characterization (1214) is used to perform operations at the work station by receiving scans that characterize the arcuate segment (or its longitudinal portion) in a desired manner. Thus, the 3D characterization describes the physical aspects of the IML and / or OML used by the work station to perform operations on the arcuate segment, particularly the mounting of the frame. In one embodiment, the 3D characterization represents the lofting of the arcuate segment. Step 1106 includes advancing the frame into the work station immediately before mounting it. In one embodiment, the frame is advanced into a recess defined by the arcuate segment.

[0112] Step 1108 includes installing the frame in the longitudinal section during the pause. This operation can be performed as discussed above regarding frame installation. In a further embodiment, the method further includes operating multiple workstations performing work on the fuselage section during the pause.

[0113] Figure 12 This is a diagram 1200 depicting the rotation of component 1210 to work station 1220 in an illustrative embodiment. The component has a length L1 and advances continuously or pulsatingly along its length L1 (e.g., via a track or drive). In one embodiment, the component is "micro-pulsating" and advances a pulsating distance corresponding to the length L2 of the longitudinal portion 1212. In the pulsating embodiment, work station 1220 operates on component 1210 during pauses between pulsations or during pulsating movement of component 1210. In embodiments where component 1210 advances continuously, work station 1220 operates on component 1210 during continuous movement.

[0114] The longitudinal portion 1212 is accompanied by indexing features 1214. In this embodiment, the indexing features 1214 are evenly spaced and located on the longitudinal portion 1212. However, in other embodiments, the indexing features 1214 are spaced at different intervals and are placed external to the longitudinal portion 1212 (e.g., at a pallet that carries the component). The indexing features 1214 comprise any suitable shape and size, and in one embodiment, the spacing, shape, size, and number of indexing features 1214 at a given location convey instructions to the work station 1220 to operate on the longitudinal portion 1213 currently exposed to the work station 1220, to operate in a particular manner, or to refrain from operating. Because the indexing features 1214 are fixed with respect to the component 1210 and are arranged at predetermined locations on the component 1210, the arrangement of indexing features 1214 can also be used to determine a 3D representation of the position, orientation, loft, inner mold line (IML), outer mold line (OML), or other aspects of the component 1210.

[0115] In one embodiment, the indexing unit 1224 physically couples with, and interacts with, the indexing features 1214, while in another embodiment, the indexing unit 1224 scans the indexing features 1214 through optical means, through the application of sonic energy, through the application of electromagnetic energy, or through other means. After the position and / or orientation of the indexing features 1214 of the longitudinal portion 1213 currently arranged at the work station 1220 has been determined, the end effector 1222 is positioned based on this information to perform a work in a repeatable, accurate, and precise manner at the longitudinal portion 1212. By repeatedly advancing, indexing, and performing work on an assembly, the entire assembly 1210 receives work from the work station 1220. In further embodiments, multiple work stations 1220 are arranged along the length of the component 1210 and perform work simultaneously (e.g., during the same pause) on different longitudinal portions of the component. The feeder line 1230 provides material 1232 to the work station 1220 in a just-in-time (JIT) manner. Figure 13A and Figure 13B is a flowchart showing other methods for operating a flowline assembly system to install a frame in illustrative embodiments. Figure 13A and Figure 13BThe method 1300 includes, at step 1302, advancing the arc segment of the fuselage in the process direction 181 along the track 310 for less than the length of the arc segment. In one embodiment, advancing the arc segment includes pulsing the arc segment in the process direction 181. In another embodiment, the arc segment includes a half-tube segment 320, and the method is performed while the support edge 329 of the half-tube segment is in contact with the track. Step 1304 includes installing the frame 350 at a longitudinal portion of the arc segment that is within view of the frame installation station at the track 310. The frame is installed at the frame spacing location 397. In one embodiment, installing the frame includes feeding the frame longitudinally under the arc segment, and subsequently connecting the frame to the arc segment with fasteners.

[0116] Step 1306 includes further advancing the arc segment in the process direction 181. Step 1308 includes cutting material from the longitudinal portion at a cut-off station (e.g., the cut-off station 370) disposed downstream of the frame installation station. Figure 3 In one embodiment, cutting material from the longitudinal portion includes cutting an opening for a window or an opening for a door, or trimming off a remaining manufacturing allowance / support edge.

[0117] The method 1350 describes another illustrative embodiment. Step 1352 of the method 1350 includes pulsing the arc segment of the fuselage for a portion of the length of the arc segment. In one embodiment, the arc segment includes a half-tube segment 320, and the method is performed while the support edge 329 of the half-tube segment is in contact with the track 310. Accordingly, step 1352 includes driving the arc segment along the track 310. Step 1354 includes installing the frame 350 at a first longitudinal portion of the arc segment that is within view of the frame installation station during a pause between pulsations of the arc segment. Step 1354 includes installing the frame 350 at the first longitudinal portion of the arc segment that is within view of the frame installation station, for example by installing the frame at the frame spacing location 397 during the pause between pulsations of the arc segment. In one embodiment, installing the frame 350 includes feeding the frame 350 longitudinally under the arc segment, and subsequently connecting the frame to the arc segment with fasteners.

