Methods, systems, and non-transitory computer-readable media for inspecting a wing panel

Abstract

The present disclosure relates to methods, systems, and non-transitory computer readable media for inspecting a wing panel. Systems and methods for inspecting a wing panel are provided. Some methods include the steps of advancing a wing panel through a non-destructive inspection (NDI) station and inspecting the wing panel at the NDI station with an inspection head. During inspection and / or advancement, the wing panel can be suspended beneath a strongback, such as by using a vacuum coupler and / or an adjustable length spring member of the strongback, and the step of suspending can include profiling the wing panel using the vacuum coupler and / or the spring member. Other methods include the steps of receiving a wing panel at an NDI station and inspecting a portion of the wing panel during movement through the NDI station. Some systems include a track, a strongback that suspends a wing panel beneath and advances the wing panel along the track, and an NDI station disposed at the track to inspect the wing panel while suspended.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the field of aircraft and, in particular, to the manufacture and assembly of aircraft wings. BACKGROUND

[0002] The fuselage defines the mechanical structure of the aircraft. The fuselage is composed of a plurality of components that provide the desired structural properties. For example, a portion of the fuselage for an aircraft wing can include components mechanically coupled together (e.g., via co-bonding, co-curing, or fasteners) according to design parameters. In particular, a wing assembly typically includes an upper wing panel and a lower wing panel, each wing panel including a wing skin stabilized by a series of stringers that together sandwich a support structure composed of a forward spar and an aft spar extending along the span of the panel, and connected together by a series of parallel ribs, each extending chordwise across the panel. According to current practice, the components of the fuselage are manufactured and assembled in predetermined units in a factory workshop. For example, the components can be laid up, cured, or otherwise manufactured in one unit, which can then be transported as a whole to a new unit for further work.

[0003] EP3726314 states in its abstract: “Systems and methods determine and correct tool bias by comparing two different three-dimensional surface scans of a composite panel after curing. Such methods and systems can allow for less accurate post-cure fixturing (e.g., holding the panel in a less constrained state compared to the prior art), while still maintaining sufficient precision for predictive shimming and shimless technology. The method includes performing a first three-dimensional surface scan, performing a second three-dimensional surface scan, and comparing the two to determine a deformation function corresponding to tool bias. In some systems, a header structure is used to hold the composite panel in a nominal configuration for the second three-dimensional surface scan. In some systems, the scanning device performs mirror scans on either side of the composite panel using a common reference frame.”

[0004] US2013 / 0185918 states in its abstract: “A method of manufacturing a structure includes an imaging device installation process in which a camera that acquires an image of a target hole formed in an upper panel is installed on an aft spar, and a positioning process in which a relative position is positioned by relatively moving the upper panel and the aft spar while aligning an image of the target hole acquired by the camera and displayed on a monitor screen with a target line preset on the monitor screen.”

[0005] While the manufacturing process discussed above is reliable, they encounter delays when certain portions of the parts finish slower than expected. For example, if a particular portion of a wing takes longer than expected to layup or fasten together, then the entire wing assembly will remain in the cell until all of the work that has been delayed is completed. Further, after moving the parts, a significant amount of time is spent cataloging the configuration of the parts. This time is not value added. Further, the frequent movement between cells adds a significant amount of time that is not value added. That is, each movement of the parts between cells (and thus, each cell used in the manufacturing process) requires setup time, and this setup time should be minimized to improve efficiency. Current designs utilize automated optical inspection techniques and / or probes to check the position of the parts along six degrees of freedom across their dimensions, but these processes are particularly time consuming and costly. SUMMARY

[0006] Accordingly, it is desirable to have a method and apparatus that at least addresses some of the problems discussed above, as well as other possible problems.

[0007] The implementations described herein provide enhanced systems and techniques that facilitate manufacturing and assembly of aircraft wings via an assembly line. According to these implementations, large components such as panels are conveyed in a pulsating manner or continuously moved. Separated workstations disposed along the assembly line perform various work tasks on the components (e.g., during pauses between pulses or while the components are continuously moved). As discussed in greater detail below, the implementations herein focus on assembling a wing assembly by following a panel as it advances through the assembly line, with other components (e.g., ribs and spars, and then another panel) being installed to the panel step-by-step. In some implementations, an indexing feature for indexing the component (e.g., the panel) to one or more of the workstations is formed in the component. In implementations where the component is a panel, the indexing feature is formed in a manufacturing excess region of the panel as part of the formation of the panel, which manufacturing excess region will eventually be trimmed away. The panel can be indexed to the workstations with the aid of these indexing features. In some implementations, the workstations are disposed close enough to one another so that the panel can encounter multiple workstations at the same time due to its size. For example, the assembly line can include a series of workstations arranged in a process direction so that as the panel moves in the process direction, a leading portion of the panel first encounters an inspection workstation (such as a non-destructive inspection or NDI workstation), then a cutout workstation, and then a rib installation workstation. These workstations can be disposed close enough to one another so that, for example, when the leading portion encounters the rib installation workstation, a middle portion of the panel encounters the cutout workstation, and a trailing portion encounters the NDI workstation, so that two or more of the workstations, or all three of the workstations, can perform work tasks on portions of the same panel that are within the range of the respective workstations, such as simultaneously or overlapping in time. This assembly technique provides technical advantages by integrating the conveying process into the assembly process and by reducing the amount of work performed on large components each time the components are moved.

[0008] Some implementations are methods of inspecting a panel, where the methods include the steps of advancing the panel in a process direction through a non-destructive inspection (NDI) workstation having one or more inspection heads, and inspecting a portion of the panel at the NDI workstation with the one or more inspection heads. Some methods further include the step of suspending the panel under a strongback, for example, prior to advancing the panel through the NDI workstation, so that the panel remains suspended under the strongback during the advancement through the NDI workstation and the inspection at the NDI workstation. In some such methods, the step of suspending the panel includes securing a vacuum coupler of the strongback to a surface of the panel. Some methods further include the step of applying a predetermined profile to the panel, such as during the advancement of the panel and / or the NDI inspection. Some methods further include the step of indexing the panel to the NDI workstation.

[0009] Some embodiments are methods of inspecting a wing panel, where the method includes the steps of receiving the wing panel at a non-destructive inspection (NDI) station having one or more inspection heads; and inspecting a portion of the wing panel at the NDI station using the one or more inspection heads during movement of the wing panel through the NDI station. In some methods, the step of inspecting is performed during pulsed movement or continuous movement of the wing panel through the NDI station.

[0010] Some embodiments are non-transitory computer readable media embodying instructions that, when executed by a processor, are operable to perform the methods summarized above.

[0011] Some embodiments are systems for inspecting a wing panel, where the system includes a track; a power back configured to hang the wing panel below it and advance the wing panel along the track in a process direction; and a non-destructive imaging (NDI) station disposed at the track and configured to inspect the wing panel while it is hung below the power back. In some systems, the power back is configured to impose a predetermined profile onto the wing panel by way of adjustable length pogo's including vacuum couplers. Some systems also include a controller configured to perform various actions such as selectively retracting one or more vacuum couplers to allow NDI inspection of the wing panel, detecting out-of-tolerance conditions at the wing panel based on input from the NDI station, reporting out-of-tolerance conditions for rework, controlling operation of inspection heads of the NDI station, controlling advancement of the wing panel in the process direction, and correlating input from the NDI station with a location on the wing panel. In some systems, the NDI station is configured to index with the wing panel and / or the power back that is hanging the wing panel. BRIEF DESCRIPTION OF DRAWINGS

[0012] Other illustrative embodiments (e.g., methods, computer readable media, systems, etc. related to the aforementioned embodiments) can be described below. The features, functions, and advantages discussed can be implemented independently in various embodiments of the present disclosure or combined in yet other embodiments, the further details of which can be seen with reference to the following description and drawings.

[0013] Some embodiments of the present disclosure will now be described, by way of example only, and with reference to the accompanying drawings. In all the drawings, like reference numerals refer to like elements or elements of the same type.

[0014] FIG. 1 is a block diagram of a layup system in an illustrative embodiment that applies indexing features to a manufacturing allowance of a preform to be hardened into a composite part.

[0015] FIG. 2AA layup mandrel being covered by a composite part in an illustrative embodiment is exemplified.

[0016] FIG. 2B A layup mandrel being covered by a composite part in an illustrative embodiment is exemplified.

[0017] FIG. 3 is a flowchart exemplifying a method for applying a manufacturing allowance to a preform to be hardened into a composite part in an illustrative embodiment.

[0018] FIG. 4 Takt timing for a feeder line for a composite part in an illustrative embodiment is depicted.

[0019] FIG. 5A to FIG. 5F is a diagram of an assembly line for a wing in an illustrative embodiment.

[0020] FIG. 5G is a diagram of an alternative configuration of an assembly line for a wing in an illustrative embodiment.

[0021] FIG. 6 is a flowchart exemplifying a method of applying a profile to a wing panel in an illustrative embodiment.

[0022] FIG. 7 and FIG. 8 is a flowchart exemplifying a method of non-destructive inspection of a wing panel in an illustrative embodiment.

[0023] FIG. 9 is a flowchart exemplifying a method of installing ribs and spars to a wing panel in an illustrative embodiment.

[0024] FIG. 10 is a flowchart exemplifying a further method of applying a profile to a wing panel in an illustrative embodiment.

[0025] FIG. 11A to FIG. 11D Installing ribs at an upper wing panel in an illustrative embodiment is exemplified.

[0026] FIG. 12 is a flowchart exemplifying a method of securing ribs to an upper wing panel in an illustrative embodiment.

[0027] FIG. 13 to FIG. 15 is a flowchart exemplifying a method of installing ribs and spars to an upper wing panel in an illustrative embodiment.

[0028] FIG. 16A to FIG. 16C is a diagram exemplifying automated installation of shims between ribs and a wing panel in an illustrative embodiment.

[0029] FIG. 17A to FIG. 17CFIG. 7 is another view of the robotic arm installing a shim between a rib and a spar in an illustrative embodiment.

[0030] FIG. 18 FIG. 8 is a flowchart illustrating a method of installing a shim using a robotic arm in an illustrative embodiment.

[0031] FIG. 19 FIG. 9 is a perspective view of an aircraft including a fully assembled wing in an illustrative embodiment.

[0032] FIG. 20 FIG. 10 is a block diagram of various components and systems discussed herein in an illustrative embodiment.

[0033] FIG. 21 Control components of a production system performing ultrasonic inspection in an illustrative embodiment are generally illustrated.

[0034] FIG. 22 An assembly line in an illustrative embodiment is depicted.

[0035] FIG. 23 FIG. 12 is a flowchart of an aircraft production and service method in an illustrative embodiment.

[0036] FIG. 24 FIG. 13 is a block diagram of an aircraft in an illustrative embodiment. DETAILED DESCRIPTION

[0037] The accompanying drawings and following description provide specific illustrative embodiments of the present disclosure. Thus, it will be understood that those skilled in the art will be able to devise various arrangements that, 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 help illustrate the principles of the disclosure and is not intended to limit the scope of the disclosure to the specific examples described or otherwise. Thus, the present disclosure is not limited to the specific embodiments described below, but is instead broadly applicable to any suitable arrangement.

[0038] For convenience, the description is presented as a series of operations that can occur in the production of an aircraft wing, as the wing is assembled from component parts on an assembly line. In particular, the description begins with the formation of a panel from a preform and proceeds through various operations performed on the panel, including the addition of structural components such as ribs and spars to the panel (which can be an upper panel) and the joining of another panel (such as a lower panel) to form a wing assembly. The term "wing assembly" is generally used herein to refer to a panel to which one or more major structural components (e.g., ribs and spars) have been affixed or installed, and thus can include a complete wing. However, as in the description, major reference is made to the formation of the panel and the addition of major structural components thereto, without necessarily including cabling and mechanical and electrical systems that are also incorporated into a complete wing. Not all of the operations, processes, steps, and other actions that are described herein need to be performed in the described order, nor do they all necessarily need to be performed, to realize the implementations described herein (e.g., implementations of wing assemblies, implementations of structural components thereof, implementations of methods related to assembly thereof, etc.), or to achieve desirable results. Further, as described, certain actions can be performed in different orders, can be performed concurrently, can be performed at different times, can be denoted alternative actions for different panels (such as an upper panel rather than a lower panel, etc.), and the like.

[0039] The wings and wing assemblies described herein can include metal parts and / or 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 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 adhesives. Dry fibers are infused with resin prior to curing. For thermoset resins, hardening is a one-way process called curing, whereas for thermoplastic resins, the resin will achieve a viscous form if reheated.

[0040] FIG. 1is a block diagram of an exemplary layup system 100 in an exemplary embodiment that applies indexing features to the manufacturing excess of a preform that is to be hardened into a composite part. In previous systems, the manufacturing excess of a composite part - that is, the material that is beyond the intended final dimensions or boundaries (e.g., the final perimeter) of the composite part - is trimmed immediately after ejection. For example, this can include placing a wing panel into a dedicated cell, scanning the wing panel to characterize it, and then trimming the wing panel (e.g., with a cutter) along the perimeter of the part until the final perimeter dimensions are achieved. A similar process is applied in trimming the manufacturing excess of the fuselage. As will be described in greater detail herein, the layup system 100 is unique in that it utilizes the material that is traditionally trimmed off of the composite part immediately after ejection. Specifically, various indexing features are formed in the manufacturing excess of the preform, which can then be used to index (e.g., position, orient, identify, etc.) the hardened composite part for further operations, such as at one or more stations in an assembly line or in other manufacturing processes. The layup system 100 includes any system, device, or component operable to apply indexing features to a preform that is to be hardened into a composite part. In this embodiment, the layup system 100 includes a layup mandrel 110 (e.g., a rigid metal mandrel) that defines a contour 112 (e.g., a curved, flat, or other shaped contour) of a preform (such as a wing panel) that is to be hardened into a composite part. The preform 200 is shown disposed on the layup mandrel.

[0041] Reference can also be made to FIG. 2A and FIG. 2B which shows an isometric view of a simplified version of the layup mandrel 110, the mandrel has surface features 114, such as indentations, protrusions, ridges, grooves, notches, through holes, blind holes, dams, etc. Similar to the contour 112 (which imparts a corresponding contour to the preform), the surface features 114 can be used to place corresponding indexing features directly onto the preform, shown at 210. Other surface features accommodate trimming the manufacturing excess at the layup mandrel 110, or drilling into the hardened composite part at the layup mandrel 110. In other words, the surface features 114 locally change the shape of the preform 200 to place indexing features 210 into the preform and / or hardened composite part, various types of surface features 114 provide different ways of forming indexing features into the composite part. One way is to layup the preform over a surface feature (e.g., a protrusion that forms a corresponding indentation in the preform that becomes part of the composite part after hardening); another way is to machine (e.g., drill) an indexing feature (e.g., a through hole) into the hardened composite part. For example, in FIG. 1In particular implementations, the surface features 114 are shown as including recesses 118 that are filled with potting compound and finished to a surface profile that is complementary to the contour 112, such that before the composite part resulting from the hardening of the preform 200 is de-molded from the mandrel 110, indexing features such as through-holes can be drilled into the part, with some of the potting compound removed using an overstroke during the drilling operation without damaging the surface of the lay-up mandrel. The surface features 114 are used to shape or implement indexing features onto (and / or into) the preform 200 that is laid up on the lay-up mandrel 110.

[0042] The overstroke during machining (such as drilling or trimming) at the lay-up mandrel 110 after hardening requires reworking of the potted surface before the lay-up mandrel 110 is used again. The preform 200 is laid up on the lay-up mandrel 110 over the contour 112 and the surface features 114.

[0043] As FIG. 1 illustrated and also visible in FIG. 2A which shows the lay-up mandrel 110 waiting to be laid up, the lay-up mandrel includes a lay-up area 120 for the preform 200, which includes the contour 112 and is surrounded by a manufacturing allowance area 122 provided with the surface features 114. Correspondingly, the preform 200 is shown in FIG. 1 as extending beyond the final trimmed boundary or final perimeter 202 of the resulting composite part. The area of the preform that extends beyond the final perimeter 202 is a manufacturing allowance, indicated at 204, which is defined by a manufacturing allowance edge 206. Thus, the surface features 114 are positioned to complementarily form indexing features 210 in the preform 200. More particularly, the surface features 114 provided in the manufacturing allowance area 122 form indexing features 210 in the manufacturing allowance 204 of the preform 200 before the preform is hardened, which, as described above, can be used for indexing after the preform 200 is hardened into the composite part 250. Although the curve of the contour 112, which is shown as a shallow concave surface, is shown as extending beyond the final perimeter 202 of the resulting composite part on the lay-up mandrel 110, this is not required for all implementations, as only the portion of the resulting composite part that is within the final perimeter 202 requires the contour 112. Furthermore, although a concave lay-up mandrel 110 is exemplified, any suitable shape of lay-up mandrel can be utilized. For example, convex lay-up mandrels and lay-up mandrels that define complex curvatures are also possible. Furthermore, although an outer mold line lay-up mandrel 110 is exemplified, an inner mold line lay-up mandrel can be utilized in another implementation.

[0044] In contrast to FIG. 2A which shows the lay-up mandrel 110 waiting to be laid up, FIG. 2BA composite part (indicated at 250) is shown that has been hardened from the preform 200, awaiting demolding from the layup mandrel 110. The indexing features 210 of the preform 200 have become the indexing features 210 of the composite part 250.

[0045] In some embodiments, the surface features 114 are separated from adjacent surface features by a predefined distance (e.g., a few centimeters (inches), a few meters (feet), etc.), such as to create evenly spaced indexing features 210 at / on / in the preform 200 and the resulting composite part 250. In another embodiment, the surface features 114 are unevenly spaced from one another. The location and / or predefined distance between indexing features can depend in part on factors such as the arrangement of workstations on an assembly line.

[0046] The locations of the surface features 114 in the layup mandrel 110 are precisely toleranced (e.g., to about 0.03 cm (i.e., one thousandth of an inch)), and thus the locations of the corresponding indexing features 210 at the preform 200 are also known to the precise tolerance, even after the preform 200 has been hardened into the composite part 250 and demolded from the layup mandrel 110. Thereafter, workstations in an assembly line can utilize the indexing features 210 in order to orient and position the resulting composite part in a desired manner so that work can be performed on the composite part. Moreover, because the layup mandrel 110 is reusable, there is no need for a separate process to apply indexing features to the preform. Performing this process at the layup mandrel, which is located within the tolerance, results in the indexing features also being within the tolerance. The recesses 118 (also referred to as potting regions) are filled with a potting compound and are provided as described above to accommodate machining overruns from machining operations (such as drilling operations) for installing indexing features (e.g., through-holes) after completion of hardening into the composite part 250, and are refilled and / or re-exposed as needed after machining and demolding to prepare for the next preform.

[0047] Some embodiments include installing a readable identification device (in FIG. 1A readable identification device, such as a radio frequency identifier (RFID) chip, is shown generally at 126. In such embodiments, one or more RFID chips are coupled, attached, or embedded into the manufacturing allowance 204 of the preform 200. A readable identification device, such as an RFID chip, can facilitate the repositioning process by reporting information that characterizes aspects of the resulting composite part to which the readable identification device is coupled. For example, an RFID chip can provide instructions to a work station regarding a structural portion within a particular work station range. One or more RFID chips can provide instructions to one work station or more work stations, and there need not be a one-to-one relationship of an RFID chip to a work station. In another example, an RFID chip reports to a work station the type of structure / wing, including right or left, or up or down, or even model number.

[0048] Further, although not shown in the figures, one or more other readable identification devices 126 can be provided to the preform 200 or the resulting composite part 250 as part of the forming process, in addition to or instead of an RFID chip. For example, a barcode or other marking that can be scanned or read by a suitable reader by one or more work stations in the assembly line can be inscribed or applied to the preform or resulting composite part prior to ejection. For purposes of this disclosure, all references herein to a particular type of readable identification device 126, such as an RFID chip or a barcode (and their descriptions, in the figures) are intended to broadly include any such readable identification device.

[0049] FIG. 1 The shown layup system also includes a cutter 130 having a blade 132 (e.g., a reciprocating or circular blade) and an actuator 134 that drives the blade 132 to cut portions of the composite part proximate to a guide 116 in the layup mandrel 110, shown in the form of an abutting groove that encloses the manufacturing allowance region 122. That is, the guide 116 disposes and / or defines a path for the cutter 130. Further, as shown, the guide 116 can be filled with a potting compound to house the blade of the cutter (and refilled after use, similar to the recess region 118). As shown, for example, in this figure, the grooves that collectively form the guide 116 are shown as rectangular perimeters for clarity, the composite part 250 is shown as including portions 252 that are within the layup region 120 and portions 254 that conform to the surface feature 114 in the manufacturing allowance region 122. A flash edge 256 of the excess material is shown at the intersection of the portions 252 and 254. FIG. 1 FIG. 2B FIG. 2B ​​The flash 256 is shown extending beyond the manufacturing allowance region 122. A cutting operation performed prior to demolding the composite part 250 from the layup mandrel 110 removes the flash 256 to define the manufacturing allowance edge 206 and leaves a sufficient amount of manufacturing allowance 204 to include the indexing feature 210 for use by a station in the assembly line. Prior to trimming the edge to the final perimeter (i.e., the final perimeter 202), the rough cut provides a consistent edge (i.e., the manufacturing allowance edge 206) to the part during the manufacturing process. This is desirable as compared to working on a part that does not have a fixed consistent perimeter relative to the manufacturing allowance. The operation of the cutter 130 is managed by the controller 140. The controller 140 can be implemented, for example, as custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

[0050] Exemplary details of the operation of the layup system 100 will be discussed with respect to the method 300 shown in FIG. 3 The steps of the method 300 will be described with respect to the components of the layup system 100 shown in

[0051] FIG. 3 is a flowchart illustrating a method 300 for applying an indexing feature to the manufacturing allowance 204 of a preform 200 to be hardened into a composite part 250 in an exemplary embodiment. Reference is made to FIG. 1 、 FIG. 2A and FIG. 2B The components of the layup system 100 shown in Figs. 1-3 describe the steps of the method 300, but one of skill in the art will understand that the method 300 can be performed in other systems. As is the case with all methods illustrated and described in this disclosure, the steps shown in the flowcharts described herein are neither inclusive nor exclusive. Additionally, steps in the flowcharts herein (such as the method 300) can be performed in any order or simultaneously, as is appropriate. FIG. 3The flowcharts in the various figures illustrate the architecture, functionality, and operation of possible implementations of methods such as method 300 in accordance with the present disclosure. In this regard, each specific method that is diagrammed in a flowchart is indicative of one specific implementation of a method in accordance with the present disclosure. Other implementations of a method consistent with the present disclosure, which are not specifically depicted in a flowchart, can include fewer or more steps than those depicted, can include steps performed in an order different than those depicted, and / or can include other (e.g., additional, fewer, and / or alternative) actions. Also, as will become apparent according to the present disclosure, because the various methods shown and discussed herein involve a number of different operations and sequences that can be performed as the wing panels are formed and assembled into a wing assembly, methods according to the present disclosure can combine or otherwise include various steps and operations of two or more of the various methods shown. Moreover, although reference numerals of the above-described components are used in the description of this method 300, it will be understood that the method (as well as the other methods described herein) is applicable to components that can have configurations different than those shown and described above.

