Methods and systems for assembling and installing rack floor joists

Abstract

Systems and methods for assembling aircraft (10) are provided, particularly methods and systems for assembling and installing rack floor joists. One such method includes: receiving a lower cylindrical portion (118) of the fuselage (12) reversed to a rib-up orientation (563-3); and installing a floor joist (365) into the lower cylindrical portion (118) while it is being reversed. One such system (500) includes: a plurality of stations for installing floor joist assemblies onto floor joists (365); a track (541) for advancing the floor joist (365) through the stations in a processing direction (199); and at least one feed line associated with one of the stations, said feed line being operable to provide floor joist assemblies to the stations in a timely manner for installation onto the floor joists (365).

Description

Technical Field

[0001] This disclosure relates to the field of aircraft, and specifically to the manufacture of aircraft, such as the installation of floor joists. Background Technology

[0002] In the aerospace industry, operations involving the transport and assembly of frame components are performed in stationary cells. In each cell, a structure is scanned and / or rotated into that cell, and then tools, equipment, and / or workers are brought to the portion of the structure that requires work within that cell. This scanning and / or rotation process occurs whenever a new structure is brought into the cell. Furthermore, when a structure is moved to the next cell, it is scanned and / or rotated again into that cell, and the necessary tools, equipment, and / or workers are brought to the portion of the structure that requires work within that cell. Current assembly methods require tools, implements, and technicians to enter the cylindrical section, which is part of the fuselage, through the cylindrical end or doorway. Implements and tools must be positioned appropriately within the cylindrical section. When the work is completed, the implements, tools, and technicians must be removed through the cylindrical end or doorway.

[0003] The abstract of US 2013 / 0019446 A1 states: "A system and method for assembling a 360-degree section of an aircraft fuselage or cabin by properly positioning multiple assembly panels relative to machine data representing an assembly-level data pattern, using the machine to drill full-size holes near a second skin edge of the panels, using the machine to trim the second edge of the panels, and then using the full-size holes near the second skin edge as alignment features to properly orient and attach multiple pairs of panels together near a first skin edge, forming panel pairs by an auxiliary machine facing the second skin edge. A control system can be separately and independently installed into the panel pairs, and then the panel pairs can be joined together, aligning the full-size holes near the second edge, and inserting fasteners into the aligned full-size holes near the second skin edge."

[0004] Therefore, it is desirable to have methods and apparatus that take into account at least some of the above-mentioned problems, as well as other possible problems. Summary of the Invention

[0005] The embodiments described herein provide continuous line assembly layouts and systems that enable operations to be performed on mobile rack assemblies that move pulsatingly or continuously in a processing direction across a path of a workstation on which the operations are performed. Operations may include laying preforms for hardening into composite parts, hardening composite parts in an autoclave, installing frames, cutting holes for windows or doors, etc. Specific embodiments relate to manufacturing floor joists and installing them into the inverted lower cylinder portion of the machine body. These arrangements offer technical benefits over existing systems because they reduce the amount of space required for manufacturing and assembly at the factory floor, increase throughput, and reduce downtime.

[0006] On one hand, a method for assembling an aircraft is described. The method includes: receiving a lower cylindrical portion of the fuselage that has been reversed to a rib-up orientation; and installing a floor joist into the lower cylindrical portion while it is being reversed. On another hand, a method for manufacturing a part of an aircraft is described. Additionally or alternatively, the method includes: feeding floor beams, interrib supports, and tracks to a workstation via feed lines associated with each workstation, and assembling the floor beams, interrib supports, and tracks together into the floor joist. Optionally, the method includes: pulsating the floor joist to travel less than its length through the workstation, wherein the workstation operation is to rotate to the floor joist before the work is performed. Optionally, the method includes: feeding fasteners, electrical equipment, and conduits to the workstation via feed lines associated with each workstation, and installing the fasteners, electrical equipment, and conduits into the floor joist.

[0007] In another aspect, a system is described. This disclosure relates to a system configured to perform the methods disclosed herein. The system may include: multiple stations for installing floor joist assemblies onto floor joists; a track that causes the floor joists to pulsate through the stations in a processing direction; and at least one feed line associated with one of the stations, the feed line operably providing the floor joist assemblies to the station in a timely manner for installation onto the floor joists; a floor joist assembly station configured to assemble the floor joists with floor beams and interrib supports; a track installation station configured to install a track; and a floor joist attachment station operable to install a reverse floor joist having floor beams and interrib supports into a reverse lower cylinder portion of the machine body, wherein the step of installing the floor joists into the lower cylinder portion includes: installing the floor joists into the lower cylinder portion in a completed state.

[0008] Other exemplary embodiments (e.g., methods and computer-readable media relating to the foregoing embodiments) are described below. The features, functions, and advantages already discussed may be implemented independently in various embodiments or may be combined in other embodiments, further details of which can be seen from the following description and accompanying drawings. Attached Figure Description

[0009] Some embodiments of this disclosure will now be described by way of example only and with reference to the accompanying drawings. Throughout the drawings, the same reference numerals denote the same elements or elements of the same type.

[0010] Figure 1 An aircraft manufactured from a half-cylinder section is shown.

[0011] Figure 2 An assembly environment for a factory in an exemplary embodiment is described.

[0012] Figure 3 An assembly line for a factory is depicted in an exemplary embodiment.

[0013] Figure 4 This is a block diagram of a floor joist assembly line for installing floor joists into the lower part of the machine body, according to an exemplary embodiment.

[0014] Figure 5 This is a block diagram of a floor joist assembly line for installing floor joists into the lower part of the machine body, according to an exemplary embodiment.

[0015] Figure 6 The lower portion of the fuselage is shown in reverse in an exemplary embodiment.

[0016] Figure 7 A cross-section of the fuselage in an exemplary embodiment is shown.

[0017] Figure 8 This illustrates the utilization in an exemplary embodiment. Figure 4 A flowchart of the method for assembling floor joists.

[0018] Figure 9 This is a flowchart illustrating a method for assembling beat times in an exemplary embodiment.

[0019] Figure 10 The control components of the production system in an exemplary embodiment are shown in general.

[0020] Figure 11 This is a flowchart illustrating a method for manufacturing floor joists according to an exemplary embodiment.

[0021] Figure 12 This is a flowchart illustrating a method for manufacturing a portion of the frame. Detailed Implementation

[0022] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. Therefore, it should be understood that those skilled in the art will be able to design various arrangements that, while not explicitly described or shown herein, embody the principles of this disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and are to be construed as not being limited to the examples and conditions specifically stated therein. Therefore, this disclosure is not limited to the specific embodiments or examples described below, but is defined by the claims.

[0023] The frame assemblies discussed in this article can be made of metal or can be manufactured as composite parts. Composite parts (such as carbon fiber reinforced polymer (CFRP) parts) are initially laid out in multiple layers (collectively referred to as preforms). Within each layer of the preform, the individual fibers are aligned parallel to each other, but different layers exhibit different fiber orientations to increase the strength of the resulting composite part along different dimensions. The preform includes a tack resin that cures to harden the preform into a composite part (e.g., for use in aircraft). Carbon fibers already impregnated with uncured thermosetting or thermoplastic resins are referred to as “prepregs.” Other types of carbon fibers include “dry fibers” that are not impregnated with thermosetting resins but may include tackifiers or adhesives. Dry fibers are infused with resin before curing. For thermosetting resins, curing is a one-way process called curing, while for thermoplastic resins, the resin reaches a tack form if reheated.

[0024] Now go to Figure 1 This document describes a view of an aircraft 10 that can implement an exemplary embodiment. In this exemplary example, the aircraft 10 has a right wing 15 and a left wing 16 attached to a fuselage 12. Each of the engines 14 is attached to the right wing 15 and the left wing 16. Known embodiments of the aircraft 10 have additional engines 14 and different engine arrangements. The fuselage 12 includes a tail section 18 and a nose section 38. Horizontal stabilizers 20, 21, and 23 are attached to the tail section 18 of the fuselage 12. The aircraft 10 is an example of an aircraft in which the majority of the fuselage 12 is formed by a plurality of semi-cylindrical sections 24. Figure 2 The manufacturing process is shown in the middle section. When attached together, the multiple semi-cylindrical sections 24 form most of the fuselage 12.

[0025] As described above, the fuselage 12 is made of a plurality of semi-cylindrical sections 24. The semi-cylindrical sections 24 are configured as upper semi-cylindrical sections 40 or lower semi-cylindrical sections 42, which are eventually connected together to form a full-cylindrical section 44. Figure 1Multiple cylindrical sections 44 are shown, including 44-1, 44-2, 44-3, 44-4, and 44-5. For completeness, cylindrical section 44-1 is manufactured using upper cylindrical section 40-1 and lower cylindrical section 42-1; cylindrical section 44-2 is manufactured using upper cylindrical section 40-2 and lower cylindrical section 42-2; cylindrical section 44-3 is manufactured using upper cylindrical section 40-3 and lower cylindrical section 42-3; cylindrical section 44-4 is manufactured using upper cylindrical section 40-4 and lower cylindrical section 42-4; and cylindrical section 44-5 is manufactured using upper cylindrical section 40-5 and lower cylindrical section 42-5. Cylindrical sections 44-1 and 44-2 correspond to view AA, and cylindrical sections 44 are shown being continuously fastened to the fuselage 12. Lower cylindrical section 42-3 is sometimes referred to as the wing box because the wing is attached to this section.

[0026] Unless otherwise specifically described, all the aforementioned semi-cylindrical portions (e.g., upper semi-cylindrical portion 40 and lower semi-cylindrical portion 42) will be collectively referred to as semi-cylindrical portion 24. Figure 1 As shown, each semi-cylindrical portion 24 includes one or more frames 146 spaced apart by frame spacing 147, which helps to define the inner mold line layout 60 and the outer mold line layout 62 of the semi-cylindrical portion 24. In some embodiments, the semi-cylindrical portion 24 includes hardened composite skin components or metal skin components, such as window surrounds 145 and door surrounds 145-1 (view AA) and frames 146, to enhance rigidity.

[0027] Figure 2 An assembly environment 100 in an exemplary embodiment is illustrated. Assembly environment 100 includes an arrangement of machines and tools that facilitate efficient and repeatable manufacturing of aircraft, such as aircraft 10. Assembly environment 100 has been enhanced to enable the manufacture and assembly of large rack assemblies, such as those for wing panels or fuselage sections, on continuous micro-pulsating and / or pulsating assembly lines. This allows work-required portions of the structure to be brought to workers, tools, and equipment, rather than requiring workers, tools, and equipment to be brought into or enter the structure. Assembly environment 100 provides significant benefits by reducing the amount of non-value-adding time consumed during rack assembly, while also reducing factory space requirements by increasing work density. The embodiment has a semi-cylindrical portion 24 as a composite skin component of an aircraft model and another semi-cylindrical portion 24 as a metal skin component continuously traveling along assembly environment 100.