[0118] At step 1356, the cut-off station 370 cuts material from a second longitudinal portion that is within view of the cut-off station (which is disposed downstream of the frame installation station) during the pause. In one embodiment, cutting material from the longitudinal portion includes cutting an opening for a window or an opening for a door, or trimming off a remaining manufacturing allowance / support edge.

[0119] Figure 14is another flowchart illustrating a method 1400 for operating a flowline assembly system to install a frame in illustrative implementations. Step 1402 includes moving a frame ridge 692 in a bow section of a fuselage into a frame installation station. Step 1404 includes feeding a frame into a recess defined by the bow section. Step 1406 includes placing a frame flange against the frame ridge 692. Step 1408 includes placing a hard stop 694 against a frame reference. Step 1410 includes fastening the frame to the bow section of the fuselage.

[0120] In one implementation, the method further includes clamping the frame into place against the frame ridge 692 prior to fastener installation. In another implementation, the method further includes establishing a plane of alignment with the frame reference within the frame installation station using the hard stop 694. In another implementation, the method further includes fitting the frame to a frame spacing location 397. In yet another implementation, the method further includes pulsing the bow section less than a length of the bow section. In yet another implementation, the method includes indexing the bow section to the frame installation station during pulsing and characterizing the bow section based on the indexing.

[0121] Examples

[0122] In the following examples, additional processes, systems, and methods are described in the context of a frame installation station.

[0123] With more particular reference to the drawings, implementations of the disclosure can be described in the context of aircraft manufacturing and service over the life of an aircraft 1502 as Figure 1 illustrated in FIG. 15 and an aircraft 1502 as Figure 15 illustrated in FIG. 16. During pre-production, the aircraft 1502 and materials procurement 1506 occur as

[0124] Each of the processes of methodology 1500 can be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator can include without limitation any number of aircraft manufacturers and major-system integrators; a third party can include without limitation any number of vendors, subcontractors, and suppliers; and an operator can be an airline, lease company, military entity, service organization, and so on.

[0125] As shown in Figure 16 Aircraft 1502 produced by methodology 1500 can include a fuselage 1518 having a plurality of systems 1520 and an interior 1522, as shown in

[0126] Turning now to Figure 17 , a diagram of an aircraft 1700 in which the illustrative implementations can be implemented is depicted. Aircraft 1700 is an example of an aircraft that can be formed from a plurality of half-barrel sections 1702 to form a major portion of a fuselage 1704 using the methodologies described herein.

[0127] In this implementation, aircraft 1700 has wings 1706 and 1708 connected to a fuselage 1710. Aircraft 1700 includes engines 1712 connected to wing 1706 and engines 1714 connected to wing 1708. Fuselage 1710 has a tail 1716. A horizontal stabilizer 1718, a horizontal stabilizer 1720, and a vertical stabilizer 1722 are connected to tail 1716 of fuselage 1710.

[0128] Fuselage 1704 is made from half-barrel sections 1702 that define an upper half-barrel section connected to a lower half-barrel section to form a complete full-barrel section.

[0129] As already mentioned above, the apparatuses and methods implemented herein can be employed during any one or more stages of production and service described in the method 1500. For example, components or subassemblies corresponding to component and subassembly manufacturing 1508 can be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 1502 is in service, e.g., in response to a maintenance or service action. Moreover, one or more apparatus embodiments, method embodiments or a combination thereof can be employed during the component and subassembly manufacturing 1508 and system integration 1510, e.g., to substantially expedite assembly of the aircraft 1502 or to reduce the cost of the aircraft 1502. Similarly, one or more apparatus embodiments, method embodiments or a combination thereof can be employed while the aircraft 1502 is in service, e.g., during maintenance and service 1516. For example, the techniques and systems described herein can be used for material procurement 1506, component and subassembly manufacturing 1508, system integration 1510, service 1514, and / or maintenance and service 1516, and / or can be used in the rack 1518 and / or interior 1522. These techniques and systems can even be used in systems 1520, including, for example, propulsion systems 1524, electrical systems 1526, hydraulic systems 1528, and / or environmental systems 1530.

[0130] In one embodiment, the component comprises a portion of the rack 1518 and is manufactured during component and subassembly manufacturing 1508. The component can then be assembled into the aircraft in system integration 1510 and then used in service 1514 until wear makes the component unusable. Then, during maintenance and service 1516, the part can be discarded and replaced with a newly manufactured part. The components and methods of the present application can be used throughout component and subassembly manufacturing 1508 in order to manufacture new components.