[0052] With method 300, at step 302, the preform 200 is laid up on the layup mandrel 110 (such as on the layup area 120) and on portions of the layup mandrel 110 that are outside of the final trim boundary (i.e., the final perimeter 202) of the composite part 250 (such as on the manufacturing allowance area 122). The manufacturing allowance area 122 of the layup mandrel 110 includes surface features 114 that are configured to complementarily form indexing features 210 in the preform 200. The layup mandrel 110 defines a profile 112 of the composite part at least in the layup area, and the preform 200 includes a manufacturing allowance 204 that extends beyond the final perimeter of the composite part. The layup can occur as the layup mandrel 110 itself is pulsed or continuously moved through the assembly line, and can include the simultaneous operation of multiple lamination machines at a time (e.g., during continuous motion of the layup mandrel, during pauses between movements of the layup mandrel, etc.). During layup, multiple plies of unidirectional fiber reinforcement material are applied in sequence to build the preform 200 to the desired size and strength. The layup process extends the preform 200 beyond the final trim (e.g., assembly size) boundary (e.g., beyond the final perimeter 202), which means that a portion of the preform 200 extends over the surface features 114. In this implementation, the preform 200 is a preform for the wing panel 550 having a plurality of layers / plies.

[0053] At step 304, the preform 200 conforms to the surface feature 114 at the layup mandrel 110, which lies outside the final trim boundary of the composite part 250 and complementarily forms / implements features to be hardened into the preform 200 as the index features 210. In one embodiment, this includes consolidating the preform 200 by vacuum bagging the preform and applying a consolidation pressure. In another embodiment, the tows of fiber reinforcement material applied during the layup of step 302 are compressed by rollers or other devices to cause the preform 200 to conform to the surface feature 114.

[0054] In the illustrative method, steps 302 and 304 are typically performed in a clean room environment to minimize the likelihood of foreign debris and other contaminants contacting the preform 200 (such as during the layup). The layup mandrel 110 is then moved to an autoclave, which hardens the preform 200 into the composite part 250 via heating and / or pressurization. At step 306, the preform 200 is hardened into the composite part 250, which includes the index features 210 complementarily formed therein, where the index features 210 are complementary to and disposed at the surface feature 114. During the hardening, the preform 200 can be heated to a cure temperature of the thermoset resin within the preform 200, or the preform 200 can be heated to a melt temperature of the thermoplastic resin and then cooled until the thermoplastic resin solidifies. This results in the resulting composite part 250 having the index features 210 disposed at the surface feature 114 on the layup mandrel 110.

[0055] In further embodiments, additional index features 210 are added by milling or drilling a manufacturing allowance (such as by installing a hole, notch, channel, and / or groove that removes material from the manufacturing allowance). In still further embodiments, additional index features 210 are utilized and / or installed (such as a pin, clip, ring, etc.).

[0056] Some embodiments include installing a readable identification device 126 (such as an RFID chip, bar code, etc.) to the preform 200 or the manufacturing allowance 204 of the composite part 250. In other words, the RFID chip and / or other readable identification device 126 is disposed in the manufacturing allowance 204 before or after the preform is hardened into the composite part 250.

[0057] At step 308, material is removed (e.g., cut or otherwise separated) from the composite part 250 while leaving behind the manufacturing allowance 204 including the indexing features 210. The cutting operation of step 308 results in a uniform perimeter / frame boundary of the manufacturing allowance 122. In one embodiment, this includes operating the cutter 130 along the guide 116 to cut off the resin flash (or flash 256) or other frame boundary of the composite part 250, resulting in the manufacturing allowance edge 206. In one embodiment, the flash 256 of the resulting composite part 250 is trimmed off prior to de-molding the composite part 250 from the layup mandrel 110. The composite part 250 retains the manufacturing allowance 204 with the indexing features 210 that will be used to index the composite part when operated through the workstations on the assembly line. The composite part 250 can also include the indexing features 210 in areas that will be trimmed off to accommodate other parts such as wing access doors or panels and / or manufacturing allowance beyond the final perimeter of the panel. The final perimeter 202 can then be obtained by trimming off the retained manufacturing allowance later in the process. That is, one or more of the indexing features can be removed to accommodate the addition of one or more components during assembly. For example, a workstation can be designed to trim off the manufacturing allowance or portions thereof, install components such as ribs or spars, join components such as panels together, etc. In further embodiments, additional indexing features 210 such as holes, notches, channels, grooves, etc. are installed / form on the composite part 250 via drilling, milling, or other operations. In further embodiments, removing material from the composite part 250 includes installing such additional indexing features 210.

[0058] At step 310, the composite part is de-molded from the layup mandrel 110 after removing material from the composite part 250 such as separating the flash 256 and / or setting, indexing one or more of the indexing features 210. The composite part 250 is then advanced (not shown) to the assembly line for further manufacturing and assembly, while the layup mandrel 110 is returned for cleaning and to receive another preform for a composite part. In one embodiment, the layup mandrel 110 is also reworked (e.g., refilled with potting compound as needed to restore the layup profile 112 after drilling or cutting overshoots into the potting region 118 prior to de-molding, repair, etc.) and transported to a starting position for beginning layup, such as on a panel layup line.

[0059] The method can then continue. For example and as described in greater detail herein, the resulting composite part 250 can be indexed via the indexing feature 210 to a work station in an assembly line, and a work can be performed on the composite part at the work station as the composite part is indexed to the work station. In some embodiments, the composite part 250 is suspended or otherwise conveyed through the assembly line by a shuttle device, such as a power back. The composite part 250 can be indexed to the shuttle device, such as by means of a corresponding indexing unit on the power back. The power back, in turn, can be indexed to the work station, in which case it can be said that the composite part is indexed to the work station via the power back. In any case, the indexing characterizes at least a portion of the composite part 250 (and / or the power back) that is within the confines of the work station to the work station. In further embodiments, multiple indexing features interact with multiple work stations and / or with the power back. Indexing can be performed for one or more work stations until the manufacturing allowance 204 is finally trimmed off of the composite part 250 (e.g., after the indexing features in the manufacturing allowance are no longer used for assembly). After trimming, the composite part 250 has its final periphery 202, and the indexing features 210 in the manufacturing allowance have been removed. The composite part 250 is then integrated into a wing assembly of an aircraft.

[0060] The method 300 provides significant advantages over the prior art in that it enables the indexing features 210 to be installed into the composite part 250 during layup by reference to the already precisely toleranced surface features 114 on the mandrel 110. This eliminates the need for precise measurement of the preform 200 in order to install the indexing features 210, as the indexing features have been set in precisely known locations by virtue of the setting of the surface features and the setting relative to the layup mandrel 110. Thus, the precision of the layup mandrel 110 and the layup process is leveraged to avoid the need for downstream profiling and indexing. Thus, the precision of the layup mandrel 110 is extended / leveraged beyond just the layup process to include post-cure processes such as trimming, milling, or drilling to add indexing features prior to the composite part 250 being de-molded. Thus, the accuracy relationship of the plurality of surface features 114 and the corresponding formed indexing features 210 set into the composite part 250 by use of the layup mandrel 110 is carried forward as the composite part advances, which can enable simultaneous manufacturing process steps to be performed on the same part.

[0061] FIG. 4 An example diagram is shown that illustrates how different feeder lines and assembly lines or layup lines can be coordinated in an assembly line for assembling, for example, a wing assembly. FIG. 4is a flow chart illustrating an example of a pattern in an exemplary embodiment, the pattern is shown as pattern 480 for feeder lines 490 and assembly / laid lines 491. Pattern 480 provides a detailed example flow chart of wing manufacturing in relation to feeder lines and takt times. For a particular embodiment, all feeder lines from layup material feeder lines to joining operations for integrating the wing to the fuselage section are depicted. Additionally, the individual steps indicated by arrows are performed according to the desired takt time based on the takt time of the component it feeds to.

[0062] In this embodiment, each feeder line is designated with a different reference number 490 (e.g., 490-1, 490-2, etc.) and each assembly line or layup line is designated with a different reference number 491 (e.g., 491-1, 491-2, etc.). More specifically, feeder line 490-1 provides layup material to wing panel layup line 491-1. Feeder line 490-2 provides layup material to spar layup line 491-5. Feeder line 490-3 provides layup material to rib layup line 491-3 and feeder line 490-4 provides layup material to stringer layup line 491-2. In addition, the layup lines feed into other layup lines. Rib layup line 491-3 feeds into rib post manufacture line 491-7, wing panel layup line 491-1 feeds into wing stringer setup line 491-4 and spar layup line 491-5 feeds into spar post manufacture line 491-6.

[0063] Each feeder line is shown as having a takt time that facilitates the manufacture of the component it manufactures. The takt times between the feeder lines and the assembly lines they feed are synchronized to provide just-in-time (“JIT”) delivery of components to the corresponding work station 520 or work stations 520 that use these components (e.g., as consumables, as inputs to the product being manufactured, etc.). The resulting components move along assembly line 500 with work stations 520 and also advance according to the takt time. The takt time for each of feeder lines 490-1 through 490-9 and or lines 491-1 through 491-9 can be the same, or some can be the same, or all can be different. Each feeder line 490-1 through 490-9 advances according to the common takt for that particular line.

[0064] The takt time for each feeder line can depend on the desired production rate of the assembly line that the feeder line feeds. For example, if a rib is attached at a rate of one per hour and attached by two hundred fasteners, then two hundred fasteners should be supplied to the rib installation station by the feeder line per hour, resulting in a fastener takt time of three and one third of a fastener per minute.

[0065] In this implementation, for example, the rib layup line 491-3 advances and feeds into the rib post-manufacturing line 491-7 at a cadence 7 time. The spar layup line 491-1 advances and feeds into the spar set line 491-4 at a cadence 3 time. The beam layup line 491-5 advances and feeds into the beam post-manufacturing line 491-6 at a cadence 5 time.

[0066] The rib post-manufacturing line 491-7 advances at a cadence 6 time, the spar set line 491-4 advances at a cadence 2 time, and the beam post-manufacturing line 491-6 advances at a cadence 4 time. All feed into the wing assembly line 491-8, which advances at a cadence 1 time, and also receives access covers from the access cover feeder line 490-5, hybrid materials from the hybrid material feeder line 490-6, fasteners from the fastener feeder line 490-7, and sealant from the sealant feeder line 490-8. The panel 550 is cured in an autoclave in line 490-10. The composite part 250 is then trimmed and (in some implementations) a indexing feature 210 is added before being separated from the mandrel 110 in line 490-11 (e.g., in a demolding station). The excess material that is trimmed off is removed from the wing assembly line 491-8 via a downward chute 490-9. After the wing is manufactured, the line 491-9 moves the wing toward the fuselage for connection. Each of the various lines discussed above can provide materials and / or components to the line to which it feeds at any rate that can be desired. The cadence time of a downstream line can or can not be equal to the line or lines that feed it. The various lines can have unique cadence times.

[0067] Any assembly line (including feeder lines) can operate as a micro-pulse, full-pulse, and / or continuous line, the manufacturing process proceeds from left to right (with respect to the schema 480), the various cadence times are synchronized to deliver components and / or materials to the next line downstream in JIT. As used herein, “pulsed” means that the component advances in the process direction through the assembly line, followed by a pause. The component can be “micro-pulsed” (the term refers herein to the component advancing in the process direction a distance that is less than its length) or can be “full-pulsed” (the component advances a distance that is equal to or exceeds its length). As part of the pulsed manufacturing, the components in the assembly line are pulsed synchronously, and multiple workstations can perform work on different parts of the component during the same pause between pulses or during the pulses themselves. In other words, the workstations perform work on a part of the panel simultaneously, such that each workstation performs work on a different part during the pause in the panel’s advancement along the track.

[0068] This parallel processing significantly increases the job density within the factory. The cadence of each of the micro-pulsed or fully-pulsed components can be the same or different, or a defined fraction of the cadence time of another assembly line that receives that component. For example, the cadence time at feeder line 490-2 for spar layup material can be different than the cadence time at feeder line 490-1 for wing panel layup material, which can be different than the cadence time for sealant provided via sealant feeder line 490-8. In one embodiment, the cadence time is constant for each of the illustrated sections.

[0069] As noted above, the individual feeder lines discussed herein can be pulsed or continuously operated. The pulsed lines can implement micro-pulsing (where the components being manufactured are advanced less than their length from the job station before receiving a job during a pause), or can be fully-pulsed (where the components are advanced an amount equal to their length). Further, the various components (e.g., wing assemblies, wing panels, ribs, spars, etc.) can be manufactured from composite parts, or via additive or subtractive manufacturing techniques of metal. For example, in one embodiment, ribs are manufactured via subtractive manufacturing of metal components at rib post-manufacturing line 491-7, while wing panels are manufactured as composite parts (e.g., pre-preg) at wing panel layup line 491-1.

[0070] FIG. 4 Various aspects of the illustrated and above-described modes can be implemented in any manufacturing environment, for example, in a factory floor and / or assembly line for a wing, such as to coordinate timing of assembly, movement (e.g., pulsed and / or continuous), and / or to deliver components and supplies on a JIT basis or otherwise, and / or other operations. Accordingly, the illustrated embodiment of assembly line (such as FIG. 5A to FIG. 5F and described below) corresponds to assembly line 491-8. However, even where not specifically mentioned in the description of embodiments, other assembly lines and manufacturing processes consistent with the present disclosure can implement such modes or any aspects thereof.

[0071] FIG. 5A to FIG. 5F Various aspects of an example assembly line 500 for a wing in an illustrative embodiment are depicted. Assembly line 500 can be used to perform jobs on wing panels (such as wing panel 550) manufactured via the techniques and systems provided above in FIG. 1 to FIG. 4 and described below. FIG. 5A to FIG. 5F The description of the structures, components, and operations illustrated therein is provided with respect to wing panels, but applies to any composite part. Wing panel 550 is somewhat generically described, and can be an upper or lower wing panel, or a right or left wing panel. Where operations or features are described with respect to a particular type of wing panel 550 (e.g., an upper wing panel), the wing panel will be so indicated. Assembly line 500 (a top view of which is depicted inFIG. 5A The assembly line 500 (shown schematically in FIG. 1) includes a track 510 along which shuttle devices (shown in the form of a set of three power backs 540) travel in a process direction 541 (e.g., in a pulsed manner from station to station, or continuously). The track 510 includes one or more rails, rollers, or other elements that facilitate movement (e.g., rolling or sliding) of the shuttle devices along the track 510. The track 510 can be mounted to the floor, suspended from above, etc., depending on the particular environment in which it is used. In the illustrated embodiment, the track 510 is disposed above the various stations, and the shuttle devices (power backs 540) carry the panels 550 in the process direction. In particular, as shown, the power backs 540 are shown to include adapters 543 that cooperate with the track 510 and are movable via the track 510. For example, the adapters 543 can drive the power backs 540 along the track 510, or can enable the track 510 to drive the power backs 540. Either way, this configuration is intended to broadly encompass any suitable manner of structuring the shuttle devices to convey the panels 550 in the process direction 541. In further embodiments, the track 510 includes a chain drive, motorized cart, or other powered system (not shown) that is capable of moving the power backs 540 in the process direction 541. FIG. 5D

[0072] One or more power backs 540 advance the panels 550 through various work stations, generally indicated at 520, that perform work on the panels 550. In the illustrated embodiment, the work stations 520 include a first work station 521 that performs a first operation on the panels 550, a second work station 522 that performs a second operation on the panels 550, and a third work station 523 that performs a third operation on the panels 550. In the illustrated embodiment, the first work station 521 is a cutting station that cuts the panels 550 to length, the second work station 522 is a drilling station that drills holes in the panels 550, and the third work station 523 is a riveting station that rivets the panels 550. In other embodiments, the work stations 520 can perform other operations on the panels 550, or can perform the same operations in a different order. FIG. 5A In the illustrated embodiment, three power backs 540 cooperatively carry a single panel 550. However, a greater or lesser number of power backs 540 can be used if appropriate. For convenience, the term “power back” is used herein generally to refer to a single structure configured to extend across a transverse cross-section (such as a chordwise cross-section) of a panel 550, but for convenience the term can be used herein to refer broadly to shuttle devices that include multiple such structures. When two or more power backs 540 cooperatively carry a component such as a panel 550, they can be coupled to one another (not shown) in a manner that maintains their constant relative positions, such that only one power back 540 is driven along the track 510. In this manner, panels 550 of different lengths can be carried through the assembly line 500, such as by coupling together a suitable number of power backs 540 to support the entire length of a panel 550.

[0073] In some embodiments, indexing features of a panel 550 (such as located in a manufacturing allowance) can be used to index the panel 550 together with the power back 540 that supports the panel 550. In the view corresponding to the arrow “5B” in FIG. 5B, the indexing features of the panel 550 are shown to include a first indexing feature 551 and a second indexing feature 552. The first indexing feature 551 is shown to include a first indexing tab 553 and a first indexing slot 554. The second indexing feature 552 is shown to include a second indexing tab 555 and a second indexing slot 556. In the illustrated embodiment, the first indexing tab 553 is configured to be received in the first indexing slot 554, and the second indexing tab 555 is configured to be received in the second indexing slot 556. In other embodiments, the indexing features of the panel 550 can be configured in other ways. FIG. 5A FIG. 5B ​​In the view, the strongback 540 is shown to include an index unit 542 configured to interface with a corresponding index feature installed in the manufacturing allowance 554 of the wing panel 550 (which can correspond to the manufacturing allowance 204 of the preform 200 that is hardened into the wing panel 550 according to the manufacturing process described above). In the illustrated embodiment, the index unit 542 is physically coupled with the index feature, where the index unit 542 is shown to include a head 549 received within the index feature 210-1 (which is shown as a through-hole). Although FIG. 5B Only one index unit 542 is shown in the view, but each strongback 540 can include any suitable number of index units, each of which can be configured to couple with an index feature 210 of a wing panel 550, such as to initially align and / or maintain alignment of the strongback with the wing panel. Like the index features 210, the index units 542 can take any suitable configuration and can include coupling means other than mechanical coupling, such as magnets and the like. The index units can be configured to couple with a variety of different index features 210 or index features that can differ from one wing panel 550 to another, for example to enable the strongback 540 to couple with different wing panels as needed.

[0074] In FIG. 5A , the workstations 520 of the assembly line 500 are shown to include a non-destructive inspection or NDI station 524, a cutout station 526, a rib installation station 528, and a spar installation station 530. These workstations and the operations performed at each of the workstations and other example workstations are discussed in greater detail below. Other embodiments can include different workstations than those shown, workstations arranged in a different order, multiple workstations of one or more types, and the like. For example, in some embodiments, a fastener sealing station is used to seal the wing, and further includes workstations for installing electrical components, electrical equipment, and / or fuel tank related systems.

[0075] As FIG. 5A shown and more clearly visible in FIG. 5B , during work at various workstations 520 such as the NDI station 524, the wing panel 550 is held suspended below the strongback 540 by a carrier 545 (e.g., an independently adjustable component such as an extension carrier, also referred to herein as a springer) that includes a vacuum coupler 548 that applies a removable vacuum connection to the wing panel in order to secure the wing panel below the strongback 540. FIG. 5B The view in FIG. 5AThe different numbers of carriers 545 shown are used to collectively support each of the three strongback 540s for the wing panel 550, with the carriers being linearly disposed along the width of the wing panel. However, any number and / or configuration of carriers 545 can be used. The carriers 545 are aligned to each contact the wing panel 550 at a predetermined location and height on the wing panel 550. Once set to the desired length, the individual carriers are rigid. Thus, the carriers 545, or more specifically the alignment of the carriers 545 relative to one another and their length relative to the wing panel 550, can be arranged to exert a force that is transmitted through the wing panel 550, and to implement the desired profile 544 into the wing panel 550. Thus, the strongback 540 suspends the wing panel 550 below it, while forcing the profile 544 onto the wing panel. This profile 544 can be the profile imparted to the wing panel by the layup mandrel 110 (e.g., the profile 112 as shown in FIG. 1 FIG. 1), or a different profile as required by the particular application. Thus, as the strongback 540 advances along the track 510 in the process direction 541, the profile 544 is implemented by holding the individual carriers 545 at the desired height, which forces the geometry at the wing panel 550 to correspond to the profile 544.

[0076] As can be seen in FIG. 5B The attachment mechanism shown in the illustrated embodiment is one in which the carriers 545 engage the upper surface 574 of the wing panel 550 to form a vacuum grip between the vacuum couplers 548 of the carriers and the wing panel 550. The length of the carriers 545 is controlled by actuators 546, such as hydraulic or pneumatic actuators, or linear actuators. For example, one of the carriers 545 is shown in the process of being shortened, as indicated by the arrow 1000. The length of the carriers 545 can be adjusted, for example, prior to forming the vacuum attachment (e.g., to facilitate initial alignment of the vacuum couplers 548), and / or after forming the vacuum attachment (to bend the wing panel 550 into the desired shape and / or to implement the desired profile on the wing panel). In some embodiments, the actuators 546 are controlled via the controller 620.

