Trimming for mobile assembly line manufacturing of aircraft

Abstract

This disclosure relates to trimming for mobile assembly line manufacturing of aircraft. Systems and methods for inspecting structures (120) are provided. One embodiment is a method for inspecting a structure (120). The method includes: advancing the structure (120) along tracks (110, 112) in a processing direction (199); aligning a non-destructive testing (NDI) station at the track (112) with an edge of the structure (120) trimmed upstream of the NDI station; imaging the edge via the NDI station; characterizing the edge based on the imaging step; and further advancing the structure (120) in the processing direction (199) via the track (112).

Description

Technical Field

[0001] This disclosure relates to the field of aircraft, and more specifically, to the manufacture of aircraft. Background Technology

[0002] To trim the edges of composite parts forming aircraft components, the composite part is moved into a cell and scanned for detail. In this way, the composite part is indexed and characterized relative to a mold within the cell. Next, a single trimming device trims the periphery to the final part size by removing manufacturing excess. Therefore, trimming is performed by carefully advancing a trimmer around the entire periphery of the composite part within a cell specifically built for trimming purposes. This single trimmer operates on the entire composite part simultaneously. At this point, no further operations can be performed within the cell. The composite part is moved to another cell before further operations can be performed; thus, upon moving to each new cell, the composite part must be scanned for indexing / performing a three-dimensional (3D) characterization of the composite part.

[0003] Patent document EP 2 006 074 A1, according to its abstract, describes a process and equipment for manufacturing preforms, wherein a preform having a branched portion in its cross-sectional profile is continuously manufactured by the following steps: among a variety of reinforcing fiber-based materials for constructing the preform, a reinforcing fiber-based material in its original form having a branched portion in its cross-sectional profile is intermittently passed in its longitudinal direction at each transfer interval; heat and / or pressure are applied to the original base material to tentatively obtain a preform material having a given configuration; and the obtained preform material having a given configuration is combined with other reinforcing fiber-based materials in their original form for constructing the preform.

[0004] Patent document EP 2 923 794 A1, according to its abstract, clarifies: a system for assembly manufacturing, the system comprising: at least one fastening unit configured to perform at least one thumbtack fastening operation on a workpiece; at least one fastening unit configured to perform at least one final fastening operation on the workpiece; and a material handling system connecting the fastening unit and the fastening unit, wherein the material handling system positions the workpiece in the fastening unit, and wherein the material handling system transfers the workpiece from the fastening unit to the fastening unit.

[0005] Patent document US 2013 / 019446 A1, according to its abstract, describes a system and method for assembling a 360-degree segment of an aircraft fuselage or cabin by means of the following steps: properly positioning multiple assembly panels relative to a machine reference representing an assembly-level reference scheme; drilling full-size holes near the second skin edge of the panels using a machine; trimming the second edge of the panels using a machine; and then using the full-size holes near the second skin edge as alignment features to correctly align multiple pairs of panels with an auxiliary machine and attach them to a first skin edge opposite the second skin edge, thereby forming panel pairs. Control systems can be installed separately and independently into the panel pairs, and then the panels can be joined together, thereby aligning the full-size holes near the second edge and inserting fasteners through the aligned full-size holes near the second skin edge.

[0006] Patent document WO 96 / 03245 A1, according to its abstract, describes a system for inspecting the edge of rolled metal strip (by trimming the edge by passing the strip between an upper rotating blade and a lower rotating blade) including a camera arranged to image the trimmed edge to provide a video signal to an image processing unit that uses the video information to derive a ratio between the depth of the strip separated by slitting and the depth of the strip separated by shearing.

[0007] Patent document EP 3 061 784 A1, according to its abstract, describes a system for manufacturing a prepreg composite sheet including a molding filler, comprising a first means for forming a precursor contour region in a resin film layer. The system further includes a second means for impregnating a fiber reinforcement including fibers with the resin film layer including the precursor contour region to form the prepreg composite sheet. The prepreg composite sheet thus formed includes a non-impregnated contour region defining the molding filler. The non-impregnated contour region in the prepreg composite sheet corresponds to the precursor contour region in the resin film layer. The system also includes a third means for guiding the fiber reinforcement and the resin film layer to the second means. The resin film layer includes the precursor contour region formed by the first means.

[0008] Patent document WO 2009 / 129007A2, according to its abstract, describes a method for forming a composite material part shaped along its length and having at least one leg. The method includes forming a stack of fiber-reinforced prepreg layers by placing individual segments of unidirectional fibers in each layer. Each segment is placed in a pre-selected orientation related to the contour of the part. The leg is formed by bending a portion of the stack over a tool.