[0131] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein can be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination of these. For example, an element can be implemented as a dedicated hardware. A dedicated hardware element can be referred to as a "processor", "controller" or some similar terminology. When provided by a processor, these functions can be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which can be shared. Moreover, explicit use of the term "processor" or "controller" should not be construed to refer exclusively to hardware capable of executing software, and can implicitly include, without limitation, digital signal processor (DSP) hardware, network processor, application specific integrated circuit (ASIC), or other circuitry, field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), nonvolatile memory, logic or some other physical hardware component or module.

[0132] Furthermore, a control element can be implemented as instructions executable by a processor or computer to perform the function of the element. Some examples of instructions are software, program code, and firmware. The instructions are operable when executed by the processor to instruct the processor to perform the function of the element. The instructions can be stored on a storage device readable by the processor. Some examples of storage devices are digital or solid state memories, magnetic storage media such as disks and tapes, hard drives, or optically readable digital data storage media.

[0133] Although specific implementations are described herein, the scope of the disclosure is not limited to those specific implementations. The scope of the disclosure is defined by the following claims and their equivalents.

[0134] The present disclosure also includes the following enumerated clauses, which are not to be confused with the appended claims that determine the scope of protection:

[0135] 1. A method (200) for assembling a fuselage (1704) of an aircraft (1700), the method (200) comprising:

[0136] indexing (204) a bow section (120) of the fuselage to a frame installation station (140);

[0137] feeding (206) a frame (142) into a recess (126) defined by the bow section (120) at the frame installation station (140);

[0138] placing (208) the frame (142) against an inner mold line (IML) (128) of the bow section (120) based on the indexing while the frame (142) is within the recess (128); and

[0139] securing (210) the frame (142) to the bow section (120).

[0140] 2. The method (200) of clause 1, wherein:

[0141] The step of feeding (206) a frame (142) includes longitudinally feeding the frame (142) under the bow section (120).

[0142] 3. The method (200) of clause 2, wherein:

[0143] The step of feeding (206) a frame (142) includes advancing the frame (142) through a feeder nip (415) and causing the frame to advance under a support edge (113) of the bow section (120).

[0144] 4. The method (200) of clause 1, further comprising the step of:

[0145] aligning the frame (142) to a position along the IML (128) by feeding the frame (142) under a support edge (113) of the arc segment with an orientation that matches the IML (128) of the arc segment (120);

[0146] coupling the frame (142) with an alignment tool (160) that facilitates placing the frame (142) against the IML (128); and

[0147] installing the frame (142) by attaching the frame to position, and then installing fasteners that secure the frame to the arc segment.

[0148] 5. The method (200) of clause 4, further comprising the steps of:

[0149] operating the alignment tool (160) to lift the frame (142) into contact with the IML (128).

[0150] 6. The method (200) of clause 1, wherein:

[0151] The step of securing (210) the frame (142) comprises performing an integrated assembly by clamping the frame (142) to the arc segment (120) while aligning the frame (142), drilling holes in the frame (142) and the arc segment (120), and installing fasteners to the holes.

[0152] 7. The method (200) of clause 1, wherein:

[0153] The arc segment (120) comprises a half-tube segment of a fuselage.

[0154] 8. The method (200) of clause 1, further comprising the steps of:

[0155] pulsing (202) or continuously moving the arc segment (120) of the fuselage along a track (110) in a process direction less than a length of the arc segment (120).

[0156] 9. The method (200) of clause 1, further comprising the steps of:

[0157] pulsing (202) or continuously moving the arc segment (120) of the fuselage along a track (110) in a process direction at a frame pitch of the arc segment (120).

[0158] 10. The method (200) of clause 1, wherein:

[0159] The step of securing (210) the frame (142) is performed during a pause between pulsations of the arcuate segment (120) in the process direction or while the arcuate segment is continuously moving.

[0160] 11. The method (200) of clause 1, wherein:

[0161] The step of indexing (204) the arcuate segment (120) includes mating a feature (124) at the arcuate segment (120) with a complementary feature (134) at the indexing unit (130) such that the mating immediately results in the arcuate segment (120) having a known position relative to the frame mounting station (140).

[0162] 12. The method (200) of clause 11, wherein:

[0163] The feature (124) at the arcuate segment (120) has a known physical offset from the frame mounting station (140).

[0164] 13. A portion of an aircraft assembled according to the method of clause 1.

[0165] 14. A non-transitory computer readable medium containing programming instructions operable when executed by a processor to perform a method 200 for assembling a fuselage (1704) of an aircraft (1700), the method (200) comprising the steps of:

[0166] indexing (204) an arcuate segment of the fuselage to a frame mounting station;

[0167] feeding (206) a frame at the frame mounting station into a recess defined by the arcuate segment;

[0168] placing (208) the frame against an inner mold line (IML) of the arcuate segment while the frame is within the recess; and

[0169] securing (210) the frame to the arcuate segment.