[0077] While the shape of the panel 550, including its contours and curvature, is determined during layup and hardening, implementation and adjustment of the contours can be desirable after the panel is de-molded. Implementation of the contours ensures that the panel 550 maintains a desired shape and does not assume an undesirable contour, such as sagging under its own weight. In some embodiments, the implementation of the contours by the strongback 540 and the carrier 545 facilitates installation of ribs and spars onto the panel, such as by ensuring proper alignment between the components and the portions of the panel to which the components are to be installed. In particular, the carrier 545 implements the chordwise and spanwise contours to a desired level of tolerance. In one embodiment (not shown), the carrier 545 is movable relative to the strongback to predefined positions in order to implement the contours for various airfoil shapes. Further, the "upper surface" 574 to which the carrier 545 is attached can be an outer surface of the panel 550 in a "right-side-up" orientation relative to the strongback 540, or can be an inverted inner surface of the panel, depending on any orientation that is preferred for contour implementation (and / or other operations as the panel 550 progresses through the assembly line 500).

[0078] During the discussion of the assembly line 500 and the operations performed by the various stations 520, reference will be made intermittently to various flowcharts presented in the accompanying drawings (e.g., FIG. 6 to FIG. 10 ), which illustrate methods in accordance with the components and operations shown in FIG. 5A to FIG. 5G . For example, FIG. 6 is a flowchart illustrating a method 800 of carrying a panel 550 in an illustrative embodiment. According to the method 800, a step 802 includes aligning a strongback 540 over the panel 550. In some embodiments, this includes driving the strongback 540 along the track 510 until it is positioned over a desired and / or predefined lateral portion of the panel 550, such as a chordwise portion. In some embodiments, this includes driving multiple strongbacks 540 until they are each positioned over different desired and / or predefined lateral (e.g., chordwise) portions of the panel 550. In one example, one strongback 540 can be moved along the track 510 until it is positioned over a different portion of the panel 550 than another strongback 540 that remains stationary. In some embodiments, aligning the strongback 540 is performed or includes indexing the strongback 540 to the panel 550. In some of such embodiments, this indexing is accomplished by coupling the strongback 540 with one or more indexing features of the panel 550, such as by physically coupling the indexing unit 542 of the strongback 540 with a corresponding indexing feature 210 of the panel 550. Indexing the strongback 540 with the panel 550 in this manner can maintain the strongback and panel in proper alignment, such as throughout subsequent actions of the method.

[0079] Step 804 includes forming a vacuum attachment between the upper surface 574 of the panel 550 and the vacuum couplers 548 of the spring members 545 extending beneath the backer 540, thereby coupling the spring members 545 to the upper surface 574 of the panel 550. In one embodiment, this includes extending each of the spring members 545 until the vacuum couplers 548 of the spring members physically contact the upper surface 574 of the panel 550. In further embodiments, the spring members are attached from the middle of the panel 550 (e.g., chordwise or spanwise) and then moved outward, attached from the outermost contour locations on the panel 550 first, or all of the spring members are attached at once, etc.

[0080] As described in greater detail below, the locations of the spring members 545 along the surface of the panel 550 can be determined by a variety of factors, one of which is the manner in which the spring members, and thus the applied stress and / or strain forces, can cooperate in different possible configurations to implement a predetermined contour to the panel. However, there are also other competing factors. As one example, as detailed below, inspection of the panel 550 (such as via non-destructive inspection (NDI) scans) can require that an NDI inspection head be positioned at or moved over one or more particular locations on the panel 550. Because the spring members can be selectively retracted, this can be accommodated by temporarily retracting the spring members 545 to allow the NDI to inspect the locations to which the vacuum couplers 548 of the spring members are coupled on the panel 550 or by initially attaching the spring members to the panel only at locations that will not interfere with the NDI inspection. As another example, attachment of the ribs and spars to the lower surface 576 (e.g., inner surface) of the panel 550 can involve fastening operations (e.g., drilling) that occur at corresponding locations on the upper surface 574 of the panel. Thus, the locations of the spring members 545 can be positioned so as not to interfere with such operations. Thus, the locations of the spring members 545 can be optimized to some or all of these (and / or other) considerations.

[0081] The applied coupling is the result of a vacuum being drawn between the vacuum couplers 548 and the panel 550 and more particularly its surface, such as the upper surface 574. The amount of vacuum force applied on a portion of the panel 550 is sufficient to clamp and hold the panel, and also to bend the panel and hold it according to the desired contour 544. In particular, the volume between the carrier members 545 and the panel 550 is evacuated to a pressure that allows atmospheric pressure around the vacuum couplers 548 to removably adhere the carrier members 545 to the panel 550. The vacuum is maintained via the carrier members 545 during transport, including during pulsing and pausing.

[0082] Step 806 includes adjusting the length of the spring members 545 to implement the predetermined profile onto the wing 550. That is, after the vacuum attachment is formed, the length of the spring members 545 is adjusted (e.g., via pressure, actuators, etc.) to cause the wing 550 to conform to the desired profile 544. In the illustrated embodiment, the spring members 545 are independently adjustable. That is, the spring members are adjusted to a desired length according to the location of the individual spring members 545 along the length and width of the wing 550 (e.g., determined via a manual or laser-assisted process) and according to the desired profile. If the wing 550 is already conforming to the desired profile, no adjustment or only slight adjustment to the length of one or more spring members 545 can be made. Alternatively, if the wing 550 is not conforming to the desired profile (e.g., not within a tolerance), the length of the spring members 545 is adjusted to bend or form the profile (e.g., by applying a desired amount and direction of strain) in order to hold the wing in the desired shape.

[0083] In some embodiments, a scan is performed to determine an initial wing profile. If the wing 550 is initially or across the entire wing or one or more portions thereof already in the desired (e.g., predetermined) profile, no change to the profile can need to be implemented. In some of such embodiments, adjustment of the length (i.e., longer or shorter) of the individual spring members 545 relative to the length of the strongback 540 pushes and / or pulls the wing 550 into the desired profile. The adjustment of the length of the individual spring members 545 is based at least in part on a determination of the extent to which the wing 550 is misaligned with the desired profile. That is, the length of some of the spring members 545 can need to be adjusted, while the length of others of the spring members 545 can not need to be adjusted (e.g., only some of the portions of the wing 550 are misaligned with the predetermined profile). The position of the vacuum couplers 548 of the spring members 545 relative to the upper surface 574 of the wing 550 is precisely positioned to ensure that the profile implemented by the spring members when at the desired length conforms to expectations.

[0084] The length of the spring members 545 can be adjusted on the fly (e.g., by adjusting the air logic applied to a pneumatic actuator controlling the length, adjusting a hydraulic actuator controlling the length, etc.) to align the spring members to establish the vacuum attachment during a first phase (e.g., step 804) and then implement the profile during a second phase (e.g., step 806). This facilitates length adjustment during the initial attachment, as if the spring members 545 are rigidly set to a particular length based on an expected shape of the wing 550, then the vacuum couplers 548 can not be able to form the vacuum attachment if the wing does not conform to the profile (i.e., because the spring members are too long or too short).

[0085] In some embodiments, a scan is performed to determine whether the panel 550 is under the predetermined profile. This can be performed while the lengths of the spring members 545 are being adjusted, or after all of the spring members have been adjusted.

[0086] The method can then continue, for example, advancing the panel 550 while the profile is being implemented (such as by moving the strong back 540 along the track 510 in the process direction 541), and / or performing operations on the panel while the profile is being implemented (such as at the various stations 520). In embodiments in which a scan is performed, the method can include a profile scan during or after the operations are performed, for example, to ensure that the panel 550 remains under the desired profile - or, in other words, that the panel has not become misaligned with the predetermined profile as a result of the operations.

[0087] Returning to FIG. 5A , the stations 520 disposed along the track 510 perform operations on the panel 550, and can all operate at the same time (or overlapping times), or in synchronization with one or more of the other stations, to perform different tasks at different portions of the panel 550 (for example, in the wing root 577, mid-span 578, wing tip 579, etc.). In this embodiment, the NDI station 524 inspects the panel 550 for out-of-tolerance conditions (for example, internal voids, foreign object debris or FOD, edge delamination or inconsistencies, etc.), the cut-in station 526 cuts an inlet into the panel 550 (for example, in the manufacturing allowance 549), the rib installation station 528 installs ribs to the panel 550, and the spar installation station 530 installs spars to the panel 550.

[0088] In this embodiment, the ribs are attached to the panel 550 during the micro-pulse advance, as will be explained in greater detail below. This can include multiple operation stations operating on the various ribs simultaneously, or multiple operation stations each operating on a different rib during the same time period. The spars are subsequently attached while the panel 550 remains at the full-pulse operation station 520. However, according to embodiments, the spars are attached prior to the ribs, or can be installed during the full-pulse or micro-pulse process. The ribs are attached to the panel 550 and spars using micro-pulse or full-pulse assemblies. Alternatively, the panel 550 is lowered into position above the ribs that are subsequently attached, and the spars are pulsed onto the panel 550.

[0089] In one embodiment, the rib and spar installation process is performed by providing the rib and spar segments from parallel feeder lines in a JIT manner, such as by means of feeder lines similar to the continuous rib feeder line 491-7 and continuous spar feeder line 491-5 shown in the pattern 480 in FIG. 4 , respectively. The feeder lines are shown individually by different reference numerals 570 (for example, 570-1, 570-2, etc.) inFIG. 5A The feeder lines can be the same as, similar to, or different from the various feeder lines 490 shown in mode 480 in terms of the materials or components provided, the cadence at which the feeder lines provide materials or components, etc. In one embodiment, multiple spar sections can be coupled, e.g., end-to-end, to form a spar. In another embodiment, there are multiple rib installation stations and one or more fastener sealing stations and multiple spar installation stations. Another embodiment has each spar include three sections that are spliced together at the ends of the ribs.

[0090] The stations 520 are arranged along the track 510 and can be separated by a length that is less than the length of the panel 550 or even a fraction thereof. In one embodiment, this arrangement enables multiple stations, such as the NDI station 524, the cutout station 526, and the rib installation station 528, to perform work on the panel 550 simultaneously or overlapping in time. In another embodiment, the stations are spaced apart and / or otherwise configured so that only one work station performs work on the panel 550 at a time.

[0091] As discussed in further detail herein, after continuing through the work stations 520 shown, the panel 550, which can be an upper panel to which ribs and spars can be installed, enters a panel joining phase, as shown in FIG. 5A The panel joining phase attaches another panel, which can be a lower panel, to form a complete section of a fuselage (e.g., a wing assembly) for a wing, as shown in the panel joining station 599 in FIG. 5F After the panel 550 stops at the panel joining station 599 for fastening, the panel joining phase operates separately (e.g., by itself across the wing without other stations operating). In one embodiment, the panel 550 remains paused at the panel joining station 599 while other panels pulse through the work stations until the other panels have advanced at least their entire length.

[0092] In the illustrated embodiment, feeder lines 570-1 through 570-6 at least partially correspond to feeder lines 491-7, 491-4, and 491-5. Feeder lines 570-1 through 570-6 provide resources and components to the various workstations 520 described above on a just-in-time (JIT) basis, and their operation is controlled and / or synchronized by controller 560 (or additional controllers 560) according to desired takt times. In one embodiment, feeder line 570-1 at least partially corresponds to entry cover feeder line 490-5, and provides newly manufactured entry covers to cutout station 526. Feeder line 570-2 provides fasteners to cutout station 526. Feeder line 570-3 provides fasteners to spar installation station 530. Feeder line 570-4 provides sealant to spar installation station 530. Feeder line 570-5 provides fasteners to rib installation station 528, and feeder line 570-6 provides sealant to rib installation station 528. In additional embodiments, additional / other feeder lines provide newly manufactured ribs, fasteners, and sealant spars, lower panels, etc. to the various workstations.

[0093] In one embodiment, the upper wing panel is advanced through the workstations 520 illustrated, followed by the lower wing panel. As briefly described above, the lower wing panel does not receive ribs or spars (i.e., because these components have already been installed to the upper wing panel). It will become clear that cutout stations, such as cutout station 526, perform most of the work on the lower wing panel, while most of the work on the upper wing panel includes installing ribs and spars. FIG. 5A

[0094] The various workstations 520 in assembly line 500 are designed to physically couple, image, and / or otherwise interact with indexing features 210 in wing panel 550 or with strongback 540, which itself is physically coupled to indexing features 210. Indexing features 210 are disposed at desired locations along wing panel 550. In some embodiments, the indexing features are aligned along wing panel 550. In some embodiments, the indexing features are not aligned. In some embodiments, the indexing features are equally spaced apart, and in some embodiments, the indexing features are not equally spaced apart. In some embodiments, the number of indexing features is equal to the number of workstations in the assembly line. In some embodiments, there can be more or fewer indexing features 210 than workstations on the assembly line. Indexing features 210 are disposed in a manufacturing allowance 554 of wing panel 550, which is trimmed off prior to assembly of the wing into a fuselage bay.

[0095] ​In this implementation, each of the stations in the assembly line 500 inserts, grips, mates, or aligns the index feature 210. In addition to (or instead of) physical (e.g., mechanical) coupling, in some implementations, indexing can be facilitated or occur with reading of an RFID chip and / or other readable identification device 126 (e.g., bar code, etc.) on the wing panel. FIG. 5B An illustrative example of physical coupling is shown, showing a portion of the wing panel 550 within the NDI station 524. Among the various structural components of the NDI station 524 is an upper NDI unit 602, which includes an upper frame 614. The upper frame 614 is shown to include an indexing unit 622. In a manner similar to that described above for the indexing unit 542 of the forcebacker 540, the indexing unit 622 of the NDI station 524 is physically coupled with the indexing feature of the wing panel 550, specifically by way of a head 624 received in the indexing feature 210-2 located in the manufacturing allowance 554, where the indexing feature 210-2 is shown as a through-hole. Again, while only one indexing unit 622 is shown in the middle, each of the work stations 520 can include any suitable number of indexing units 622, each of which can be configured to couple with the indexing feature of the wing panel 550, such as to initially align and / or maintain the alignment of the wing panel with the work station. As with the indexing feature, the indexing unit 622 can take any suitable configuration, and can include coupling devices other than magnets to achieve mechanical coupling. The indexing unit can be configured to couple with various different indexing features or locations that can differ from one wing panel to another, for example to enable the work station to couple with different wing panels as needed. FIG. 5B

[0096] In the illustrated implementation, the indexing feature 210-1 of the wing panel 550 is shown coupled to the indexing unit 542 of the force-backer 540, while the indexing feature 210-2 is shown coupled to the indexing unit 622 of the NDI station 524. For purposes of explanation, this is intended to exemplify an example indexing configuration, and not to suggest that all implementations require indexing of the wing panel by way of physical coupling with both the force-backer and the work station. In some implementations, one or more work stations are indexed with the force-backer that supports the wing panel, rather than directly with the wing panel. In some implementations, one or more work stations are indexed with the wing panel 550, rather than with the force-backer 540. In some implementations, a work station is indexed with both the wing panel and the force-backer. In any of these implementations, the force-backer can also be indexed with the wing panel.

[0097] ​When using RFID chips (or other readable identification devices), for example, in addition to or alternative to another type of indexing feature, an RFID scanner (or suitable reader) can be coupled to provide indexing when communicating at the workstations. In further embodiments, the powerback 540 itself is physically coupled with the indexing features 210, RFID chips, and / or hard stops or other features to index the powerback 540 to the workstations. During assembly, the powerback 540 is coupled / installed with the track 510 for movement along the track 510 and is pulsed (e.g., a micro-pulse less than the length of the wing panel 550, according to a cadence that can or can not be commonly shared with other assembly lines). In one embodiment, the limiting factor of the cadence is the amount of time a portion of the wing panel 550 spends within the range of a particular workstation plus the pulse time. This time can be adjusted by changing the work range of a particular workstation or adding additional workstations to do the same work (such as multiple rib installation workstations 528 instead of just one), etc. The pulsing discussed herein can be implemented to be at least equal to the shortest distance between indexing features 210 (e.g., the pitch between ribs, or "rib pitch," or a multiple or fraction of the rib pitch, etc.) or a full length or fractional length of the wing panel 550. In embodiments where the pitch between ribs and / or the rib pitch is used for the pulse length, it can be used to establish the micro-pulse length. The wing panel 550 can move continuously and be indexed to the workstations 520. Once indexed, the work is performed by the workstations 520. Each time an indexing feature 210 (and / or RFID chip) and the powerback 540 mate or otherwise communicate, the powerback 540 is indexed to one or more of the workstations 520 and the position of the wing panel 550 is indexed to a position in a coordinate space shared by the track 510 and known by the workstations. In further embodiments, indexing also includes communicating 3D features of the structure (such as the profile 544) within the range of the workstations. For example, the RFID chip or other identification device 126 (e.g., a bar code) can convey information indicative of the geometry of the composite part being worked on.

[0098] In one embodiment, the indexing is performed based on at least the wing panel 550 carried on a strongback 540 that moves along a track 510 that includes a rail system above the workstations 520. The rail system can be coupled to a crane frame or structure above the workstations, such as a ceiling or floor, such as embedded within a floor, bolted to a floor, etc., or can be coupled to another portion of the factory. The wing panel 550 has been manufactured on a layup mandrel 110 according to precise dimensions as described above. Because the layup mandrel 110 has precisely toleranced surface features, and because the preform 120 for the wing panel 550 is laid up on and conforms to these surface features, the wing panel 550 includes indexed features 210 that are precisely positioned in a manufacturing tolerance 554. Thus, once the wing panel 550 is indexed and hung below the strongback 540 and pushed to the workstation 520, the 3D position and orientation of the wing panel 550, including the contours 544, are transferred by the indexing and are precisely known at the workstation 520. Thus, the indexing can eliminate the need for full scans at each workstation 520 via probes or robust optical techniques, for example. As needed, the information is provided to the workstation 520 as part of the indexing, such as via information provided by an RFID chip. This allows one line to work sequentially on different parts of an aircraft (e.g., right and left wing panels, upper and lower wing panels) or even different parts (e.g., wing panels) of different aircraft models. Thus, the characteristics of the wing panel 550 within the scope of the workstation 520 are transferred to the workstation as part of each pulse or micro-pulse. Because wing panels have more variation between pulse locations and pulse locations than fuselage panels, the manufacturing tolerance at the wing panel can include a large number of surface features to facilitate the indexing.

[0099] Because of the precise indexing performed, the position of the tools at each workstation 520 relative to the wing panel 550 is precisely known when indexed to the workstation. In some embodiments, the wing panel 550 is locked in place at the workstation 520. The 3D position and orientation of the wing panel is then established or indexed into any numerical control (NC) programming, or manual or automated systems used at the workstation. Thus, setup time or scanning can not be needed after each movement of the wing panel (e.g., pulse and / or micro-pulse). Furthermore, structures added to or removed from the wing panel 550 in existing workstations 520 can be added to any wing panel model or representation within the system without the need to scan the wing panel for changes.

[0100] The operation of the workstations 520 is managed by a controller, which is typically in communication with the rail system and the workstations 520. The controller can be a single controller or multiple controllers, and can be located at the workstations 520 or at another location in the factory. The controller can be a computer or computers, and can be a single computer or multiple computers. The controller can be a single computer or multiple computers. FIG. 5AThe controller 560 is designated as such. In one embodiment, the controller 560 determines the advance of the support material 540 along the track 510 (e.g., based on input from a technician) and uses this input to manage the operation of the work station according to instructions stored in the NC program. For example, the controller 560 may be implemented as custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

[0101] The following paragraphs discuss FIG. 5A The operation of various workstations 520 is shown. For example... FIG. 5A As shown, in assembly line 500, three workstations 520—specifically, NDI workstation 524, cutting workstation 526, and rib mounting workstation 528—are positioned close enough along track 510 that the wingplate 550 can encounter all three workstations as it advances along the process direction 541. More specifically, considering the wingspan 590 of the wingplate 550 from its leading edge to its trailing edge (e.g., from wingtip to wing root, oriented as shown in the illustrated embodiment), different portions of the wingplate can simultaneously advance through two or more different workstations 520. For example, the wingplate 550 is shown positioned such that the rear portion (shown as wing root 577) encounters NDI workstation 524, while the front portion (shown as wingtip 579) encounters rib mounting workstation 528, and the middle portion (shown as middle length portion 578) encounters cutting workstation 526. Therefore, one, two, or all three of these work stations 520 can simultaneously perform operations on corresponding portions of the wing 550. In some embodiments, not all of these operations need to be performed simultaneously, even if portions of the wing 550 are positioned in the respective work stations 520. In one embodiment, NDI is performed at NDI station 524 when a portion of the wing 550 pulsates through a work station. Therefore, NDI occurs at NDI station 524 only when that portion of the wing 550 is within the work station at any given time.

[0102] FIG. 5B This is a front view of the NDI station 524 in the exemplary embodiment (and as described above, corresponding to...). FIG. 5A The view arrow “5B” in the diagram shows the process of inspecting the wing 550, which is shown in cross section. FIG. 5B Examples of inspection techniques and systems that can be implemented, for instance, before the ribs and spars are mounted onto the wingplate. FIG. 5B A strong backing material 540 is depicted suspending the wing plate 550 below it. The NDI station 524 is set at the track 510 and inspects the wing plate 550 while it is suspended below the strong backing material 540.