[0009] Patent document US 5,301,587 A, according to its abstract, describes a method for cutting a three-dimensional shaped workpiece of material with large holes in a block by means of the following steps: trimming the block with adjacent cuts of a predetermined width guided along a plane extending tangentially to the surface of the shaped workpiece, thereby producing material chips; and cutting the cuts into chips no later than trimming along a plane extending radially relative to the surface of the shaped workpiece and substantially parallel to each other longitudinally, the cutting planes being separated from each other at the surface of the shaped workpiece by a maximum distance corresponding to the predetermined width of the adjacent cuts. For this purpose, an ultrasonic assembly can be used, the ultrasonic assembly including a cutter having a shaft portion extending in the vibration direction of the cutter and a cutting portion attached to the shaft portion and extending transversely to the vibration direction, the shaft portion and the cutting portion having cutting edges.

[0010] Patent document EP 3 736 203 A1, according to its abstract, describes an aircraft part comprising a laminated structure formed by laminating multiple composite material layers, and as a three-dimensional structure, including at least one of upright, convex, or curved portions. The multiple composite material layers include composite material layers in which reinforcing fibers are single, continuous fibers excluding joint portions and including partial slit portions. When the thickness of a flat sheet forming body comprising the same laminated structure as the aircraft part but excluding a three-dimensional structure is considered a reference thickness, the aircraft part includes a sheet portion having a thickness less than the reference thickness while maintaining the laminated structure, and the reinforcing fibers also include notched portions, which are slit portions in an open state.

[0011] Patent document EP 3 287 228 A1, according to its abstract, describes a long component assembly device comprising: a plurality of hands configured to hold a long component; arms and torso configured to adjust the position of each of the plurality of hands; hands configured to hold the long component, the number of said hands being less than the plurality of hands; arms and torso configured to move the hands and adjust the position of the hands holding the long component, the positioning accuracy of the position adjustment of the arms and torso being higher than the positioning accuracy of the plurality of hands; and a control unit configured to drive the arms and torso based on the original shape of the long component stored in a memory to adjust the plurality of hands and the position of said hands such that the shape of the long component held by the hands matches the original shape.

[0012] Patent document US 2015 / 298824 A1, according to its abstract, describes: a device for supporting a wing assembly at a wing assembly support height. Base sections are provided, each with a predetermined height relative to the other. A movable platform carries the base sections, and the wing assembly support section is disposed on a selected base section and includes a wing assembly connector movable in a first plane and a second plane substantially perpendicular to the first plane. A height difference is defined relative to the bottom of the wing assembly support section between the wing assembly support height and the combined height of the platform and the wing assembly connector. At least one of the base sections has a predetermined height close to the height difference and is carried on the platform. The wing assembly support section is carried on this base section.

[0013] Patent document WO 2013 / 009909A2, according to its abstract, describes a unit for manufacturing parts having reinforcing fibers embedded in a matrix, comprising a cleaning section for performing a cleaning operation including placing the reinforcing fibers on a mandrel tool. The cleaning section meets the cleanroom requirements for handling uncured composite materials. The unit also includes an adjacent contaminated section for performing a contamination operation after curing, including processing the laid contamination, a common end effector positioning system movable between the cleaning section and the contaminated section, and means for preventing contaminants from the contaminated section from entering the cleanroom.

[0014] Therefore, it is desirable to have methods and equipment that take into account at least some of the problems discussed above, as well as other possible problems. In other words, the manufacturing operation density per unit area of ​​the current manufacturing system used for assembling aircraft is lower than the desired manufacturing operation density. Summary of the Invention

[0015] The embodiments described herein provide stations supporting edge trimming, which remove manufacturing excess from multiple aircraft fuselage sections advancing in a processing direction during assembly. During these processes, multiple fuselage sections can advance in series to receive work from the edge trimming station. Furthermore, multiple edge trimming stations can be arranged in series to provide roughing and fine trimming operations as desired (e.g., within the same time period at the same fuselage section). One embodiment is a method for inspecting a structure. The method includes: advancing the structure along a track in a processing direction; aligning a non-destructive testing (NDI) station at the track with an edge of the structure trimmed upstream of the NDI station; imaging the edge via the NDI station; characterizing the edge based on the imaging step; and further advancing the structure in the processing direction via the track.