[0170] 15. The non-transitory computer readable medium of clause 14, wherein:

[0171] The step of feeding (206) a frame includes feeding the frame longitudinally under the arcuate segment.

[0172] 16. The non-transitory computer readable medium of clause 15, wherein:

[0173] Feeding the frame includes advancing the frame through a feeder nip under the arcuate segment.

[0174] 17. The non-transitory computer readable medium of clause 14, wherein the method (200) further comprises:

[0175] connecting the frame with an alignment tool facilitates placement of the frame on the IML.

[0176] 18. The non-transitory computer readable medium of clause 17, wherein the method further comprises the step of:

[0177] operating the alignment tool to lift the frame into contact with the IML.

[0178] 19. The non-transitory computer readable medium of clause 14, wherein:

[0179] the step of securing (210) the frame comprises installing fasteners that secure the frame to the arcuate segment.

[0180] 20. The non-transitory computer readable medium of clause 19, wherein:

[0181] the step of securing (210) the frame comprises performing an integrated assembly by simultaneously clamping the frame to the arcuate segment, drilling holes in the frame and arcuate segment, and installing fasteners into the holes.

[0182] 21. The non-transitory computer readable medium of clause 14, wherein:

[0183] the arcuate segment comprises a half-tube segment.

[0184] 22. The non-transitory computer readable medium of clause 14, wherein the method further comprises the step of:

[0185] pulsing the trajectory of the arcuate segment of the body in the process direction is less than the length of the arcuate segment.

[0186] 23. The non-transitory computer readable medium of clause 14, wherein:

[0187] the step of securing (210) the frame is performed during a pause between pulsations of the arcuate segment in the process direction.

[0188] 24. The non-transitory computer readable medium of clause 14, wherein:

[0189] indexing (204) the arcuate segment comprises mating a feature at the arcuate segment with a complementary feature at the indexing unit such that the mating immediately results in the arcuate segment having a known position relative to the frame mounting station.

[0190] 25. The non-transitory computer readable medium of clause 24, wherein:

[0191] Features at the arc segment have a known physical offset from the frame installation station.

[0192] 26. A portion of an aircraft assembled according to the method defined by the instructions stored on the computer readable medium of clause 14.

[0193] 27. A flowline assembly system (100) for assembling a fuselage (1704) of an aircraft (1700), the system (100) comprising:

[0194] a track (110) that receives an arc segment (120) of the fuselage and advances the arc segment (120) to an indexing position;

[0195] an indexing unit (130) comprising complementary features (134) that mate with a plurality of features (124) at the arc segment;

[0196] a frame installation station (140) arranged at the indexing unit (130), the frame installation station comprising:

[0197] a loader (150) that feeds a frame (142) into a recess (126) defined by the arc segment (120);

[0198] an alignment tool (160) that places the frame (142) against an inner surface (128) of the arc segment (120) when the frame (142) is within the recess (126); and

[0199] a fastener machine (144) that secures the frame (142) to the arc segment (120).

[0200] 28. The system (100) of clause 27, wherein:

[0201] the loader (150) feeds the frame (142) under the arc segment (120).

[0202] 29. The system (100) of clause 27, wherein:

[0203] the alignment tool (160) generates a force that lifts the frame (142) into contact with the inner surface (128).

[0204] 30. The system (100) of clause 27, wherein:

[0205] the fastener machine (144) secures the frame (142) by installing a fastener.

[0206] 31. The system (100) of clause 27, wherein:

[0207] The track (110) pulsates the arc segment (120) in the process direction less than the length of the arc segment.

[0208] 32. The system (100) of clause 27, wherein:

[0209] The arc segment (120) comprises a half barrel segment of the fuselage.

[0210] 33. The system (100) of clause 27, wherein:

[0211] The indexing unit (130) has a known physical offset to the frame mounting station (140) such that mating of the complementary feature (134) to the feature (124) at the arc segment (120) results in the arc segment (120) having a known position relative to the frame mounting station (140).

[0212] 34. Manufacturing a portion of an aircraft using the system (100) of clause 27.

[0213] 35. An apparatus (400) in the form of a loader (410) for loading a frame to an arc segment of a fuselage, the loader (410) comprising:

[0214] A pinch roller (412) disposed at a support edge (329) of the arc segment (320) of the fuselage, the support edge (329) being supported by rollers (314) connected to the struts (312).

[0215] 36. The apparatus (400) of clause 35, the method further comprising the steps of:

[0216] An electric motor (412) driving the pinch roller (414) to advance the frame (35) under the support edge (329) and via a gap (G) between the struts (312) to advance the frame (35) into the recess (326) of the arc segment (320).

[0217] 37. The apparatus (400) of clause 36, wherein:

[0218] The pinch roller (414) forms a feeder nip (415) for driving the frame (350) into the recess (326) of the arc segment (320).

