Pulsed production line for manufacturing fuselages using stations

Abstract

The invention relates to pulsating production line manufacturing of fuselages using stations. Systems and methods for manufacturing a fuselage (819) of an aircraft (802) are provided. The method includes: disposing a segment (120) of the fuselage (819) at a track (110) of a factory such that a recess (127) of the segment (120) of the fuselage (819) faces a floor (150) of the factory and a support edge (122) of the segment (120) of the fuselage (819) directly contacts the track (110); synchronously advancing the segment (120) of the fuselage (819) along the track (110) in a process direction (199); performing work within the recess (127) of the segment (120) of the fuselage (819) via a station disposed below the recess (127) and directly mounted to the floor (150) of the factory during pauses between pulsations of the segment (120) of the fuselage (819).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the field of manufacturing, and in particular, to the manufacturing of aircraft fuselage sections. BACKGROUND

[0002] The airframe defines the mechanical structure of the aircraft. The airframe is made of a plurality of components that provide the desired structural properties. For example, a portion of the airframe for an aircraft fuselage can include a frame, a skin, and stringers that are mechanically coupled together (e.g., via co-bonding, co-curing, or fasteners) according to design parameters. As presently practiced, the components of the airframe are manufactured and assembled in predefined units at a factory floor. For example, in some cases, the skin of an aircraft can be assembled at one unit, which can then be transported to a new unit where the frame is installed into the skin to form a fuselage section.

[0003] While the manufacturing processes discussed above are reliable, they suffer from delays when work at particular portions of the components is completed slower than expected. For example, if a particular portion of a fuselage section takes longer than expected to install a frame, it is often moved into the next unit where work is completed out of sequence in what is referred to as “misfit work.” This often delays work in the new unit because the “misfit work” prevents other work in the “misfit work” area, which can then be completed, from being completed.

[0004] Further complicating the manufacturing process is that work inside the fuselage section is often placed on a pedestrian floor or a cargo floor, which complicates the process of installing and manipulating these components. It would therefore be desirable to have a method and apparatus that takes into account at least some of the problems discussed above as well as other possible problems. The abstract of EP 3 378 789 Al states that the present disclosure relates to an aircraft panel production method and an aircraft panel production system that can accurately assemble an aircraft panel. The aircraft panel production method has a step of holding a jig (1) that holds a main panel (10) having a plurality of plate-like members of a curved cross-sectional shape such that a cross section of the main panel (10) has a curved shape that bulges upward; a step of overlapping the plate-like members of the main panel (10) held by the holding jig (1) with each other and joining the overlapping portions by rivets; a step of moving the holding jig (1) that holds the main panel (10) whose plate-like members have been joined with each other; and a step of joining a frame (32) that follows the curved shape of the main panel (10) to the plate-like members of the main panel (10) held by the moved holding jig (1) by rivets.

[0005] The abstract of EP 2 952 890 A2 states: Systems and methods are provided for high speed non-destructive inspection of semi-tubular or full-tubular workpieces, such as a tubular section of an aircraft fuselage. These workpieces can be scanned from the exterior using a mobile (e.g., translational) archway system including a translatable arched frame disposed exterior to the fuselage section, a trolley travelable along a curved track carried by the arched frame, a radially inwardly extending telescoping arm fixedly coupled to a proximal end of the trolley, and an NDI sensor unit coupled to a distal end of the telescoping arm. Stiffening ribs of the fuselage section can be scanned using a mobile scanner platform disposed interior to the fuselage section including a radially outwardly extending telescoping arm rotatably coupled to a mobile (e.g., full or linear motion) platform and an NDI sensor unit coupled to a distal end of the telescoping arm. Scan data is matched with position data acquired using any of a plurality of tracking systems to enable NDI features / defects to be displayed on a three-dimensional representation of the workpiece.

[0006] The abstract of EP 2 221 151 A2 states: An apparatus is provided that includes a plurality of mobile robots (806, 808, 810, 814, 816, 818), a wireless communication system (712), and a motion control system (714). The plurality of mobile robots (806-818) are capable of moving to a plurality of locations in an assembly area (702) and performing operations in the assembly area (702) to assemble a structure (800). The wireless communication system (712) is capable of providing communication with the plurality of mobile robots (806-818) within the assembly area (702). The motion control system (714) is capable of generating position information for the plurality of mobile robots (806, 818) in the assembly area (702) and communicating the position.

[0007] The abstract of EP 3 718 699 Al states: Systems (100) and methods (1100) are provided for proximity detection in a manufacturing environment. One embodiment is a method (1100) of reporting proximity in an assembly environment (130). The method (1100) includes: inserting (1102) an arm (1026) of a holder (1020) into an interior (1004) of a part (1000) held by a cradle (1010) and on which a robot (140, 1030, 1250) works; placing (1104) an indexing feature (1016) at the holder (1020) in contact with an indexing feature (1023) of the cradle (1010); operating (1106) a sensor (120, 1028, 1270) at the holder (1020) to directly detect a position of a first proximity detector (160, 300, 410, 1260) worn by a technician (150, 920) and a position of a second proximity detector (162, 300, 420, 430, 1290) at the robot (140, 1030, 1250); and directing (1108) the first proximity detector (160, 300, 410, 1260) to provide a warning to the technician (150, 920) if a distance between the first proximity detector (160, 300, 410, 1260) and the second proximity detector (162, 300, 420, 430, 1290) is less than a threshold value.

[0008] The abstract of EP 3 511 252 Al states: A production system (50) for automated assembly of vehicle components (1), in particular for automated assembly of structural components of an aircraft or spacecraft (100) is provided. The production system (50) comprises: vehicle components (1) provided with state sensors (10), each state sensor (10) being configured to determine state data (12) of the respective vehicle component (1); a positioner unit (2) configured to clamp a respectively associated vehicle component (1) at a mounting point (7) and to move the respectively associated vehicle component (1) to an assembly position (3); a position measurement system (4) configured to determine the assembly position (3) of each vehicle component (1); a force sensor (5) configured to determine at least one of a reaction force and a moment of each clamped vehicle component (1) at the mounting point (7) in the assembly position (3); and a computer-based control system (30) in data communication with the vehicle components (1), the positioner unit (2), the position measurement system (4) and the force sensor (5) and configured to control the positioner unit (2) based on the determined state data (12), the determined assembly position (3) and the determined reaction force and moment of the vehicle components. SUMMARY

[0009] The implementations described herein provide techniques and systems that facilitate human interaction with the arcuate fuselage sections of a track that traverses an assembly line. The fuselage sections are oriented such that their concavities point toward the floor of the factory, forming an inverted "U." This enables technicians to easily enter and / or exit the "tunnel" formed by the fuselage sections to facilitate inspection and work. Moreover, in implementations where the fuselage sections "pulse" along the assembly line, the movement of technicians and materials into and out of the tunnel can be performed during pauses between pulses or during pulses.

[0010] Other illustrative implementations (e.g., methods and computer-readable media related to the implementations described above) can be described below. The features, functions, and advantages described can be implemented independently in various implementations of the present disclosure or combinations thereof, further details of which can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF DRAWINGS

[0011] Some implementations of the present disclosure are now described, by way of example only, with reference to the accompanying drawings. The same elements have been named the same in all of the drawings.

[0012] Figure 1 is a block diagram of a fuselage assembly system in an illustrative implementation.