[0028] The processing tracking server 102 tracks and / or manages the operation of the assembly environment 100 via memory 104 and controller 106. In the illustrated embodiment, controller 106 includes assembly lines 110 and 120. Assembly line 110 operates to perform assembly operations on upper cylindrical portions 116 and lower cylindrical portions 118. Assembly line 120 operates to perform assembly operations on upper cylindrical portions 126 and lower cylindrical portions 128. One difference between assembly lines 110 and 120 is that assembly line 110 is configured for assembling non-cylindrical cylindrical portions, while assembly line 120 is configured for assembling cylindrical cylindrical portions. Typically, the operation of assembly lines 110 and 120 is identical, and reference numerals for components found in both assembly lines 110 and 120, such as stations 114 and 124, will be used, where station 114 is located within assembly line 110 and station 124 is located within assembly line 120. A similar approach is used when referring to components assembled in assembly lines 110 and 120. For example, the upper cylindrical portion 116 is assembled in assembly line 110, while the upper cylindrical portion 126 is assembled in assembly line 120. Similarly, the lower cylindrical portion 118 is assembled in assembly line 110, while the lower cylindrical portion 128 is assembled in assembly line 120. Explanations will be provided here when differences between the two assembly lines 110 and 120 are relevant.

[0029] As further discussed herein, the processing tracking server 102 guides the operation of one or more workstations 114, 124 in the assembly environment 100. In this embodiment, the processing tracking server 102 includes a memory 104 that stores one or more numerical control (NC) programs for operating the assembly lines 110, 120. The controller 106 of the processing tracking server 102 can further process feedback from workstations 114, 124 and / or assembly lines 110, 120, and provide instructions to workstations 114, 124 or report to operators based on this feedback.

[0030] In one embodiment, an RFID reader or other rotation component 115, 125 associated with the corresponding workstations 114, 124 enables the rotation action to directly provide instructions to workstations 114, 124. These instructions pertain to the portions of the upper cylinder portions 116, 126 and the lower cylinder portions 118, 128 within the ranges 114-1, 124-1 of workstations 114, 124. In this embodiment, instructions can be transferred between the controller 106 and specific workstations 114, 124. The controller 106 can be implemented as, for example, custom circuitry, a hardware processor executing programmed instructions, or a combination thereof. The memory 104 stores instructions for operating the controller 106 and stores digital data.

[0031] In this embodiment, the assembly environment 100 includes an assembly line 110 for manufacturing multiple portions of the fuselage 12 that exhibit a non-uniform cross-section along its length, and an assembly line 120 for manufacturing multiple portions of the fuselage 12 that exhibit a substantially uniform cross-section along its length. Assembly line 110 processes the upper cylindrical portion 116 and the complementary lower cylindrical portion 118, respectively. Assembly line 120 processes the upper cylindrical portion 126 and the complementary lower cylindrical portion 128, respectively. When "upper" or "lower" is irrelevant, the upper cylindrical portion 116 and the lower cylindrical portion 118 are sometimes referred to together herein as cylindrical portion 117, and the upper cylindrical portion 126 and the lower cylindrical portion 128 are sometimes referred to together herein as cylindrical portion 127. An arcuate portion 119 refers to any type of cylindrical portion, including cylindrical portions 117, 127, quarter-cylinder portions, and third-cylinder portions, having or not having a uniform cross-section.

[0032] The semi-cylindrical portions 117 and 127 correspond to the semi-cylindrical portion 24 after processing by the assembly environment 100. The assembly lines 110 and 120 discussed herein can be further operated to manufacture multiple sets of semi-cylindrical portions 117 and 127 or other curved portions 119.

[0033] Assembly line 110 is configured with station 114, which is capable of accommodating upper cylindrical portion 116 and lower cylindrical portion 118 with more unusual shapes (such as conical), as well as other arched portions 119 near the nose 38 or tail 18. Station 114 associated with assembly line 110 exhibits a wide range of movement to accommodate the conical characteristics of these cylindrical portions 117 and the non-uniform cross-section arched portions 119.

[0034] Assembly line 110 also includes a track 112 along which an upper cylindrical portion 116 and a lower cylindrical portion 118 travel in a processing direction 199. Track 112 includes a drive system 113 to advance the cylindrical portion 117 along track 112. Track 112 enables the cylindrical portion 117 to reach tools and equipment (not shown) at stations 114, 124 arranged consecutively in the processing direction 199.

[0035] Track 112 may include a series of discrete supports having rollers, rails, or a set of rails (not shown), and the rack assembly at track 112 may pulse incrementally across stations 114, 124 in the processing direction 199. Stations 114, 124 are sequentially aligned, and the semi-cylindrical portion 117 or the bow-shaped portion 119 travels sequentially through stations 114, 124. Although only a few stations 114, 124 are shown, many stations are considered because stations 114, 124 may be configured to perform multiple operations, such as, but not limited to, demolding, installing window enclosures, installing door enclosures, trimming manufacturing overruns, installing frames, cutting out window manufacturing overruns or otherwise removing material, NDI inspection, edge sealing, cutting out door manufacturing overruns, installing windows, and installing doors. Some stations 114, 124 may perform multiple tasks listed above, while other stations 114, 124 are dedicated to a single task.

[0036] In one embodiment, stations 114 and 124 are spaced apart and operated such that multiple stations simultaneously perform operations on the upper cylindrical portion 116 of the machine body 12. The same applies to the lower cylindrical portion 118. In another embodiment, stations 114 are arranged at a work density based at least in part on the cycle time for manufacturing the cylindrical portion 117 or the bow-shaped portion 119. The same applies to stations 124 with respect to the upper cylindrical portion 126 and the lower cylindrical portion 128. That is, stations 124 are arranged at a work density based at least in part on the cycle time for manufacturing the cylindrical portion 127 or the bow-shaped portion 119.

[0037] Assembly line 110 processes the upper cylindrical portion 116 and delivers it to assembly station 320 (e.g., configured as a crown module attachment station) for attaching crown module 364. Assembly line 110 processes the lower cylindrical portion 118 for delivery to assembly station 330 (e.g., configured as a floor joist attachment station) for engagement with cabin floor joists 326 and / or cargo hold floor joists 324.

[0038] In a substantially similar manner, workstations 124 are spaced apart and operate in assembly line 120 to process the upper cylindrical portion 126 and the lower cylindrical portion 128 (i.e., the semi-cylindrical portion 127) along track 122 having drive system 113-1. Assembly line 120 processes the upper cylindrical portion 126 and delivers it to assembly table 321 for engagement with crown module 364, and processes the lower cylindrical portion 128, which is delivered to assembly table 331 for engagement with cabin floor joists 326 and / or cargo hold floor joists 324. It should be understood that the crown module for the upper cylindrical portion 116 is different from the crown module for the upper cylindrical portion 126 because the upper cylindrical portion 126 is represented as cylindrical and is longer than the upper cylindrical portion 116, but for ease of understanding, both crown modules will be referred to herein as crown module 364. Similarly, regardless of which lower section is referred to, the cabin floor joists are referred to as cabin floor joists 326 and the cargo hold floor joists as cargo hold floor joists 324, and the floor joists are collectively referred to as floor joists 365 in the following figures herein. Figure 5 ).

[0039] Assembly line 120 includes a track 122, an upper cylindrical portion 126, and a lower cylindrical portion 128 that travel along track 122 in a processing direction 199 in a manner similar to that described above for assembly line 110. Assembly line 120 also includes stations 124 with indexing components 125. Stations 124, indexing components 125, and track 122 can be implemented in a manner similar to the components described in the similar narrative for assembly line 110. However, these stations 124 may differ in that they can more closely conform to each of the upper cylindrical portion 126 and the lower cylindrical portion 128 on which they are working. The cross-sectional variation between the upper cylindrical portion 126 and the lower cylindrical portion 128 is less than the cross-sectional variation between the upper cylindrical portion 116 and the lower cylindrical portion 118. As mentioned above, the upper cylindrical portion 126 and the lower cylindrical portion 128 of assembly line 120 are more uniform in shape and size than the upper cylindrical portion 116 and the lower cylindrical portion 118 of assembly line 110.

[0040] In another embodiment, an additional assembly line manufactures wings 15, 16 for assembly with fuselage 12 to form a complete fuselage. Assembly lines 110, 120 operate in a pulsating manner, wherein the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128 advance in the processing direction 199 by a distance equal to the length of pulsations 123, 123-1 or micro-pulsations 129. Both pulsations 123 and 123-1 are used to illustrate that the pulsation length can be different for assembly lines 110 and 120. Micro-pulsations 129 are smaller than pulsations 123, 123-1, and in an embodiment, micro-pulsations 129 are equal to the frame spacing 147 or a fraction or multiple thereof between the frames 146 of the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128. For assembly lines 110 and 120, the length of pulsation 123 or the length of micro-pulsations 129 can be the same, or they can be different. In one embodiment, the frame spacing 147 is approximately 45.7 cm to approximately 91.4 cm (approximately 18 inches to approximately 36 inches). After micropulsation 129, the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128 are paused, and then micropulsation 129 is generated again in the processing direction 199.

[0041] Another embodiment has upper cylindrical portions 116, 126 and lower cylindrical portions 118, 128 that move continuously without pausing in the processing direction 199. Therefore, the assembly lines 110, 120 discussed herein enable the cylindrical portions 117, 127 to travel at a desired pace at multiple different stations 114, 124 in a pulsating, micro-pulsating, or continuous manner.

[0042] During these processes, tools (such as laying reels) can be placed onto or removed from tracks 112, 122 as needed. In one embodiment, tracks 112, 122 include drive systems 113, 113-1 for moving half-tube portions 117, 127, such as chain drives, but in a further embodiment, these portions are driven independently along tracks 112, 122.

[0043] In one embodiment, and referring to assembly line 110, the upper cylinder portion 116 and the lower cylinder portion 118 simultaneously pulse the same amount of distance in the processing direction 199. Then, station 114 performs work on the upper cylinder portion 116 or the lower cylinder portion 118 during pauses between pulses and / or during pauses in a common cycle time. Thus, during the manufacturing process, multiple stations 114 perform work on the upper cylinder portion 116 and / or the lower cylinder portion 118 during the same pause between micro-pulses 129 and / or during micro-pulses 129.

[0044] Similarly, and referring to assembly line 120, the upper cylinder portion 126 and the lower cylinder portion 128 simultaneously pulse the same amount of distance in the processing direction 199. Then, station 124 performs work on the upper cylinder portion 126 or the lower cylinder portion 128 during pauses between pulses and / or during pauses in a common cycle time. Thus, during the manufacturing process, multiple stations 124 perform work on the upper portion 126 and / or the lower portion 128 during the same pauses between micro-pulses 129 and / or during micro-pulses 129.

[0045] In one embodiment of assembly line 110, one or more stations 114 also perform their operations independently or synchronously on the same semi-cylindrical portion 117 or bow-shaped portion 119 during pulsation. Similarly, with respect to assembly line 120, one or more stations 124 also perform their operations independently or synchronously on the same semi-cylindrical portion 127 or bow-shaped portion 119 during pulsation. Such stations may be referred to as traveling stations 139, 139-1, because they are attached to the semi-cylindrical portion and move with it. The operation may include non-destructive inspection (NDI), trimming of oversized parts, or application of sealant or other treatments. In another embodiment, the semi-cylindrical portions 117 and 127 continue to travel along tracks 112 and 122, and as the semi-cylindrical portions 117 and 127 and the traveling stations 139 and 139-1 attached to the semi-cylindrical portions 117 and 127 continue to move, the stations 114 and 124 perform operations on the semi-cylindrical portions 117 and 127.

[0046] In some embodiments of assembly lines 110 or 120, the semi-cylindrical portions 117, 127 are separated by a predetermined gap 131, such as a fraction or multiple of the micro-pulsation 129 distance, or any distance less than or equal to the length of the semi-cylindrical portions 117, 127, or the arcuate portion 119. Such a gap 131 helps to mitigate production delays, such as rework or off-center operations during maintenance of the semi-cylindrical portions 117, 127, or the arcuate portion 119, or during technician rest periods at stations 114, 124.