[0219] 38. The apparatus (400) of clause 35, wherein:

[0220] The pinch roller (414) drives the frame (350) in a direction perpendicular to the process direction of the arc segment (320) of the fuselage.

[0221] 39. The apparatus (400) of clause 35, wherein:

[0222] The pinch roll (414) feeds the frame (320) to the alignment machine (420) of the frame installation station (340).

[0223] 40. Manufacturing a portion of an aircraft using the apparatus (400) of clause 35.

[0224] 41. A method (700) for assembling a fuselage (1704) of an aircraft (1700), the method (700) comprising:

[0225] Moving (702) an arc segment (320) of the fuselage comprising a frame ridge (692) in a process direction until a frame spacing location (397) is within a field of view of a frame installation station (340);

[0226] Feeding (704) a frame (350) into a recess (326) defined by the arc segment (320);

[0227] Performing (706) a circumferential alignment of the frame (350) within the recess (326) that circumferentially positions the frame (350) within the frame ridge (692);

[0228] Identifying (708) a datum at a frame datum plane (690) based on a datum mating with the frame spacing location (397), the frame datum plane (690) establishing a plane within the frame installation station (340);

[0229] Aligning (710) the plane having the frame datum plane (690) within the frame installation station and the frame ridge (692); and

[0230] Attaching (712) the frame (350) to the frame ridge (692) when the plane is aligned with the frame datum plane (690).

[0231] 42. The method (700) of clause 41, wherein:

[0232] The datum at the frame (350) is selected from a flange edge, a flange hole edge, a flange hole centerline, and a web face.

[0233] 43. The method (700) of clause 41, wherein:

[0234] Identifying the datum at the frame (350) comprises maintaining a loader (410) feeding the frame (350) in contact with the datum.

[0235] 44. The method (700) of clause 43, further comprising the steps of:

[0236] using a loader (410) to hold the frame (350) within a frame ridge (692).

[0237] 45. The method (700) of clause 41, wherein:

[0238] establishing a plane within the frame installation station (340) comprises holding a hard stop (694) in contact with a datum and holding the frame in contact with the hard stop (694).

[0239] 46. The method (700) of clause 41, wherein:

[0240] the datum comprises a pin (662) and establishing a plane comprises slotted matrix assembly (D / A) holes (652) on the pin (662) of the frame (350).

[0241] 47. The method (700) of clause 41, wherein:

[0242] connecting the frame (350) to the arcuate segment (320) comprises installing a fastener through the frame (350) and the arcuate segment (320).

[0243] 48. A portion of an aircraft assembled according to the method of clause 41.

[0244] 49. A flowline assembly system (300) for assembling a fuselage (1704) of an aircraft (1700), the system (300) comprising:

[0245] a track (310) along which arcuate segments (320) of the fuselage are advanced;

[0246] a frame installation station (340) coupled with the track (310) that acquires a datum of a frame (350), the frame installation station (340) comprising:

[0247] a loader (410) that feeds the frame (350) into a recess (326) defined by the arcuate segment (320) and performs circumferential alignment of the frame (350) within the recess (326), the loader circumferentially positioning the frame (350) within the recess (326) of the arcuate segment (320); and

[0248] a fastening machine (430) establishes a plane based on a datum of the frame (350), aligns the plane with a datum of the frame installation station (340) and a datum of the arcuate section (320), and attaches the frame (350) to the arcuate section (320) while the plane is aligned.

[0249] 50. The system (300) of clause 49, wherein:

[0250] The fastening machine (430) obtains the datum at the frame (350) by contacting the frame (350).

[0251] 51. The system (300) of clause 49, wherein:

[0252] The datum comprises a pin (662), and the frame (350) comprises a slotted assembly (D / A) hole (652) on the pin (662).

[0253] 52. The system (300) of clause 49, wherein:

[0254] The fastening machine 430 attaches the frame 350 to the arcuate section 320 by installing fasteners through the frame and the arcuate section.

[0255] 53. Manufacturing a portion of an aircraft using the system (300) of clause 49.

[0256] 54. A method (900) for acquiring a frame datum plane (690), the method comprising:

[0257] pulsing (902) a barrel section (320) of a fuselage in a process direction;

[0258] engaging (904) an indexing feature (322) at the barrel section (320);

[0259] passing (906) a frame (350) under the barrel section (320);

[0260] positioning (908) a frame datum plane (690) relative to the indexing feature (322); and

[0261] placing (910) a coplanar portion of the frame (350) against the frame datum plane (690).

[0262] 55. The method (900) of clause 54, further comprising the step of:

[0263] attaching the frame (350) to the barrel section (320).

[0264] 56. A portion of an aircraft assembled according to the method of clause 54.