[0103] FIG. 5BThe NDI station 524 shown includes an upper NDI unit 602 and a lower NDI unit 604. The upper NDI unit 602 includes a support 614 and a frame 612 that carries one or more NDI inspection heads 606 (shown as upper NDI inspection head 608), which are configured to move relative to the flange 550 and inspect its upper surface 574. The lower NDI unit 604 of the NDI station 524 is also shown including a frame 614 and a support 616 that carries additional NDI inspection heads 606 (shown as lower NDI inspection head 610) in a manner that allows the inspection heads to inspect the lower surface 576 of the flange 550. For simplicity, the NDI inspection head 606 is also referred to as an "inspection head," or simply a "head." The inspection heads 606 can be movable – that is, they can be configured to move relative to the upper NDI unit 602, the lower NDI unit 604, and / or the wing plate 550, or they can instead be stationary or fixed. For example, in the illustrated embodiment, the upper inspection head 608 is shown in the process of moving relative to the upper surface 574 of the wing plate 550 (e.g., by means of a track and / or drive or any suitable mechanism (not shown) of the upper NDI unit 602) via directional arrow 1002. Some or all of the lower inspection heads 610 can also be movable, in which case they can be independently movable, configured to move in an array-like manner, etc., or they can be stationary. Additional embodiments may include, except... FIG. 5BAny number or configuration of inspection heads other than that shown. Mobile inspection heads can be used to conduct surface inspection during pauses between advancement or other movement of the wing panel 550 relative to the NDI station 524, such as by separately traversing different area portions of the surface of the wing panel 550. Fixed inspection heads can be used to conduct surface inspection as the wing panel 550 is pulsed or otherwise moved relative to the NDI station 524. For efficiency, the arrangement of the position of the inspection heads 606 relative to the NDI station 524 and / or the wing panel 550 as it advances through the work station 520 can be arranged to place inspection heads at locations of interest, e.g., locations where out-of-tolerance conditions are more likely to be found, such as locations where inspection of a prior wing panel and / or analysis of a prior wing panel indicates that inspection is needed or desired, and not at locations where inspection is less needed. Other arrangements of inspection heads can be used as desired or needed for a particular application. Some embodiments can include upper and lower inspection heads disposed in pairs on either side of the wing panel 550, such as to perform through-transmission inspection techniques. In some embodiments, the inspection heads 606 are disposed to inspect the entire surface or surfaces of the wing panel 550. For example, in further embodiments, fixed NDI inspection heads are disposed so that inspection occurs during pulsing, and the inspection heads are disposed to cover the entire surface without the need for head movement. Such a disposition can be used for the upper and lower surfaces, and can be implemented with less complexity than systems that utilize mobile heads. The inspection heads 606 discussed herein can include ultrasonic transducers that emit ultrasonic energy that penetrates the wing panel 550 in order to characterize internal features of the wing panel. Operation of the inspection heads 606 (e.g., the upper inspection heads 608 and the lower inspection heads 610) is managed by a controller shown at 620, which operates the NC program to coordinate the actions of the inspection heads to facilitate scanning of the wing panel 550 in a pulsed echo or transmission mode. The controller 620 can interface with and be distinct from the controller 560. In some embodiments, the controller 560 can provide the above-described functionality of the controller 620.

[0104] As noted above, the NDI station 524 is shown in the illustrated embodiment to be physically indexed to the wing panel 550 by means of an indexing unit 622 of the NDI station, the head 624 of which is received within the indexing feature 210-2 of the wing panel 550.

[0105] The forceback 540 includes telescoping or adjustable length load or spring members 545 that include vacuum couplers 548 configured to be removably attached to the upper surface 574 of the wing panel 550 to thereby create a vacuum grip between the vacuum couplers 548 and the wing panel 550. As noted above, the length of the load members 545, such as to apply or enforce a contour to the wing panel 550, is controlled by actuators 546, such as hydraulic or pneumatic actuators, or linear actuators. The controller 620 can coordinate control of the actuators 546. In some embodiments, the controller 620 coordinates control of the actuators 546 with operation of the NDI station 524, such as to allow inspection of the wing panel 550 in a manner that avoids or accommodates the vacuum couplers 548 coupled to the surface of the wing. In one such embodiment, the controller 620 directs the forceback 540 to selectively retract one or more of the vacuum couplers 548 by shortening the corresponding load members 545 to allow the upper inspection head 608 of the NDI station 524 to inspect a portion of the upper surface 574 of the wing panel 550 to which the vacuum couplers 630 have been attached, such as the portion 582. This is illustrated in FIG. 5B FIG. 10, where one of the load members 545 is coordinated to shorten to retract its vacuum coupler 548 from the portion 582, as indicated by directional arrow 1000, and the upper inspection head 608 is moved toward the portion 582, as indicated by directional arrow 1002. After the NDI inspection of the portion 582 is complete, for example, the corresponding load member 545 is extended so that its vacuum coupler 548 is again vacuum connected to the upper surface 574 of the wing panel 550. In a similar manner, other portions of the upper surface 574 of the wing panel 550 that are obscured by the vacuum couplers 548 can be inspected in due course. Of course, not all embodiments need such a configuration. In additional embodiments, for example, the inspection head 606 is routed around the load members 545 and the vacuum couplers 548 that are not retracted during the NDI inspection. In additional embodiments, the contour of the wing panel 550 varies according to the type of wing panel or the type of wing panel of different models, and the load members 545 are therefore extended to different positions / extensions according to the contour of the wing panel.

[0106] In additional embodiments that use the forceback 540, the wing panel 550 is inspected via NDI for locations of contact with the forceback (e.g., by means of the spring members 545 and the vacuum couplers 548) on the wing panel prior to suspending the wing panel below the forceback.

[0107] FIG. 7 is a flowchart illustrating an embodiment of a method of inspecting a wing panel designated as method 820. The method 820 proceeds in a series of steps that include reference to FIG. 5B and in FIG. 1 to FIG. 4 and FIG. 5AThe actions described above with respect to the components and structures shown in FIG. 6. The method 820 is shown as beginning with step 822, which includes suspending the wing panel 550 beneath a shuttle device, such as the strongback 540. In one embodiment discussed above, suction is applied via retractable vacuum couplers 548 to hold the wing panel 550 in place and to implement the desired profile 544 onto the wing panel 550. Specifically, the vacuum coupling of the vacuum couplers 548 and the inflexibility of the strongback 540 and the extensibility of the spring members 545 allow profile implementation to be performed on the wing panel 550. The spring members 545 are removably coupled to the wing panel 550 in order to manipulate it into the desired profile.

[0108] Step 824 includes advancing the wing panel 550 through the NDI station 524 in the process direction via the shuttle device. In embodiments where the shuttle device is the strongback 540, this includes driving the strongback 540 along the track 510, as described above with respect to earlier methods, and can be performed via pulsed or continuous movement techniques. In embodiments where the shuttle device takes another form (e.g., a cart, an automated guided vehicle (AGV), etc.), this step includes driving the shuttle device along a guide rail or appropriate path.

[0109] Step 826 includes inspecting the wing panel 550 via the NDI station 524 while the wing panel 550 is suspended beneath the strongback 540. In one embodiment, this includes performing pulsed echo techniques (e.g., via one or more individual inspection heads 606) or transmission techniques (e.g., via a pair of inspection heads 606 disposed on either surface of the wing panel 550). These arrangements detect timing differences from expected values as the ultrasonic energy travels through the thickness of the wing panel 550. This can include operating an array of inspection heads 606 immediately at the NDI station 524. The detected timing differences are analyzed by the controller 620 to determine whether there are out-of-tolerance conditions at the wing panel 550 that require rework. Rework can be accomplished at a dedicated work station downstream of the NDI station 524. That is, the controller 620 detects an out-of-tolerance condition at the wing panel 550 based on input from the NDI station 524 and reports the out-of-tolerance condition for rework (e.g., via a notification provided to a technician). In further embodiments, the controller 620 controls the NDI station 524 and controls the advancement of the wing panel 550 in the process direction and correlates the input from the NDI station with a location on the wing panel 550.

[0110] As noted above, in some embodiments, when one or more inspection heads 606 inspect the surface of a wing panel, the inspection involves selectively retracting one or more vacuum couplers 548, such as by the forceback 540, such as to allow inspection of corresponding portions of the surface that would otherwise be obscured by the vacuum couplers. In further embodiments, the inspection is performed by arranging the carriers 545 and / or otherwise disposing the vacuum couplers 548 at locations on the surface of the wing panel 550 that do not require NDI inspection, inspecting the wing panel via NDI at locations on the wing panel that contact the forceback 540, such as the portions described above to which the vacuum couplers 548 are connected, prior to hanging the wing panel under the forceback, and / or operating an array of inspection heads 606 to perform the entire inspection without moving individual inspection heads, etc.

[0111] As also noted above, the NDI station 524 can include NDI inspection heads 606 that are mobile, or fixed, or a combination thereof. In some embodiments, the method includes positioning at least some of the inspection heads at locations of interest, such as those locations that prior inspection and / or analysis indicate require or desire inspection. In some embodiments, the inspection heads are positioned so as to be able to inspect an entire desired portion of the wing panel 550, such as one or more entire portions thereof, or the entire wing panel. In some embodiments in which the NDI inspection heads are fixed, advancing the wing panel 550 includes advancing the wing panel past the fixed inspection heads as the fixed inspection heads inspect portions of the wing panel. In such embodiments, it can be said that steps 824 and 826 occur simultaneously, or overlap in time. In some embodiments in which the NDI inspection heads are mobile, advancing the wing panel 550 includes advancing the wing panel past the mobile inspection heads. In some such embodiments, such as those in which advancing the wing panel 550 includes pulsing the wing panel in the process direction, the inspection is performed during pauses between pulses and / or during pulses. In some embodiments that include an array of inspection heads, the method includes moving the inspection heads relative to the wing panel 550 while operating the array. In any of these manners, the NDI station 524 inspects a portion of the wing panel 550 at a time as the wing panel 550 is advanced through the NDI station.

[0112] In some embodiments, as noted above, the position of the wing panel 550 relative to the NDI station 524 is monitored by indexing the wing panel to the NDI station, such as by way of various indexing features and / or RFID chips. In some embodiments, indexing the wing panel to the work station, either directly or via a forceback supporting the wing panel, communicates information about the wing panel to the NDI station controller, which in turn can direct NDI inspection of the wing panel based at least in part on the information. In some embodiments in which the indexing features are located in a manufacturing allowance of the wing panel, the manufacturing allowance is generally not inspected.

[0113] In some embodiments, the method continues FIG. 7 additional steps not shown in FIG. 5. For example, the method can continue by advancing the panel to a next work station (e.g., a cut-out station such as cut-out station 526). In embodiments in which the panel is suspended beneath the strongback, such a method can advance the panel to the next work station while the panel remains suspended beneath the strongback. Some embodiments utilize multiple NDI stations for inspection, while some embodiments utilize an NDI station (or more than one NDI station) for NDI inspection of additional components. For example, in some such embodiments, the NDI station scans the stiffener flanges while scanning the panel, and an additional NDI station scans the stringers attached to the panel.

[0114] The above, note that in some embodiments, the NDI inspection is performed as the panel is advanced past the NDI inspection head. This can be done regardless of the manner in which the panel is conveyed (e.g., via a strongback or otherwise). FIG. 8 A method 840 of inspecting a panel 550 in an illustrative embodiment is further depicted. According to FIG. 8 , step 842 includes receiving the panel 550 at the NDI station 524. Step 844 includes inspecting a portion of the panel 550 via the NDI station 524 during movement of the panel through the NDI station. The panel can be advanced through the NDI station pulsed or continuously, with inspection occurring during movement of the panel through the NDI station. As with method 820, in method 840, the NDI station can include moving and / or stationary NDI inspection heads. In one embodiment, the panel remains suspended beneath the strongback while the panel is at the NDI station. In further embodiments, the moving inspection heads of the NDI station individually pass through different area portions of the panel via the moving inspection heads of the NDI station. In this manner, the inspection includes moving the inspection heads relative to the panel while operating the array of inspection heads at the NDI station.

[0115] Returning to FIG. 5A , a mid-length portion 578 of the panel 550 is shown within the cut-out station 526. Broadly, the cut-out station 526 is configured to remove material from the panel 550, for example within the manufacturing allowance 554 or elsewhere. In some embodiments, the cut-out station 526 cuts out one or more areas of the panel 550, for example to install an opening (such as an inlet to be utilized in a downstream work station), such as to enable access to an interior volume between panels after the panels are joined together at a joining station. While not necessary for all embodiments, such an inlet is typically installed in a lower panel as opposed to an upper panel. As discussed in relation to caulking operations (e.g., as with respect to FIG. 16A to FIG. 16C and FIG. 17A to FIG. 17CAs will become clear herein (as shown and described), in some embodiments, the lower wing plate is provided with multiple entrances that allow access to the compartments between adjacent ribs, for example, to facilitate the installation of pads by a robotic arm. Therefore, in such embodiments, the cutting station 526 can perform more operations on the lower wing plate than on the upper wing plate. In either case, the cutting station 526 can install an entrance cover and / or door into the wing plate 550, along with edge sealing, painting, and performing fastener drilling and installation (as applicable to the wing plate). In some embodiments, edge trimming for manufacturing allowances and entrance trimming are performed at different work stations.

[0116] In the illustrated embodiment, the terms "upper surface" and "lower surface" of wing 550 are used herein for convenience to indicate the relative orientation of opposite surfaces of the wing when the wing is suspended below the reinforcing backing 540. However, as will become clear herein, additional components (such as ribs and spars) can be mounted to the lower surface 574 of the wing 550 while the upper surface 576 of the wing 550 continues to be held by the vacuum coupling 548 of the spring member 545 to produce the wing assembly 600. Therefore, in FIG. 5A to FIG. 5G The surface designated as the lower surface of wing panel 550 becomes a surface that can be considered as the inner surface of wing assembly 600, and the surface designated as the upper surface of wing panel 550 becomes a surface that can be considered as the outer surface of wing assembly 600. Therefore, the terms "upper surface" and "lower surface" should not be interpreted in a restrictive sense.

[0117] FIG. 5C Corresponding to FIG. 5A The diagram shows a top view of assembly line 500, but with the reinforcing backing 540 shown as having been advanced along the process direction 541, such that the wing root 577 of the wingplate 550 is located within the rib mounting station 528. For simplicity, FIG. 5C Not shown in the middle FIG. 5A Some aspects (e.g., various feeder lines, etc.). FIG. 5D It shows the corresponding FIG. 5C A simplified side view of the view arrow "5D", where the view is omitted. FIG. 5C Some components are visible in the diagram to better illustrate the ongoing configuration / progress of the wing panel 550 to the wing assembly 600. As described above, rib mounting station 528 secures (in other words, temporarily and / or permanently mounts) rib 572. For ease of explanation, although rib 572 is generally more complex in configuration and appearance, rib 572 is shown in a simplified form in these views, as described in more detail below.

[0118] FIG. 5CIt is also shown that in the spar mounting station 530, a spar 580 has been advanced from a feeder line (not shown) to the station 530. As noted above, the supply of spars 580 to the spar mounting station 530 can be coordinated for just-in-time delivery for mounting to the wing panel. Thus, FIG. 5C A state of the assembly line 500 can be shown just before the wing panel 550 is moved to the spar mounting station 530 to mount the spar 580 that was just supplied to the station.

[0119] FIG. 5C The use of a mobile station 552 (also referred to as a “slave”) is also exemplified, which is configured to be coupled to the wing panel 550 and the strong back 540 and to perform work (such as trimming, mounting fasteners, applying sealant, etc.) by traveling across the wing panel 550, e.g., along a mobile station track 551 that can be removably mounted to the wing panel 550. While not required for all embodiments, the mobile station 552 can perform work during pulsing (e.g., micro-pulsing), pausing (e.g., between micro-pulsing), or continuous movement of the wing panel 550 as it advances through the assembly line 500. Depending on the design, the mobile station 552 can “advance with” (or “follow”) the wing panel 550 in multiple pulses across multiple work stations 520 and can operate independently of other work stations of the assembly line 500. In this process, the position and size of the gaps (e.g., spacing) between the strong backs 540 can enable placement of the mobile station track 551 and / or the mobile station 552. In further embodiments, chutes and other complementary elements are provided at the factory such that the mobile station 552 passes over or through these elements during the manufacturing process. The mobile station 552 can be removed along a return line (shown at 547 in FIG. 5B) and fed out, e.g., in a direction opposite the process direction 541 (e.g., upstream of the assembly line 500) for mounting on a next wing panel as needed. In further embodiments, one or more of the strong backs 540 form a “smart bridge” by dynamically moving relative to the wing panel 550 to enable the mobile station 552 to access the wing panel 550 to the greatest extent possible. FIG. 5C

[0120] As noted above, FIG. 5D ​is a simplified side view of assembly line 500 showing a wing panel 550 with attached ribs 572 being conveyed along track 510 and simultaneously suspended beneath a set of three strongback materials 540. As briefly summarized above, one or more adapters 543 can facilitate movement of strongback materials 540 along track 510. Ribs 572 are attached to the lower surface 576 of wing panel 550 at a suitable angle, which angle is indicated as angle Θ. As will be explained below, in some embodiments, ribs 572 are aligned perpendicularly and elevated to a suitable position for attachment to the lower surface 576 of wing panel 550 (or more specifically, an upper wing panel). Thus, the wing panel can be suspended beneath the strongback at an angle that corresponds to and / or facilitates installation of the ribs at angle Θ. This is shown in FIG. 5D FIG. 6, where wing panel 550 is slightly tilted upward from the trailing edge portion 577 to the leading edge portion 579.

[0121] FIG. 5D Another view of an illustrative configuration of spring members 545 and vacuum couplers 548 is also provided. In the illustrated embodiment, vacuum couplers 548 are capable of angular deflection relative to spring members 545 and strongback materials 540. Angular deflection can be facilitated by a universal type connection at the point where vacuum couplers 548 are coupled to spring members 545 and / or the point where spring members 545 are coupled to strongback materials 540. Angular deflection can accommodate coupling to wing panel 550 during profile changes of the wing panel to suspend the wing panel at a desired angle (as shown), etc. Due to the angular flexibility of the vacuum couplers, the wing panel can be suspended at any desired angle by adjusting the spring members to the appropriate length. In further embodiments, load bearing members 545 are otherwise configured to grip the upper surface 574 of wing panel 550 (e.g., via clamping, interference fit, etc.). As explained in detail above, a desired profile can be implemented by adjusting spring members 545 to a predetermined length that corresponds to the desired vertical inclination of the profile at each of a plurality of chordwise and spanwise locations.

[0122] As noted above, a number of factors can determine the position of spring members 545 and their respective vacuum couplers 548 relative to the upper surface 574 of wing panel 550, such as to implement a profile to wing panel 550. In some embodiments, one factor is the manner in which the ribs and spars are attached to the wing panel. For example, spring members 545 and vacuum couplers 548 can be placed such that the location of vacuum couplers 548 on the upper surface 574 is spaced apart from the corresponding location on the lower surface 576 of the wing panel where the ribs 572 will be attached to the wing panel (as shown in the view of FIG. 5D FIG. 6). This can be done, for example, to allow access to the rib 572 mounting area, and can facilitate manual or automated drilling and fastener installation to connect the ribs to the wing panel.

[0123] In FIG. 5DIn this embodiment, one rib 572 is shown attached to the portion of the panel 550 that is within the rib installation station 528. Other ribs 572 that are shown attached to the portion of the panel 550 that has advanced past the rib installation station 528 were installed while those portions were within the rib installation station 528. Although four are shown, the number of ribs 572 can be, and often is, greater in an actual wing assembly 600. FIG. 5D The panels, ribs, spars, and other components shown in the figures and elsewhere are for illustrative purposes only and are not necessarily drawn to scale or to contour. For example, the ribs 572 are shown in simplified, schematic form in this series of figures. Later figures, such as FIG. 11A to FIG. 11D and FIG. 17A to FIG. 17C show exemplary ribs in greater detail. The rib configuration or number of ribs 572 of an actual wing assembly 600 can differ from that depicted herein.

[0124] FIG. 5E The top view of the assembly line 500 (corresponding to the assembly line in FIG. 5A and FIG. 5C ) illustrates that the panel 550 has been transferred from the strongback 540 to the spar installation station 530, where the spar 580 is attached (e.g., as part of a full impulse process). In this embodiment, the spar 580 is installed after the ribs 572, but in some embodiments, the ribs 572 are installed before the spar 580. In addition, FIG. 5E illustrates that the individual spars (generally indicated at 580) are assembled from a plurality of individual spar segments, each of which is indicated as 580-1 through 580-7 (however, the reference number 580 is used herein to refer to the spar, as well as to the spar segments or spar portions, unless specifically indicated otherwise). The spar installation station 530 can be fed from one or more feeder lines 570 (a representative one of which is shown in FIG. 5EThe pre-assembled spar 580, or individual spar segments or portions (e.g., 580-1 through 580-7) assembled at the spar mounting station, or both, are received (as shown in FIG. 5B) at the spar mounting station 530. In embodiments in which the spar segments are provided to the spar mounting station 530, the spar segments can be assembled to one another prior to mounting to the wing panel, e.g., to form a partial or entire spar that will then be mounted to the wing panel, and / or the spar segments can be mounted to the wing panel as spar segments, forming the spar as they are mounted respectively. Additional components, such as fasteners, sealants, etc., are also supplied to the spar mounting station 530 to facilitate mounting. After mounting, the power back 540 conveys the wing panel 550 back to the track 510, and the wing panel 550 is also conveyed to receive additional work. In the illustrated embodiment, the power back 540 proceeds to the spar mounting station 530 in any suitable manner, such as a redirect track (not shown) configured to allow movement in direction 1004 to the spar mounting station 530. After mounting, the power back can proceed in direction 1006 back to the track 510 via the same redirect track, e.g., to proceed further along the track 510 (e.g., toward a panel joining station), or be directed to another track, or proceed along a different track than the track 510. Another embodiment has the spar mounting station 530 disposed along the track 510 such that advancement of the power back 540 in the process direction brings the wing panel into, through, and out of the station.

[0125] The illustrated configuration is an example of a configuration that can allow selective bypass of work stations 520 such as the spar mounting station 530. As noted above, in some embodiments, the ribs and spars are attached only to the upper wing panel, not the lower wing panel. In such embodiments, efficiency in conveying and / or performing work on the wing panel can be achieved in a configuration that can allow selective bypass of one or more work stations 520, such as advancing the upper wing panel into the spar mounting station 530, but the lower wing panel is advanced past the station. In some such embodiments, the lower wing panel can instead be directed to a work station configured to work on the lower wing panel exclusively, rather than on the upper wing panel, such as a work station that cuts an inlet into the lower wing panel (e.g., a work station such as the cutout station 526). In these embodiments, additional spars and / or spar segments are then fed to the spar mounting station 530 for attachment to the next wing panel 550 advancing along the track 510.

[0126] FIG. 5FAn example is illustrated in which, after work is completed at the spar installation station 530, the wing panel 550 has moved back to track 510 in direction 1006 and is ready to be advanced along track 541 (in a pulsed or continuous manner) in process direction 541 to another work station 520, shown as rib-to-spar attachment station 598 and panel connection station 599, where the lower wing panel can be connected to the upper wing panel already attached with ribs and spars. This operation allows the wing assembly 600 to await the installation of, for example, additional components and / or electrical and other systems.