[0047] Rework or repositioning is rarely required, but in certain situations, rework or repositioning can be performed when the half-cylinder portion 117, 127 or part of the bow-shaped portion 119 requiring rework or repositioning is between stations 114, 124 or in stations where no work is required (such as a window frame installation station opposite the lower half-cylinder portion 118). This allows unforeseen delays to be absorbed into the production process. The aforementioned rework or repositioning can be performed within the gap 131 between stations 114, 124. Furthermore, in one embodiment, during rework or repositioning, the half-cylinder portion 117, 127 or the bow-shaped portion 119 continues to travel through stations 114, 124. Therefore, the assembly environment 100 does not stop moving forward in the processing direction 199 to work on the half-cylinder portion 117, 127 or the bow-shaped portion 119 to accommodate the rework or repositioning. Such repositioning can include planned and unplanned maintenance.

[0048] During movement or between micro-pulses 129 of pulsations 123, 123-1, the semi-cylindrical portions 117, 127 or the arcuate portion 119 encounter indexing assemblies 115, 125 at stations 114, 124. Indexing assemblies 115, 125 physically interact with or non-destructively inspect the indexing features 133 on or in the upper semi-cylindrical portions 116, 126 and the lower semi-cylindrical portions 118, 128, and enable alignment with stations 114, 124 before the operation is performed.

[0049] The indexing feature 133 (such as a physical feature or a radio frequency identification (RFID) chip) is used by indexing components 115 and 125 associated with stations 114 and 124. Each indexing component 115 and 125 transmits a 3D representation of the upper cylindrical portions 116 and 126 and the lower cylindrical portions 118 and 128 within ranges 114-1 and 124-1 of stations 114 and 124. Indexing also enables the determination of which tasks will be performed on a particular cylindrical portion 117 at stations 114 and 124. Work / tasks are transmitted to indexing components 115 and 125 based on the information from the indexing feature 133.

[0050] Return to reference Figure 1 Examples of 3D representation include inner mold line (IML) lofting 60 and / or outer mold line (OML) lofting 62. The aforementioned indexing results in instructions to stations 114, 124 regarding the operations to be performed by stations 114, 124 on the upper cylinder portions 116, 126 and the lower cylinder portions 118, 128. For the respective multiple stations 114, 124, this indexing process can be performed multiple times and simultaneously per pulse or micro-pulse 129. Stations 114, 124 can then perform operations during pauses between micro-pulses 129 or during the micro-pulse 129 itself.

[0051] Indexing assemblies 115, 125 may include hard stops, pins, holes, or grooves complementary to indexing feature 133 for physical fixation to indexing feature 133. Embodiments have numerous indexing features arranged on upper cylindrical portions 116, 126 and lower cylindrical portions 118, 128, for example, for manufacturing excess parts. In another embodiment, indexing assemblies 115, 125 may include sensors, such as laser, ultrasonic, or visual inspection systems, that track indexing feature 133 and then align with it.

[0052] The additional transposition feature 133 also includes an RFID chip. An RFID reader is another embodiment of the transposition components 115, 125 for reading RFID chips. These contactless technologies can be utilized, for example, within assembly lines 110, 120 that continuously move the upper half-cylinder portions 116, 126 and the lower half-cylinder portions 118, 128, and can be further used to control the movement of the half-cylinder portion 117 and / or the bow-shaped portion 119.

[0053] In another embodiment, indexing assemblies 115, 125, which are complementary to indexing feature 133, with hard stops, pins, holes, or grooves, are used in a continuous movement system utilizing travel stations 139, 139-1. In these embodiments, engagement of indexing feature 133 with indexing assemblies 115, 125 occurs as the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128 advance within the range 114-1, 124-1 of the next station 114, 124. Stations 114, 124 can track the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128 as they advance in the processing direction 199. Continuing on, the traveling stations 139, 139-1 are attached to the upper half-cylinder portions 116, 126 or the lower half-cylinder portions 118, 128 in stations 114, 124, and travel together with the half-cylinder portions 117, 127 as they advance with micro-pulses 129, pulsations 123 or continuous movements.

[0054] Traveling stations 139 and 139-1 perform their operations on the semi-cylindrical sections 117 and 127, and then detach and return to attachment point 139-2 for future use. Examples of traveling stations 139 and 139-1 are flexible track devices or similar devices that follow tracks removably mounted to the upper semi-cylindrical sections 116 and 126 and / or the lower semi-cylindrical sections 118 and 128.

[0055] Before entering assembly environment 100, the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128 are laid on a laying reel (not shown) oriented with the crown portions 135, 135-1 upward and the ridge portions 137, 137-1 upward, respectively. The orientation of the lower cylindrical portions 118, 128 is maintained by demolding from the laying reel, installing through the floor joists 365, until the lower cylindrical portions 118, 128 are reversed so that the ridge portions 137, 137-1 are oriented downward. This reversal occurs just before pulsating to the joining station 194 at the reversal station 560. Figure 6 This occurs during manufacturing. This configuration allows different stations 11 and 124 to continuously process the upper cylinder portions 116 and 126 and the lower cylinder portions 118 and 128 in a pulsed manner through the same stations 114 and 124 during manufacturing.

[0056] In one embodiment, the orientation of the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128 on assembly lines 110, 120 is set by a lay-up reel, on which the portions are laid. The lay-up reel advances by laying and curing a preform laid thereon. After curing, the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128 are then removed from the respective lay-up reels without altering the orientation of the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128.

[0057] In this implementation, multiple aircraft models are processed continuously on assembly lines 110 and 120. The upper cylindrical portions 116 and 126 and the lower cylindrical portions 118 and 128 for one model proceed continuously downwards along assembly lines 110 and 120, followed by the upper cylindrical portions 116 and 126 and the lower cylindrical portions 118 and 128 for different models. For example, the lower cylindrical portions 118 and 128 proceed downwards along assembly lines 110 and 120, followed by complementary upper cylindrical portions 116 and 126. Similarly, if this production method meets the demand, these lower cylindrical portions 118 and 128 and upper cylindrical portions 116 and 126 may be followed by the lower cylindrical portions 118 and 128 and the upper cylindrical portions 116 and 126 for another aircraft model, and so on, for yet another model. In addition, in some embodiments, more than one assembly line 110, 120 is envisioned to ensure that the upper half-tube portions 116, 126 and the lower half-tube portions 118, 128 are produced at the desired rate.

[0058] In some embodiments, the stations 114, 124 discussed herein have the capability to perform operations on different portions of the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128, and are adaptable to different diameters of different models. Each indexing operation between the indexing assemblies 115, 125 and the indexing feature 133 informs stations 114, 124 which lower cylindrical portions 118, 128 and upper cylindrical portions 116, 126, and which aircraft models are within their ranges 114-1, 124-1, and what operations need to be performed, or whether no operations are required. For example, when the lower cylindrical portions 118, 128 are within their ranges 114-1, 124-1, window manufacturing excess part cutting stations can avoid window cutting because it is not required.

[0059] The processing tracking server 102 tracks and / or manages the operations of the assembly lines 110, 120 discussed herein, for example, by directing the operations of one or more workstations 114, 124 in the assembly environment 100. In this embodiment, the processing tracking server 102 includes a memory 104 that stores one or more numerical control (NC) programs for operating the assembly lines 110, 120. The controller 106 of the processing tracking server 102 can further process feedback from workstations 114, 124 and / or assembly lines 110, 120, and based on this feedback provide instructions to workstations 114, 124 or report to operators. In one embodiment, an RFID reader or other shifting component 125 performs shifting actions to provide instructions directly to workstations 118, 128 for portions of the upper and lower cylinder portions 116, 126 and 118, 128 within ranges 114-1, 124-1 of workstations 114, 124. In this implementation, instructions can be passed between the controller 106 and specific workstations 114, 124. The controller 106 can be implemented as, for example, custom circuitry, a hardware processor that executes programmed instructions, or some combination thereof. The memory 104 stores instructions for operating the controller 106 and may include suitable containers for storing digital data.

[0060] according to Figure 2 At each station 114 of assembly line 110, materials and / or components can be fed / provided by a corresponding feed line 149 (e.g., based on the cycle time of a portion of the fuselage, and as...). Figure 3(As shown), and these materials and / or components are attached to the upper cylindrical portions 116, 126 and the lower cylindrical portions 118, 128, on which work is being performed by stations 114, 124. Feed line 149 provides additional materials / components to stations 114, 124. Each feed line 149 is designed to produce material in a cycle time so that additional materials / components are provided to stations 114, 124 in just-in-time (JIT) for assembly into a larger structure (e.g., a fuselage section) (which also pulsates in the cycle time). That is, feed line 149 delivers components JIT to stations 114, 124 in the order they are used by stations 114, 124. In one embodiment, feed line 149 has a cycle time equal to a fraction of the fuselage cycle time.

[0061] The cycle times of feed lines 149 and / or assembly lines 110, 120 do not need to be the same. For example, the upper half-tube section 116 and the lower half-tube section 118 can simultaneously micro-pulse through multiple stations 114. The upper half-tube section 116 and the lower half-tube section 118 are transposed to station 114, and each dedicated feed line 149 performs, for example, NDI, window enclosure installation, door enclosure installation, window manufacturing excess trimming / removal, door manufacturing excess trimming / removal, window installation, and door installation. Feed line 149 also includes outputs from station 114, including NDI check data and any excess trimming of the upper half-tube section 116 and the lower half-tube section 118. A similar situation can occur for assembly line 120 and the various components therein and the various components assembled therein.

[0062] In another example, feed line 149 provides frame 146 JIT to station 114 where frame 146 is mounted onto upper cylinder portion 116 and lower cylinder portion 118. Similarly, feed line 149 provides window enclosures to station 114 JIT for installing window enclosures and door enclosures to station 114 JIT for installing door enclosures. For each feed line 149, production time is designed based on the cycle time of the associated station 114. Feed lines 149 continuously pulse components during manufacturing, and completed components arrive at each station 114 with a common cycle time. This cycle time design progresses through each feed line 149 from the smallest component to the largest final component.

[0063] If the cycle time cannot be achieved, the work statement for a specific station 114 can be adjusted to reduce or increase the workload occurring at that station 114. In another embodiment, stations 114 can be added or removed from the process based on the work statement and expected cycle time for the entire assembly line 110. Cycle time is considered to be the number of minutes per month divided by the expected number of units (e.g., aircraft, stringers, frames, etc.) per month. The sum of micro-pulsations of cycle time equals the pulsation of the cycle time. That is, after multiple micro-pulses equal to the full pulsation, the entire unit has advanced its length through the assembly line 110. For example, the assembly line 110 consists of standard modular stations 114 that are integer multiples of each other, which allow it to be pre-designed to have low-rate blank or unused stations, and functional stations 114 can be added to those unused stations 114 if certain processes require it, to accommodate higher product output in areas sensitive to product output.

[0064] according to Figure 2 And specifically referring to assembly line 120, and similar to assembly line 110, each station 124 at assembly line 120 can be fed / provided with materials and / or components (e.g., based on the cycle time of the half-cylinder section 127, and as follows) via a corresponding feed line 149. Figure 3 (As shown), and these materials and / or components are attached to the upper half-cylinder portion 126 and the lower half-cylinder portion 128, which are being operated by station 124. Feed line 149 provides additional materials / components to station 124. Each feed line 149 is designed to generate material in a cycle time so that additional materials / components can be provided to the station in just-in-time (JIT) for assembly into a larger structure (e.g., a fuselage section), which also pulsates in the cycle time. The cycle time of feed line 149 may be the same as or different from the cycle time of assembly line 120. That is, feed line 149 delivers components to station 124 in the order they are used by station 124 in JIT. In one embodiment, feed line 149 has a cycle time equal to or a portion of the fuselage cycle time.