[0265] 57. A method (1400) for assembling a fuselage of an aircraft, the method comprising:

[0266] moving (1402) a frame ridge (692) in a bow section (320) of a fuselage into a frame mounting station (340);

[0267] feeding (1404) a frame (350) into a recess (326) defined by the bow section (320);

[0268] placing (1406) a frame flange against the frame ridge (692);

[0269] placing (1408) a frame datum against a hard stop (694); and

[0270] fastening (1410) the frame (350) to the bow section (320) of the fuselage.

[0271] 58. The method (1400) of clause 57, further comprising the step of:

[0272] clamping the frame (350) to the frame ridge (692) prior to fastening the frame (350) to the bow section (320) of the fuselage.

[0273] 59. The method of clause 57, further comprising the step of:

[0274] establishing a plane of alignment of the frame datum within the frame mounting station (340) with the hard stop (694).

[0275] 60. The method (1400) of clause 57, further comprising the step of:

[0276] fitting a frame (320) to a frame spacing location (397).

[0277] 61. The method (1400) of clause 57, further comprising the step of:

[0278] pulsing the bow section along a track that moves the bow section into the frame mounting station a length less than a length of the bow section.

[0279] 62. The method (1400) of clause 61, further comprising the step of:

[0280] indexing the arc segment to a frame installation station during the pulsing; and

[0281] characterizing the arc segment based on the indexing.

[0282] 63. A method (1300) for assembling a fuselage (1704) of an aircraft (1700), the method (1300) comprising:

[0283] advancing (1302) an arc segment (320) of the fuselage in a process direction along a track (310) less than a length of the arc segment;

[0284] further advancing (1306) the arc segment (320) in the process direction; and

[0285] cutting (1308) material from the arc segment (320) of the fuselage at a cut-off station (370) downstream of a frame installation station (340) disposed at the track (310).

[0286] 64. The method (1300) according to Clause 63, further comprising the step of:

[0287] installing (1304) a frame (350) at a longitudinal portion of the arc segment (320) within a field of view of the frame installation station (340).

[0288] 65. The method (1300) according to Clause 64, wherein:

[0289] cutting (1308) the material comprises cutting the material from the longitudinal portion.

[0290] 66. The method (1300) according to Clause 65, wherein:

[0291] cutting (1308) the material from the longitudinal portion comprises cutting away a manufacturing allowance (129).

[0292] 67. The method (1300) according to Clause 65, wherein:

[0293] cutting (1308) the material from the longitudinal portion comprises cutting away an opening of a window.

[0294] 68. The method (1300) according to Clause 65, wherein:

[0295] cutting (1308) the material from the longitudinal portion comprises cutting away an opening for a door.

[0296] 69. The method (1300) according to Clause 64, wherein:

[0297] Installing (1304) the frame (350) includes feeding the frame (350) longitudinally under the arcuate section (320).

[0298] 70. The method (1300) of clause 63, wherein:

[0299] Advancing (1302) the arcuate section (320) includes advancing the arcuate section (320) (320).

[0300] 71. The method (1300) of clause 70, wherein:

[0301] Pulsing the arcuate section (320) includes repeatedly advancing the arcuate section (320) less than a length of the arcuate section (320) and pausing.

[0302] 72. The method (1300) of clause 63, wherein:

[0303] The arcuate section (320) includes a half-tube section, and the method is performed while a support edge (329) of the half-tube section contacts the track (310).

[0304] 73. A portion of an aircraft assembled according to the method of clause 63.

[0305] 74. A method (1350) for assembling a fuselage (1704) of an aircraft (1700), the method (1350) comprising:

[0306] Pulsing (1352) an arcuate section (320) of the fuselage a portion of a length of the arcuate section (320);

[0307] During a pause between pulsing of the arcuate section (320), installing (1354) a frame (350) at a first longitudinal portion of the arcuate section (320) within a field of view of a frame installation station (340); and

[0308] During the pause, cutting (1356) material from a second longitudinal portion of the arcuate section (320) within a field of view of a cut-off station (370) disposed downstream of the frame installation station (340).

[0309] 75. The method (1350) of clause 74, wherein:

[0310] Installing (1354) the frame (350) includes feeding the frame (350) longitudinally under the arcuate section (320).

[0311] 76. The method (1350) of clause 74, wherein:

[0312] Cutting (1356) material from the second longitudinal portion includes cutting an opening for a window.

[0313] 77. The method (1350) of clause 74, wherein:

[0314] Cutting (1356) material from the second longitudinal portion includes cutting an opening for a door.

[0315] 78. The method (1350) of clause 74, wherein:

[0316] Pulsing (1352) the arc segment (320) includes driving the arc segment along the track (310).

[0317] 79. The method (1350) of clause 74, wherein:

[0318] The arc segment (320) includes a half barrel segment (320), and the method is performed while a support edge (129) of the half barrel segment (320) contacts the track (310).

[0319] 80. The method (1350) of clause 74, wherein:

[0320] The second longitudinal portion includes a manufacturing allowance (129).