[0127] exist FIG. 5F In this diagram, the rib-to-spar attachment station 598 is shown positioned on track 510, while the panel connection station 599 is shown positioned away from track 510, requiring the wing plate 550 to move in direction 1008 to the panel connection station 599. This can represent a configuration in which only the upper wing plate advances along this portion of the assembly line 500, while the lower wing plate has been redirected to another track (not shown) or station, for example, by bypassing the spar mounting station 530 and the rib-to-spar attachment station 598, and is instead delivered to the panel connection station 599 to await connection to the upper wing plate. Alternatively, the lower wing plate can be simply conveyed through the rib-to-spar attachment station 598 without any work operations being performed on it, thus effectively bypassing the rib-to-spar attachment station. Alternatively, in some embodiments, one or more work stations 520 can be configured to serve multiple purposes, such as performing certain work operations on, for example, the upper wing plate, and other work operations on the lower wing plate. Such configurations are within the scope of this disclosure.

[0128] According to the above text... FIG. 5A to FIG. 5FThe concepts, components, systems, and apparatuses discussed are, obviously, consistent with other embodiments of assembly line 500 that can employ other configurations than those specifically exemplified and described. For example, some embodiments can produce wing assemblies using different sequences of operations to attach the ribs, spars, and panels, and can thus include some or all of the various stations 520 in a different order, or include stations in addition to those shown, or multiple stations 520, or stations that perform some or all of the functions of stations 520 in addition to other tasks, etc. In some such embodiments, instead of separately installing the spars and ribs to the panels (such as the upper panels), as in the illustrated embodiment of assembly line 500, the spars and ribs can instead be attached to each other to form a ladder-like structure (with the spars as the "rails" of the ladder and the ribs forming the "rungs" of the ladder), which is then installed to the panels. Such embodiments can thus include one or more stations that assemble the spars to the ribs (which can be supplied to the one or more stations from appropriate feeder lines with the ribs, spars or spar portions, and fasteners), and one or more stations that install the rib and spar structure to the panels and / or install the rib and spar structure between upper and lower panels. As with the illustrated embodiment of assembly line 500, the various components and structures supplied to the above-described stations can be configured for JIT delivery to the appropriate stations.

[0129] Examples of this aspect are shown in FIG. 5G which shows an alternative configuration of an assembly line indicated as assembly line 500'. FIG. 5G corresponding generally to FIG. 5C and FIG. 5E the plan view of assembly line 500 shown. However, while FIG. 5C and FIG. 5E the assembly line configuration shown includes a rib installation station 528 and a spar installation station 530 (the ribs 572 and spars 580 are separately and separately installed to the panels 550 at the rib installation station 528 and the spar installation station 530), the assembly line 500' shown in FIG. 5G instead is shown as including different stations 520; specifically, a support structure assembly station 532 and a support structure installation station 534. The support structure assembly station 530 is supplied with the ribs 572 and spars 580, as well as fastening and / or sealing supplies, from one or more feeder lines 570 (a representative one of which is shown in FIG. 5G ). For example, as with the assembly line 500 shown in FIG. 4The corresponding feeder lines for 491-6 and 491-7 shown can provide the spars and ribs, respectively, to the support structure assembly station 532 in a timely manner and in a desired order for assembly into the truss support structure indicated at 588. The spars 580 can be pre-assembled or completed prior to being provided to the support structure assembly station 532, or can be provided to the support structure assembly station in the form of individual spar segments or portions (not shown separately) for assembly with the ribs 572 into the support structure 588.

[0130] When assembled, the support structure 588 is conveyed (e.g., laterally) into the support structure installation station 534 (as indicated by arrow 1014) and installed to the wing panel 550. A cart or other manner of shuttle device can convey the support structure 588, which can then be raised upward to the wing panel for installation. Alternatively or additionally, the wing panel can be lowered to the support structure 588. Although FIG. 5G not shown in the view of FIG. 5A, fasteners and other supplies can be provided with the support structure to the support structure installation station 534, or provided separately via one or more feeder lines or supply lines. Thus, FIG. 5G A state of the assembly line 500’ can be shown just prior to the fully assembled support structure 588 being delivered to the support structure installation station 534 for installation to the waiting wing panel 550. The wing panel 550 via movement of the strongback 540 along the track 510 can be coordinated with the provision of the assembled support structure 588 such that both the wing panel 550 and the support structure 588 are delivered to the support structure installation station 534 at the same time, or one or the other can be provided in a timely manner for installation, etc.

[0131] The wing panel 550 with the support structure 588 installed with the ribs 572 and spars 580 can be advanced to a panel connection station (such as the panel connection station 599 shown in FIG. 5F FIG. 5B) so that another wing panel (such as a lower wing panel) can be installed to the assembly. Alternative configurations discussed above with respect to FIG. 5G FIG. 5B can provide advantages over the configuration shown in the assembly line 500, such as not involving lateral conveyance of the wing panel relative to the track 510 for spar installation (as shown in FIG. 5E FIG. 5A), or efficiencies realized by installing the ribs and spars together rather than separately, etc.

[0132] With reference to the various components of the assembly line 500 presented in FIGS. 5A through FIG. 5G 5B and described above, as well as the concepts and operations embodied therein, FIG. 9is a flowchart illustrating a method 860 of manufacturing a wing via an assembly line, such as the assembly line 500, in an illustrative embodiment. At step 862, the wing panel 550 is suspended beneath a shuttle (such as the strongback 540) that implements the profile 544 onto the wing panel 550. For example, in one embodiment, the carrier 545 is secured to the wing panel 550 via the vacuum couplers 548 and positioned vertically to implement the profile. As described above, in some embodiments, suspending the wing panel 550 includes indexing the strongback 540 with the wing panel. Indexing can be a physical coupling (e.g., physically attached or otherwise linked) between the strongback 540 and one or more indexing features installed in the wing panel 550 (e.g., installed in a manufacturing allowance of the wing panel 550). Additionally or alternatively, the indexing features can contain or include readable identification devices (such as RFID chips / tags or barcodes), and indexing includes reading the identification devices with a suitable reader (such as an RFID reader, a scanner, or a barcode reader, etc. (not shown)).

[0133] At step 864, while the profile 544 (e.g., the profile defined by the upper surface 574 of the FIG. 5B wing panel 550 is advanced through at least one work station 520 (and typically a plurality of work stations 520) in the assembly line 500 via the strongback 540 in a process direction (such as the process direction 541) while the profile 544 is implemented (e.g., by the strongback 540). For example, the strongback 540 can be advanced along the track 510 while the vacuum couplers 548 of the carrier 545 to the wing panel 550 are disposed at vertical positions corresponding to the profile 544. As described above, a desired profile can be implemented by aligning the carriers 545 that contact the wing panel at predefined locations on the wing panel, and during this process, the wing panel 550 can be advanced through an NDI station (such as the NDI station 524) that performs NDI on the wing panel. During pauses between pulsations or during continuous motion, the wing panel 550 is indexed to the respective work stations 520. This can be performed by indexing the work stations 520 to indexing features 210 of the wing panel 550 itself (such as described above with respect to indexing the strongback 540 to the wing panel) or by indexing the work stations 520 to indexing features of the strongback 540 that carries the wing panel 550.

[0134] At step 866, structural components such as ribs 572 and spars 580 are installed into the wing panel 550 while the profile 544 (via the combination of the strongback 540, the carrier 545, and the vacuum coupler) is implemented. This can include co-joining and / or fastening the ribs 572 and spars 580 to the wing panel 550 while the wing panel 550 remains suspended under the strongback 540. Alternatively, it can involve assembling the ribs 572 and spars 580 into a support structure 588, and then installing the support structure to the wing panel 550 while the wing panel remains suspended under the strongback. In one embodiment, advancing the wing panel 550 includes pulsing the wing panel in the process direction (e.g., by full-pulsing or micro-pulsing), and performing the installation of the ribs 572 and spars 580 during the pauses between pulses. In a further embodiment, advancing the wing panel 550 includes continuously moving the wing panel in the process direction, and performing the installation of the ribs 572 and spars 580 while the wing panel is continuously moving.

[0135] Although not specifically shown in FIG. 9 , in some embodiments, the method 860 further includes additional operational stations 520 arranged along the process direction to perform various different operational operations, such as installing ribs and / or spars, connecting ribs and / or spars to each other and / or to the wing panel, performing rework, inspecting the wing panel, cutting / installing inlets, etc. In some embodiments, multiple operational stations 520 are provided to perform the same type of operation.

[0136] The method 860 can provide one or more technical advantages over the prior art, for example, because it enables the wing panel 550 or a portion thereof to remain indexed to each of the operational stations 520 in the manufacturing environment, even as the wing panel is conveyed through multiple operational stations 520 to receive operations. That is, the wing panel 550 remains indexed to the strongback 540 during conveyance, which means that the operational stations 520 can quickly index themselves to the strongback 540, the wing panel 550, or both. Moreover, the technique of suspending the wing panel 550 under the strongback 540 enables more and more ergonomic access and inspection of the wing panel 550 during assembly processes (e.g., by technicians).

[0137] FIG. 10is a flowchart depicting a method 880 of profiling a wing panel in illustrative embodiments. According to the method 880, a step 882 includes positioning a wing panel of an aircraft under a forcebacker. As described in detail above, this step can involve moving the wing panel 550 under the forcebacker 540 configured to extend over a lateral portion of the wing panel, indexing the wing panel to the forcebacker via indexing features (e.g., physical indexing features and / or readable identification devices) of the wing panel, hard stops, vision techniques, and / or other processes. A step 884 includes engaging spring members of the forcebacker to an upper surface of the wing panel at locations different from locations corresponding to structural components (such as ribs and spars) that will be attached to the wing panel (e.g., corresponding locations on an underside surface of the wing panel). As noted above, this is performed to allow access to rib or spar mounting areas, for example, to facilitate manual or automated drilling, fastener installation, etc., to allow ribs and spars to be mounted to the wing panel. The ribs can be made of a metallic material or a composite material. If the ribs are made of aluminum, one or more layers of fiberglass or other material are placed at intersections between the aluminum and carbon fibers. This can be achieved via a fiberglass spacer layer and a sealant in the area of the wing panel where the ribs will be placed (sometimes referred to as a “rib panel area”). In one embodiment, this includes physically engaging the spring members to the upper surface and activating a vacuum system that applies suction to the wing panel via the spring members.

[0138] A step 886 includes controlling the length of the spring members to profile the wing panel while the wing panel is suspended under the forcebacker. The spring members can be adjusted independently. In one embodiment, the length of the spring members is controlled by setting the spring members to a predetermined length, while in another embodiment this includes operating actuators or air pressure to implement a particular length on the individual spring members. When the spring members are all set to their desired lengths, the wing panel is held in conformity with the desired profile for mounting ribs, provided that the vacuum couplers of the respective spring members are positioned correctly for the particular wing panel.

[0139] As noted above, in some embodiments a scan is performed to determine an initial wing panel profile. If the wing panel is already in the desired profile, no profile changes can be needed to be implemented. In this case, the holding force applied by the individual spring members can be less than in the case where the spring members are actively implementing a wing panel profile. Adjusting the length (i.e., longer or shorter) of the individual spring members relative to the forcebacker, for example, to push and / or pull the wing panel to the desired profile, is determined by the design parameters of the wing panel. The position of the vacuum couplers of the spring members relative to the upper surface of the wing panel is precisely positioned to ensure that the profile implemented by the spring members when the spring members are at the desired lengths conforms to expectations.

[0140] As noted above, in the various aspects of the assembly line 500 (or 500’) for a wing assembly 500 (or 500’) are shown, including operations that occur as the wing panel 550 advances through various workstations 520 disposed along the assembly line,FIG. 5A to FIG. 5G In order to facilitate explanation, many systems, operations and components are shown in a simplified form and / or schematically (e.g., rib 572). FIG. 11A to FIG. 11D The installation of additional components onto the wing panel 550 during the production of the wing assembly 600 is illustrated in more detail. Specifically, FIG. 11A to FIG. 11D The installation of rib 572 to wingplate 550 at rib mounting station 528 is shown. In the illustrated embodiment, this wingplate is upper wingplate 550-1. Therefore, for convenience, wingplate 550 may be referred to as "upper wingplate 550-1" or simply "wingplate 550-1" in the following sections. The term "wing assembly" refers to the structure produced when wing components (such as wingplates, ribs, and / or spars) are assembled together. As described in more detail below, FIG. 11A This illustrates how rib 572 is moved to a position below upper wingplate 550-1 by means of a shuttle device, and FIG. 11B and FIG. 11C The rib is shown to be raised upward toward the lower surface of the upper wing for mounting to that lower surface. FIG. 11D The resulting wing assembly 600 is shown, wherein rib 572 is mounted to wingplate 550-1, and a pair of spars 580 are mounted at either end of rib 572.

[0141] FIG. 11A and FIG. 11B The view shown generally corresponds to FIG. 5C The view indicated by arrow "11" shows the wing 550-1 in a chordal section. As explained above, the wing 550-1 is suspended below the strong backing material 540 by means of a spring 545, which is connected to the upper surface 574 of the wing via a vacuum coupling 548. The wing 550-1 or at least FIG. 11A The section shown is located within the rib mounting station 528. As detailed in the discussion above, the flange 550-1 can be directly or via one or more of the supporting backing materials 540 to the work station 520. The flange 550-1 is shown having a plurality of longitudinal beams 640 mounted to its lower surface 576, which are shown to have a T-shaped cross-section. Although six longitudinal beams 640 are shown, more or fewer longitudinal beams may be used for specific upper flanges and / or ribs 572, and / or for specific locations along the spanwise length of the flange. In the assembly line (such as...) FIG. 5A to FIG. 5F Assembly line 500 (and / or shown) FIG. 5G In the context of the assembly line 500' shown, the longitudinal beam 640 may be installed at any point upstream of the rib mounting station 528 prior to rib mounting, or provided during the initial manufacturing of the upper flange from the precast component.

[0142] Although multiple rib configurations are possible and within the scope of this disclosure, FIG. 11A to FIG. 11DRib 572 is shown as an elongated solid structure including a web 646, which is reinforced (i.e., retains the profile) by a stiffener 648 (e.g., a beam or bracket that profiles the rib before it is secured to the flange 550). The top and bottom edges of rib 572 are shaped to follow the corresponding profile of the flange to which rib 572 will be mounted, and are provided with a plurality of openings or “rat holes” 650, the size of which is determined and positioned to accommodate, for example, a longitudinal beam 640, as well as cables and other structures (not shown) that can be mounted. For a similar purpose, web 646 also includes a plurality of access holes 652 positioned inwardly from the edge of the rib.

[0143] exist FIG. 11A In the middle, rib 572 is advanced into the position, and in one embodiment, it enters the rib mounting station 528 from a feeder line (denoted as 570), which may be a rib feeder line (such as rib feeder lines 491-7) that supplies rib 572 to the rib mounting station 528 in a just-in-time or JIT schedule. More specifically, in FIG. 11A In this configuration, rib 572 is kept vertically oriented while being conveyed via shuttle 700 (e.g., a manual or automated trolley, autonomous guided vehicle (AGV), etc., propelled on a guide rail). As described above, rib 572 can be fed to shuttle 700 via a timed feeder line and can move during pauses between pulses to enter rib mounting station 528. In the illustrated configuration, shuttle 700 is propelled perpendicular to the process direction of wing plate 550. Shuttle 700 is shown driven by wheels 702 (e.g., motorized wheels) on floor 710, but may alternatively be mounted on guide rails or tracks, etc. Wheels 702 drive chassis 708, which translates chassis 708 horizontally / laterally in direction 1008, thus conveying rib 572 to a position / location directly below wing plate 550. The shuttle 700 may include indexing features (not shown) to facilitate indexing of the trolley relative to the rib mounting station 528 to ensure proper positioning of the shuttle relative to the rib mounting station before advancing to a position below the wing plate 550, and / or proper positioning of the shuttle (and therefore the rib) relative to the upper wing plate 550-1 when the shuttle is advanced to the appropriate position. This indexing feature may take the form of a cup cone of a cup cone indexing system, a hard stop, and / or other configurations. The chassis 708 holds one or more actuators 704, and supports 706 fixed to the actuators 704. The supports 706 are configured to support the rib 572 in a vertical orientation. The actuators 704 (or other lifting devices) are configured to vertically drive the supports 706, such as to vertically lift the rib 572 into contact with the lower surface 576 of the wing plate 550.

[0144] FIG. 11BRib 572 is shown after having been driven vertically upward in direction 1010 to contact the lower surface 576 of upper panel 550-1 (e.g., onto the ribbed region). The size of the mousehole 650 disposed along the upper edge of rib 572 can now be more clearly seen as being sized and positioned to accommodate stringer 640. The clearance between rib 572 and stringer 640 at mousehole 650 can be greater or less than that shown. Rib 572 is held at the desired orientation and position by support 706 during coupling to the panel. Although the term "mounting" is used in the previous discussion of the disclosure, this term can include temporary attachment or permanent attachment. Thus, when rib 572 first comes into contact with the panel, the coupling can be temporary (e.g., by clamping and / or nailing rib 572 in place) or permanent (such as by using temporary or permanent fasteners (e.g., via automated or manual drilling and fastener installation techniques, either before and / or after removal of shuttle 700), or rib 572 can be permanently fixed while in alignment with upper panel 550-1. In some embodiments (e.g., those described further below with reference to FIG. 16A to FIG. 16C and FIG. 17A to FIG. 17C After rib 572 has been temporarily fastened to the panel but before permanent mounting to the panel, a shim can be installed to fill the gap of the rib to panel interface in some embodiments (e.g., those described further below with reference to

[0145] In other embodiments, one or more strongbacks 540 suspend the upper panel below via a spring member 545 that forms a vacuum attachment with the panel, and the panel is lowered into contact with rib 572 by adjusting the length of the spring member (and / or lowering the strongback 540) rather than raising the rib 572 upward to the panel. Still other embodiments can employ a combination of movement of the rib 572 and the upper panel in order to bring the two components into contact. In some embodiments, rib 572 is installed after the spar or spar segment (not shown in this view) is installed, and the spar facilitates maintaining the profile (e.g., the spanwise profile, while the chordwise profile is maintained by the ribs). Specifically, in such embodiments, the spar 580 can prevent lateral (e.g., chordwise) displacement of the ribs 572, spanwise displacement of the ribs relative to one another, twisting of the ribs 572 and upper panel 550-1 about the spanwise 590 axis, etc. Further, in some embodiments, a support structure (such as support structure 588) is assembled from the ribs and the spar, and then the support structure is mounted to the panel. Such embodiments can involve the use of multiple shuttles and / or shuttles having different configurations than shuttle 700 to transport and / or lift the support structure to the panel.

[0146] FIG. 11C Corresponding to FIG. 11Bof shuttle 700, rib 572, and upper wing panel 550-1. FIG. 11C Also illustrated in this implementation is that upper wing panel 550-1, and specifically its lower surface 576, includes alignment features 584 configured to align with complementary alignment features 586 at rib 572. The configuration of alignment features 584 and 586 can be any configuration that enables alignment of the rib with upper wing panel 550-1, such as cup and cone configurations, etc. There can be multiple corresponding indexing feature pairs for each rib. Further, in some implementations, alignment features 584 are installed as indexing features 210 during manufacture of upper wing panel 550-1. These alignment features facilitate alignment of rib 572 prior to fastening rib 572 to upper wing panel 550-1. Thus, in one implementation, lifting rib 572 includes mating rib 572 with alignment features 584 at wing panel 550. Rib 572 is delivered to rib installation station 528 from a parallel assembly line / feed line as needed. In this way, different ribs are continuously produced as needed in a pulsed environment for placement in wing assembly 600.

[0147] FIG. 11D is an end view of wing assembly 600 including a wing panel 550 (e.g., upper wing panel 550-1) with attached ribs, where rib 572 is visible (i.e., rib 572 blocks the view of other ribs behind it). In the illustrative implementation, upper wing panel 550-1 is conveyed along an assembly line; for example, via strong back 540, which conveys upper wing panel 550-1 (now part of wing assembly 600) along track 510. Wing assembly 600 can be at least partially disposed within rib installation station 528, such as FIG. 5C is shown. However, in the implementation shown in FIG. 11D Wing spar 580 is shown installed to either side / end of rib 572; thus, wing assembly 600 can be at least partially disposed within wing spar installation station 530, such as FIG. 5E is shown, or within rib-to-wing spar attachment station 598, such as FIG. 5F is shown, for example, depending on the order in which wing spar 580 and rib 572 are installed.

[0148] According to the components and operations discussed above, FIG. 12is a flowchart illustrating a method 900 of installing a rib into an upper wing panel in the production of a wing assembly in an illustrative embodiment. The description of the method will refer to components and concepts discussed above and shown in the drawings, but the method is applicable to a variety of settings. Step 902 includes suspending an upper wing panel 550-1 of an aircraft below a shuttle device, such as a strongback 540. Depending on the method of the above, this step can include (and / or be preceded by) un-molding the upper wing panel 550-1 from a layup mandrel, indexing the upper wing panel to the strongback 540, and / or coupling the wing panel with the strongback (such as via a vacuum coupler 548 of a spring member 545) to hold the upper wing panel while contours are implemented onto the upper wing panel.

[0149] Step 904 includes translating a rib to a position below the upper wing panel. This step can be performed while the wing panel is paused between pulses through the work station. In some embodiments, this includes driving a shuttle device (such as a cart 700, which can be a manually operated cart, an AGV, or other configured vehicle) that supports the rib into the desired position. The cart can be controlled according to an NC program, and can be positioned based on a track / rail system that implements the desired orientation, or that is marked at the factory floor indicating the desired position for placement via radar or lidar, visual tracking, etc. In the illustrated embodiment, the position to which the rib is translated is directly below the position on the upper wing panel to which the rib is to be installed.