[0016] Another embodiment is a non-transitory computer-readable medium containing program instructions that, when executed by a processor, operate to perform a method for inspecting a structure. The method includes: advancing the structure along a track in a processing direction; aligning a non-destructive testing (NDI) station at the track with an edge of the structure trimmed upstream of the NDI station; imaging the edge via the NDI station; characterizing the edge based on the imaging step; and further advancing the structure in the processing direction via the track.

[0017] Another embodiment is a system for inspecting a structure. The system includes: a track that supports the structure from its edge while contacting the edge, allowing the structure to move in a processing direction; and a non-destructive testing (NDI) station that characterizes the edge of the structure as it is advanced in the processing direction via the track.

[0018] Another embodiment is a system for inspecting a structure. The system includes: a structure conveyor that supports the structure at its final cut edge while contacting any excess material in the structure, allowing the structure to move in a processing direction; and a non-destructive testing (NDI) station located at the structure conveyor for inspecting the final cut edge of the structure.

[0019] Other exemplary embodiments (e.g., methods and computer-readable media related to the foregoing embodiments) may be described below. The features, functions, and advantages discussed may be implemented independently in various embodiments or may be combined in other embodiments, and further details of these aspects may be found with reference to the following description and drawings. Attached Figure Description

[0020] Now, some embodiments of the present disclosure will be described by way of example only with reference to the accompanying drawings. In all the drawings, the same reference numerals denote the same elements or elements of the same type.

[0021] Figure 1 This is a block diagram illustrating a production line assembly system in an exemplary embodiment.

[0022] Figure 2 This is a flowchart illustrating a method for trimming the structure in an exemplary implementation.

[0023] Figure 3 and Figure 4 An illustrative embodiment illustrates a cutting edge station for removing material from a structure.

[0024] Figure 5 This is a perspective view of the edge-cutting station in an exemplary embodiment.

[0025] Figure 6 This is a top view of a series of stations that facilitate trimming, inspection, cleaning, and sealing in an exemplary embodiment.

[0026] Figure 7 This is a flowchart illustrating a method for cleaning a structure in an exemplary embodiment.

[0027] Figures 8 to 9 An example of a cleaning station at the edge of a sealing structure in an exemplary embodiment is shown.

[0028] Figure 10 This is a perspective view of the cleaning station in an exemplary embodiment.

[0029] Figure 11 This is a flowchart illustrating a method for inspecting a structure in an exemplary implementation.

[0030] Figures 12 to 13 The illustration shows a non-destructive testing (NDI) station for characterizing the edges of a structure in an exemplary embodiment.

[0031] Figure 14 This is a perspective view of the non-destructive testing (NDI) station in an exemplary embodiment.

[0032] Figure 15 This is a flowchart illustrating a method for sealing the edge of a sealing structure in an exemplary embodiment.

[0033] Figures 16 to 17 An edge sealing station of the edge of the sealing structure in the exemplary embodiment is shown.

[0034] Figure 18 This is a perspective view of the edge sealing station in an exemplary embodiment.

[0035] Figure 19 This is a block diagram of a control system for facilitating a mobile assembly line process in an exemplary embodiment.

[0036] Figure 20 This is a flowchart illustrating the processing flow for components in a moving assembly line in an exemplary embodiment.

[0037] Figure 21 This is a flowchart of an aircraft manufacturing and maintenance method in an exemplary embodiment.

[0038] Figure 22 This is a block diagram of an aircraft in an exemplary embodiment. Detailed Implementation

[0039] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. Therefore, it will be understood that those skilled in the art will be able to devise various arrangements that, while not expressly described or shown herein, implement the principles of this disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and are to be construed as not being limited to such specific examples and conditions. Consequently, this disclosure is not limited to the specific embodiments or examples described below, but is defined by the claims and their equivalents.

[0040] The structures described herein can include composite or metallic parts. Composite parts, such as carbon fiber reinforced polymer (CFRP) parts, are initially laid out in multiple layers, which together are referred to as a preform. Individual fibers within each layer of the preform are aligned parallel to each other, but different layers exhibit different fiber orientations to increase the strength of the final composite part along different dimensions. The preform includes a viscous resin that cures to harden the preform into a composite part (e.g., for use in aircraft). Carbon fibers impregnated with uncured thermosetting or thermoplastic resins are referred to as “prepregs.” Other types of carbon fibers include “dry fibers,” which are not impregnated with thermosetting resins but may include tackifiers or binders. Dry fibers are injected with resin and then cured. For thermosetting resins, curing is a unidirectional process called curing, while for thermoplastic resins, if the resin is reheated, it reaches a viscous form.