[0065] The cycle times of feed line 149 and / or assembly line 120 do not need to be the same. For example, the upper half-tube section 126 and the lower half-tube section 128 can simultaneously micro-pulse through multiple stations 124. The upper half-tube section 126 and the lower half-tube section 128 are transposed to station 124, and each dedicated feed line 149 performs NDI, window enclosure installation, door enclosure installation, window manufacturing excess trimming / removal, door manufacturing excess trimming / removal, window installation, and door installation, etc. Feed line 149 also includes outputs from station 124, including NDI check data and any excess trimming of the upper half-tube section 126 and the lower half-tube section 128. Feed line 149 is synchronized with the pulsation time or speed of the main assembly line to provide the required content when needed.

[0066] In another example, feed line 149 provides frame 146 JIT to station 124 where frame 146 is mounted onto upper cylinder portion 126 and lower cylinder portion 128. Similarly, feed line 149 provides window enclosures to station 124 JIT for installing window enclosures and door enclosures to station 124 JIT for installing door enclosures. For each feed line 149, production time is designed based on the cycle time of the associated station 124. Feed lines 149 continuously pulse components during manufacturing, and completed components arrive at each station 124 with a common cycle time. This cycle time design proceeds along each feed line 149 from the smallest component to the largest final component.

[0067] If assembly line 120 or feeder line 149 cannot achieve the required cycle time, the work report for a specific station 124 can be adjusted to reduce or increase the workload occurring at that station 124. In another embodiment, stations 124 can be added to or removed from assembly line 120 based on the work report for the entire assembly line 120 and the expected cycle time. Cycle time is considered to be the number of minutes per month divided by the expected number of units per month (e.g., aircraft, stringers, frames 146, etc.). The sum of micro-pulse cycle times equals the total cycle time. That is, multiple micro-pulse 129 equals the length of the advance through assembly line 120.

[0068] Figure 2 The rack assembly areas 180 and 190, which receive the outputs of assembly lines 110 and 120 respectively, are further depicted. Upper cylindrical portions 116 and 126 and lower cylindrical portions 118 and 128 are connected to form approximately... Figure 1 The various cylindrical sections 44 are described. It is important to note that the upper cylindrical section 116 and the lower cylindrical section 118 appear in various shapes and lengths, such as... Figure 2 As shown.

[0069] The engagement of the upper cylindrical portion 116 and the lower cylindrical portion 118 occurs within engagement station 182, and the engagement of the upper cylindrical portion 126 and the lower cylindrical portion 128 occurs within engagement station 192. Engagement station 184 is part of station 182, and engagement station 194 is part of station 192. Therefore, the full cylindrical portion 44 advances along tracks 186 and 196 to work unit 188 or 198. In another embodiment, the operations of assembly lines 110 and 120 discussed herein are combined into a single assembly line.

[0070] Arrow 101 indicates the positions of the upper cylindrical portions 116 and lower cylindrical portions 118 of different shapes as they move from assembly line 110 into rack assembly area 180. For example, arrow 101 depicts the lower cylindrical portion 118 and upper cylindrical portion 116 moving to assembly table 320 and assembly table 330 respectively, then to joining station 184 for joining, and moving to different assembly lines, etc. Arrow 101 indicates the positions of the upper cylindrical portions 126 and lower cylindrical portions 128 of similar shapes as they move from assembly line 120 into rack assembly area 190. For example, arrow 101 depicts the lower cylindrical portion 128 and upper cylindrical portion 126 moving to assembly table 321 and assembly table 331 respectively, then to joining station 194 for joining, and moving to different assembly lines, etc.

[0071] In the implementation, at assembly stations 320 and 330, the upper cylindrical portion 116 engages with the crown module 364, and the lower cylindrical portion 118 engages with the cargo hold floor joists 324 and / or the passenger cabin floor joists 326, respectively. Assembly stations 320 and 330 are part of the assembly process for the upper cylindrical portion 116 and the lower cylindrical portion 118, much like assembly stations 321 and 331 are part of the assembly process for the upper cylindrical portion 126 and the lower cylindrical portion 128, wherein the crown module 364, the cargo hold floor joists 324, and the passenger cabin floor joists 326 are similarly installed. Similarly, the engagement station 184 is part of the assembly process for the upper cylindrical portion 116 and the lower cylindrical portion 118, and similarly corresponds to engagement station 194, which is part of the assembly process for the upper cylindrical portion 126 and the lower cylindrical portion 128.

[0072] Figure 3 Assembly line 150 for components 170-1, 170-2 in a factory according to an exemplary embodiment is depicted. Assembly line 150 can be used for any of components 170-1, 170-2, such as for post-hardening or pre-hardening manufacturing and / or assembly processes, and can be used as feed line 149 ( Figure 2This provides components 170-1 and 170-2 for use by downstream assembly line 150. Component 170-1 may be different from and distinguishable from component 170-2, or components 170-1 and 170-2 may be identical. For example, and in connection with the following figures, components 170-1 and 170-2 are interrib supports 513, floor beams 511, or may be crown modules 364 or floor joists 365 in the finished individual stages.

[0073] Components 170-1 and 170-2 advance through a series of workstations 152-1 to 152-n, wherein these multiple workstations 152 perform work on component 170-1 during micro-pulses 129-3 or pauses between micro-pulses 129-3, while additional workstations 152 perform work on component 170-2. It should be understood that as the components move along assembly line 150, depending on the component's travel along assembly line 150, only a single workstation 152 may perform work on a single component 170.

[0074] In this embodiment, assembly line 150 includes stations 152-1 to 152-n, which perform operations such as laying, inspection, hardening, trimming, picking and placing, joining, and fastening as components 170-1 and 170-2 travel along track 154. The pulsations 123 and 123-1 of components 170-1 and 170-2 in the processing direction 199... Figure 2 ) or micropulsation 129-3 ( Figure 2 During the same pause between workstations, workstation 152 performs jobs on components 170-1 and 170-2, such as those mentioned in the preceding paragraphs.

[0075] In the illustrated embodiment, one of the workstations 152-n is positioned at the gap 121 between components 170-1 and 170-2, which move or pulsate in the processing direction 199. When positioned at the gap 121, workstation 152-n receives maintenance and / or inspection, and / or the technician operating workstation 152-n may take a break when workstation 152-n is not performing work on one of the components 170.

[0076] In one example of the illustrated implementation, exit line 169-1 carries inspection data 167-1 from station 152-1, while exit line 169-2 carries removed material 167-2 from one of stations 152-n. An example of inspection data 167-1 is inspection data from assembly 170 at station 152, which is configured as an NDI station. Similarly, when assembly 170 is mechanically trimmed, removed material 167-2 is taken from both stations 152-n on exit line 169-2, with particular station 152-n configured as a trimming station.

[0077] Feed lines 160-1 to 160-n provide sub-components 162-1 and 162-n to one of stations 152-2, 152-3 and 152-n. In one example, sub-component 162-1 is connected to component 170 present in station 152-2. Sub-components 162-1 and 162-n reach each station 152-2 and 152-n, and these stations 152-2 and 152-n utilize sub-components 162-1 and 162-n by consuming, placing, or otherwise utilizing them to facilitate the manufacture of components 170-1 and 170-2.

[0078] Path 164 passes through the inlet 165-2 and outlet 165-3 of each station 152, and an example of it is shown at station 152-2 for component 170. In this embodiment, each feed line 160-1, 160-n provides sub-components 162-1, 162-n to stations 152-1, 152-2, 152-3, 152-n, and can provide sub-components 162-1, 162-n via inlet / outlet ports 165-1 independent of path 164.

[0079] The removed material 167-2 can also be removed via a separate inlet / outlet port 165-1. In one embodiment, the operations of feed lines 160-1, 160-n and assembly line 150 are coordinated to facilitate just-in-time (JIT) delivery of components 170-1, 170-2 operating according to station 152 to their subsequent assembly line 150-1. In one embodiment, assembly line 150 is used to manufacture floor joists 324, 326, and feed line 160 provides floor joist assemblies, such as rib supports, floor beams, rails, electrical installations, piping, and flooring, which are then provided just-in-time (JIT) for engagement into floor joists 365.

[0080] In one implementation, one or more of stations 152-1, 152-2, 152-3, and 152-n include NDI stations and rework stations downstream of these NDI stations that address any out-of-tolerance conditions identified by NDI inspection. Many of these stations 152-1, 152-2, 152-3, and 152-n include feed lines 160-1 and 160-n dedicated to inputting material intended for addition at said stations 152-1 and 152-n. Assembly line 150 represents one or all of assembly lines 110, 120, assembly area 180, and assembly area 190. As further described herein, assembly line 150 may also represent assembly tables 320, 321, 330, and 331.

[0081] Figure 4This is a block diagram of an assembly line 500, in an exemplary embodiment, for manufacturing and installing floor joists 365 (specifically passenger cabin floor joists 326 and cargo hold floor joists 324) into the lower cylindrical portion 128. Specifically, Figure 4 The diagram shows a line of assembly units arranged in a continuous, pulsating pattern between each. Cargo hold floor joists 324 and passenger cabin floor joists 326 advance individually via rails 541 and, as the work progresses, are rotated to workstations 520, 520-1, 540, 542, 543, 544, 545, 545-1, 550, and 550-1, respectively, via indexing assemblies 541-1 and 541-2 connected to each corresponding cargo hold floor joist 324 and passenger cabin floor joist 326. As described, the multiple workstations include multiple workstations configured in two parallel lines, a first section for assembling passenger cabin floor joists 326, and a second section for assembling cargo hold floor joists 324. Track 541 includes two tracks, namely, a first track and a second track, the first track being operable for manufacturing cargo hold floor joists 324 and the second track being operable for manufacturing passenger cabin floor joists 326; and the plurality of workstations includes a first workstation associated with the first track and a second workstation associated with the second track. Although only workstations 540 and 542 are shown, each of workstations 520, 520-1, 540, 542, 543, 544, 545, 545-1, 550, and 550-1 is connected to indexing units 541-8 and 541-9. Cargo hold floor joists 324 and passenger cabin floor joists 326 are transposed to workstations 520, 520-1, 540, 542, 543, 544, 545, 545-1, 550, and 550-1 via transposition assemblies 541-1 and 541-2, which are docked to transposition units 541-8 and 541-9 in a manner similar to that described elsewhere herein. Transposition units 541-8 and 541-9 are associated with each of the plurality of workstations and are operable to dock with transposition units 541-1 and 541-2 associated with floor joists 365 to control the position of floor joists 365 relative to the workstation.

[0082] As shown, multiple of each of the cargo hold floor joists 324 and passenger cabin floor joists 326 are shown on track 541, and the cargo hold floor joists 324 can be located at each of workstations 520, 542, 544, 545, and 550. Similarly, the passenger cabin floor joists 326 can be located at each of workstations 520-1, 540, 543, 545-1, and 550-1. The embodiment has cargo hold floor joists 324 and passenger cabin floor joists 326 at each of workstations 520, 520-1, 540, 542, 543, 544, 545, 545-1, 550, and 550-1, and pulses continuously to the next workstation. Figure 4 As shown, the floor joist assembly line 500 includes a processing tracking server 510, which uses a controller 512 and a memory 514 to track the progress of the floor joists 365 as they pass through the assembly table 331.