[0321] 81. The method (1350) of clause 80, further comprising the step of:

[0322] Cutting (1356) material from the second longitudinal portion includes cutting the remaining manufacturing allowance (129).

[0323] 82. A portion of an aircraft assembled according to the method of clause 74.

[0324] 83. A line assembly system (300) comprising:

[0325] a track (310) along which an arc segment (320) of a fuselage is advanced in a process direction;

[0326] a frame installation station (340) that installs a frame (350) at a longitudinal portion of the arc segment (320) within view of the frame installation station (340) at the track (310); and

[0327] a cutting station (370) arranged downstream of the frame installation station (340) and that cuts material from a longitudinal portion that enters within view of the cutting station (370).

[0328] 84. The system (300) of clause 83, wherein:

[0329] The arcuate segment (320) advances in the process direction less than a length of the arcuate segment (320).

[0330] 85. The system (300) of clause 84, wherein:

[0331] The arcuate segment (320) advances in the process direction a frame spacing.

[0332] 86. The system (300) of clause 83, wherein:

[0333] Cutting material from the longitudinal portion is performed after the arcuate segment (320) of the fuselage advances through the frame installation station (340).

[0334] 87. The system (300) of clause 83, wherein:

[0335] The arcuate segment (320) comprises a half-barrel segment (320) of the fuselage.

[0336] 88. The system (300) of clause 83, wherein:

[0337] The frame installation station (340) feeds the frame (350) under the support edge (329) of the arcuate segment (320).

[0338] 89. The system (300) of clause 83, wherein:

[0339] The cutout station (370) cuts an opening for a window (170) or door (180).

[0340] 90. Manufacturing a portion of an aircraft using the system (300) of clause 83.

[0341] 91. A method (800) for assembling a fuselage of an aircraft, the method comprising:

[0342] Placing (802) a manufacturing allowance (129) defining a lower boundary of an arcuate segment (120) of the fuselage into contact with a track (110);

[0343] Conveying (804) the arcuate segment (120) through the manufacturing allowance (129) in a process direction along the track (110);

[0344] Indexing (806) the arcuate segment (120) to a frame installation station (140);

[0345] feeding (808) a frame (142) at the frame mounting station (140) below the manufacturing allowance (129) into contact with an inner mold line (IML) (128) of the arcuate section (120); and

[0346] securing (810) the frame (142) to the arcuate section (120).

[0347] 92. The method (800) of clause 91, wherein:

[0348] the track (110) comprises a stanchion (114) separated by a predetermined distance along the process direction; and

[0349] feeding the frame (142) at the frame mounting station (140) below the manufacturing allowance (129) comprises feeding the frame (142) between the stanchions (114).

[0350] 93. The method (800) of clause 91, wherein:

[0351] feeding (808) the frame (142) at the frame mounting station (140) below the manufacturing allowance (129) comprises driving a pinch roller (414) that forms a feeder nip (415) that receives the frame (142) and advances the frame (142) into the recess (126) of the arcuate section (120).

[0352] 94. The method (800) of clause 91, wherein:

[0353] feeding (808) the frame (142) at the frame mounting station (140) below the manufacturing allowance (129) comprises moving the frame (142) from outside of the arcuate section (120) to inside of the arcuate section (120).

[0354] 95. The method (800) of clause 91, wherein:

[0355] feeding the frame (142) at the frame mounting station (140) below the manufacturing allowance (129) comprises feeding the frame (142) through or below the track (110).

[0356] 96. The method of clause 91, wherein:

[0357] feeding (808) the frame (142) at the frame mounting station (140) below the manufacturing allowance (129) comprises rotating the frame (142).

[0358] 97. A portion of an aircraft assembled according to the method of clause 91.

[0359] 98. A method (1100) for operating a flowline assembly system for assembling a portion of a fuselage of an aircraft, the method comprising:

[0360] pulsing (1102) a bow section (120) of the fuselage in a process direction along a track (110) to present a longitudinal portion of the bow section (120) to a station (140) at the track (110);

[0361] communicating (1104) a 3d characterization of the longitudinal portion to the station (140) during a pause between pulsing of the bow section (120);

[0362] advancing (1106) a frame (142) into the station (140) immediately prior to the station (140) installing the frame;

[0363] installing (1108) the frame at the longitudinal portion during the pause.

[0364] 99. The method of clause 98, wherein:

[0365] communicating (1104) the 3d characterization comprises reading an index feature (126) of the bow section (120).

[0366] 100. The method (1100) of clause 99, wherein:

[0367] the index feature (126) is in the form of an RFID chip.

[0368] 101. The method (1100) of clause 99, further comprising:

[0369] receiving a scan that characterizes the bow section (120).