[0041] Figure 1 This is a block diagram of a pipeline assembly system 100 in an exemplary embodiment, which significantly increases the manufacturing operation density per unit area for assembling aircraft. Specifically, in addition to performing peripheral trimming during and / or between pulses, the pipeline assembly system 100 increases the number of manufacturing operations per square foot by performing multiple operations on the same segment of a composite part.

[0042] The assembly line system 100 includes any system, apparatus, or component operable to iteratively pulse a structure 120 (e.g., less than the full length of the structure) along a structure conveyor 102 (e.g., track 110) and perform work on the structure 120 while pausing between pulses. In other embodiments, the assembly line system 100 continuously moves the structure 120 at a desired rate in a processing direction 199 while performing work.

[0043] Structure 120 includes a part of the body, such as a fuselage segment. Figure 1In the embodiment depicted, structure 120 includes a semi-cylindrical section of fuselage approximately 7.6m to 12.2m long (25 to 40 feet), the semi-cylindrical section including a window cutout 128 and a manufacturing excess 124 disposed at the lower edge of structure 120. Additional manufacturing excesses 121 are found at the leading and trailing edges of structure 120. The manufacturing excess 124 includes a bearing edge 125 and an indexing feature 126, which upstream stations can utilize to perform work on structure 120. In one embodiment, the bearing edge 125 and the indexing feature 126 are provided for multiple stations to perform work on multiple (e.g., different) sections 127 of structure 120 within the range of multiple stations. In other embodiments, structure 120 may, as desired, include any suitable arcuate section of fuselage, such as one-third, one-quarter, or one-sixth of a fuselage cylindrical section. In the following text, any bow-shaped fuselage section is referred to as a "tube" section, while a "full tube" section refers to a fuselage section comprising an arc forming a complete circle (i.e., a joined upper and lower tube section). In other embodiments, structure 120 includes hardened composite material or metal parts, such as skinned sections of aircraft, in which stringers and / or frames have been installed to enhance rigidity.

[0044] The assembly line system 100 includes a track 110 that contacts and supports the manufacturing excess portion 124 of the structure 120 as it advances in the processing direction 199. The track 110 includes one or more guide rails, supports with rollers or grooves, and other elements that facilitate movement (e.g., rolling or sliding) of the structure 120 along the track 110 while also forcing a desired position and / or orientation on the structure 120. In other embodiments, the track 110 includes a chain drive, a motorized trolley, powered rollers, or other power system capable of moving the structure 120 in the processing direction 199. As the structure 120 advances in the processing direction 199, the manufacturing excess portion 124 reaches a trimming station 140. In one embodiment, multiple trimming stations 140 operate on the structure 120 during its passage through the trimming stations 140.

[0045] The trimming station 140 includes a cutter head 142, such as an actuated cutting tool capable of reciprocating along the processing direction 199. In some exemplary examples, movement in or parallel to the processing direction 199 is referred to as horizontal movement. In some exemplary examples, the cutter head 142 operates horizontally to remove manufacturing excess 124 from the structure 120. The controller 144 controls the operation of the trimming station 140, for example, by: activating a tool (e.g., a reciprocating insert, a circular insert, a punch, etc.) at the cutter head 142; moving the cutter head 142; receiving input from a sensor 146 (e.g., a motion sensor, a laser, an ultrasonic sensor, or a visual positioning sensor, etc.) indicating pauses between pulses in the structure 120, etc. The indexing / characterization discussed herein ensures that trimming is performed in the desired position. In one embodiment, trimming includes engagement during indexing to determine the position. The indexing method for each downstream assembly station will depend on the positional accuracy requirements necessary for the type of job being performed. As an example, the window frame installation position can have more permissible tolerances because no further structural integration occurs after the window frame is installed. In contrast, the frame is integrated with other frames and the floor, so their positional requirements are more tightly controlled. The inversion feature 126 can convey specific instructions for a particular operation. For example, position, configuration, and type can convey specific instructions. In this case, just before the inversion feature is cut off as part of the pulsation process, the inversion feature helps to position the half-body relative to the trim line with each pulsation.