[0013] Figures 2A-2B is a flowchart illustrating a method of operating a fuselage assembly system in an illustrative implementation.

[0014] Figure 3 is a perspective view of a fuselage section traveling through a fuselage assembly system in an illustrative implementation.

[0015] Figure 4 is an elevational view of a worktable for a fuselage assembly system in an illustrative implementation.

[0016] Figure 5 is an elevational view of an extendable worktable for a fuselage assembly system in an illustrative implementation.

[0017] Figure 6 is a flowchart illustrating another method of operating a fuselage assembly system in an illustrative implementation.

[0018] Figure 7 depicts a radio frequency identification (RFID) scanner that tracks movement of materials and / or personnel into and / or out of an assembly area in an illustrative implementation.

[0019] Figure 8 is a flowchart of a method of aircraft production and service in an illustrative implementation.

[0020] Figure 9 is a block diagram of an aircraft in an illustrative implementation. DETAILED DESCRIPTION

[0021] The accompanying drawings and following description provide exemplary illustrative embodiments of the present disclosure. It will be apparent, however, that one of ordinary skill in the art will be able to devise various arrangements which, although not explicitly described or shown herein, embody the principles of the disclosure and are included within its scope. Furthermore, any example described herein is intended to be illustrative of the principles of the disclosure and should not be construed as limiting the disclosure to only the specifically described examples and conditions. As a result, the disclosure is not limited to the specific embodiments or examples described below, but by the claims and their equivalents.

[0022] The fuselage sections discussed herein can be manufactured as composite parts. The fuselage sections described herein include one or more composite parts. Composite parts such as carbon fiber reinforced polymer (CFRP) parts are initially laid up in multiple layers, which together are referred to as a preform. The individual fibers within each layer of the preform are aligned parallel to one another, but different layers exhibit different fiber orientations in order to increase the strength of the resulting composite part along different dimensions. The preform includes a viscous resin that is cured to harden the preform into a composite part (e.g., for use in an aircraft). Carbon fibers 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 tackifiers or binders. Dry fibers are infused with resin prior to hardening. For thermoset resins, hardening is a one-way process called curing, while for thermoplastic resins, if reheated, the resin reaches a viscous form that can then be set into a desired shape and cured. As used herein, the general term for the process used to transform a preform into a final hardened shape (i.e., to transform a preform into a composite part) is referred to as “hardening,” which term encompasses both the curing of thermoset preforms and the shaping / curing of thermoplastic preforms into a final desired shape.

[0023] Figure 1 A fuselage assembly system 100 of a factory in an illustrative embodiment is shown. The fuselage assembly system 100 includes any system, device, or component that is operable to iteratively advance / pulse the arcuate segments 120 (shown in Figure 9 (e.g., half-tube segments or other half-circumferential segments) of a fuselage 819 along a track 110 a distance less than its length. The fuselage assembly system 100 is also operable to perform work at inner mold lines (IMLs) 128 on the arcuate segments 120 while the arcuate segments 120 are paused between pulses.

[0024] The arcuate segments 120 comprise a portion of the airframe, such as a half-tube segment of the fuselage 819 approximately 40 feet long (other lengths are possible, such as 25 feet). In some embodiments, the arcuate segments 120 comprise a hardened composite part or metal part, such as a segment of aircraft skin awaiting installation of stringers and frames to enhance rigidity. The arcuate segments 120 comprise an outer mold line (OML) 126 and an IML 128, and define a recess 127 in which the setup station 140 (including the worktable 142) is disposed.

[0025] In this embodiment, the arcuate segments 120 are moved along the track 110 in the process direction 199 via their support edges 122. The track 110 comprises one or more rails, rollers 114, or other elements that facilitate the movement (e.g., rolling or sliding) of the arcuate segments 120 along the track 110. The track 110 synchronously pulsates the arcuate segments 120 of the fuselage 819 in the process direction 199 while maintaining the shape of the arcuate segments 120 such that the recesses 127 face the floor 150 of the factory. That is, the upper and lower arcuate segments 120 of the fuselage 819 are continuously aligned and advanced along the track 110 such that the recesses 127 face the floor 150 of the factory.

[0026] In this embodiment, the track 110 comprises a series of pogo posts 112 (also referred to herein as “pogos”) that are provided with rollers 114. The pogo posts 112 are separated by a pogo post gap (referred to herein as “pogo gap”), which can be 3 feet or more or less, depending on the work being performed in the particular station 140 and access to the stations 140 between the pogo posts 112 by personnel or the material line 198. The pogo gap enables technicians to easily enter and / or exit the track 110 without having to step over the pogo posts 112. In further embodiments, the track 110 is elevated or disposed above the technicians such that the technicians / personnel and / or materials can pass underneath the track 110 to access the stations 140. The support edges 122 of the arcuate segments 120 directly contact the rollers 114 of the track 110. The rollers 114 physically support the support edges 122 of the arcuate segments 120 and enforce the desired profile / loft on the arcuate segments 120 by forcing a distance between the various support edges 122 without distorting the arcuate segments 120 as they are advanced along the track 110. Figure 1

[0027] The track 110 also comprises motors 115 that drive the arcuate segments 120 of the fuselage 819 (e.g., by rotating the rollers 114 or by pulling the arcuate segments 120). In further embodiments, the track 110 comprises a chain drive, motorized cart, powered rollers 114, or other powered system that enables the arcuate segments 120 to be moved in the process direction 199.

[0028] Figure 1 ​A radio frequency identification (RFID) scanner 170 is also depicted at or near track 110 (e.g., RFID scanner 170 is integrated into workstation 140). RFID scanner 170 identifies the flow of materials and / or personnel entering and exiting the assembly area 131 defined by track (110) (more importantly, entering the individual workstations 140). That is, the RFID chip 372 (shown in the figure) placed on the bow section 120 by RFID scanner 170... Figure 3 The input indication read by the indexing feature 124 in the form of a ) indicates what materials, parts, tools, and / or personnel are needed and will be provided to station 140 via feed line 198 or other systems (also RFID-tracked on each of those feed lines 198). The indexing feature 124 can also be used to provide similar information to station 140 to help coordinate the determination of which materials, parts, tools, and / or personnel are needed and / or will be provided to station 140 via feed line 198 or other systems (also RFID-tracked on each of those feed lines 198). This tracking technology is via Figure 3 The RFID chip 372 allows for Just-In-Time (JIT) delivery of desired parts, where materials are delivered to station 140 as needed without station 140 needing to stock more than a few hours or enough for a single shift or day. Therefore, each item entering station 140 (e.g., a frame or window frame, etc.) may have a unique RFID chip 372, and the end of feed line 198 and / or receiving station 140 may include one or more RFID scanners 170 that send RFID information to station 140 for assembly. On the pre-hardening side, the RFID chip 372 is disposed on a carrier (not shown) transporting the pre-hardened bow section 120. In one embodiment, the RFID scanner 170 reads the RFID chip 372 disposed at the material to determine what enters and leaves station 140 and even assembly area 131. In another embodiment, the RFID scanner 170 also tracks personnel flow into and out of assembly area 131 by reading the RFID chip 372 worn by personnel (not shown).