[0150] The method 900 is shown as including a step 906 of vertically uprightly orienting the rib 572. In some embodiments, the rib 572 is assembled or otherwise manipulated while in an upright position, such as on a jig or similar frame, after un-molding, and thus can not need to be uprightly oriented for installation (e.g., if moved directly from the jig to the cart 700 without changing its orientation). A jig can be used to place or implement a desired contour, such as a flat contour, onto the rib. As discussed above, a stiffener extending along the length of the rib is attached to the rib after un-molding to implement a contour onto the rib. In some embodiments, the rib can be (or become) oriented in a direction other than the vertical orientation, such as during assembly or when supplied to the rib installation station, so that a vertical upright orientation is needed prior to installation. In some embodiments, the orienting is performed by placing the rib 572 on the cart 700, which then holds the rib in the desired vertical orientation by the support member 706. In some embodiments, the method 900 can include supplying the rib in a just-in-time (JIT) manner, such as via a feeder line configured to have a suitable JIT delivery cadence.

[0151] Although in the illustrated embodiment the "orient" step 906 is shown as following the "translate" step 904, this is not necessary for all embodiments. In some embodiments, the "orient" step (906) is performed as part of or at least partially during the "translate" step (904). In some embodiments, the orienting is performed prior to the translating, such as during loading of the rib 572 onto the cart 700.

[0152] At step 908, the rib 572 is placed in contact with the upper panel. As described above, this can be performed by vertically lifting the rib, such as by driving the actuator 904 of the cart 900 to raise the rib 572 into contact with the lower surface 576 of the upper panel 550-1. In some embodiments, this can be performed by lowering the upper panel into contact with the rib, such as by means of the spring member 545 of the strongback 540. In some embodiments, a combination of lifting the rib and lowering the panel is performed to bring the components into contact. In some embodiments, placing the rib 572 in contact with the upper panel 550-1 includes mating the rib with one or more indexing features of the panel, such as by FIG. 11C the illustrated coupling alignment features 584 and 586). This can ensure final precise alignment of the rib 572 with the upper panel 550-1.

[0153] For example, as FIG. 5D illustrated, in some embodiments the rib 572 can be fastened to the panel 550 or at least one or more portions of the lower surface thereof at an angle, which is shown as the installation angle Θ. Thus, in a manufacturing method in which the rib 572 is oriented vertically or in other words at an angle generally perpendicular to the track 510 and / or floor surface 710 and then lifted upward to the lower surface of the panel, installing the rib at the desired installation angle Θ relative to the panel can be facilitated by setting the panel in the appropriate orientation (e.g., by setting the panel such that its lower surface is inclined at an angle complementary to the installation angle Θ). This can be done during initial suspension of the upper panel 550-1 beneath the strongback in the appropriate orientation, or the spring member can adjust its length to a length appropriate for installing the rib in a manner configured to change the orientation of the panel prior to the rib installation procedure.

[0154] At step 910, the ribs 572 are secured to the upper panel 550-1 while the upper panel remains suspended under the strong back 540. As the term is used herein, securing includes both temporarily holding the ribs in place (such as by pinning, clamping, and / or other techniques) as well as permanently mounting. In some embodiments, the ribs 572 are held in place prior to permanent mounting, such as to allow selective installation of shims into play (if any) at the rib-to-panel interface. In some embodiments, the installation includes driving or otherwise causing installation fasteners to pass through the upper panel 550-1 and the ribs 572. These operations can be performed via an end effector that installs lock bolts or by other means. In some embodiments, in order not to hinder or interfere with the fastening operations, the vacuum attachment is performed via the vacuum couplers 548 that are located between or among the rib installation locations but in any case distinct from the rib installation locations. Thus, in such embodiments, the vacuum couplers 528 are disposed on the panel 550 such that their location does not interfere with the operations of pinning and / or permanent fastener installation of the ribs 572, such as by a technician or automation.

[0155] Steps 904 (translation of the ribs), 908 (placement of the ribs in contact with the panel), and 910 (securing of the ribs to the panel) are all performed while the panel 550 is suspended and / or while the ribs 572 are held vertically upright. One or more of the steps or all of the steps of the method 900 are performed at a rib installation station. The method 900 or series of steps thereof can be performed repeatedly to install multiple ribs 572 onto the same panel 550.

[0156] The method 900 provides technical advantages over existing systems and techniques in that it enables the implementation of a profile on the panel 550 and the rapid installation of ribs 572 into the panel while maintaining the implemented profile. By maintaining the vertical orientation of the ribs throughout the installation process, the method 900 can save labor and increase efficiency on the factory floor and / or assembly line.

[0157] In some embodiments, after at least one rib has been secured (e.g., mounted to the upper panel 550-1), the spar 580 is secured to the rib and to the panel, such as to close the leading edge portion and the trailing edge portion of the panel / rib. In some such embodiments, portions of the spar are longitudinally connected to one another at the rib to form the spar, such that the rib becomes part of the splice between spar segments. In some such embodiments, the spar 580 is secured at a station downstream of the rib installation station, such as a spar installation station, such as FIG. 5E and FIG. 5Fspar mounting station 530 of the assembly line 500 shown in FIG. 6. In one embodiment, the spar 580 is composed of three spar portions, thus there are two spar / rib splices. In some embodiments, the spar 580 and the ribs 572 are fixed to the wing panel 550 simultaneously, such as at two different stations and / or two different locations on the wing panel 550.

[0158] Mounting the ribs and spars to the wing panel and to each other can include any suitable technique, including those disclosed herein. Some embodiments of the method 900 continue, such as connecting a lower wing panel to the ribs and spars that have been mounted to an upper wing panel. Reference is made below to FIG. 16A to FIG. 16C A more detailed explanation of one way of performing this operation is provided, FIG. 16A to FIG. 16C One way of installing shims during assembly of a wing assembly is illustrated.

[0159] In some embodiments, there is a work station upstream of the spar mounting station at which the wing panel is trimmed to the final production size (e.g., its final perimeter) and the indexing features in the manufacturing allowance are removed (i.e., along with the manufacturing allowance). This trimming is followed by sealing and painting, performed in a pulsatile or continuous manner. In some embodiments, the wing panel is trimmed to its final perimeter (and / or sealed and painted) after the ribs and / or spars are mounted.

[0160] FIG. 13 is a flowchart of a method 920 of assembling a wing assembly in an illustrative embodiment, involving the components, concepts, and processes discussed in detail above, but focusing on aspects of mounting ribs and spars to an upper wing panel while the wing panel is suspended below a shuttle. Thus, step 922 includes suspending an upper wing panel 550 of an aircraft below a shuttle, such as a power backer (e.g., the power backer 540). Step 924 includes mounting ribs 572 onto the upper wing panel 550-1. Step 926 includes mounting spars 580 onto the upper wing panel 550-1. Step 928 includes fastening the spars 580 to the ribs 572. Finally, step 930 includes connecting a lower wing panel 550-2 to the spars 580 and ribs 572.

[0161] As noted above, the connections of various wing assembly components can occur in a different order than shown in the illustrated embodiments. In some embodiments, one or more of the ribs are mounted prior to mounting the spars (or spar portions). In some embodiments, all of the ribs are mounted prior to mounting the spars (or spar portions). In some embodiments, the ribs and spars are mounted simultaneously or overlapping in time, such as in multiple work stations in an assembly line, and / or at multiple locations on the wing panel.

[0162] Further, in some embodiments, the spar 580 (or spar portion) is connected to the ribs 572 to create a wing assembly having a horizontally open trapezoidal structure (such as the support structure 588 (best seen in FIG. 5G FIG. 6) before the ribs are secured to the wing panels (such as the upper wing panel 550-1), and then the upper and lower wing panels 550 are installed to the horizontally open trapezoidal structure. FIG. 14 is a flowchart illustrating another method 940 of assembling a wing assembly in such embodiments. This embodiment includes connecting the spar 580 to the ribs 572 at step 942. The upper wing panel 550 is then connected to the spar 580 and the ribs 572 or support structure 588 on one side at step 944. This process can involve suspending the upper wing panel 550-1 under a shuttle device (such as the strongback in the other example methods) and raising the connected ribs and spar support structure 588 into position to secure it to the upper wing panel. In some such embodiments, all of the ribs and spar are fastened together before connecting to the upper wing panel; in other such embodiments, additional ribs and / or spars or spar portions are attached to the wing assembly after the support structure 588 is connected to the upper wing panel. The lower wing panel is finally connected to the opposite side of the connected spar 580 and ribs 572 support structure 588 to complete the wing assembly at step 946.

[0163] As noted above, in some configurations of an assembly line for a wing assembly, various workstations can be arranged in a manner that facilitates performing multiple operations on a wing panel simultaneously or overlapping in time as the wing panel moves along the assembly line in the process direction. For example, FIG. 5A A configuration is shown in which different portions of the same wing panel 550 are positioned within multiple workstations 520 (specifically, the NDI workstation 524, the cutout workstation 526, and the rib installation workstation 528). In other embodiments, additional workstations 520 (such as the spar installation workstation 530 FIG. 5E ), the support structure assembly workstation 532, and / or the installation workstation 534 FIG. 5G ), and the rib-to-spar attachment workstation 598 and / or the panel connection workstation 599 (see FIG. 5F )) can also be arranged in this manner.

[0164] FIG. 15is a flowchart illustrating aspects of multiple operations performed on a wing panel concurrently or overlapping in time in an illustrative implementation, and shows a method 960 of assembling a wing or wing assembly, such as by installing ribs and spars to an upper wing panel. Step 962 includes suspending an upper wing panel 550-1 of an aircraft below a shuttle device, such as a strongback (e.g., strongback 540). Step 964 includes installing one or more ribs 572 and one or more spars 580 (or portions of spars 580) to the upper wing panel 550 concurrently or at least overlapping in time via stations 520 disposed at the upper wing panel while the upper wing panel remains suspended. Step 966 includes pulsing the upper wing panel through the work stations 520 in a process direction. In some implementations, additional work stations 520 also perform operations on the wing panel during these operations, including installing access portals (at cutout stations), attaching ribs to spars (at rib-to-spar attachment stations), etc. In further implementations, the work stations install the ribs and spars during pauses between pulsing of the upper wing panel. In further implementations, the method further includes securing a lower wing panel to the ribs and spars installed to the upper wing panel.

[0165] Various aspects of wing assembly, such as installing ribs and spars to a wing panel, can involve installing shims between the wing panel and one or more ribs and / or spars, for example, in the event that any gaps between the various components exceed a particular dimension, such as a shim tolerance threshold. For example, shim installation can be performed after the ribs and spars have been clamped into and / or pinned into place but before the ribs and spars have been fastened together in the assembly line 500 of FIG. 6. Once the components have been positioned to one another and pinned / clamped into place, shims are filled into the gaps between the various components (e.g., between a rib and an upper or lower wing panel, between a spar and an upper or lower wing panel, between a rib and a spar, etc.). FIG. 5A

[0166] FIG. 16A FIG. 16B is a diagram in an illustrative implementation illustrating automatic installation of shims between ribs and a wing panel, specifically by way of an end effector of a robotic arm that can be detachably coupled to a stiffener of each rib. In more detail and as shown in FIG. 16A FIG. 16B is a diagram in an illustrative implementation illustrating automatic installation of shims between ribs and a wing panel, specifically by way of an end effector of a robotic arm that can be detachably coupled to a stiffener of each rib. In more detail and as shown in FIG. 16A shows an implementation in which the wing assembly 600 includes one wing panel 550 in the form of an upper wing panel, indicated at 550-1, while FIG. 16B ​​​An embodiment is shown in which the wing assembly 600 also includes a second panel 550 in the form of a lower panel (indicated at 550-2). The wing assembly 600 is shown as having a plurality of ribs 572 fixed to the lower surface 576 of the upper panel 550-1.

[0167] In some embodiments, there can be one or more gaps between the coupling components of the wing assembly 600, such as between the ribs 572 and the surface of the panel to which they are mounted, between the spars 580 and the panels 550, between the ribs 572 and the spars 580, etc. If it is determined that a gap exceeds a particular dimension (i.e., one or more dimensions of the gap (e.g., width, depth, length, etc.) exceeds a particular threshold, which is also referred to herein as a shim tolerance threshold), a shim of a suitable size and configuration is installed into the gap to fill the gap. In the illustrated embodiment, this is accomplished by the robotic arm 750, and more particularly by the end effector 752 of the robotic arm. The end effector 752 is shown in FIG. 16A including a grasping device 754 configured to hold a shim 756, such as to be installed into a gap that has been determined to be a shim location (indicated at 758). In some embodiments, the end effector 752 includes components or devices (not shown) for inspection, such as a camera, laser, ultrasonic device, probe, or feeler gauge, etc., so as to scan or otherwise visually or physically detect or assess the gap along the joint between the connecting components, and also determine or be able to determine whether the gap exceeds the shim tolerance threshold and is thus a suitable location for installation of the shim 756 (i.e., the shim location 758). In some embodiments, the robotic arm 750 includes a plurality of end effectors 752, such as one for inspection and another for installation.

[0168] Although other configurations are possible, in the illustrated embodiment, the robotic arm 750 is configured to move the end effector 752 along the joint between the connecting components, such as along the joint between the ribs 572 and the surface of the panel to which they are mounted, between the spars 580 and the panels 550, between the ribs 572 and the spars 580, etc. In some embodiments, the robotic arm 750 is configured to move the end effector 752 along the joint between the connecting components in a direction that is substantially perpendicular to the joint, such as along a direction that is substantially perpendicular to the surface of the panel to which the ribs 572 are mounted, along a direction that is substantially perpendicular to the panels 550, along a direction that is substantially perpendicular to the spars 580, etc. FIG. 16AIn this design, the robotic arm 750 is shown as an actuator 760 and a kinematic chain of a rigid body 762 extending from a carriage 764. The carriage 764 is in turn mounted on a reinforcement 648 of the rib 572. The reinforcement 648 is also referred to herein as a "support". In some embodiments, such as as described above, the support 648 is mounted to the rib 572 before the rib is mounted to the wing plate 550 to serve as a reinforcement, i.e., to stabilize the rib and / or to implement a desired (e.g., flat) profile to the rib. Thus, in some embodiments, the support 648 serves both as a reinforcement and as a connection point for the robotic arm. In other embodiments, the support 648 may additionally or alternatively serve as a general connection point for a machine or device for moving or otherwise manipulating the rib during manufacturing and / or assembly operations. In some embodiments, the support is removably attached, for example, using bolts or other similar fasteners. As further detailed below, the connection between the slide 764 of the robotic arm 750 and the support 648 of the rib 572 is a removable connection, allowing the robotic arm to be connected to and disconnected from the support via the detachable mounting of the slide 764 to the support. Furthermore, in the illustrated embodiment, the connection allows the slide 764 to move independently along the length of the support, such as to facilitate the robotic arm's access to the gap and / or shim position 758 along the length of the rib 572.

[0169] The robotic arm 750 can be moved (e.g., repositioned) from one support to another (such as by detaching from the first support and then attaching to the second support) to operate at different locations along the wing assembly 600. FIG. 16A In the illustrated embodiment, this is accomplished by means of a trolley 770. The trolley 770 includes a set of wheels 772 mounted and configured to support a trolley body 774 relative to a surface (such as a floor surface). One or more wheels 772 may be motorically or otherwise driven. The trolley body 774, in turn, supports a telescopic lift 776 configured to engage and raise or lower a carriage 764. Thus, the trolley 770 is configured to position the carriage 764 for engagement with a bracket 648, or to move the carriage to a position where it can be engaged with a bracket of a second rib after separation from the bracket of the first rib 572, such as by a combination of raising or lowering the lift 776 and moving the trolley body relative to the floor surface (and / or rib 572) by means of the wheels 722.

[0170] As shown, the cart 770 also includes a controller 778 that can partially or fully control movement of the cart body 774 and / or the lift 776, and / or coupling / detaching of the skid 764 relative to the cradle of the rib 572. The controller 778 can control, in whole or in part, operation of the robotic arm 750 and its end effector 752. In some embodiments, the robotic arm 750 is operated by the controller 778 according to an NC program to visually inspect the position between the rib 572 and the flap 550 in order to determine whether a shim 756 is to be used and what size shim is to be used and / or to install the shim. In other embodiments, some or all of these movements are remotely controlled, such as by an operator or by a floor controller (not shown). Thus, it will be appreciated that FIG. 16A A number of operations are illustrated. For example, the cart 770 and the lift 776 are shown cooperating to position the skid 764 into contact with the cradle 648 of the rib 572. Further, the robotic arm 750 extending from the skid 764 is shown with its end effector 752 holding a shim 756 for installation into a shim location 758. For ease of explanation, various components of the cart 770 and the robotic arm 750 are shown in simplified, partially schematic form. Cable routing and wiring, such as to provide power to the robotic arm 750 and / or the cart 770 from an external or integrated power source (not shown) are not illustrated in this view.

[0171] FIG. 16A Also shown is a shim feeder line, shown schematically at 780, which in the illustrated embodiment is configured to supply shims 756 for installation by the robotic arm 750. In some embodiments, the shim feeder line 780 is configured to dynamically manufacture shims 756 for installation based on input received from the end effector 752, which is configured to measure or otherwise assess various gaps encountered during analysis, such as in response to a signal or communication provided by an operator and / or the controller 778.

[0172] Accordingly, it can be seen that example operations for automated shim installation for a wing assembly can be performed by evaluating individual ones of a series of locations in the wing assembly (such as, for example, individual ones of a series of locations for which prior analysis indicates that a shim location 758 exists (or can exist)) or individual ones of joints between components that are connected together, among others. In one example, the carriage 764 of the robotic arm 750 is sequentially coupled with the bracket 648 mounted to each of a plurality of ribs 572 of the wing panel 550 to perform detection and analysis of individual gaps and / or shim installation for individual shim locations 758 in a space bounded by one or two adjacent ribs 572. This space is also referred to as a compartment 790. As described above, in such examples, the carriage 764 can be moved along the bracket 648 to allow inspection and / or installation of an entire length of a rib 572 or at least a side of a rib (or ribs) that defines a compartment for installation of the robotic arm 750. In the illustrated example, the carriage 764 is coupled with the bracket 648 of the rib 572-4 to allow the end effector 752 of the robotic arm 750 to inspect and / or install shims 756 not only to the side of the rib 572-4 on which the bracket 648 is mounted, but also to the side of the next adjacent rib (i.e., rib 572-3) and any other locations in the compartment 790-4 that are accessible. Accordingly, by coupling the carriage 764 of the robotic arm 750 with the bracket 648 of individual ribs 572, shim installation can be performed in individual compartments 790-1, 790-2, etc. In compartments (such as the compartment 790-6 in FIG. 7B) that do not have a bracket 648 with which the carriage 764 can be coupled, gap inspection and / or shim installation can be performed by moving the robotic arm 750 by means of the cart body 774 and the telescoping lift 776. In other embodiments, additional brackets can be installed in order to allow inspection and / or shim installation by the robotic arm 750 by means of bracket-mounted alone. There can be more or fewer ribs (and correspondingly more or fewer compartments) in different wing assemblies. In some embodiments, the robotic arm 750 is coupled with the bracket 648 of a rib 572 prior to the rib 572 being placed against a wing panel. FIG. 16A In the illustrated embodiment, five ribs 572 (also individually indicated as 572-1, 572-2, 572-3, 572-4, and 572-5) are shown mounted to the upper wing panel 550-1, thereby forming six compartments 790 (which are individually indicated as 790-1, 790-2, 790-3, 790-4, 790-5, and 790-6 only). The carriage 764 is shown coupled to the bracket 648 of the rib 572-4, thereby allowing the end effector 752 of the robotic arm 750 to inspect and / or install shims 756 not only to the side of the rib 572-4 on which the bracket 648 is mounted, but also to the side of the next adjacent rib (i.e., rib 572-3) and any other locations in the compartment 790-4 that are accessible. Accordingly, by coupling the carriage 764 of the robotic arm 750 with the bracket 648 of individual ribs 572, shim installation can be performed in individual compartments 790-1, 790-2, etc. In compartments (such as the compartment 790-6 in FIG. 7B) that do not have a bracket 648 with which the carriage 764 can be coupled, gap inspection and / or shim installation can be performed by moving the robotic arm 750 by means of the cart body 774 and the telescoping lift 776. In other embodiments, additional brackets can be installed in order to allow inspection and / or shim installation by the robotic arm 750 by means of bracket-mounted alone. There can be more or fewer ribs (and correspondingly more or fewer compartments) in different wing assemblies. In some embodiments, the robotic arm 750 is coupled with the bracket 648 of a rib 572 prior to the rib 572 being placed against a wing panel. FIG. 16B In the illustrated embodiment, five ribs 572 (also individually indicated as 572-1, 572-2, 572-3, 572-4, and 572-5) are shown mounted to the upper wing panel 550-1, thereby forming six compartments 790 (which are individually indicated as 790-1, 790-2, 790-3, 790-4, 790-5, and 790-6 only). The carriage 764 is shown coupled to the bracket 648 of the rib 572-4, thereby allowing the end effector 752 of the robotic arm 750 to inspect and / or install shims 756 not only to the side of the rib 572-4 on which the bracket 648 is mounted, but also to the side of the next adjacent rib (i.e., rib 572-3) and any other locations in the compartment 790-4 that are accessible. Accordingly, by coupling the carriage 764 of the robotic arm 750 with the bracket 648 of individual ribs 572, shim installation can be performed in individual compartments 790-1, 790-2, etc. In compartments (such as the compartment 790-6 in FIG. 7B) that do not have a bracket 648 with which the carriage 764 can be coupled, gap inspection and / or shim installation can be performed by moving the robotic arm 750 by means of the cart body 774 and the telescoping lift 776. In other embodiments, additional brackets can be installed in order to allow inspection and / or shim installation by the robotic arm 750 by means of bracket-mounted alone. There can be more or fewer ribs (and correspondingly more or fewer compartments) in different wing assemblies. In some embodiments, the robotic arm 750 is coupled with the bracket 648 of a rib 572 prior to the rib 572 being placed against a wing panel.

[0173] In some cases, the shim position 758 can be detected and / or evaluated from both sides of rib 572, in which case shim installation can be performed from either side where more efficient operation is possible. In some embodiments, multiple robotic arms are deployed simultaneously on the same wing assembly, which (among other benefits) can facilitate efficient shim installation at shim positions that can be filled from either side. In some such embodiments, a single trolley can facilitate the positioning (and repositioning) of each of the multiple robotic arms, such as by raising the carriage of the first robotic arm into place for mounting on a first support, then separating it from the carriage to leave the robotic arm on the first support, and then moving it to engage the carriage of the second robotic arm, such as to move it into place for mounting on a second support (e.g., in a different compartment), etc.