[0370] 102. The method (1100) of clause 98, wherein:

[0371] a second work station is positioned along the track (110), the second work station receives the bow section (120) during the pause between pulsing of the bow section, and the method further comprises the steps of:

[0372] performing a work process on the bow section (120) at the second work station (365) during the pause between pulsing of the bow section (120).

[0373] 103. The method (1100) of clause 102, wherein:

[0374] Performing a work process on the arcuate segment (120) at a second work station (365) includes removing a portion of the arcuate segment (120).

[0375] 104. A portion of an aircraft assembled according to the method of clause 98.

[0376] 105. A flowline assembly system (300) for assembling an aircraft fuselage, the system comprising:

[0377] a track (310) that pulses arcuate segments of the fuselage along a length of the track;

[0378] a frame installation station (340) associated with the track; and

[0379] an indexing unit (330) for indexing the arcuate segments of the fuselage to the frame installation station (340), wherein the frame installation station (340) secures a frame to an inner mold line (IML) of the arcuate segment.

[0380] 106. The system (300) of clause 105, further comprising:

[0381] a work station (365) positioned along the track that receives a portion of the arcuate segment during a pause between pulsing of the arcuate segment and performs a work process on the arcuate segment during the pause between pulsing of the arcuate segment.

[0382] 107. The system of clause 106, wherein:

[0383] the work station (365) is a cutout station (370) disposed downstream of the frame installation station (340) and cuts out material from a longitudinal portion that is within a field of view into the cutout station (370).

[0384] 108. The system (300) of clause 105, wherein:

[0385] the indexing unit (130) includes a complementary feature (134) that mates with a feature (124) of the arcuate segment such that the mating of the complementary feature (134) with the feature (124) in the segment (120) results in the segment (120) having a known position relative to the frame installation station (340).

[0386] 109. The system (300) of clause 105, wherein:

[0387] the frame installation station (340) includes:

[0388] a loader (150) that feeds a frame (142) into a recess (126) defined by the segment (120);

[0389] an alignment machine (420) that places the frame (142) against an inner surface (128) of the segment (120) when the frame (142) is within the recess (126); and

[0390] a fastening machine (430) that secures the frame (142) to the segment (120).

[0391] 110. Use of the system of clause 105 to manufacture a portion of an aircraft.

Claims

1. A method for assembling a fuselage of an aircraft, the method comprising the steps of: indexing a segment of the fuselage to a frame installation station; feeding a frame into a recess defined by the segment of the fuselage at the frame installation station; placing the frame against an inner mold line (IML) of the segment of the fuselage when the frame is within the recess; and securing the frame to the segment of the fuselage, wherein the step of feeding a frame includes advancing the frame through a feeder nip and under a support edge of the segment of the fuselage.

2. The method of claim 1, further comprising the steps of: aligning the frame to a position along the IML by feeding the frame under a support edge of the segment of the fuselage in an orientation that matches the IML of the segment of the fuselage; coupling the frame to an alignment tool that facilitates placing the frame against the IML; and installing the frame by attaching the frame in place and then installing fasteners that secure the frame to the segment of the fuselage.

3. The method of claim 2, further comprising the step of: operating the alignment tool to lift the frame into contact with the IML.

4. A flowline assembly system for assembling a fuselage of an aircraft, the flowline assembly system comprising: a track that receives a segment of the fuselage and advances the segment to an indexing position; an indexing unit that includes complementary features that mate with features at the segment of the fuselage; a frame installation station arranged at the indexing unit, the frame installation station including: a loader that feeds a frame into a recess defined by the segment of the fuselage; an alignment tool that places the frame against an inner surface of the segment of the fuselage when the frame is within the recess; and a fastening machine that secures the frame to the segment of the fuselage, wherein the loader advances the frame through a feeder nip and under a support edge of the segment of the fuselage.

5. The flowline assembly system of claim 4, wherein: the alignment tool generates a force that lifts the frame into contact with the inner surface.

6. The flowline assembly system of claim 4, wherein: the fastening machine secures the frame by installing fasteners.

7. The flowline assembly system of claim 4, wherein: the track pulses the segment of the fuselage in a process direction by less than a length of the segment of the fuselage.

8. An apparatus in the form of a loader for loading a frame to a segment of a fuselage of an aircraft, the loader comprising: a pinch roller disposed at a support edge of a segment of a fuselage of an aircraft, the support edge supported by rollers attached to struts; a motor that drives the pinch roller to advance a frame under the support edge and through a gap between the struts into a recess of the segment of the fuselage, ​ wherein the pinch roll forms a feeder nip for driving the frame into the recess of the arcuate section, wherein the pinch roll advances the frame through the feeder nip and under the support edge of the arcuate section.

9. The apparatus of claim 8, wherein: the pinch roll drives the frame in a direction perpendicular to a process direction of the arcuate section of the machine body.

10. The apparatus of claim 8, wherein: the pinch roll feeds the frame to an alignment machine of a frame mounting station.

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