[0029] Stations 140 are disposed below recesses 127 and include worktables 142 that physically support at least one technician and are directly mounted to the factory floor 150. As the arcuate segments 120 pulse, the recesses 127 are advanced over the stations 140 in the process direction 199. In this manner, as new portions of the arcuate segments 120 come into view of the stations 140, technicians at the stations 140 have access to new portions of the IML 128. Individual stations 140 are adapted / specifically for different types of tasks (e.g., drilling, bolt lock installation, trimming, sealing, inspection, etc.) and can include specialized tools to facilitate these tasks. In some embodiments, the stations 140 include worktables 142 that are extendable (e.g., via automated actuators, via a spring-loaded peg system, etc.) and include safety stops and / or control programs that limit the range of positions or heights provided during operation so as to avoid collisions with the arcuate segments 120. This ensures that the stations 140 and / or the technicians do not collide with the arcuate segments 120 during assembly. In further embodiments, the stations 140 are used on the floor grid mounting units and crown module mounting units. However, the stations 140 can be used anywhere that access to the interior of the arcuate segments 120 from the factory floor 150 is available. Depending on the embodiment, the stations 140 contemplated herein can be several feet long, 4 feet long, or 6 feet or more. The individual dimensions of the stations 140 are adjusted to accommodate the particular type of work to be performed on the arcuate segments 120. The dimensions of the stations 140 are also adjusted to facilitate personnel and / or material (e.g., consumable materials) access in and out of the stations 140. In further embodiments, the dimensions of the stations 140 are adjusted to accommodate particular types of work, such as drilling, frame installation, assembly, etc.

[0030] The fuselage assembly system 100 also includes indexing units 130. Individual indexing units 130 are designed to physically couple with indexing features 124 (e.g., machined features such as holes or slots) in the arcuate segments 120. The indexing features 124 are placed at known locations along the arcuate segments 120, and in one embodiment, individual indexing features 124 are separated by the same distance along the arcuate segments 120. In further embodiments, the indexing features 124 are provided in the manufacturing allowance 129 of the arcuate segments 120, which is trimmed off prior to the arcuate segments 120 being put into service.

[0031] In further embodiments, tracking with RFID chips 372 is used for indexing. That is, the RFID chips 372 can be used for indexing in this way: a radio frequency identification (RFID) scanner 170 is installed on the arc segment 120 and reads the RFID information as part of the indexing of the portion of the arc segment 120 within the view of a particular station 140. In such embodiments, the RFID chips 372 themselves are indexing features, and are continuously positioned (e.g., linearly aligned or non-linearly aligned) on the manufacturing allowance 129 of the arc segment 120. The RFID chips 372 align with and communicate to each of the continuously positioned stations 140 (or automated stations) the details needed for 3D characterization of the arc segment 120. In some embodiments, these RFID chips 372 also include instructions for the work to be performed by the station 140. For example, in embodiments where the station 140 works on different arc segments 120 of an upper fuselage (not shown), then different arc segments 120 of a lower fuselage (not shown), then different segments of another model of aircraft, the RFID chips 372 embedded into each of the arc segments 120 communicate to the station 140 what work (if any) needs to be done on the particular arc segment 120 (and / or portions thereof) currently within the view of the station 140.

[0032] In this implementation, each indexing unit 130 includes complementary features 134 for insertion into, clamping, or otherwise interacting with indexing features 124 provided at the manufacturing allowance 129 of the arcuate segment 120. The indexing units 130 are provided in fixed, known positions relative to the stations 140 and / or even the track 110. During assembly, the arcuate segment 120 is pulsed a distance (e.g., at least equal to a distance less than the length of the arcuate segment 120 and as short as a fraction of the frame pitch), indexed to the indexing units 130, and worked on by one or more technicians or one or more robots or mechanisms within the recess 127. That is, the arcuate segment 120 is pulsed to an indexing position. Each time the indexing features 124 in the arcuate segment 120 match the complementary features 134 in the indexing units 130, the position of the arcuate segment 120 is indexed to a known position in a coordinate space shared by the track 110, the indexing units 130, and the stations 140 within the recess 127. Indexing via the RFID chip 372 enables the stations 140 to know the 3D characteristics of the particular portion of the arcuate segment 120 within the stations' 140 field of view. The work to be performed by the stations 140 on the particular portion of the arcuate segment 120 within the stations' 140 field of view is also communicated to the stations 140. In particular, each indexing unit 130 is provided in a known offset (e.g., along three axes) relative to the stations 140, meaning that the act of indexing the arcuate segment 120 to the indexing units 130 results in the position of the arcuate segment 120 being known relative to the stations 140 (i.e., because the indexing units 130 are in a known position relative to the arcuate segment 120, and the indexing units 130 are in a known offset relative to the stations 140). The indexing units 130 can also be provided at particular stations 140 as needed. In one RFID indexing scenario, indexing combined with RFID scanning is used to communicate the upstream 3D scan of the arcuate segment 120 to the stations 140, and also to instruct the stations 140 on the work to be performed on the particular portion of the arcuate segment 120 within the stations' 140 field of view.

[0033] In one implementation, indexing is performed at least according to the following description. Structures in the form of arcuate segments 120 are carried on a track 110, which includes a set of struts 112 affixed to the factory floor 150. The arcuate segments 120 are manufactured to precise dimensions on layup mandrels, such precise layup enabling indexing features 124 (and / or RFID) to be precisely positioned in the manufacturing allowance 129 of the arcuate segments 120. Thus, once the arcuate segments 120 are positioned on precisely positioned struts 112 (and possibly additional internal mold line (IML) or outer mold line (OML) forcing tools), the 3D position and orientation of the arcuate segments 120 are precisely known when the indexing features 124 are engaged, without the need for full scanning via probes or optical techniques at each station 140 and / or worktable 142 therein.

[0034] The relative stiffness of the bow segment 120, which can rely on the precision located rails along with the precision located bow segment 120, helps the bow segment 120 maintain the desired loft / IML 128 / OML 126 and does not require any substantial shape defining tooling during the pulsing assembly. In this arrangement, the indexing features 124 are precisely located on or in the bow segment 120 relative to the loft / IML 128 / OML 126 of the bow segment 120, and the precision located rails help transfer the bow segment 120 from station 140 to station 140 without distortion. Thus, the 3D position and orientation of the bow segment 120 (e.g., including the loft / IML 128 / OML 126) is known (i.e., indexed) quickly and precisely after each pulse without the need to rescan the bow segment 120 each time the bow segment 120 is advanced. The indexing can be performed at multiple stations 140 during the pause between pulsing of the bow segment 120, and multiple stations 140 can be indexed to the same bow segment 120 in order to perform a greater density of work during the pause of the bow segment 120.

[0035] Due to the precision indexing performed, the technicians and / or automated systems at each station 140 are able to know exactly where to set and / or position the tools at the station 140 relative to the bow segment 120 based on the information communicated to and / or at the station 140, and what action to perform on the bow segment 120 when the bow segment 120 is within the view of the indexing unit 130. The 3D position and orientation of the bow segment 120 and / or the loft / IML 128 / OML 126 is then established or indexed to any numerical control (NC) programming or automated systems used at the station 140 (and any station set therein). Thus, less setup time or scanning is required after each pulse of the bow segment 120. Furthermore, structures added to or removed from the bow segment 120 in previous stations 140 can be added regardless of any bow segment 120 model or representation within the system without the need to scan the changes to the bow segment 120.