[0083] In this embodiment, assembly line 500 includes floor beam assembly feeder lines 524-1 and 524, which manufacture floor beams (including pre-cured and post-cured) for floor joists 365 (specifically, passenger cabin floor joists 326 and cargo hold floor joists 324), respectively. Rib support feeder lines 522-1 and 522 manufacture rib supports 513 (including pre-cured and post-cured) for floor joists 365 (specifically, passenger cabin floor joists 326 and cargo hold floor joists 324), respectively. Rib support feeder lines 522-1 and 522 and floor beam assembly feeder lines 524-1 and 524 feed the rib supports 513 and floor beams 511 to floor joist assembly stations 520 and 520-1, respectively, for installation of passenger cabin floor joists 326 and cargo hold floor joists 324. These components are assembled together in floor joist assembly station 520.

[0084] Unlike existing systems where the floor joists 365 are assembled when installed into the full-tube section 44, Figure 4 The illustration depicts how floor joists 365 (particularly cargo hold floor joists 324 and passenger cabin floor joists 326) can be assembled in full-pulse and installed in a finished state. Floor joist assemblies can be received from feed lines 502, which are assembled together before being installed into the inverted lower cylinder portion 128. Each feed line 502 is operable to provide the floor joist assembly to an associated workstation. The lower cylinder portion 128 is then inverted to a rib-down orientation 563-1 ( Figure 6 At floor panel installation stations 550 and 550-1, the floor panels are installed from feed lines 502-11 and 502-12 into the lower cylinder section 128 while the lower cylinder section 128 is reversed. However, the installation of the cargo hold floor and the passenger cabin floor can be completed via different components.

[0085] For clarity, before reversing the lower cylindrical portion 128 to the rib-down orientation 563-1, the floor joists 365 (especially the passenger cabin floor joists 326 and the cargo hold floor joists 324) are assembled in parallel and installed into the lower cylindrical portion 128 in a finished or slightly less finished state.

[0086] The passenger cabin floor joists 326 and cargo cabin floor joists 324 are assembled parallel to each other and parallel to the lower half-tube portion 128 (e.g.) Figure 2 (As shown). Each cabin floor joist 326 and cargo floor joist 324 begins manufacturing processing in full-pulse by assembling floor beams and interrib supports at cargo floor joist assembly station 520 and cabin floor joist assembly station 520-1. Stations 520, 520-1 are transposed to cabin floor joists 326 and / or cargo floor joists 324 during pauses between full-pulse operations or while advancing through assembly line 500 during a full-pulse operation. Cabin floor joists 326 and / or cargo floor joists 324 are transposed to each of the arranged stations 520, 520-1 to transfer a 3D representation of the cabin floor joists 326 and / or cargo floor joists 324 within the range 550-9 of stations 520, 520-1 before commencing work on the cabin floor joists 326 and / or cargo floor joists 324. The indexing components 541-1 and 541-2 (similar to the indexing component 115 described elsewhere in this document) may be located on multiple portions of the floor joists 365 or on multiple portions of the movable fixtures that transport the floor joists 365.

[0087] Next, the cargo hold floor joists 324 and passenger cabin floor joists 326, assembled with floor beams and interstitial supports, are fully pulsed and transposed to cargo hold lashing rail installation station 542 and seat rail installation station 540, respectively. Cargo hold lashing material is delivered to cargo hold lashing rail installation station 542 via feed line 502-6 by JIT. Seat rail material is delivered to seat rail installation station 540 via feed line 502-5 by JIT. Then, cargo hold floor joists 324 and passenger cabin floor joists 326 are fully pulsed and transposed to cargo hold roller rail installation station 544 and another seat rail installation station 543, respectively. Seat rail installation station 540, cargo hold roller rail installation station 542, and another seat rail installation station 543 are sometimes collectively referred to herein as rail installation stations.

[0088] Cargo hold roller track material is delivered by JIT to cargo hold roller track installation station 544 via feeder line 502-8. Seat track material is delivered by JIT to seat track installation station 543 via feeder line 502-7. Then, cargo hold floor joists 324 and passenger cabin floor joists 326 are fully pulsed and rotated to electrical equipment and piping installation stations 545 and 545-1, respectively. Electrical equipment and piping systems are delivered by JIT to electrical equipment and piping system installation station 545 via feeder line 502-10. Electrical equipment and piping systems are delivered by JIT to electrical equipment and piping system installation station 545-1 via feeder line 502-9.

[0089] Finally, the cargo hold floor joists 324 and passenger cabin floor joists 326 are then fully pulsed and rotated to floor panel installation stations 550 and 550-1, respectively. The floor panels are delivered by JIT to floor panel installation station 550 via feed line 502-12. The floor panels are delivered by JIT to floor panel installation station 550-1 via feed line 502-11. Optionally, the cargo hold floor joists 324 and passenger cabin floor joists 326 do not pass through floor panel installation stations 550 and 550-1 and are installed first, instead of proceeding directly to the floor joist attachment station 530. In this embodiment, the floor panels are installed while the cargo hold floor joists 324 and passenger cabin floor joists 326 are being installed into the lower cylinder portion 128. The cargo hold floor joists 324 reach the floor joist attachment station 530 and are first reversed and installed into the reversed lower cylinder portion 128. The cabin floor joists 326 then reach the floor joist attachment station 530 and are subsequently reversed and installed into the lower cylinder section 128. Sealant and fasteners are supplied to the floor joist attachment station 530 in a just-in-time (JIT) manner, with only the necessary components delivered via feed lines 519-8, 519-8 respectively. The lower cylinder section 128 then proceeds in the processing direction 199 to the reversing station 560, and then to the joining station 194.

[0090] exist Figure 5In another embodiment shown and discussed below, the passenger cabin floor joists 326 and cargo cabin floor joists 324 advance via micro-pulsations 129-1 through assembly stations 504-1 to 504-7 and 504-11 to 504-17, respectively, to reach floor joist attachment station 530, as part of floor joist 365 being installed into the lower cylinder portion 128 in a fully pulsed manner. The passenger cabin floor joists 326 advance via micro-pulsations 129-1 through assembly stations 504-1 to 504-7 in a rhythmic manner. The cargo cabin floor joists 324 advance via micro-pulsations 129-1 through assembly stations 504-11 to 504-17 in a (same or different) rhythmic manner. The floor joists 365 have two components, the cargo cabin floor joists 324 and the passenger cabin floor joists 326. Cargo hold floor joists 324 and passenger cabin floor joists 326 are assembled in parallel for use with the lower cylinder section 128, so that the completed floor joists 365 arrive for installation, thereby minimizing the time the lower cylinder section 128 spends in the floor joist attachment station 530.

[0091] First, the cargo hold floor joists 324 are installed into the lower cylinder portion 128, and then the passenger cabin floor joists 326 are installed. This means that the passenger cabin floor joists 326 are received in the floor joist attachment station 530 immediately after the cargo hold floor joists 324 are installed. The passenger cabin floor joists 326 and the cargo hold floor joists 324 must be assembled parallel to the lower cylinder portion 128 to minimize the attachment time of the floor joists 365 in the floor joist attachment station 530. Both the passenger cabin floor joists 326 and the cargo hold floor joists 324 are assembled in reverse order. The cargo hold floor joists 324 arrive at the floor joist attachment station 530, ready for installation in a completed state or slightly less than a completed state.

[0092] The cargo hold floor joists 324 are assembled from floor beams 511 with interrib supports 513, and then cargo hold lashing rails 515, cargo hold roller rails 516, floor panels 517, and electrical equipment and piping 518 are added. The cargo hold floor joists 324 are assembled from floor beams 511 with interrib supports 513. Next, before installing the cargo hold floor joists 324 into the lower cylinder portion 128, the cargo hold lashing rails 515, cargo hold roller rails 516, floor panels 517, and electrical equipment and piping system 518 are added.

[0093] The cargo hold floor joists 324 are assembled via micro-pulsations 129-1 through consecutively arranged stations 504-11, 504-12, and 504-13 on feed lines 503-1. Each station has feed lines 519-1, 519-2, and 519-3, which deliver floor beams 511 and interrib supports 513 in just-in-time (JIT) delivery to stations 504-11, 504-12, and 504-13 for assembly into the cargo hold floor joists 324. Micro-pulsations 129-1 are shown as having a length equal to the space between two adjacent stations 504-11 to 504-17, or equal to the range 504-18, or a multiple or fraction thereof. Cargo hold floor joists 324 are continuously assembled on feed line 503-1 via micro-pulsations 129-1 through consecutively arranged workstations 504-14, 504-15, 504-16, and 504-17. Each workstation has feed lines 519-4, 519-5, 519-6, and 519-7, which respectively JIT deliver the correct components of cargo hold lashing rails 515, cargo hold roller rails 516, electrical equipment and piping systems 518, and floor panels 517 for assembly into cargo hold floor joists 324.

[0094] During pauses between micro-pulses 129-1 and / or during micro-pulses 129-1, stations 504-11 to 504-17 are transposed to cargo hold floor joists 324 as they advance through floor joist feed line 503-1. Cargo hold floor joists 324 are transposed individually or in multiples to each of the consecutively arranged stations 504-11 to 504-17 to convey a 3D representation of the cargo hold floor joists 324 within a range 504-18 of each station 504-11 to 504-17 before operations are performed on the cargo hold floor joists 324 at stations 504-11 to 504-17. During pauses between micro-pulses 129-1 and / or during micro-pulses 129-1, one or more stations 504-11 to 504-17 perform operations on the cargo hold floor joists 324. The indexing assembly 541-1 may be located on multiple parts of the floor joists 324 or on multiple parts of the movable clamps of the cargo compartment floor joists 324.

[0095] Cargo hold floor joists 324 are assembled parallel to the lower cylindrical portion 128, and the JIT (Just-In-Time) reaches the floor joist attachment station 530 before the lower cylindrical portion 128 is reversed to a rib-down orientation 563-1 for reverse installation into the lower cylindrical portion 128. Each of feed lines 519-1 to 519-7 is shown as the end of an assembly / manufacturing line (which manufactures floor beams 511, interrib supports 513, cargo hold lashing rails 515, cargo hold roller rails 516, electrical equipment and piping 518, and floor panels 517, respectively) for delivering only the correct components to the station for addition to the cargo hold floor joists 324. In this illustration, the second cargo hold floor joist 324 is a subsequent assembly that advances after the first cargo hold floor joist 324 passes through feed line 503-1.

[0096] When positioned within clearance 121-1, stations 504-11 to 504-17 receive maintenance and / or inspection, and / or operate the technicians at stations 504-11 to 504-17 while they continue to rest and / or perform maintenance, and stations 504-11 to 504-17 do not perform work on the cargo hold floor joists 324. Although seven stations 504-11 to 504-17 and feed lines 519-1 to 519-7 are shown, any number of stations or feed lines 519 are possible during the manufacture of the cargo hold floor joists 324.

[0097] The cabin floor joists 326 are assembled on feed line 503 via micro-pulsations 129-2 through consecutively arranged workstations 504-1, 504-2, and 504-3, each workstation having feed lines 519-11, 519-21, and 519-31 respectively. Floor beams 511-1 and interrib supports 513-1 are delivered just-in-time (JIT), with only the correct components delivered to workstations 504-1, 504-2, and 504-3 for assembly into the cabin floor joists 326. Micro-pulsations 129-2 are shown as having a length equal to the space between two adjacent workstations 504-1 to 504-7, or equal to the range 504-8, or a multiple or fraction thereof.