[0174] exist FIG. 5A As described above, wing assembly 600 is shown to also include lower wingplate 550-2. Furthermore, telescopic lift 776 is shown extending through inlet 792 in lower wingplate 550-2 to access support 648, such as to attach carriage 764 to (or detach from) the support. Inlet 792 may already be located at upstream work station 520 (such as...). FIG. 16A The robot arm 750 (including carriage 764) is installed at the cutting station 526 shown. The inlet 792 is sized to allow insertion and subsequent removal of the robot arm 750. To minimize the size of the inlet 792, the robot arm 750 may be extended, folded, or otherwise aligned to have a configuration with a minimum cross-section for insertion and withdrawal through the inlet. Alternatively, the robot arm 750 may be specifically designed and / or configured to match a predetermined inlet size. The lower wing 550-2 is shown to include a plurality of inlets 792, one inlet per compartment, to allow the robot arm 750 to be inserted and then engaged to perform inspection and / or shim installation in the respective compartments. In one embodiment, when the robot arm 750 is positioned within a compartment, the robot arm inspects and / or shims fill the sides of two ribs defining the compartment, which reduces the number of times the robot arm 750 needs to be aligned with the inlet 792 for inspection or removal.

[0175] In some implementations... FIG. 16B and FIG. 16A The sequential operation is described in two phases, where the first phase is executed (e.g., ... FIG. 16B As shown, a shim 756 (e.g., an upper shim) is installed at shim position 758 between rib 572 and the lower surface of upper wingplate 550-1. Then, lower wingplate 550-2 is installed to wing assembly 600, and a shim (e.g., a lower shim) is installed at shim position 758 between rib 572 and the upper surface 574 of lower wingplate 550-2. FIG. 16AThe lower wing panel 550-2 is installed after the upper shim is installed (as shown). In other words, in such embodiments, the lower wing panel 550-2 is installed after the upper shim is installed. In other embodiments, FIG. 16B and FIG. 16A depicts alternative operations - e.g., FIG. 16B may represent a first phase of the sequential operations described above, while FIG. 16C may represent the operation of installing the lower wing panel 550-2 to the wing assembly 600 prior to installation of any (upper or lower) shims 756. In either case, the robotic arm 750 can be moved along the length of the wing assembly from compartment to compartment by means of the cart 770 in order to perform the shim installation in the various compartments. As noted above, in some embodiments, multiple robotic arms are deployed to perform shim location detection and / or analysis and / or shim installation in more than one compartment simultaneously.

[0176] FIG. 16A depicts a view of the rib 572 (specifically, the rib 572-4 as FIG. 16A shown) to which the carriage 764 of the robotic arm 750 is installed, and thus corresponds to the view arrow 16C of FIG. 16A However, FIG. 16C the components shown in FIG. 16A are applicable to any rib 572 in the illustrated embodiment. For clarity, FIG. 16C only the carriage 764 of the robotic arm is shown in FIG. 16A, and the components of the stiffened backsheet (e.g., the spring members and vacuum couplers) are not shown in this view as well. FIG. 16C A view of an illustrative example configuration of the bracket or stiffener 648 is provided, shown installed against the web 646 of the rib 572. More specifically, the bracket 648 is shown cooperating with an indexing feature at the rib 572, which is generally shown as indexing feature 794. The indexing feature can facilitate alignment of the bracket 648 with the rib 572 during installation, and can take any suitable form, such as a through-hole in the web 646 configured to receive a fastener such as a bolt. FIG. 16C It is also illustrated that the bracket 648 includes a rack 796 having teeth 798 to which the carriage 764 is clamped or otherwise removably attached. The carriage 764 is configured to translate back and forth along the bracket 648 in a controlled and indexed manner with the teeth 798 (e.g., via a drive mechanism engaged with the teeth, such as a pinion, worm gear, etc.). Thus, based on the position of the bracket 648 (or relative to the bracket 648) and the position of the carriage 764 along the bracket 648, the position of the robotic arm can be indexed relative to the rib to which the carriage of the robotic arm is coupled. While not necessary for all embodiments, FIG. 16C The bracket 648 in FIG. 16A is also shown as including a centering feature 654 that can facilitate indexing, such as by enabling a more rapid determination of the position of the carriage relative to a known reference point.

[0177] In one implementation, the carriage 764 is operable to drive a robotic arm (not shown) along the cradle 648 via a rack and pinion system, with the teeth 798 forming the rack. Other implementations of the cradle 648 and / or the carriage 764 have different configurations to enable the carriage 764 to move along the cradle. In the illustrated implementation, the carriage 764 is also rotatable as indicated by arrow 1012 in order to enhance movement and access of the robotic arm.

[0178] FIG. 16C A representative pair of spars 580 mounted to the upper panel 550-1 at either end of the rib 572 is also shown. The spars 580 are illustrated in simplified form and thus are not shown, for example, to include specialized upper cap and lower cap shapes that facilitate fastener connection to the panel. The teeth 798 are shown extending sufficiently toward the end of the cradle 648, which in this implementation is contiguous with the rib 572 to which it is mounted, to allow the carriage 764 to move close enough to the spar that gap assessment and / or shim installation by the robotic arm can be performed at the joint between the spar and the panel and / or at the joint between the spar and the rib. In further implementations, the cradle 648 facilitates rail mounting of collar and / or nut mounts. This can be particularly beneficial in cases where the lower panel has already been installed and access is only possible through an access portal. Moreover, while the rib 572 and the panel 550 are not shown to scale or dimension, it is understood that the rib 572 and the panel 550 are each formed of a material having a thickness that is less than the thickness of the spar 580. FIG. 17A to FIG. 17C A plurality of gaps are shown to exist between the rib 572 and the lower surface 576 of the upper panel 550-1, such as at representative shim locations 758.

[0179] As noted above, in some implementations, the robotic arm 750 performs operations other than shim installation, such as detection and / or inspection of gaps to facilitate identification of shim locations 758. In some implementations, the robotic arm performs additional operations, including sealing, sealant inspection, fastener installation, collar or nut installation on fasteners, collar or nut installation inspection, and the like. The robotic arm 750 can perform such operations via selection of interchangeable end effectors 752 (e.g., the end effector can be replaced while the carriage 764 of the robotic arm 750 is coupled to the cradle 648, such as via the access portal 792), or with a multifunctional end effector 752, or with multiple robotic arms 750 (each of which can be installed and left in place on the cradle, in some cases more than one such robotic arm is coupled to the cradle). The robotic arm 750 can be operated automatically or remotely via a floor-based controller that enables a technician to operate the robotic arm (e.g., via remote control). After the robotic arm 750 has completed its job, it can be reattached to the cart 770 and removed.

[0180] FIG. 17Ais an isometric view of a robotic arm 750, each robotic arm 750 operative to inspect a gap in a compartment 790 disposed between two ribs 572 and bounded on one side by a spar 580 of an example wing assembly 600, install a shim 756 in a shim location 758, install a sealant or collar / nut, etc. in the embodiment depicted in these figures, a technician sets up, operates, and maintains the robotic arm 750 after placement of the carriage 764 of the robotic arm on the stand 648 via a cart (not shown). For simplicity, the following discussion assumes that in each of this series of figures, the robotic arm 750 is operating in the same compartment 790 between the same two ribs 572, numbered 572-1 and 572-2, respectively. In FIG. 17B , the robotic arm 750 is installed on a stand 648 mounted against the rib 572-1 and operates its end effector 752 to inspect a location between the rib 572-2 placed against the upper wing panel 550 and the surface of the wing panel 550 against which it is positioned. Based on the inspection, the robotic arm 750 will selectively install a shim 756 at a shim location 758 within the compartment. In FIG. 17A , the carriage 764 of the robotic arm 750 has been advanced along the stand 648 to a position closer to the end of the stand than in FIG. 17C , and is shown using its end effector 752 to inspect a location near the bottom of the rib 572-2. In FIG. 18 , the robotic arm 750 has used its end effector 752 to place a shim (not shown) at a shim location 758 above the stand 648, where the rib 572-1 is affixed to the upper wing panel 550. With the shim in place, a fastener can be installed through the upper wing panel 550 and the rib 572-1 to affix the panel to the rib, or at least the portion of it where the shim is in place. In some embodiments, the shim is affixed in place with the aid of one or more fasteners; in some embodiments, the shim is instead held in place in a friction fit, as the rib is fastened to the panel.

[0181] With the foregoing components and concepts in mind, FIG. 16A to FIG. 17Cis a flowchart illustrating a method 920 for operating a robotic arm (such as robotic arm 750) to perform tasks related to a wing assembly (e.g., in wing assembly 600) in illustrative implementations. Step 922 includes mounting a cradle 648 to a rib 572. In some implementations, this is done prior to holding or placing the rib against a wing panel 550, such as after the rib is de-molded and during (or after) other preparation of the rib for mounting to the wing panel. In some implementations, this is done after holding or placing the rib against the wing panel. Mounting the cradle 648 can be facilitated by aligning the cradle with indexing features of the rib 572 (e.g., complementary cup-cone features, through-holes for receiving bolts, etc.). Once mounted, the cradle 648 imparts a desired profile (such as a flat profile) onto the rib 572. In some implementations, the cradle is removably mounted.

[0182] After the cradle 648 has been mounted to the rib 572, step 924 includes coupling a robotic arm 750 to the cradle. In some implementations, this is performed by detachably mounting a carriage 764 on the cradle. In some such implementations, a wheeled cart 770 equipped with a telescoping lift 776 configured to support the carriage is deployed, e.g., to move the carriage into a suitable orientation and / or position for mounting on the cradle. Coupling of the robotic arm 750 to the cradle 648 can be achieved via clamping, suction, magnets, mechanical alignment with tracks on the cradle, etc. In some implementations, the coupling is configured to allow movement of the robotic arm 750 relative to the cradle 648, such as by way of a carriage 764 configured to move along the cradle. In some such implementations, the cradle includes teeth that facilitate a rack-and-pinion system through the carriage. With the carriage 764 and / or the robotic arm 750 coupled to the cradle 648, the position of the robotic arm 750 within a frame of reference of the wing assembly 600 (e.g., relative to one or more components of the wing assembly, such as a wing panel or a rib or a cradle mounted to a rib or a spar, etc.) is known. In this sense, coupling the robotic arm 750 to the cradle 648 can include indexing the position of the robotic arm relative to the cradle.

[0183] Once coupled, in step 926 the robotic arm 750 is operated to mount one or more spacers between the rib and the wing panel at the rib-to-wing panel interface (i.e., while the robotic arm is coupled to the cradle 648 via the carriage 764). As described above, this can include moving the robotic arm 750 along the length of the cradle 648 (e.g., by driving the carriage 764) so as to align the robotic arm 750 with a spacer position at the rib, and / or moving the robotic arm within a range of additional spacer positions.

[0184] In some embodiments of the method 920, the robot arm is operated via an appropriately configured end effector to inspect the rib-to-pan interface, such as to detect, inspect, and / or measure gaps between components. In some such embodiments, the results of the measurements are communicated, for example to a technician or controller, to determine whether a particular gap exceeds a shim tolerance threshold (which can represent an out-of-tolerance condition) and is therefore considered a shim location (where a shim is to be installed). In some such embodiments, the results of the measurements are used to select an appropriate shim (e.g., by size, dimensions, taper, or other characteristics) to be installed to correct the out-of-tolerance condition.

[0185] The shims 756 can be supplied via a shim feeder line in any suitable manner. For example, alternative shims (e.g., having different tapers and / or sizes, etc.) can be stored in a bin accessible to the robot arm. In some embodiments, new shims are dynamically manufactured, or pre-manufactured shims are adjusted (e.g., trimmed) (such as based on the inspection and / or measurement of the gaps), and then communicated for insertion into the shim locations 758 and provided on-time for placement.

[0186] After installation of the shims 756, the method can also include retracting the robot arm 750, and moving the carriage 764 along the cradle 648 to a new location for additional shim installation and / or other operations. If the installation of the shims 756 into the shim locations 758 accessible from the cradle 648 is complete, the carriage 764 can be detached from the cradle and moved to a new location (such as to a cradle of another rib). In some embodiments, this is facilitated by a wheeled cart equipped with a telescoping lift. In some embodiments, this involves removing the robot arm 750 through an access gap (such as in the lower pan 550-2).

[0187] As with the method 910, the method 920 can be performed in any suitable manner. For example, the method 920 can be performed in a manner similar to that described above with respect to the method 910. FIG. 19The above description can be understood to mean that the method 900 can be used in the wing assembly 600 including a variety of components and configurations. For example, although described in the context of an embodiment in which one rib is held against a wing panel, the method can be used repeatedly in a wing assembly including multiple ribs held against a wing panel. In other words, once steps 922, 924, and 926 are performed to install a shim at a shim location between a first rib and a wing panel, these steps can be repeated to install a shim to a shim location between a second rib and the wing panel. The method 900 can also be used in a wing assembly 600 in which multiple ribs 572 are held against a wing panel (such as an upper wing panel 550-1) at their upper edges, and another wing panel (such as a lower wing panel 550-2) is held against the opposite (or lower) edges of the ribs. In such a configuration, the lower wing panel 550-2 can be added to the wing assembly before or between shim installation operations. In one example, the method includes first performing steps 922, 924, and 926 for upper shim locations between the ribs and the upper wing panel, then adding the lower wing panel to the wing assembly, then performing steps 922, 924, and 926 for lower shim locations between the ribs and the lower wing panel. As described above, after the shims are installed between the ribs and the wing panels, the ribs can be fastened (e.g., installed) to the wing panels. In another example, the method includes performing shim installation on both upper and lower shim locations, for example in a configuration in which the lower wing panel has already been placed. In either of these examples, the method includes repositioning the robotic arm, for example to couple the carriage to a different rib’s cradle by moving (e.g., withdrawing and inserting) the robotic arm through an entry gap in the wing panel (such as in the lower wing panel).

[0188] Turning now to FIG. 1 , an illustration of a representative aircraft 1200 is depicted in which illustrative embodiments of wing panels and / or wing assemblies produced in accordance with aspects of the present disclosure can be implemented. In other words, the aircraft 1200 is an example of an aircraft that can be formed using composite parts, wing panels, and / or wing assemblies produced in accordance with one or more of the following aspects: FIG. 2A and FIG. 2B as well as FIG. 4 illustrative manufacturing methods shown in FIGS. 1-3; FIG. 5A to FIG. 5F illustrative patterns shown in FIGS. 4-6; FIG. 11A to FIG. 11D illustrative assembly line 500 shown in FIG. 7; FIG. 16A to FIG. 16C illustrative rib and spar installation techniques shown in FIGS. 8-10; FIG. 17A to FIG. 17C and FIG. 20one or more of the methods shown in the remaining figures; and / or any of the above. In this illustrative example, aircraft 1200 has wings 1202 attached to either side of fuselage 1204. Aircraft 1200 includes engines 1206 attached to each wing 1202. Disposed at the rear of fuselage 1204 is tail 1208, which includes a pair of opposing horizontal stabilizers 1210 and vertical stabilizer 1212. Wings 1202 are formed from upper and lower wing panels 550 and 550 (not shown) connected together, with a component of ribs and spars (not shown) forming at least a portion of their internal structure.

[0189] FIG. 20 is a block diagram of various components and systems (or stages) discussed herein in illustrative implementations. Specifically, FIG. 20A factory 1300 is depicted that includes a first assembly line 1310 in a clean room environment indicated at 1312 and a second assembly line 1314 in a non-clean room environment 1316. A boundary (e.g., one or more walls or enclosures) is represented at 1318 that separates the clean room 1312 and non-clean room 1316 environments. At layup 1320, indexing features (such as indexing features 122) are integrated into a laminate 1322 (such as preform 200) for a wing panel. The laminate 1322 is hardened into a composite part 1326 in autoclave 1324. In accordance with embodiments herein, the composite part 1326 is a wing panel (e.g., wing panel 550), and more particularly an upper wing panel, although factory 1300 can be configured to manufacture, machine, and otherwise operate on composite parts in the form of other aircraft components besides wing panels. The composite part 1326 is then transferred to assembly line 1314, which in the illustrated embodiment is shown advancing the composite part 1326 through various systems and stages specific to those suitable for an upper wing panel in a process direction 1328. For example, at assembly line 1314, a trimming stage 1330 removes excess material and / or installs additional indexing features into the composite part 1326. At demolding 1332, the composite part 1326 is demolded (e.g., removed from a layup mandrel), after which a profile is implemented onto the composite part 1326 via profile implementation 1334, with the composite part 1326 being secured to a shuttle 1336 (such as one or more robust backer materials 540) that includes a carrier 1338 (e.g., adjustable length spring members 545 including vacuum couplers 548). The shuttle 1336 implements the profile onto the composite part 1326 such as via the carrier 1338 as the composite part is advanced along assembly line 1314. As the composite part 1326 is advanced through rib installation 1340 and spar installation 1342, ribs and spars are installed onto the composite part 1326. Inspection of the rib and spar assembly and shim installation are performed by a robotic arm 1344 as needed. A lower wing panel 1346 is then attached to form a wing assembly (e.g., wing assembly 600). The various systems and stages described with respect to factory 1300 can incorporate or take the form of the various workstations 520 described above. Moreover, for simplicity, not all of the workstations 520 described above are specifically shown in FIG. 20 factory 1300, although assembly line 1314 can include workstations such as one or more NDI workstations 524, cutout workstations 526, etc. Other operations described above with respect to FIG. 4 factory 1300 can incorporate or take the form of one or more of the feeder lines, layup lines, or assembly lines shown in patterns 480 and FIG. 21 shown in factory 1300; for example, trimming 1330 and demolding 1332 can be performed in demolding operation 490-11.

[0190] Attention is now directed to FIG. 22 which broadly illustrates control components of a production system that performs (e.g., continuously) lamination and / or ultrasonic inspection in illustrative embodiments. The controller 1400 coordinates and controls operation of the laminator 1420 and movement of one or more mobile platforms 1470 along a movement line 1460 having a power assembly 1462. The controller 1400 can include a processor 1410 coupled with a memory 1412 that stores a program 1414. In one example, the mobile platform 1470 is driven along a movement line 1460 that is continuously driven by a power assembly 1462 that is controlled by the controller 1400. In this example, the mobile platform 1470 includes a utility connection 1472 that can include electrical, pneumatic, and / or hydraulic quick disconnects that couple the mobile platform 1470 with utility 1440 from an external source. In other examples, as previously described, the mobile platform 2470 can include, for example, mandrels and / or other tools, parts, supplies, etc. on automated transport tools such as automated guided vehicles (AGVs) that include on-board utilities and GPS / automated navigation systems 1474. In further examples, movement of the mobile platform 1470 is controlled using a laser tracker 1450. Position and / or motion sensors 1430 coupled with the controller 1400 are used to determine the position of the mobile platform 1470 and the power assembly 1462.

[0191] Example A view is depicted that illustrates aspects of a series of work zones 1502 of an assembly line 1500 (e.g., of a continuous assembly line) arranged along a movement line and configured to perform various operations in illustrative embodiments. The work zones include a work zone for tool preparation 1510, which involves cleaning of a tool 1504 (e.g., laying up a mandrel 110), or applying a coating and / or potting compound to the tool 1504, or performing maintenance on the tool 1504, which is subsequently conveyed on a platform 1506 to additional work zones 1502. The additional work zones include a work zone for material application 1520 (e.g., where lamination operations are performed) to form a preform 1522 (such as the preform 200). The preform 1522 can then be conveyed via the assembly line 1500 to downstream work zones that include a work zone for reduction 1530 and a work zone for compaction 1540 and a work zone for molding 1550. Reducing and / or compacting the preform 1522 can include vacuum compaction via a vacuum bag 1532. Molding the preform 1522 can be performed via pre-cured shaping and / or via a combination of molding between the tool 1504 and a backing plate 1542.

[0192] The preform 1522 is further moved to work areas for, for example, hardening the preform 1522 1560 into a composite part 1564 (e.g., composite part 250, which may be in the form of a flange 550) at an autoclave 1562, for trimming the composite part 1564 1570 (e.g., via a cutter 1572), for inspecting the composite part 1564 1580 (e.g., via an NDI machine 1582), for rework 1590, and / or for surface treatment 1595.

[0193] In one implementation, the finishing process may involve extensive finishing of the preform 1522 before it hardens, followed by more specific finishing after the composite part 1564 has been formed. Inspection of the composite part 1564 may include visual inspection as well as inspection using NDI (non-destructive testing) equipment. Although reworking the composite part 1564 along assembly line 500 is possible, in many cases, reworking may not be necessary. The composite part 1564 then proceeds through assembly line 500 in process direction 541.

[0194] FIG. 23

[0195] In the following examples, additional processes, systems, and methods are described in the context of manufacturing and assembling systems for aircraft wings.

[0196] Referring more specifically to the accompanying drawings, embodiments of this disclosure can be implemented as follows: FIG. 24 The aircraft manufacturing and maintenance methods shown in 1600 and such FIG. 24 The description is given within the context of the aircraft 1602 shown. During pre-production, method 1600 may include the specification and design 1604 of the aircraft 1602 and the procurement of materials 1606. During production, the manufacturing of components and sub-assemblies of the aircraft 1602 and system integration 1610 may be performed. Subsequently, the aircraft 1602 may undergo certification and delivery 1612 for entry into service 1614. When in use by the customer, routine maintenance and upkeep 1616 (which may also include modifications, reconfigurations, refurbishments, etc.) are scheduled for the aircraft 1602. The apparatus and methods specifically implemented herein may be employed during any one or more suitable stages of production and use as described in method 1600 (e.g., specification and design 1604, material procurement 1606, component and sub-assembly manufacturing 1608, system integration 1610, certification and delivery 1612, commissioning 1614, maintenance and servicing 1616) and / or any suitable component of aircraft 1602 (e.g., frame 1618, system 1620, interior 1622, propulsion system 1624, electrical system 1626, hydraulic system 1628, environment 1630).

[0197] Each process in Method 1600 can be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator can include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party can include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator can be an airline, leasing company, military entity, service organization, etc.