[0036] That is, indexing of the barrel segment 120 can be performed by aligning the barrel segment 120 to the indexing unit 130. The station 140 has a known relationship to the indexing unit 130, so this also indexes the barrel segment 120 directly or indirectly to the station 140. When the two are in a known relationship, a technician at the station 140 is indexed to the barrel segment 120 because of the known relationship between the station 140 and the barrel segment 120. Thus, indexing the barrel segment 120 of the fuselage 819 can include mating the indexing feature 124 at the barrel segment 120 with a complementary feature 134 at the indexing unit 130 that has a known physical offset relative to the station 140, such that the mating instantaneously results in the barrel segment 120 having a known position relative to the station 140 (e.g., characterizing the desired 3D properties of the segment of the barrel segment 120 that is indexed). This is because the position and size of the complementary feature 134 at the indexing unit 130 is predetermined to fit when the barrel segment 120 is at a particular and precisely determined position.

[0037] Operation of the track 110, the station 140, and / or other components is managed by a controller 160. In one implementation, the controller 160 determines progress of the 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 operation of the various components according to instructions stored in a numerical control (NC) program. The controller 160 can be implemented as, for example, custom circuitry, a hardware processor executing programmed instructions, or some combination thereof. In further implementations, the controller 160 operates one or more speakers 180 to indicate that pulsing is about to begin.

[0038] Exemplary details of operation of the fuselage assembly system 100 will be discussed with respect to Figures 2A-2B For this implementation, it is assumed that a barrel segment 120 (e.g., a barrel segment, a one-third barrel segment, or any suitable circumferential portion) of a fuselage 819 has been de-molded and is awaiting assembly work (e.g., trimming, frame installation, inspection, or other activities).

[0039] Figure 2A is a flowchart showing a method 200 of operation of the fuselage assembly system 100 in an exemplary implementation. Steps of the method 200 are described with respect to the fuselage assembly system 100 of Figure 1 but those skilled in the art will appreciate that the method 200 can be performed in other systems. Not all steps of the flowcharts described herein are included, and other steps not shown can be included. Steps described herein can also be performed in alternative orders.

[0040] In step 202, the arcuate segments 120 (e.g., half-tube segments) are set at the track 110 of the factory such that the concave portions 127 of the arcuate segments 120 face the floor 150 of the factory and the support edges 122 of the arcuate segments 120 directly contact the rollers 114 of the track 110. In other words, the arcuate segments 120 form an inverted "U" shape. At each end of the inverted "U", the support edges 122 are held / supported by the rollers 114 of the track 110 and directly contact these rollers 114. In one embodiment, securing the arcuate segments 120 to the track 110 includes placing the arcuate segments 120 onto the track 110 such that the support edges 122 are held in place by the rollers 114.

[0041] In step 204, the arcuate segments 120 are pulsed (e.g., pulsed in unison) along the track 110 in the process direction 199. In one embodiment, pulsing the arcuate segments 120 includes pulsing the arcuate segments 120 a distance between indexing features 124 that are adjacent to each other. In another embodiment, the arcuate segments 120 are pulsed a frame pitch (i.e., a distance between frames that will be placed into the segments), but any suitable pulsing distance can be utilized. For example, the pulsing distance can include a full length of the arcuate segments 120 or some fraction less than the full length. In one embodiment, a gap of at least 3 feet or some other multiple of the pulsing length that is less than the length of the arcuate segments 120 is left between the arcuate segments 120 of the machine body 819 during pulsing. This allows a technician to exit the work station 140 during the time that the work station 140 is not occupied by an arcuate segment 120. Maintenance can also be performed during these "downtime periods" of the work station 140. In addition, a technician can exit the work station 140 by passing under the support edges 122 or exiting the end of the arcuate segment 120 that is immediately adjacent to the work station 140.

[0042] In step 206, work is performed within the concave portions 127 of the arcuate segments 120 during the pauses between pulsing of the arcuate segments 120. The work is performed via the work stations 140 that are disposed below the concave portions 127 and are directly mounted to the floor 150 of the factory. In some embodiments, the pauses between pulsing last for several minutes to many minutes (e.g., fifteen to thirty minutes) or one to two hours. These pauses are equal for all work stations. During these pauses, a technician at the work station 140 performs work on the IML 128 of the arcuate segment 120. That is, the work station 140 provides access to the IML work area. Additional technicians at the work stations 140 that are disposed outside of the track 110 perform additional work and machines can also participate in the work at the arcuate segments 120 to perform operations such as trimming, cutting, frame installation, etc.

[0043] After the pause is complete, work proceeds to step 204 and the arcuate segment 120 is pulsed (e.g., a distance equal to its length, a frame spacing, or other distance less than its length, etc.). In certain implementations (e.g., a floor grid installation environment), the arcuate segment 120 remains at a single work station for multiple pulses to receive additional work. Thus, in one implementation, the controller 160 knows the amount of time assigned to each pulse and determines that the pulse of the arcuate segment 120 of the machine body 819 will occur within a threshold period of time (e.g., within a minute, ten seconds, etc.). The controller 160 then operates the speaker 180, which transmits an audible and / or visual warning during the threshold period of time to ensure that technicians and materials do not obstruct the advancement of the arcuate segment 120 and that all technicians are aware that the arcuate segment 120 is about to advance.

[0044] The method 200 provides a technical benefit by enabling personnel, tools, and work stations 140 and any work tables 142 to remain stationary while the large arcuate segments 120 of the machine body 819 are transported. Further, the work stations (e.g., work stations 140) do not have to be removed and then repositioned after each pulse of the arcuate segment 120 of the machine body. This enables the work stations 140 and work tables 142 to be dedicated to various tasks without moving. Further, because multiple work stations 140 are positioned within the recess 127 of a single machine body arcuate segment 120, various types of work (e.g., drilling, trimming, sealing, etc.) can be performed on portions of the arcuate segment 120 of the machine body 819 within the view of the multiple work stations 140 during the same pause.

[0045] The work stations 140 include work tables 142 that are customized for the work performed within the particular work station 140. This feature increases assembly speed and work density on the factory floor 150 because many assembly operations can be performed simultaneously on the segments 120 of the machine body 819 during the pause between pulses, thereby increasing work density. The machine body assembly system 100 brings the arcuate segments 120 to the technicians, any work tables, and tools, rather than bringing the technicians and tools to the arcuate segments 120. The passageway provided to the technicians by the inverted "U" of the arcuate segment 120 (i.e., the recess 127) allows for stationary work tables 142 and associated tools while enabling the arcuate segment 120 to move relative to the work stations 140 and expose new portions to the view of the work stations 140. This saves transportation time for the technicians, tools, and work tables and the repeated setup at multiple locations along the arcuate segment 120. Further, the method 200 enables the transportation time of the arcuate segment 120 to be converted into value-added time performing work on the arcuate segment 120.