[0098] The cabin floor joists 326 continue to be assembled on feed line 503 via micro-pulsations 129-2 through a series of stations 504-4, 504-5, 504-6, and 504-7. Each station has feed lines 519-41 to 519-71, which respectively JIT deliver the correct components of cargo hold lashing rails 515-1, cargo roller rails 516-1, electrical equipment and piping 518-1, and floor panels 517-1 for assembly into the cabin floor joists 326. During pauses between micro-pulsations 129-1 and / or during micro-pulsations 129-2 of the cabin floor joists 326, stations 504-1 to 504-7 are rotated onto the cabin floor joists 326 as they advance through the floor joist feed lines 503-1. Using the indexing assembly 541-2, the cabin floor joists 326 are individually or in multiples indexed to each of the consecutively arranged workstations 504-1 to 504-7 to transfer a 3D representation of the cabin floor joists 326 within a range 504-8 of each workstation 504-1 to 504-7 before operations are performed on the cabin floor joists 326 at workstations 504-1 to 504-7.

[0099] During pauses between micro-pulsations 129-2 and / or during micro-pulsations 129-2, one or more stations 504-1 to 504-7 perform operations on the cabin floor joists 326. The indexing assembly 541-2 can be on multiple portions of the cabin floor joists 326 or on multiple portions of the movable clamps that transport the cabin floor joists 326. The cabin floor joists 326 are assembled parallel to the lower cylindrical portion 128 and JIT-reach the floor joist attachment station 530 for inverted installation into the lower cylindrical portion 128 before reversing the lower cylindrical portion 128 into a rib-down orientation 563-1. Each of feed lines 519-11 to 519-71 is shown as the end of a component manufacturing line that manufactures floor beams 511-1, interrib supports 513-1, cargo hold lashing rails 515-1, cargo hold roller rails 516-1, electrical equipment and piping systems 518-1, and floor panels 517-1, respectively, for JIT delivery of only the correct components to the workstation for addition to cabin floor joists 326. A second cabin floor joist 326 is shown, and it is a subsequent component that travels via feed line 503 after the first cabin floor joist 326.

[0100] When positioned at clearance 121-2, station 504-4 receives maintenance and / or inspection, and / or the technicians operating station 504-4 continue to rest and / or perform maintenance, while no work is performed on cabin floor joists 326 at station 504-4. Although seven stations 504-1 to 504-7 and feeder lines 519-11 to 519-17 are shown, any number of stations or feeder lines are possible during the manufacture of cabin floor joists 326.

[0101] Figure 5 It also includes a passenger cabin floor joist 326, which advances via micro-pulsation 129-2 through assembly stations 504-1 to 504-7 to reach the floor joist attachment station 530 for full-pulsation installation of the floor joist into the lower cylinder portion 128. As previously described, the floor joist 365 has two components, a cargo hold floor joist 324 and a passenger cabin floor joist 326. The cargo hold floor joist 324 and the passenger cabin floor joist 326 are assembled in parallel with and for the lower cylinder portion 128, such that the components of the floor joist 365 reach for installation, minimizing the time the lower cylinder portion 128 spends in the floor joist attachment station 530. Feed lines 503 and 503-1, which are used for the passenger cabin floor joists 326 and cargo cabin floor joists 324 respectively at the floor joist attachment station 530, provide the assembled and reversed passenger cabin floor joists 326 and cargo cabin floor joists 324 to the floor joist attachment station 530 on time, and prepare them for reverse installation into the reversed lower cylinder section 128.

[0102] First, the cargo hold floor joists 324 are installed into the lower cylinder portion 128, and then the passenger cabin floor joists 326 are installed. This means that the passenger cabin floor joists 326 are received in the floor joist attachment station 530 immediately after the cargo hold floor joists 324 are installed. The passenger cabin floor joists 326 and the cargo hold floor joists 324 must be assembled parallel to the lower cylinder portion 128 to minimize the floor joist attachment time in the floor joist attachment station 530. Both the passenger cabin floor joists 326 and the cargo hold floor joists 324 are assembled in reverse order. The cargo hold floor joists 324 arrive at the floor joist attachment station 530 ready for installation.

[0103] The feed lines 503, 503-1 of the cargo hold floor joists 324 and passenger cabin floor joists 326 advance via pulsating or micro-pulsating 129-1, 129-2. In one embodiment, the floor panels 517, 517-1 in the feed lines 503, 503-1 of the cargo hold floor joists 324 and passenger cabin floor joists 326 may be installed first, rather than during the installation of the cargo hold floor joists 324 and passenger cabin floor joists 326 into the lower cylinder portion 128. The cargo hold floor joists 324 reach the floor joist attachment station 530 and are first reversed and installed into the reversed lower cylinder portion 128. Then, the passenger cabin floor joists 326 reach the floor joist attachment station 530 and are subsequently reversed and installed into the lower cylinder portion 128. Sealant and fasteners are supplied in a JIT manner to the floor joist attachment station 530 via feed lines 519-8 and 519-81, delivering only the necessary items on feed lines 519-8 and 519-81 respectively. The lower half-cylinder 128 then advances in the processing direction 199 to the reversing station 560, and then to the joining station 194.

[0104] like Figure 6 As shown, the vertical reversing position 560 rotates the lower cylindrical portion 128 about the longitudinal centerline 567 to position it in a rib-down orientation 563-1. More specifically, Figure 6 The lower cylindrical portion 128 in an exemplary embodiment is shown in reverse. Figure 6 In the vertical reversing station 560, a frame 562 is included, to which a rotating element 564 is attached. The lower cylinder portion 128 is joined to the upper cylinder portion 126 (in... Figure 7 (As shown in the diagram) Previously rotated about the longitudinal centerline 567. Support column 566 protrudes from rotating element 564 and is attached to lower half-cylinder portion 128, in which one or more floor joists 365 have been installed. Rotating element 564 then rotates, thereby reversing the joists 563-2 of lower half-cylinder portion 128 from rib-upward orientation 563-3 to rib-downward orientation 563-1, and arranging lower half-cylinder portion 128 in a position for engagement with upper half-cylinder portion 126 in engagement station 194.

[0105] As described elsewhere herein, joining station 194 joins the lower cylindrical portion 128 to the upper cylindrical portion 126. This joining process results in the upper cylindrical portion 126 and the lower cylindrical portion 128 being longitudinally spliced ​​together, including the splicing skin and frame 146 and any surrounding elements therein. The splicing panel (not shown) can be fully installed in joining station 194. Figure 7 The image depicts a cross-section of the cylindrical portion 44 in the assembly station 194, which includes the cargo hold floor joists 594 and the cabin floor joists 596. Figure 7It is also shown that a crown module 599 and a reinforcement 597 have been added to the full-cylinder portion 44 of the fuselage. In one embodiment, the crown module 599 includes a loading box and internal lighting, and for clarity, in Figure 7 These details are not shown. Insulator 591 and internal panel 593 are also shown as being mounted.

[0106] Figure 8 This illustrates the use of, respectively, in exemplary embodiments. Figure 4 , Figure 5 A flowchart of method 600 for floor joist assembly lines 500 and 500-1. Method 600 includes receiving a reversed lower portion of body 12 602. In some exemplary examples, method 600 includes receiving a lower cylindrical portion 128 of body 12 reversed to rib-up orientation 563-3. In some exemplary examples, method 600 includes receiving the lower cylindrical portion 128 or other curved portion of body 12 reversed to rib-up orientation 563-3. Method 600 also includes installing floor joists 365 604 into the lower portion while they are being reversed. In some illustrative examples, method 600 also includes installing floor joists 365 604 into the lower cylindrical portion 118 while they are being reversed. In some illustrative examples, method 600 further includes: installing 604 cargo hold floor joists 324 and then passenger cabin floor joists 326 into the lower cylinder portion 128 while the lower cylinder portion 128 is in rib-up orientation 563-3. In one embodiment, the lower cylinder portion 128 is positioned in assembly table 330 approximately twice the length of the upper cylinder portion 126 in assembly table 320. That is, by definition, the upper cylinder portion 126 and the lower cylinder portion 128 must have the same cycle time. In other words, both the upper cylinder portion 126 and the lower cylinder portion 128 are required within the user-required time interval. Continuing, the workload of manufacturing and processing the lower cylinder portion 128 may be more or less than the workload of manufacturing and processing the upper cylinder portion 126, but the cycle time is the same, and this is addressed in the forward design of assembly lines 110, 120.

[0107] Before the lower half-cylinder portion 128 is reversed to a rib-down orientation 363-1, piping and electrical systems, as well as insulation and wall panels not in the joint area, are added to the assembly table 330. Method 600 continues by rotating the lower half-cylinder portion 128 606 to a rib-down orientation 363-1 and attaching the lower half-cylinder portion 128 608 to the upper half-cylinder portion 126 to form the full-cylinder portion 44. This operation can be performed, for example, during full pulsation.

[0108] In a further embodiment, the lower cylinder portion 128 advances in the processing direction before receiving material generated by the floor joist assembly line 500, and after the floor joists 365 are installed, the lower cylinder portion 128 advances in the processing direction 199, and after being rotated, it advances further in the processing direction 199.

[0109] Method 600 offers the technical benefit of allowing the lower cylindrical portions 128 to be handled and receive the floor joists 365 while being reversed, eliminating the need to rotate the lower cylindrical portions 128 until they are engaged with the corresponding upper cylindrical portions 126. This reduces the need for specialized equipment at the factory floor. Another benefit is that technicians can remove the floor joists from brackets installed to or directly on the workshop floor before reversing, without the difficulties of installing cargo hold or passenger cabin floors, while positioning the technician support area in the same space as the floor installation with the ribs facing downward 563-1. This is an example of bringing work to tools, equipment, and technicians. The ribs facing upward 563-3 allows for a more comfortable installation position for tools, equipment, and technicians on the floor joists 365.

[0110] Figure 9 This is a flowchart illustrating a cycle time assembly method 1400 in a representative embodiment. Method 1400 includes causing a series of sub-assemblies 162 (162-1 to 162-n) to travel 1402 through a series of stations 152 during a common cycle time. In one embodiment, a station may be referred to as a manufacturing station. In one embodiment, the sub-assemblies 162 are conveyed according to the common cycle time. Therefore, deliveries are provided from feed lines 160 JIT, and each feed line 160 may or may not have a common cycle time. Feed lines 160 may have their own cycle time, and this cycle time may or may not be equal to a fraction of the fuselage cycle time.