[0198] like ​ As shown, an aircraft 1602 produced according to method 1600 may include a frame 1618 having multiple systems 1620 and an interior 1622. Examples of systems 1620 include one or more of the following: a propulsion system 1624, an electrical system 1626, a hydraulic system 1628, and an environmental system 1630. Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention can be applied to other industries such as the automotive industry.

[0199] As mentioned above, the apparatus and methods specifically implemented herein can be used during any one or more of the production and maintenance phases described in method 1600. For example, components or sub-assemblies corresponding to component and sub-assembly manufacturing 1608 can be made or manufactured in a manner similar to that of components or sub-assemblies produced when aircraft 1602 is put into service. Moreover, during sub-assembly manufacturing 1608 and system integration 1610, one or more apparatus embodiments, method embodiments, or combinations thereof can be utilized, for example, by significantly accelerating the assembly of aircraft 1602 or reducing the cost of the aircraft. Similarly, when aircraft 1602 is put into service (e.g., and without limitation, during maintenance and servicing 1616), one or more apparatus embodiments, method embodiments, or combinations thereof can be utilized. Therefore, the present invention can be used at any stage or any combination thereof (such as specification and design 1604, material procurement 1606, component and sub-component manufacturing 1608, system integration 1610, certification and delivery 1612, commissioning 1614, maintenance and upkeep 1616) and / or any suitable component of the aircraft 1602 (e.g., frame 1618, system 1620, interior 1622, propulsion system 1624, electrical system 1626, hydraulic system 1628 and / or environment 1630).

[0200] In one embodiment, the part comprises a portion of the fuselage 1618 and is manufactured during component and subassembly manufacturing 1608. The part can then be assembled into an aircraft during system integration 1610 and then utilized in service 1614 until wear makes the part unusable. The part can then be discarded and replaced with a newly manufactured part during maintenance and service 1616. The inventive components and methods can be utilized throughout component and subassembly manufacturing 1608 to manufacture new parts.

[0201] Any of the various control elements (e.g., electrical or electronic components) shown in the drawings or described herein can be implemented as hardware, a processor executing software, a processor executing firmware, or some combination of these. For example, an element can be implemented as dedicated hardware. A dedicated hardware element can be referred to as a "processor" or "controller" or some similar terminology, depending upon the particular context. 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 or other memory for storing software, logic, or some other physical hardware component or module.

[0202] 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 operational when executed by the processor to direct the processor to perform the functions of the element. The instructions can be stored in storage devices that are readable by the processor. Some examples of storage devices are digital or solid state memory, magnetic storage media such as diskettes and tape cartridges, hard disk drives, or optical digital data storage media.

[0203] Although specific implementations were 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 any equivalents thereof.

[0204] The following examples are also provided herein and are not to be confused with the appended claims.

[0205] 1. A first example relates to a method (820) of inspecting a vane (550), the method comprising the steps of advancing (824) the vane (550) in a process direction (541) through a non-destructive inspection (NDI) station (524) having one or more inspection heads (624), and inspecting (826) a portion of the vane at the NDI station with one or more inspection heads.

[0206] 2. The method of example 1,

[0207] wherein the NDI station (524) comprises a fixed inspection head (606), and wherein the step of inspecting (826) a portion of the vane (550) comprises inspecting the portion with the fixed inspection head as the vane is advanced past the fixed inspection head.

[0208] 3. The method of example 1 or 2, further comprising the step of positioning an inspection head (606) at a location indicated by a previous inspection to require inspection.

[0209] 4. The method of any of the preceding examples, further comprising the step of positioning an inspection head (606) at a location that enables inspection of an entire desired portion of the vane.

[0210] 5. The method of any of the preceding examples, wherein the NDI station (524) comprises a mobile inspection head (606), and wherein the step of advancing (824) the vane (550) comprises advancing the vane past the mobile inspection head.

[0211] 6. The method of any of the preceding examples, wherein the NDI station (524) inspects a portion of the vane (550) at a time.

[0212] 7. The method of any of the preceding examples, wherein the step of inspecting a portion of the vane (550) comprises operating an array of inspection heads (606) at the NDI station (524).

[0213] 8. The method of example 7, further comprising the step of moving an inspection head (606) relative to the vane (550) while operating the array of inspection heads at the NDI station (524).

[0214] 9. The method of any of the preceding examples, wherein the step of advancing (824) the vane panel (550) comprises pulsing the vane panel in the process direction (541), and wherein the step of inspecting (826) a portion of the vane panel is performed during a pause between the pulses.

[0215] 10. The method of any of the preceding examples, wherein the NDI station (524) comprises a mobile inspection head (606), and wherein the step of inspecting (826) a portion of the vane panel (550) comprises moving the mobile inspection head relative to the portion of the vane panel.

[0216] 11. The method of any of the preceding examples, further comprising the step of indexing the vane panel (550) to the NDI station (524).

[0217] 12. The method of example 11, wherein the step of indexing the vane panel (550) to the NDI station (524) is performed prior to the step of inspecting (826) a portion of the vane panel.

[0218] 13. The method of example 11 or 12, wherein the step of inspecting a portion of the vane panel (550) is performed based at least in part on information provided by indexing the vane panel to the NDI station (524).

[0219] 14. The method of any of the preceding examples, further comprising the step of suspending (822) the vane panel (550) beneath a strong back (540).

[0220] 15. The method of example 14, wherein the step of suspending (822) the vane panel (550) beneath the strong back (540) is performed prior to the step of advancing (824) the vane panel through the NDI station (524), and wherein the vane panel remains suspended beneath the strong back during advancement through and inspection at the NDI station.

[0221] 16. The method of example 14 or 15, further comprising the step of advancing the vane panel (550) to a next work station (520) while the vane panel (550) remains suspended beneath the strong back (540).

[0222] 17. The method of any of examples 14-16, wherein the step of suspending (822) the panel (550) includes securing vacuum couplers (548) of the strong back (540) to a surface (574, 576) of the panel, and wherein the step of inspecting (826) a portion of the panel includes selectively retracting one or more vacuum couplers as the panel is inspected by an inspection head (606) of the NDI station (524).

[0223] 18. The method of any of examples 14-17, further comprising the step of inspecting, via NDI, a location on the panel (550) that contacts the strong back (540) prior to suspending the panel beneath the strong back.

[0224] 19. The method of any of examples 14-18, wherein the step of suspending (822) the panel (550) beneath the strong back (540) includes imposing a predetermined profile (544) on the panel.

[0225] 20. The method of example 19, wherein the step of suspending (822) the panel (550) includes forming a vacuum attachment between an upper surface (574) of the panel and an adjustable length spring member (545) extending beneath the strong back (540), and wherein the step of imposing the predetermined profile (544) includes adjusting a length of at least one of the spring members.

[0226] 21. The method of example 19 or 20, wherein the predetermined profile (544) is imposed while the panel (550) is advanced through the NDI station (524).

[0227] 22. The method of any of examples 19-21, wherein the predetermined profile (544) is imposed while the panel (550) is inspected.

[0228] 23. The method of any of the preceding examples, further comprising the step of imposing a predetermined profile (544) on the panel (550).

[0229] 24. The method of example 23, wherein the step of imposing is performed during one or more of advancing (824) the panel (550) and inspecting (826) a portion of the panel.

[0230] 25. The method of example 23 or 24, wherein the step of implementing is performed by means of a powered backer (540) that suspends the panel (550) and propels the panel through the NDI station (524).

[0231] 26. The method of any of the preceding examples, wherein the step of inspecting (826) a portion of the panel (550) comprises operating an array of inspection heads (606) at the NDI station (524).

[0232] 27. A second example relates to a portion of an aircraft assembled according to the method of any of the preceding examples.

[0233] 28. A third example relates to a method (840) of inspecting a panel, the method comprising the steps of receiving (842) a panel (550) at a non-destructive inspection (NDI) station (524) having one or more inspection heads (606); and inspecting (844) a portion of the panel at the NDI station with the one or more inspection heads during movement of the panel through the NDI station.

[0234] 29. The method of example 28, wherein the step of inspecting (844) is performed during pulsatile movement of the panel (550) through the NDI station (524).

[0235] 30. The method of example 28 or 29, wherein the step of inspecting (844) is performed during continuous movement of the panel (550) through the NDI station (524).

[0236] 31. The method of any of examples 28 to 30, wherein at least one inspection head (606) is movable, and wherein the movable inspection head moves during inspection.

[0237] 32. A fourth example relates to a portion of an aircraft assembled according to the method of any of examples 28 to 31.

[0238] 33. A fifth example relates to a non-transitory computer readable medium comprising programming instructions operable, when executed by a processor, to perform a method (820) of inspecting a panel (550), the method comprising the steps of propelling (824) the panel (550) in a process direction (541) through a non-destructive inspection (NDI) station (524) having one or more inspection heads (624); and

[0239] inspecting (826) a portion of the vane panel at the NDI station with one or more inspection heads.

[0240] 34. The medium of example 33, wherein the NDI station (524) comprises a fixed inspection head (606), and wherein the step of inspecting (826) a portion of the vane panel (550) comprises inspecting the portion with the fixed inspection head as the vane panel is advanced past the fixed inspection head.

[0241] 35. The medium of example 33 or 34, wherein the method (820) further comprises the step of positioning an inspection head (606) at a location indicated by a previous inspection to require inspection.

[0242] 36. The medium of any of examples 33 to 35, wherein the method (820) further comprises the step of positioning an inspection head (606) at a location that enables inspection of an entire desired portion of the vane panel.

[0243] 37. The medium of any of examples 33 to 36, wherein the NDI station (524) comprises a mobile inspection head (606), and wherein the step of advancing (824) the vane panel (550) comprises advancing the vane panel past the mobile inspection head.

[0244] 38. The medium of any of examples 33 to 37, wherein the NDI station (524) inspects a portion of the vane panel (550) at a time.

[0245] 39. The medium of any of examples 33 to 38, wherein the step of inspecting a portion of the vane panel (550) comprises operating an array of inspection heads (606) at the NDI station (524).

[0246] 40. The medium of example 39, wherein the method (820) further comprises the step of moving an inspection head (606) relative to the vane panel (550) while operating the array of inspection heads at the NDI station (524).

[0247] 41. The medium of any of examples 33 to 40, wherein the step of advancing (824) the vane panel (550) comprises pulsing the vane panel in the process direction (541), and wherein the step of inspecting (826) a portion of the vane panel is performed during a pause between the pulses.

[0248] 42. The medium of example 41, wherein the NDI station (524) includes a mobile inspection head (606), and wherein the step of inspecting (826) a portion of the vane panel (550) includes moving the mobile inspection head relative to the portion of the vane panel.

[0249] 43. The medium of any of examples 33 to 42, wherein the method (820) further comprises the step of indexing the vane panel (550) to the NDI station (524).

[0250] 44. The medium of example 43, wherein the step of indexing the vane panel (550) to the NDI station (524) is performed prior to the step of inspecting (826) a portion of the vane panel.

[0251] 45. The medium of example 44, wherein the step of inspecting a portion of the vane panel (550) is performed based at least in part on information provided by indexing the vane panel to the NDI station (524).

[0252] 46. The medium of any of examples 33 to 45, wherein the method (820) further comprises the step of suspending (822) the vane panel (550) under a strong back (540).

[0253] 47. The medium of example 46, wherein the step of suspending (822) the vane panel (550) under the strong back (540) is performed prior to the step of advancing (824) the vane panel through the NDI station (524), and wherein the vane panel remains suspended under the strong back during advancement through the NDI station and inspection at the NDI station.

[0254] 48. The medium of example 46 or 47, wherein the method (820) further comprises the step of advancing the vane panel (550) to a next work station (520) while the vane panel (550) remains suspended under the strong back (540).

[0255] 49. The medium of any of examples 46 to 48, wherein the step of suspending (822) the vane panel (550) includes securing vacuum couplers (548) of the strong back (540) to a surface (574, 576) of the vane panel, and wherein the step of inspecting (826) a portion of the vane panel includes selectively retracting one or more vacuum couplers while the vane panel is inspected by an inspection head (606) of the NDI station (524).

[0256] 50. The medium of any of examples 46 to 49, wherein the method (820) further comprises the step of inspecting, via NDI, a location on the flap (550) that contacts the strongback (540) prior to suspending the flap below the strongback.

[0257] 51. The medium of any of examples 46 to 50, wherein the step of suspending (822) the flap (550) below the strongback (540) comprises imposing a predetermined profile (544) on the flap.

[0258] 52. The medium of example 51, wherein the step of suspending (822) the flap (550) comprises forming a vacuum attachment between an upper surface (574) of the flap and an adjustable length spring member (545) extending below the strongback (540), and wherein the step of imposing the predetermined profile (544) comprises adjusting a length of at least one of the spring members.

[0259] 53. The medium of example 51 or 52, wherein the predetermined profile (544) is imposed while advancing the flap (550) through the NDI station (524).

[0260] 54. The medium of any of examples 51 to 53, wherein the predetermined profile (544) is imposed while inspecting the flap (550).

[0261] 55. The medium of any of examples 33 to 54, wherein the method (820) further comprises the step of imposing a predetermined profile (544) on the flap (550).

[0262] 56. The medium of example 55, wherein the step of imposing is performed during one or more of advancing (824) the flap (550) and inspecting a portion of the flap (826).

[0263] 57. The medium of example 55 or 56, wherein the step of imposing is performed by a strongback (540) that suspends the flap (550) and advances the flap through the NDI station (524).

[0264] 58. The medium of any of examples 33 to 57, wherein the step of inspecting (826) a portion of the flap (550) comprises operating an array of inspection heads (606) at the NDI station (524).

[0265] 59. A sixth example relates to a portion of an aircraft assembled according to a method defined by instructions stored on the computer readable medium of any of examples 33 to 58.

[0266] 60. A seventh example relates to a non-transitory computer readable medium comprising programmed instructions operable, when executed by a processor, to perform a method (840) of inspecting a wing panel (550), the method comprising the steps of receiving (842) a wing panel (550) at a non-destructive inspection (NDI) station (524) having one or more inspection heads (606); and inspecting (844) a portion of the wing panel at the NDI station with one or more inspection heads during movement of the wing panel through the NDI station.

[0267] 61. The medium of example 60, wherein the step of inspecting (844) is performed during pulsatile movement of the wing panel (550) through the NDI station (524).

[0268] 62. The medium of example 60, wherein the step of inspecting (844) is performed during continuous movement of the wing panel (550) through the NDI station (524).

[0269] 63. The medium of any of examples 60 to 62, wherein at least one inspection head (606) is movable, and wherein the movable inspection head is moved during inspection.

[0270] 64. An eighth example relates to a portion of an aircraft assembled according to a method defined by instructions stored on the computer readable medium of any of examples 60 to 63.

[0271] 65. A ninth example relates to a system of inspecting a wing panel, the system comprising:

[0272] - a track (510);

[0273] - a strongback (540) configured to suspend a wing panel (550) thereunder and propel the wing panel (550) along the track in a process direction (541); and

[0274] - a non-destructive imaging (NDI) station (524) disposed at the track and configured to inspect the wing panel while the wing panel is suspended thereunder by the strongback.

[0275] 66. The system of example 65, wherein the NDI station (524) comprises an inspection head (606) configured to move relative to a surface (574, 576) of the panel (550).

[0276] 67. The system of example 65 or 66, wherein the NDI station (524) comprises an array of inspection heads (606).

[0277] 68. The system of any one of examples 65-67, wherein the strongback (540) comprises vacuum couplers (548) configured to couple with an upper surface (574) of the panel (550); and further comprising a controller (560) configured to direct the strongback to selectively retract one or more vacuum couplers while an inspection head (606) of the NDI station (524) is inspecting the panel, such that an NDI inspection is performed on a location from the panel while a vacuum coupler is retracted from the location.

[0278] 69. The system of example 68, wherein the strongback (540) is configured to impose a predetermined profile (544) onto the panel (550) by means of adjustable-length spring members (545), each of the adjustable-length spring members comprising one of the vacuum couplers (548).

[0279] 70. The system of any one of examples 65-69, further comprising a controller (620) configured to perform an action selected from the group consisting of:

[0280] - detecting an out-of-tolerance condition at the panel (550) based on input from the NDI station (524),

[0281] - reporting an out-of-tolerance condition for rework,

[0282] - controlling operation of an inspection head (606) of the NDI station,

[0283] - controlling advancement of the panel in the process direction (541), and

[0284] - correlating input from the NDI station with a location on the panel.

[0285] 71. The system of any of examples 65-70, wherein the NDI station (524) includes one or more upper inspection heads (608) and one or more lower inspection heads (610), and wherein the one or more upper inspection heads and the one or more lower inspection heads are disposed to be positioned on either side of a wing panel (550) advanced into the NDI station (524).

[0286] 72. The system of example 71, wherein at least one upper inspection head (608) and at least one lower inspection head (610) form a pair of inspection heads (606) configured to perform inspection of the wing panel (550) via a transmission technique.

[0287] 73. The system of example 71 or 72, wherein at least one of the inspection heads (606) is configured to perform inspection of the wing panel (550) via a pulse-echo technique.

[0288] 74. The system of any of examples 65-73, wherein the NDI station (524) is configured to index with one or more of the wing panel (550) and a strong-back (540) that suspends the wing panel.

[0289] 75. The system of example 74, wherein the NDI station (524) includes an indexing unit (622) configured to physically couple with an indexing feature (210, 542) of at least one of the wing panel (550) and the strong-back (540).

[0290] 76. A tenth example relates to manufacturing a portion of an aircraft using the system of any of examples 65-75.

Claims

1. A method of inspecting a vane, the method comprising the steps of: - indexing a strongback to a vane; - suspending the vane below the strongback by forming a vacuum attachment between an upper surface of the vane and an adjustable length spring member extending below the strongback; - advancing the vane in a process direction through a non-destructive inspection (NDI) station having one or more inspection heads; - inspecting a portion of the vane at the NDI station with the one or more inspection heads; and - advancing the vane to a next work station while the vane remains suspended below the strongback, wherein the step of suspending the vane below the strongback comprises imparting a predetermined profile to the vane by adjusting the length of at least one of the spring members.

2. The method of claim 1, further comprising the step of: indexing the vane to the NDI station.

3. The method of claim 2, wherein, The step of indexing the vane to the NDI station is performed prior to the step of inspecting a portion of the vane; and / or wherein the step of inspecting a portion of the vane is performed based at least in part on information provided by indexing the vane to the NDI station.

4. The method of claim 1 or 2, wherein, The step of suspending the vane below the strongback is performed prior to the step of advancing the vane through the NDI station, and wherein the vane remains suspended below the strongback during advancement through the NDI station and inspection at the NDI station.

5. The method of claim 1 or 2, wherein, The step of suspending the vane comprises securing vacuum couplers of the strongback to a surface of the vane, and wherein the step of inspecting a portion of the vane comprises selectively retracting one or more vacuum couplers while the vane is inspected by an inspection head of the NDI station; and / or The method further comprises the step of inspecting, via NDI, a location on the vane where the strongback is contacted prior to suspending the vane below the strongback.

6. The method of claim 1, wherein The predetermined profile is imparted while advancing the vane through the NDI station; and / or wherein the predetermined profile is imparted while inspecting the vane.

7. The method of claim 1 or 2, further comprising the step of: Imparting a predetermined profile to the vane.

8. The method of claim 7, wherein, The step of imparting is performed during one or more of advancing the vane and inspecting a portion of the vane, and / or the step of imparting is performed by the strongback suspending the vane and advancing the vane through the NDI station.

9. The method of claim 1 or 2, comprising the steps of: The portion of the vane is inspected at the NDI station with one or more inspection heads during movement of the vane through the NDI station.

10. The method of claim 9, wherein, At least one inspection head is movable, and wherein the movable inspection head moves during inspection.

11. The method of claim 10, wherein: the step of inspecting is performed during pulsatile movement of the vane through the NDI station; or the step of inspecting is performed during continuous movement of the vane through the NDI station.

12. A non-transitory computer readable medium comprising programming instructions operable when executed by a processor to perform a method of inspecting a wing panel according to any one of claims 1 to 11.

13. A system of inspecting a wing panel, the system comprising: - a track; - a strongback configured to be indexed with a wing panel, to suspend the wing panel below the strongback, and to advance in a process direction along the track; and - a non-destructive imaging (NDI) station disposed at the track and configured to inspect the wing panel while the wing panel is suspended below the strongback, wherein the strongback comprises vacuum couplers configured to couple with an upper surface of the wing panel by forming a vacuum attachment between the upper surface of the wing panel and an adjustable length spring member extending below the strongback; wherein the strongback is configured to impose a predetermined profile onto the wing panel by means of the adjustable length spring member. the NDI station comprises an inspection head configured to move relative to a surface of the wing panel; and / or 14. The system of claim 13, wherein, wherein the NDI station comprises an array of inspection heads; and / or the system further comprises a controller configured to direct the strongback to selectively retract one or more vacuum couplers while an inspection head of the NDI station inspects the wing panel such that an NDI inspection is performed on a location while a vacuum coupler is retracted from the wing panel at the location. each of the adjustable length spring members comprises one of the vacuum couplers.

15. The system of claim 14, wherein, the system further comprises a controller configured to perform an action selected from the group consisting of:

16. The system of claim 13 or 14, wherein, - detecting an out-of-tolerance condition at the wing panel based on input from the NDI station, - reporting an out-of-tolerance condition for rework, - controlling operation of an inspection head of the NDI station, - controlling advancement of the wing panel in the process direction, and - correlating input from the NDI station with a location on the wing panel. the NDI station comprises one or more upper inspection heads and one or more lower inspection heads, and wherein the one or more upper inspection heads and the one or more lower inspection heads are disposed to be positioned on either side of a wing panel advanced into the NDI station.

17. The system of claim 13 or 14, wherein, at least one upper inspection head and at least one lower inspection head form a pair of inspection heads configured to perform an inspection of the wing panel via a transmission technique; and / or 18. The system of claim 17, wherein, wherein at least one of the inspection heads is configured to perform an inspection of the wing panel via a pulse-echo technique. the NDI station is configured to be indexed with one or more of the wing panel and a strongback suspending the wing panel.

19. The system of claim 13 or 14, wherein, ​ 20. The system of claim 19, wherein, The NDI station includes an indexing unit configured to physically couple with an indexing feature of at least one of the wing panel and the strongback.

Images