[0046] Figure 2BThis is a flowchart illustrating a method 250 for operating a fuselage assembly system 100 in an exemplary embodiment. Step 252 includes advancing a recess 127 of the bow-shaped segment 120 of the fuselage 819 in the process direction 199 above station 140, resulting in a new portion of the IML 128 of the bow-shaped segment 120 being exposed to station 140. Step 254 includes pausing the bow-shaped segment 120 of the fuselage. Step 256 includes moving materials (e.g., fasteners and sealants consumed during additive manufacturing and not used as tools) and personnel into and out of station 140 during the pause. Although materials may be moved in during the majority of pauses, technicians do not need to move into and out of station 140 during every pause. In one embodiment, this includes moving materials and personnel into and out of station 140 by entering or leaving below the end of the bow-shaped segment 120. In another embodiment, this includes advancing materials and personnel below the support edges 122 of the arcuate section 120 supported by track 110 (e.g., between supports 112, via holes / grooves below the plant floor 150, etc.). These techniques and others can be used to supply materials from feed line 198 to station 140. Step 258 includes performing work on the arcuate section 120 of the fuselage 819 via station 140 during pauses. Method 250 can be iteratively repeated for each of a series of arcuate sections 120 of a continuously arranged fuselage 819, such that the series of arcuate sections 120 advance synchronously and iteratively in the process direction 199. Furthermore, pauses are synchronized between arcuate sections 120 to create uniform periods of operation at station 140.

[0047] Figure 3 In an exemplary embodiment, the fuselage that travels through the fuselage assembly system 100 (e.g., Figure 9 The figure shows a perspective view of the bow-shaped segment 120 of the fuselage 819. In this embodiment, the bow-shaped segment 120 includes a recess 127 and a shifting feature 124 for shifting to the shifting unit 130. The track 110 includes a plurality of supports 112, each support 112 including a roller 114 fixed and driving the bow-shaped segment 120 in the process direction 199.

[0048] Figure 3 The factory floor 150 and an RFID scanner 170 are also depicted. The RFID scanner 170 detects the passage of materials (e.g., frames, scrap, tools, etc.) and / or personnel entering and exiting the assembly area 131 by reading / scanning RFID chips 372 set / attached to materials or worn by personnel. Furthermore, one or more RFID scanners 170 detect RFID chips 372 embedded in the manufacturing allowance 129 of the bow segment 120. Based on the information detected in the embedded RFID chips, the 3D characteristics of the bow segment 120 are determined for its respective longitudinal portions, and instructions can also be determined therefrom.

[0049] Figure 4 is an elevational view of a workbench 400 for the fuselage assembly system 100 in an illustrative embodiment, and corresponds to the viewing arrow 4 of Figure 3 In the Figure 4 , the workbench 400 is subdivided into segments 410, each segment 410 physically supporting a technician 416 at a platform 414. The platform 414 is accessible via a step 412. The workbench 400 is fixed directly to the factory floor 150, for example via bolts or other fasteners. This arrangement means that the workbench 400 does not need to be attached to the arcuate segment 120 of the fuselage 819, and also enables the technician to quickly and easily elevate directly from the factory floor 150 to inspect the recess 127. This arrangement also ensures that the position of the workbench 400 is accurately known relative to the rails 110. The technician 416 is therefore able to work on the recess 127 by installing frames, window frames and / or door frames or other interior work. In further embodiments, the workstations have a specialist configuration appropriate to the work performed at the workstation 400. The workbench 400 can also be implemented in a static unit such as a crown module unit or a floor grid installation unit.

[0050] Figure 5 is an elevational view of an extendable workbench 500 for the fuselage assembly system 100 in an illustrative embodiment, and corresponds to the viewing arrow 4 of Figure 3 The extendable workbench 500 comprises a base 530 attached directly to the factory floor 150. An arm 520 extends from the base 530 and is driven to adjust the vertical position of a platform 510 relative to the recess 127. In this way, adjusting the vertical position of the extendable workbench 500 moves the technician at the extendable workbench 500 towards the recess 127 of the fuselage segment. This enables the technician to controllably elevate and inspect the recess 127. From this position, the technician can also perform work on the recess 127, including installing frames, window frames and / or door frames or other interior work. The workbench 500 can have a specialist configuration appropriate to the particular workstation and the work performed at that workstation 140. In further embodiments, the workbench 500 is numerically controlled and comprises safety sensors to prevent an extension that would result in a collision with the recess 127.

[0051] Figure 6is a flowchart illustrating another method 600 of operating a fuselage assembly system 100 in an illustrative implementation. In step 602, an arcuate segment (e.g., arcuate segment 120) of a fuselage 819 is set at a track 110 of a factory such that a concave portion 127 of the arcuate segment 120 of the fuselage 819 faces a floor 150 of the factory and a support edge 122 of the arcuate segment 120 of the fuselage 819 directly contacts the track 110. In other words, the arcuate segment 120 forms an inverted "U" shape. At each end of the inverted "U", the support edge 122 is held / supported by rollers 114 of the track 110 and directly contacts these rollers 114. In one implementation, securing the arcuate segment 120 to the track 110 includes placing the arcuate segment 120 onto the track 110 such that the support edge 122 is held in place by the rollers 114.

[0052] In step 604, the arcuate segments 120 of the fuselage 819 are pulsed synchronously along the track 110 in the process direction 199 with the concave portions 127 oriented downward. In one implementation, pulsing the arcuate segments 120 of the fuselage 819 includes pulsing the segments to vary the distance between indexing features 124 adjacent to one another. In another implementation, the arcuate segments 120 pulse the frame spacing (i.e., the distance between frames that will be placed into the fuselage segments), although any suitable pulsing distance can be utilized. During the pauses between pulsing, material is advanced through the passageway to the assembly zone 131 and an RFID scanner 170 is positioned at the passageway. In this way, material is passed through the gap between the arcuate segments 120 of the fuselage 819 during the pauses between pulsing.

[0053] In step 606, the RFID scanner 170 is operated. The RFID scanner 170 identifies a flow of material provided to an additive manufacturing station (e.g., station 140) on a just-in-time (JIT) basis via the feed line 198. As used herein, material being provided on a JIT basis means that they are provided to the station 140 as needed without the station 140 needing to pause or delay operation to receive the material. At the same time, JIT delivery of the material also indicates that the station 140 does not need to maintain a large inventory of material (e.g., more than an hour or a day of operation). The material is provided to pass into and out of the assembly zone 131 bounded by the track 110. In one implementation, operating the RFID scanner 170 includes reading the RFID chip 372 disposed at the material.

[0054] In further implementations, the RFID scanner 170 is positioned at a predefined entry or exit point of the assembly zone 131. This ensures that the material passes through the RFID scanner 170 and can be detected. The material includes consumable materials, materials integrated into the body (e.g., frames for the fuselage), tools, sensors, scrap, or any other component capable of receiving an RFID chip 372.

[0055] In one embodiment, the RFID chip 372 uniquely identifies each type of material and / or instance from other sources, allowing for the tracking of different types of materials, instances of materials, etc. That is, the RFID chip 372 used herein is configured to include an identifier for the type of thing it accompanies (e.g., frame, fastener, tool, etc.) and a serial number for that type. This uniquely identifies each incoming component, which is highly beneficial for tracking and ensuring the delivery time of the Just-In-Time (JIT) feed line 198 to workstation 140. The RFID chip 372 is used to track the JIT delivery of individual components to each workstation. Thus, each item entering a workstation (e.g., frame or window frame, etc.) has an RFID chip 372 providing uniquely identifiable RFID information, and the feed line 198 may include an RFID scanner 170 that sends RFID information to workstation 140 for assembly. In another embodiment, the RFID chip 372 is also worn by personnel, allowing for the tracking of personnel at assembly area 131. In this way, the RFID scanner 170 is operated to track the flow of people entering and leaving the assembly area 131 defined by track 110 (e.g., by reading the RFID chip 372 worn by the person).