[0111] The term "beat time" requires further explanation. For example, and refer to... Figure 3For each assembly line 150 and for each feed line 160, there exists a cycle time for the product (TTP). This description applies to other figures described herein, such as assembly lines 110, 120, and feed line 149. Typically, since feed line 160 always needs to be synchronized with assembly line 150, the cycle time is the same, but can be different. For example, if there is only one assembly line 150 and there are eight half-cylinder sections 117 along assembly line 150, combined with the product demand for eight half-cylinder sections 117 every 32 available hours, then the TTP for assembly line 150 is 4 hours. TTP equals pulsation time only when the pulsation length is the full length of the produced product. In the case of micro-pulsation lines, where the pulsation length is a portion of the total product length, the gap 121 between products must be taken into account, and the pulsation time (PT) is much smaller. All feed lines 160 need to support the main line TTP, PT, or speed. As an additional example, if the pulse length equals the frame spacing 147 (approximately 60.1 cm (approximately 2 feet)), the frame feed line will need to deliver multiple frames 146 per frame station (e.g., two). Doors may not be present on some half-cylinder sections 117, so feed line 160 may need to provide two frames 146 per pulse time. Some half-cylinder sections 117 include doors, and in these areas, frames 146 are not required for at least several micro-pulses. However, feed line 160 must still be synchronized with the pulse time of assembly line 150. If the number of products per pulse is greater than one and there is only one feed line 160, feed line 160 can have a larger TTP. If the number of products is greater than one and the number of feed lines 160 for that product is the same as the number of products in feed line 160, then the PT of feed line 160 is the same as the PT of assembly line 150. When it is not necessary to feed products to assembly line 150, the PT of feed line 160 is variable.

[0112] At feed line 160, an additional station 152 performs operations on sub-assembly 162 during pauses between pulses in the processing direction 199. Some sub-assemblies 162 may be produced in a continuous, non-pulsating, non-micro-pulsating manner. Method 1400 includes timely delivery 1404 of a first type of sub-assembly 162-1 and a second type of sub-assembly 162-n produced in parallel with the first type of sub-assembly 162-1 to station 152-2. Sub-assemblies 162 are delivered to the station in just-in-time (JIT) according to their usage sequence. Method 1400 includes joining 1406 of the second type of sub-assembly 162-n to the first type of sub-assembly 162-1 to form assembly 170-1. In one embodiment, sub-assembly 162 is part of the machine body (e.g., upper half-cylinder portion 126 or lower half-cylinder portion 128). In a further embodiment, component 170-1 is a full-cylinder portion 44 formed by an upper half-cylinder portion 126 and a lower half-cylinder portion 128.

[0113] In another embodiment, method 1400 further includes simultaneously performing operations on sub-component 162 via more than one workstation 152. According to one embodiment, travel includes iteratively pulsating sub-component 162 less than its length, and then pausing while performing operations on sub-component 162. Alternatively, travel includes iteratively pulsating sub-component 162 at least its length, and then pausing while performing operations on sub-component 162. Alternatively, forward travel includes continuously moving sub-component 162 while performing operations on sub-component 162. In the pulsating embodiment, first-type sub-component 162-1 and second-type sub-component 162-n are added to component 170 at workstation 152 after pulsation.

[0114] Now let's turn our attention to... Figure 10 This diagram broadly illustrates the control components of a production system (e.g., assembly environment 100) performing continuous manufacturing. A controller 1600 coordinates and controls the operation of workstation 1620 along a movement line 1660 having a power system 1662 (corresponding to the movement of any and all workstations 114, 124, 504-1 to 504-7, and 504-11 to 504-17, as well as one or more aircraft components described herein). The controller 1600 may include a processor 1610 coupled to a memory 1612 of a stored program 1614. In one example, a moving platform 1670 is driven along a movement line 1660 continuously driven by a power system 1662 controlled by the controller 1600. In this example, the moving platform 1670 includes a utility connection 1672, which may include an electrical, pneumatic, and / or hydraulic quick-disconnect connection for connecting the moving platform 1670 to external utilities. In other examples, as previously described, mobile platform 1670 includes an automated guided vehicle (AGV) containing onboard utilities and a GPS / automated guidance system 1674. Mobile platform 1670 also includes some or all of the previously discussed transposition systems, barcode and RFID systems. In still other examples, a tracker 1650 is used to control the movement of mobile platform 1670. Laser tracker 1650 uses a transposition unit, barcode reader, or RFID reader. Position and / or motion sensors 1630, coupled to controller 1600, are used to determine the position of mobile platform 1670 and power system 1662.

[0115] Figure 11 This is a flowchart illustrating a method 1900 for installing floor joists 365 (specifically, cabin floor joists 326 and cargo hold floor joists 324) into assembly lines 500, 500-1 in the lower cylindrical section 128, as shown in the figure. Figure 4As shown. Method 1900 includes feeding floor beams 511, interrib supports 513, and tracks 515, 516 to the workstation via feed lines 502 associated with each workstation. In some illustrative examples, method 1900 includes feed lines 1902 feeding floor beams 511 and interrib supports 513 to floor joist assembly workstation 520. Method 1900 includes feeding floor beams 511 and interrib supports 513 to floor beam assembly feed lines 524, 524-1 and interrib support feed lines 522, 522-1, respectively, and... Figure 4 On the floor joist assembly station 520 of the floor joist assembly line 500, cargo hold floor joists 324 and passenger cabin floor joists 326 are assembled respectively. Method 1900 includes assembling floor beams 511, interrib supports 513, and tracks 515, 516 together 1904 to form floor joists 365. Method 1900 includes assembling floor beams 511 and interrib supports 513 1904 to form joists 324, 326 for use in the corresponding floor joist assembly stations 520, 520-1 for cargo hold floor 594 and passenger cabin floor 596.

[0116] After or during a pulse, the cabin floor joists 326 and / or cargo floor joists 324, or other sub-components 162, are transposed 1906 to each workstation to convey 3D features within the workstation's scope. The cabin floor joists 326 and / or cargo floor joists 324 are transposed 1906 to each of the consecutively arranged workstations 504 to convey the 3D representation of the cabin floor joists 326 and / or cargo floor joists 324 within the workstation's scope 504-8, 504-18 before commencing workstation operations on the cabin floor joists 326 and / or cargo floor joists 324.

[0117] Next, the assembled floor beams 511 and interrib supports 513 from the floor joist assembly station 520 are fully pulsed 1908 to the cargo hold lashing rail installation station 542 and the seat rail installation station 540. The cargo hold lashing rails and seat rails are then installed in the cargo hold lashing rail installation station 542 and the seat rail installation station 540, respectively, as described herein.

[0118] Continuing, the cargo hold floor joists 324 and passenger cabin floor joists 326 are then fully pulsed 1910 to the cargo hold roller rail installation station 544 and another seat rail installation station 543, where the cargo hold roller rail material and the seat rail material are respectively installed at the other seat rail installation station as described herein.

[0119] The cargo hold floor joists 324 and passenger cabin floor joists 326 are fully pulsed 1912 to electrical equipment and piping installation stations 545 and 545-1, wherein electrical and piping equipment is just-in-time delivered to electrical equipment and piping installation stations 545 and 545-1, wherein electrical equipment and piping equipment are respectively added to each of electrical equipment and piping installation stations 545 and 545-1.

[0120] Continuing with method 1900, the cargo hold floor joists 324 and passenger cabin floor joists 326 are fully pulsed 1914 to floor panel installation stations 550 and 550-1, where floor panels are delivered by JIT to the floor panel installation stations and floor panels are added to the two components respectively.

[0121] Optionally, the cargo hold floor joists 324 and passenger cabin floor joists 326 do not pass through floor panel installation stations 550 and 550-1, and the floor panels 517 and 517-1 are installed first, instead of proceeding directly 1916 to the floor joist attachment station 530 respectively.

[0122] Floor panels 517 and 517-1 are installed 1918 during the installation of the lower cylindrical portion 128 at the floor joist attachment station 530 on cargo hold floor joists 324 and passenger cabin floor joists 326. The lower cylindrical portion 128 then advances in the processing direction 199 to the reversing station 560, and then to the joining station 194.

[0123] Finally, floor panels 517 and 517-1 are added 1920 to cargo hold floor joists 324 and passenger cabin floor joists 326 at installation stations 550 and 550-1, respectively, and are first installed in reverse to the inverted lower cylinder portion 128. First, cargo hold floor joists 324 are installed into the lower cylinder portion 128. Then, passenger cabin floor joists 326 reach floor joist attachment station 530 and are subsequently installed in reverse to the lower cylinder portion 128. Floor joist attachment station 530 is operable for installing inverted floor joists 365 into the inverted lower cylinder portion 118 of the fuselage 12. In some exemplary examples, installing floor joists 365 includes installing floor joists 365 with a length substantially equal to the lower cylinder portion 118 of the fuselage 12. Sealant and fasteners are supplied to the floor joist attachment station 530 in a just-in-time (JIT) manner, so that only the necessary items are delivered on feed lines 519-8, 519-81. In some exemplary examples, method 1900 includes: feeding fasteners 519-81, electrical equipment, and conduits 518 to the station via feed lines associated with each station; and installing fasteners 519-81, electrical equipment, and conduits 518 into the floor joists 365. The lower cylindrical portion 128 then advances in the processing direction 199 to a reversing station 560, and then to an engagement station 194. The vertical reversing station 560 is operable to rotate the lower cylindrical portion 118 to a rib-down orientation after the floor joists 365 have been installed.

[0124] Figure 12 This is a flowchart 2000 illustrating a method for manufacturing multiple portions (e.g., full-cylinder portions) of a manufacturing rack in an exemplary embodiment. The illustrated method includes performing operations 2022 on the lower half-cylinder portions 118, 128 in a processing direction 199 at multiple stations 114, 124 spaced apart along assembly lines 110, 120 with a length less than that of the lower half-cylinder portion 118. The method also includes performing operations 2024 on the upper half-cylinder portions 116, 126 in the processing direction 199 after the lower half-cylinder portions 118, 128. The lower half-cylinder portions 118, 128 are removed 2026 from assembly lines 110, 120. Subsequently, the upper half-cylinder portions 116, 126 are removed 2028 from assembly lines 110, 120. Finally, the lower half-cylinder portions 118, 128 are attached 2029 to the upper half-cylinder portions 116, 126.

[0125] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein may be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination thereof. For example, an element may be implemented as dedicated hardware. A dedicated hardware element may be referred to as a “processor,” a “controller,” or some similar term. When provided by a processor, functionality may be provided by a single dedicated processor, by a single shared processor, or by multiple separate processors, some of which may be shared. Furthermore, the explicit use of the terms “processor” or “controller” should not be construed as exclusively referring to hardware capable of executing software, and may implicitly include, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic, or some other physical hardware component or module.

[0126] Furthermore, control elements can be implemented as instructions executable by a processor or computer to perform the functions of the element. Some examples of instructions are software, program code, and firmware. Instructions, when executed by a processor, are operable to instruct the processor to perform the functions of the element. Instructions can be stored on processor-readable storage devices. Some examples of storage devices are digital or solid-state memories, magnetic storage media such as disks and tapes, hard disk drives, or optically readable digital data storage media.

[0127] While specific embodiments have been described herein, the scope of this disclosure is not limited to those specific embodiments. The scope of this disclosure is defined by the appended claims.

[0128] Illustrative, non-exclusive examples for understanding the background art of the present invention are described in the following paragraphs.

[0129] According to one aspect of this disclosure, a method for assembling an aircraft (10) is disclosed, the method comprising:

[0130] The lower cylindrical portion (118) of the fuselage (12) is received after being reversed to a rib-up orientation (563-3); and

[0131] The floor joists (365) are installed into the lower cylinder portion (118) while being reversed.

[0132] Optionally, the step of installing the floor joists (365) includes: installing floor joists (365) of the lower half-cylinder portion (118) of the body (12) with a length substantially equal to that of the body (12).

[0133] Optionally, the step of installing the floor joists (365) into the lower cylinder portion (118) includes: installing the cabin floor joists (324).

[0134] Optionally, the step of installing the floor joists (365) into the lower cylinder portion (118) includes: installing the cargo hold floor joists (326).