[0056] In other embodiments and as Figure 3 As discussed, RFID tracking can be used to facilitate transposition. In such an embodiment, an RFID chip 372 is mounted on the arcuate segment 120 and reads the longitudinal portion of the arcuate segment 120 within the field of view of a specific station 140 as part of the transposition. The RFID chip 372 operates at the manufacturing allowance 129 of the arcuate segment 120 as a transposition feature 124 for continuous positioning, but does not need to be linearly aligned with other RFID chips 372. The RFID chip 372 is aligned with each of the respective continuous positioning stations 140 and communicates details of the 3D representation stored at the controller 160 of the arcuate segment 120 as well as instructions from the station 140. Figure 7 A radio frequency identification (RFID) scanner 170 is depicted in an exemplary embodiment to track the movement of materials and / or personnel entering and / or leaving assembly area 131 of manufacturing environment 700. Therefore, input from the RFID scanner 170 can be used to identify personnel within station 140 (e.g., additive manufacturing station) or materials within station 140 at any given time.

[0057] Figure 7 Presented with Figure 3 Observe the top view corresponding to arrow 7. Figure 7In this embodiment, the RFID scanners 170 are positioned outside the bounds of the track 110 and in a passageway 760 leading to the station 140. The arcuate segments 120 of the machine body 819 advance in the process direction 199 and intermittently block the passageway 760. However, multiple sets of passageways 760 and RFID scanners 170 are positioned at intervals that ensure that at least one passageway 760 is always available for scanning materials in and out during the pulse. In another embodiment, the RFID scanners 170 on either side of the passageway do not need to scan the material stream and RFID chips 752 in order for those materials to be detected by the RFID scanners 170. The RFID scanners 170 do not need to be attached to the pillars 112, but should be positioned relative to the passageway.

[0058] The materials 750 come from a feed line 198 and can include structural elements such as frames, window / door frames, or even fasteners. RFID chips 752 for fasteners can be placed in a container or otherwise associated with the fasteners. The materials 750 enter and exit the station 140 via the passageway 760 at which point radio energy from the RFID scanners 170 activates RFID chips 752 coupled to (e.g., attached via removable adhesive, integral with the material, or accompanying the material packaging, etc.) the materials 750 moving relative to (e.g., into and out of) the station 140 or to RFID chips of personnel moving relative to the station 140.

[0059] Figure 7 Also depicted is a technician 770, one of many personnel wearing RFID chips 754 (e.g., on badges, clothing, safety equipment items, etc.) that allow tracking as the technician advances through the passageway 760. The controller 160 tracks the readings taken by the RFID scanners 170 to determine the contents (of personnel and materials) within the station or stations (not shown) of the station 140 at any point in time. In one embodiment, the controller 160 is coupled to the RFID scanners 170 and also operates the feed line 198 that supplies the material stream to the station 140. The RFID scanners 170 are coupled to the feed line 198. Based on input from the RFID scanners 170, the controller 160 controls the rate of material entering the station and / or the stations of the station 140 by controlling the cadence of the feed line 198 that feeds material 750 into the station or the stations of the station 140. In one embodiment, the flow rate from the feed line 198 into the station 140 is based on feedback control of the cadence of the feed line 198 performed by the controller 160. That is, if the material is flowing too fast or too slow to the station 140, the controller 160 can direct the feed line 198 to decrease or increase the manufacturing / distribution rate as needed.

[0060] In another implementation, certain passages 760 are used as dedicated entries, and others as dedicated exits. This increases the ease with which the controller 160 can determine whether a technician or material is entering or exiting. That is, detection of an RFID chip 752 at an exit indicates that material is exiting the station 140, while detection of an RFID chip 752 at an entry indicates that material is entering the station 140. If an RFID chip 752 is identified at an exit, but has not been determined to be part of the entry group, the controller 160 can assume that the associated material or personnel is entering the assembly area 131, update the tracking data, and / or can cause the speaker 180 to beep to indicate an attempted entry via a passage intended for use as an exit.

[0061] In further implementations, the controller 160 maintains real-time lists of materials and personnel within the assembly area 131 based on the detected RFID chips 752. The controller 160 also utilizes these lists to generate reports, and electronically sends them to personnel for review. Based on input from personnel, the controller 160 resolves conflicts in the lists, and / or issues notifications via the speaker 180 and / or visual signals in the assembly line.

[0062] Figure 7 The illustrated arrangement allows for feedback-based control of the flow rate from the feed line 198 into the additive manufacturing station based on the takt time of the feed line 198. It also allows for determination of materials or personnel within the additive manufacturing station (e.g., by operating the RFID scanner 170 by reading RFID chips 752 coupled to personnel / worn by personnel or coupled to materials). The arrangement also allows for entry of materials into the additive manufacturing station through passages, passage of materials and / or personnel under the track 110 into the additive manufacturing station, passage of personnel between the gaps between the arcuate segments 120 of the fuselage 819 during the pulses and the pauses between the pulses, etc.

[0063] Example

[0064] In the following examples, additional processes, systems, and methods are described in the context of the fuselage assembly system 100.

[0065] Referring more particularly to the drawings, embodiments of the disclosure can be described in the context of Figure 8 manufacturing and servicing aircraft as illustrated in the method 800 and as illustrated in the system 1000. Figure 9The context of an aircraft 802 is shown. Prior to production, the method 800 can include specification and design 804 of the aircraft 802 and material procurement 806. During production, component and subassembly manufacturing 808 and system integration 810 of the aircraft 802 takes place. Thereafter, the aircraft 802 can go through certification and delivery 812 in order to be placed in service 814. While in service 814 by a customer, the aircraft 802 is scheduled for routine maintenance and service 816 (which can also include modification, reconfiguration, refurbishment, etc.). The apparatus and methods embodied herein can be employed during any one or more appropriate stages of production and service 800 (e.g., specification and design 804, material procurement 806, component and subassembly manufacturing 808, system integration 810, certification and delivery 812, service 814, maintenance and service 816) and / or any appropriate component of the aircraft 802 (e.g., body 818, systems 820, interior 822, propulsion system 824, electrical system 826, hydraulic system 828, environmental system 830).

[0066] The various processes of method 800 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 subcontractors; a third party can include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator can be an airline, leasee, military entity, service organization, or other customer.

[0067] As shown, Figure 9 The aircraft 802 produced by the method 800 can include a body 818 having a plurality of systems 820 and interiors 822. Examples of systems 820 include one or more of a propulsion system 824, an electrical system 826, a hydraulic system 828, and an environmental system 830. Any number of other systems can be included. Although an aerospace example is shown, the principles described herein can be applied to other industries, such as the automotive industry.

[0068] As already mentioned above, the apparatuses and methods embodied herein can be employed during any one or more of the production and service stages described in method 800. For example, components or subassemblies corresponding to component and subassembly manufacturing 808 can be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft 802 is in service. Additionally, one or more apparatus embodiments, method embodiments or a combination thereof can be utilized during the assembly or service of aircraft 802 (e.g., a new aircraft can employ an innovative apparatus, method or a combination thereof while in a manufacturing stage at an assembly line, and a production method can be utilized while the aircraft is in service and being modified, maintained or upgraded).

[0069] In one embodiment, the part comprises a portion of the fuselage 818 and is manufactured during component and subassembly manufacturing 808. The part can then be assembled into an aircraft during system integration 810 and then used in service 814 until wear and tear makes the part unusable. The part can then be discarded and replaced with a newly manufactured part during repair and maintenance 816. The components and methods of the present application can be used throughout component and subassembly manufacturing 808 in order to manufacture new parts.

[0070] 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 software-implemented processor, a firmware-implemented processor, 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, the 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 storage medium (e.g., flash drive), logic or some other physical hardware component or module.

[0071] Additionally, a control element can be implemented as instructions, which are 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, when executed by the processor, can 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 memory, magnetic storage media (e.g., disks and tapes), hard drives, or optically readable digital data storage media.

[0072] The present disclosure also includes the following illustrative clauses without departing from the fact that the scope is defined by the appended claims.

[0073] 1. A method for manufacturing a fuselage (819) of an aircraft (802), the method comprising:

[0074] positioning a segment (120) of the fuselage (819) at a track (110) of a factory such that a concave portion (127) of the segment (120) of the fuselage (819) faces a floor (150) of the factory and a support edge (122) of the segment (120) of the fuselage (819) directly contacts the track (110);

[0075] synchronously advancing the segment (120) of the fuselage (819) along the track (110) in a process direction (199); and

[0076] performing work within the concave portion (127) of the segment (120) of the fuselage (819) via a station positioned below the concave portion (127) and directly mounted to the floor (150) of the factory during pauses between pulsations of the segment (120) of the fuselage (819).

[0077] 2. The method of clause 1, wherein:

[0078] advancing the segment (120) of the fuselage (819) comprises pulsating the segment (120) of the fuselage.

[0079] 3. The method of clause 1 or 2, further comprising:

[0080] adjusting a vertical position of the station (140) relative to the concave portion (127) of the segment (120) of the fuselage (819).

[0081] 4. The method of any of clauses 1-3, further comprising sizing the station (140) to:

[0082] accommodate a particular type of work;

[0083] facilitate personnel access to the station (140); and / or

[0084] Facilitating material access to and from the stations (140).

[0085] 5. The method of any of clauses 1-4, further comprising:

[0086] Operating a radio frequency identification (RFID) scanner (170) that tracks:

[0087] Material flow to and from an assembly area (131) bounded by the track (110);

[0088] Material flow to and from the stations (140);

[0089] Personnel flow to and from the assembly area (131) bounded by the track (110); and / or

[0090] Personnel flow to and from the stations (140).

[0091] 6. The method of any of clauses 1-5, further comprising:

[0092] Determining that pulsing of the bow section (120) of the fuselage (819) will occur within a threshold period of time; and

[0093] Transmitting an audible warning during the threshold period of time.

[0094] 7. A method for manufacturing a portion of an aircraft (802), optionally the method for manufacturing a fuselage of any of the preceding clauses, the method comprising:

[0095] Advancing a recess (127) of a bow section (120) of a fuselage (819) over a stationary station (140) in a process direction (199); and

[0096] Performing work on the bow section (120) of the fuselage (819) via the station (140).

[0097] 8. The method of clause 7, wherein:

[0098] The step of advancing the recess (127) causes a new portion of an inner mold line (IML) (128) of the bow section (120) of the fuselage (819) to be exposed to the station.

[0099] 9. The method of clause 7 or 8, further comprising:

[0100] Pausing the bow section (120) of the fuselage.

[0101] 10. The method of clause 9, wherein:

[0102] The step of performing work on the bow section (120) of the fuselage (819) via the station (140) is performed during the pause.

[0103] 11. The method of any of clauses 7-10, further comprising:

[0104] Moving materials and personnel into and out of the station.

[0105] 12. The method of any of clauses 7-11, wherein:

[0106] The bow section (120) is advanced in synchronization with other bow sections (120) of the fuselage.

[0107] 13. The method of any of clauses 7-12, further comprising:

[0108] Scanning radio frequency identifier (RFID) chips (372) embedded in the manufacturing allowance (129) of the bow section (120).

[0109] 14. The method of any of clauses 7-13, further comprising operating a radio frequency identification (RFID) scanner (170) that tracks:

[0110] a flow of materials into and out of the station (140); and / or

[0111] a flow of personnel into and out of the station (140).

[0112] 15. A method for manufacturing a fuselage (819) of an aircraft (802), optionally according to the method of any of the preceding clauses, the method comprising:

[0113] Pulsing the bow section (120) of the fuselage (819) in synchronization along the track (110) in a process direction (199) with the recesses (127) oriented downward; and

[0114] Identifying a flow of materials provided via a feed line (198) to an additive manufacturing station (140) performing work on the bow section (120) in a just-in-time (JIT) manner.

[0115] 16. The method of clause 15, further comprising:

[0116] Positioning the bow section (120) of the fuselage (819) at the track (110) such that the support edge (122) of the bow section (120) of the fuselage (819) directly contacts the track (110).

[0117] 17. The method of clause 15 or 16, wherein:

[0118] The additive manufacturing station (140) includes a worktable (142, 400, 500).

[0119] 18. The method of any of clauses 15-17, further comprising:

[0120] identifying, via a radio frequency identification (RFID) scanner (170), an RFID chip (372) coupled to:

[0121] material moving relative to the additive manufacturing station (140); and / or

[0122] personnel moving relative to the additive manufacturing station (140).

[0123] 19. The method of any of clauses 15-18, wherein:

[0124] material is supplied to the additive manufacturing station (140) via a feed line (198).

[0125] 20. The method of any of clauses 15-19, further comprising:

[0126] passing material through a passageway into the additive manufacturing station (140).

[0127] 21. The method of any of clauses 15-20, further comprising:

[0128] passing material under the track (110) into the additive manufacturing station (140).

[0129] 22. The method of any of clauses 15-21, further comprising:

[0130] passing personnel under the track (110) into the additive manufacturing station (140).

[0131] 23. The method of any of clauses 15-22, further comprising:

[0132] passing personnel through gaps between arcuate segments (120) of the fuselage (819) between pulses during pauses between pulses.

[0133] 24. The method of any of clauses 15-23, further comprising:

[0134] determining personnel within the additive manufacturing station (140).

[0135] 25. The method of clause 24, wherein:

[0136] The step of identifying the person includes operating an RFID scanner (170) by reading a radio frequency identification (RFID) chip (372) worn by the person.

[0137] 26. The method of any of clauses 15-25, further comprising:

[0138] Determining material within the additive manufacturing station (140).

[0139] 27. The method of any of clauses 15-26, further comprising:

[0140] Controlling flow rate from the feed line (198) into the additive manufacturing station (140) based on feedback control of the tact time of the feed line (198).

[0141] 28. A portion of an aircraft (802) assembled according to the method of any of the preceding clauses.

[0142] 29. A non-transitory computer readable medium embodying programmed instructions that, when executed by a processor, are operable to perform the method of any of clauses 1-27.

[0143] 30. A system (100) for manufacturing a fuselage (819) of an aircraft (802), the system (100) comprising:

[0144] a track (110) that synchronously advances arc segments (120) of the fuselage (819) in a process direction (199) while maintaining the arc segments (120) such that concave portions (127) of the arc segments (120) of the fuselage (819) face a floor (150) of the factory and at the same time support edges (122) of the arc segments (120) of the fuselage (819) directly contact the track (110); and

[0145] a station (140) disposed below the concave portions (127) that physically supports at least one technician and is directly mounted to the floor (150) of the factory.