[0135] Optionally, the step of installing the floor joists (365) into the lower cylinder portion (118) includes: installing the cargo hold floor joists (326) and then installing the cabin floor joists (324).

[0136] Optionally, the step of installing the floor joists (365) into the lower half-cylinder portion (118) includes: installing the floor joists (365) into the lower half-cylinder portion (118) in a completed state.

[0137] Optionally, the step of installing the floor joists (365) into the lower half-cylinder portion (118) includes: installing a floor panel (517) into the floor joists (365), and then installing the floor joists (365) into the lower half-cylinder portion (118).

[0138] Optionally, the method further includes:

[0139] After the floor joists (365) are installed, the lower cylindrical portion (118) is advanced in the processing direction (199); and

[0140] The lower cylindrical portion (118) is rotated so that the ribs are oriented downwards (563-1).

[0141] Optionally, the method further includes:

[0142] Receive floor beam (511) from floor beam assembly feed line (524);

[0143] Receive interrib support (513) from interrib support feed line (522); and

[0144] At the floor joist assembly station (520), the floor joist (365) is assembled from the interrib support (513) and the floor beam (511). Optionally, the method further includes: rotating the floor joist (365) to the floor joist assembly station (520).

[0145] Optionally, the method further includes:

[0146] The floor joists (365) are pulsating to reach the track installation positions (540, 542, 544);

[0147] Rotate the floor joists (365) to the track installation positions (540, 542, 544); and

[0148] At the track installation stations (540, 542, 544), the tracks are installed onto the floor joists (365). Optionally, the track installation steps include installing one or more of the cargo hold lashing tracks (515), cargo hold roller tracks (516), and seat tracks.

[0149] Optionally, the method further includes:

[0150] The floor joists (365) are pulsed to the electrical equipment and piping installation station (545);

[0151] The floor joists (365) are rotated to the electrical equipment and piping installation station (545); and

[0152] At the electrical equipment and piping installation station (545), the electrical equipment and piping (518) are installed onto the floor joists (365).

[0153] Optionally, the method further includes:

[0154] The floor joists (365) pulsate to the floor panel installation station (550); and

[0155] The floor joists (365) are rotated to the floor panel installation station (550); and

[0156] At the floor panel installation station (550), the floor panel (517) is installed onto the floor joists (365).

[0157] Optionally, the method further includes:

[0158] Floor beams (511), interrib supports (513), and tracks (515, 516) are fed to the workstation via feed lines (502) associated with each workstation; and

[0159] The floor beams (511), interrib supports (513), and tracks (515, 516) are assembled together to form the floor joists (365). Optionally, the method further includes:

[0160] The floor joist (365) is moved forward in a pulsating manner, with a length less than that of the floor joist, through the work station, wherein the work station is operated by rotating to the floor joist (365) before performing the operation.

[0161] Optionally, the method further includes:

[0162] Fasteners (519-8A), electrical equipment, and conduits (518) are fed to the workstation via feed lines associated with each workstation; and

[0163] Install the fasteners (519-8A), electrical equipment, and pipes (518) into the floor joists (365).

[0164] According to one aspect of this disclosure, a portion of an aircraft (10) assembled according to any of the foregoing examples is disclosed.

[0165] According to one aspect of this disclosure, a system (500) is disclosed, the system (500) comprising:

[0166] Multiple workstations are used to install floor joist components onto the floor joists (365);

[0167] Track (541) that allows the floor joists (365) to advance through the workstation in the processing direction (199); and

[0168] At least one feed line is associated with one of the workstations, the feed line being operable to provide the floor joist assembly to the workstation on time for installation onto the floor joist (365).

[0169] Optionally, the system further includes a floor joist attachment station (530) operable to install a reversed floor joist (365) into a reversed lower cylinder portion (118) of the body (12).

[0170] Optionally, the system further includes a vertical reversing station (560) operable to rotate the lower cylindrical portion (118) to a rib-down orientation after the floor joists (365) have been installed.

[0171] Optionally, the track (541) includes two tracks, namely, a first track and a second track, the first track being operable for manufacturing the cargo hold floor joists (324), and the second track being operable for manufacturing the passenger cabin floor joists (326); and

[0172] The plurality of workstations includes a first workstation associated with the first track and a second workstation associated with the second track.

[0173] Optionally, the plurality of workstations further includes a plurality of workstations configured as two parallel lines, wherein a first portion of the workstation is used for assembling passenger cabin floor joists (326), and a second portion of the workstation is used for assembling cargo hold floor joists (324). Optionally, the first portion of the workstation includes:

[0174] Cabin floor joist assembly station (520-1);

[0175] Seat track installation stations (540, 543);

[0176] Electrical equipment and piping installation station (545-1); and

[0177] Floor panel installation station (550-1).

[0178] Optionally, the second part of the workstation includes:

[0179] Cargo hold floor joist assembly station (520);

[0180] Cargo hold lashing rail installation station (542);

[0181] Cargo hold roller track installation station (544);

[0182] Electrical equipment and piping installation station (545); and

[0183] Floor panel installation station (550).

[0184] Optionally, the system further includes a shifting unit (541-8, 541-9) associated with each of the plurality of workstations, the shifting unit (541-8, 541-9) being operable to interface with shifting units (541-1, 541-2) of the floor joists (365) to control the position of the floor joists (365) relative to the workstation.

[0185] Optionally, the system also includes feed lines (502), each feed line (502) operable to provide floor joist assemblies to an associated workstation in the workstation.

[0186] According to one aspect of this disclosure, a portion of a system for manufacturing an aircraft (10) using any of the above examples is disclosed.

Claims

1. A method for assembling an aircraft (10), the method comprising: receiving a lower barrel section (118) of a fuselage (12) inverted to a rib-up orientation (563-3); pulsing the lower barrel section (118) through an assembly line (110); receiving a floor beam (511) from a floor beam assembly feed line (524); receiving an inter-rib support (513) from an inter-rib support feed line (522); assembling the floor beams (365) from the inter-rib support (513) and floor beam (511) at a floor beam assembly station (520); pulsing the floor beams (365) to a rail installation station (540, 542, 544); indexing the floor beams (365) to the rail installation station (540, 542, 544); installing rails onto the floor beams (365) at the rail installation station (540, 542, 544); and installing floor beams (365) into the lower barrel section (118) while inverted, wherein the step of installing the floor beams (365) into the lower barrel section (118) comprises installing the floor beams (365) into the lower barrel section (118) in a finished state. the step of installing the floor beams (365) comprises installing floor beams (365) having a length substantially equal to the lower barrel section (118) of the fuselage (12), and / or 2. The method of claim 1, wherein, wherein the step of installing the floor beams (365) into the lower barrel section (118) comprises installing passenger cabin floor beams (326), and / or wherein the step of installing the floor beams (365) into the lower barrel section (118) comprises installing cargo cabin floor beams (324), and / or wherein the step of installing the floor beams (365) into the lower barrel section (118) comprises installing cargo cabin floor beams (324) and then installing cockpit floor beams (324), and / or wherein the step of installing the floor beams (365) into the lower barrel section (118) comprises installing floor panels (517) into the floor beams (365) and then installing the floor beams (365) into the lower barrel section (118), and / or wherein the step of installing rails comprises installing one or more of cargo cabin tie-down rails (515), cargo cabin roller rails (516), and seat rails, and / or the method further comprising: indexing the floor beams (365) to the floor beam assembly station (520).

3. The method of claim 1 or 2, further comprising: advancing the lower barrel section (118) in a processing direction (199) after installing the floor beams (365); and rotating the lower barrel section (118) to a rib-down orientation (563-1).

4. The method of claim 1 or 2, further comprising: ​ ​ pulsing the floor stringers (365) to an electrical equipment and plumbing installation station (545); indexing the floor stringers (365) to the electrical equipment and plumbing installation station (545); and installing electrical equipment and plumbing (518) onto the floor stringers (365) at the electrical equipment and plumbing installation station (545).

5. The method of claim 1 or 2, further comprising: pulsing the floor stringers (365) to a floor panel installation station (550); and indexing the floor stringers (365) to the floor panel installation station (550); and installing floor panels (517) onto the floor stringers (365) at the floor panel installation station (550).

6. The method of claim 1 or 2, further comprising: feeding floor beams (511), intercostal supports (513), and tracks (515, 516) to a station via a feed line (502) associated with each station; and assembling the floor beams (511), intercostal supports (513), and tracks (515, 516) together into floor stringers (365).

7. The method of claim 6, further comprising: pulsing the floor stringers (365) through the station via a pulse that is less than the length of the floor stringers, wherein the station is operable to index to the floor stringers (365) prior to performing a job.

8. The method of claim 6, further comprising: feeding fasteners (519-8A), electrical equipment and plumbing (518) to a station via a feed line associated with each station; and installing the fasteners (519-8A), electrical equipment and plumbing (518) into the floor stringers (365).

9. A system (500), comprising: a plurality of stations that install floor stringer assemblies onto floor stringers (365); a first track that pulses the floor stringers (365) through the stations in a processing direction (199); at least one feed line (502) associated with one of the stations, the feed line (502) operable to provide floor stringer assemblies to the station on-time for installation onto the floor stringers (365); a floor stringer assembly station (520) configured to assemble the floor stringers (365) with floor beams (511) and intercostal supports (513); track installation stations (540, 542, 544) configured to install second tracks; and a floor stringer attachment station (530) operable for installing inverted floor stringers (365) into an inverted lower barrel portion (118) of a fuselage (12), ​ wherein the step of installing the floor beams (365) into the lower barrel section (118) comprises installing the floor beams (365) into the lower barrel section (118) in a finished condition.

10. The system of claim 9, further comprising a vertical inversion station (560) operable to rotate the lower barrel section (118) to a rib down orientation after installation of the floor beams (365).

11. The system of claim 9 or 10, wherein: the first track is operable for manufacturing cargo compartment floor beams (324) and the second track is operable for manufacturing passenger compartment floor beams (326); and the plurality of stations comprises a first station associated with the first track and a second station associated with the second track, and / or wherein the plurality of stations further comprises a plurality of stations configured in two parallel lines, a first portion of the stations being for assembling passenger compartment floor beams (326) and a second portion of the stations being for assembling cargo compartment floor beams (324).

12. The system of claim 11, wherein, the first portion of the stations comprises: a passenger compartment floor beam assembly station (520-1); a seat track installation station (540, 543); an electrical equipment and plumbing installation station (545-1); and a floor panel installation station (550-1).

13. The system of claim 11, wherein, the second portion of the stations comprises: a cargo compartment floor beam assembly station (520); a cargo compartment lashing track installation station (542); a cargo compartment roller track installation station (544); an electrical equipment and plumbing installation station (545); and a floor panel installation station (550).

14. The system of claim 9 or 10, further comprising an indexing unit (541-8, 541-9) associated with each of the plurality of stations, the indexing unit (541-8, 541-9) being operable to interface with an indexing unit (541-1, 541-2) associated with the floor beams (365) to control a position of the floor beams (365) with respect to the stations, and / or the system further comprises feed lines (502), each feed line (502) being operable to provide a floor beam assembly to an associated one of the stations.

15. Manufacturing a portion of an aircraft (10) using the system of any one of claims 9 to 14, comprising the steps of: providing the system of any one of claims 9 to 14; providing a lower barrel section (118) or an upper barrel section (116); and continuously performing operations on the lower barrel section (118) or the upper barrel section (116) in a processing direction (199) at the plurality of stations (114).

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