[0146] 31. The system (100) of clause 30, wherein:

[0147] the station includes an extendable worktable (142, 400, 500).

[0148] 32. The system (100) of clause 30 or 31, wherein:

[0149] the track (110) includes a discrete series of struts (112) that are separated in the process direction (199).

[0150] 33. The system (100) of any of Clauses 30-32, wherein:

[0151] The track (110) includes a motor (115) that drives the arcuate segments (120) of the fuselage.

[0152] 34. The system (100) of any of Clauses 30-33, further comprising:

[0153] A radio frequency identification (RFID) scanner (170) that reads an RFID chip (372) embedded in the arcuate segments (120) of the fuselage.

[0154] 35. The system (100) of any of Clauses 30-34, wherein the dimensions of the station are adjusted to:

[0155] accommodate a particular type of work;

[0156] facilitate personnel access to the station; and / or

[0157] facilitate material access to the station.

[0158] 36. The system (100) of any of Clauses 30-35, further comprising:

[0159] A radio frequency identification (RFID) scanner (170) that tracks material flow into and out of the station (140) and / or personnel flow into and out of the station (140).

[0160] 37. A system (100) for manufacturing a fuselage (819) of an aircraft (802), optionally according to any of Clauses 30-36, the system (100) comprising:

[0161] a track (110) that pulsates the arcuate segments (120) of the fuselage (819) in a process direction (199) while maintaining the arcuate segments (120) such that the concave portions (127) are oriented downward, and while the support edges (122) of the arcuate segments (120) of the fuselage (819) are in direct contact with the track (110); and

[0162] a radio frequency identification (RFID) scanner (170) disposed at the track (110) that identifies material flow relative to the station (140).

[0163] 38. The system (100) of Clause 37, wherein:

[0164] The track (110) pulsates the arcuate segments (120) of the fuselage (819) synchronously.

[0165] 39. The system (100) of clause 37 or 38, wherein:

[0166] The track (110) holds the arcuate segment (120) of the fuselage (819) such that the concave portion (127) of the arcuate segment (120) of the fuselage (819) faces the floor (150) of the factory.

[0167] 40. The system (100) of any one of clauses 37 to 39, wherein:

[0168] The RFID scanner (170) reads an RFID chip (372) coupled to the material and / or an RFID chip (372) coupled to a person accessing the station (140).

[0169] 41. A portion of an aircraft (802) manufactured using the system (100) of any one of clauses 30 to 40.

[0170] 42. An apparatus for tracking access of a station (140) of an assembly line, the apparatus comprising:

[0171] a radio frequency identifier (RFID) scanner (170) coupled to the station (140); and

[0172] an RFID chip (372) moved relative to the station (140).

[0173] 43. The apparatus of clause 42, wherein:

[0174] The RFID scanner (170) is coupled to an infeed line (198) of the station (140).

[0175] 44. The apparatus of clause 42 or 43, wherein:

[0176] The RFID chip (372) is coupled to a material moved relative to the station (140) or to a person moved relative to the station (140).

[0177] 45. The apparatus of any one of clauses 42 to 44, further comprising:

[0178] a controller (160) coupled to the RFID scanner (170) and operative to control the infeed line (198).

[0179] 46. A portion of an aircraft (802) assembled using the apparatus of any one of clauses 42 to 45.

Claims

1. A method for manufacturing the fuselage (819) of an aircraft (802), the method comprising the steps of: The arc-shaped section (120) of the fuselage (819) is positioned at the track (110) of the factory, such that the recess (127) of the arc-shaped section (120) of the fuselage (819) faces the floor (150) of the factory, and the supporting edge (122) of the arc-shaped section (120) of the fuselage (819) directly contacts the track (110); The bow-shaped section (120) of the fuselage (819) is advanced synchronously along the track (110) in the process direction (199); During the pause between the pulses of the arcuate section (120) of the fuselage (819), work is performed within the recess (127) of the arcuate section (120) of the fuselage (819) via a workstation located below the recess (127) and directly mounted to the floor (150) of the factory. The method also includes the following steps: It is determined that the pulsation of the arcuate segment (120) of the fuselage (819) will occur within a threshold time period; and Audible and / or visual warnings are transmitted during the threshold time period.

2. The method according to claim 1, wherein: The step of advancing the bow-shaped segment (120) of the fuselage (819) includes pulsating the bow-shaped segment (120) of the fuselage.

3. The method according to claim 1 or 2, further comprising the following step: Adjust the vertical position of the station (140) relative to the recess (127) of the arc-shaped section (120) of the body (819).

4. The method according to claim 1 or 2, further comprising adjusting the dimensions of the workstation (140) to: Adaptable to specific types of work; To facilitate personnel access to and from the workstation (140); and / or This facilitates the entry and exit of materials at the workstation (140).

5. The method according to claim 1 or 2, further comprising moving materials and / or personnel into and out of the workstation.

6. The method according to claim 1 or 2, further comprising the following step: Operate the radio frequency identification (RFID) scanner (170), which tracks: Material flow entering and exiting the assembly area (131) defined by the track (110); Material flow into and out of workstation (140); Personnel flow entering and exiting the assembly area (131) defined by the track (110); and / or Personnel flow in and out of workstation (140).

7. A portion of an aircraft (802) assembled by the method according to any one of claims 1 to 6.

8. A system (100) for manufacturing the fuselage (819) of an aircraft (802), the system (100) comprising: A track (110) synchronously advances the arcuate section (120) of the fuselage (819) in the process direction (199) while maintaining the arcuate section (120) such that the recess (127) of the arcuate section (120) of the fuselage (819) faces the factory floor (150), and simultaneously the support edge (122) of the arcuate section (120) of the fuselage (819) directly contacts the track (110); and A workstation (140) is disposed below the recess (127), physically supporting at least one technician, and directly mounted to the floor (150) of the factory, wherein the system includes a controller (160) configured to determine that a pulsation of the arcuate segment (120) of the fuselage (819) will occur within a threshold time period and to transmit an auditory and / or visual warning during the threshold time period.

9. The system (100) according to claim 8, wherein: The workstation includes an extendable workbench (142, 400, 500).

10. The system (100) according to claim 8 or 9, wherein: The track (110) includes a discrete series of pillars (112) separated in the process direction (199).

11. The system (100) according to claim 8 or 9, wherein: The track (110) includes a motor (115) that drives the bow section (120) of the fuselage.

12. The system (100) according to claim 8 or 9, further comprising: Radio Frequency Identification (RFID) scanner (170) reads RFID chip (372) embedded in the bow-shaped segment (120) of the body.

13. The system (100) according to claim 8 or 9, wherein, The dimensions of the workstation were adjusted as follows: Adaptable to specific types of work; To facilitate personnel access to and from the workstations; and / or This facilitates the entry and exit of materials at the workstation.

14. The system (100) according to claim 8 or 9, further comprising: Radio Frequency Identification (RFID) scanner (170) tracks the flow of materials and / or personnel entering and leaving workstation (140).

15. Manufacturing the fuselage of an aircraft using the system described in any one of claims 8 to 14.

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