[0046] In this implementation, the trimming station 140 is configured to facilitate insertion to grip or otherwise engage with the indexing feature 126. During assembly, the structure 120 is pulsated a distance (e.g., at least equal to the shortest distance between the indexing features 126, the frame pitch, the distance equal to the length of each section 127, etc.) and indexed to the trimming station 140 when the cutter head 142 operates on the structure 120. The track 110 enforces the desired position of the structure 120 in / out of the page. Furthermore, whenever the indexing feature 126 in the structure 120 matches the trimming station 140, the position of the structure 120 is indexed to a known position in the coordinate space shared by the track 110 and the cutter head 142. In addition, the indexing also applies forces transmitted from one side to the other through the structure 120, thereby forcing the loft in the structure 120 and causing the structure 120 to maintain the desired loft. In other words, any outward bending force applied to the sides of structure 120 is resisted by track 110, resulting in maintaining the arc shape, allowing track 110 to force conformation to the desired mold line, inner mold line (IML), and / or outer mold line (OML). This also prevents the introduction of distortion into structure 120 during pulsation. In other embodiments, structure 120 maintains the desired IML and / or OML shape without externally applied forces (i.e., forces beyond those applied by the rollers that propel structure 120 along track 110). In any case, structure 120 conforms to the desired IML and / or OML when it receives work from trimming station 140. Specifically, the action of transposing structure 120 to trimming station 140 results in the position of structure 120 relative to trimming station 140 being known. In this way, a 3D representation of structure 120 within the range of the station is conveyed to the station without needing to scan structure 120 at each station stop. The width of track 110, along with the shape of the cylindrical section and the delay in cutting until after the installation of the frame, window and door surrounds, as well as other possible means of maintaining the desired curvature, help ensure that the configuration is as desired when the section is rotated at a particular workstation, and also help maintain the desired stiffness / rigidity.

[0047] In one embodiment, the indexing is performed at least according to the following description. A cylindrical segment-shaped structure 120 is supported on a track 110. The track 110 may include elements such as powered rollers mounted on a discrete series of supports arranged in the processing direction 199, or tracks (e.g., mounted to or raised above a floor). The elements of the track 110 are positioned in known locations. The cylindrical segment is manufactured on a laying mandrel according to precise dimensions. Furthermore, the mandrel has precise features that facilitate the positioning of features within the manufacturing excess 124 of the cylindrical segment, and this precise laying allows the indexing feature 126 to be precisely positioned within the manufacturing excess 124 of the cylindrical segment. At this stage, in one embodiment, a radio frequency identifier (RFID) chip is placed within the manufacturing excess 124. Once the cylinder segment is positioned on a precisely positioned track element (and possibly an additional inner mold line (IML) or outer mold line (OML) forced realization tool located upstream or downstream of the station), the 3D position of the cylinder segment and the IML or OML mold line are accurately known when the indexing feature is engaged, without the need for a complete scan at each station via probes or optical technology.

[0048] The relative stiffness of the demolded or otherwise formed cylinder segments can be relied upon to help maintain the desired mold lines / IML / OML along with precisely positioned track elements that facilitate the transport of the cylinder segments without requiring any substantial shape-defining tools during pulse assembly. In this arrangement, features are precisely positioned within the cylinder segments relative to the mold lines / IML / OML of structure 120, and the precisely positioned track elements help transport the cylinder segments from one station to another without distortion. Therefore, the 3D position and orientation (e.g., including the mold lines / IML / OML) of the cylinder segments can be known quickly and accurately (i.e., indexed) after each pulse without requiring rescanning of the cylinder segments each time.

[0049] Because precise indexing is performed, the cutter heads 142 at the trimming station 140 can know precisely their positions relative to the cylinder segment when it is locked in place. The 3D position and orientation of the cylinder segment and / or mold lines / IML / OML are then established or indexed into any CNC programming or automation system used at the station. Therefore, no time setting or scanning is required after each pulse of the cylinder segment. Furthermore, structures added to or removed from the cylinder segment in previous stations can be added to any cylinder segment model or representation within the system without needing to scan changes in the cylinder segment. Manufacturing excess 124 is cut from structure 120 to obtain chips 150 of any suitable length or size (e.g., a length equal to or a portion of the pulse length), which are removed from structure 120 and fall into a chute 160 (e.g., a gravity chute). Chips 150 include the removed manufacturing excess 124.

[0050] This removes the indexing feature 126 utilized by the upstream station performing the work on structure 120 and / or by the trimming station 140. The indexing feature 126 is separated as the excess manufacturing portion 124 is trimmed into a trimmed edge (e.g., an intermediate trimmed edge or a final trimmed edge 129). Removing the excess manufacturing portion 124 separates the indexing feature 126 utilized by the upstream station performing the work on structure 120 from structure 120. Structure 120 advances in the processing direction 199 after trimming to obtain the final trimmed edge 129. The portion 127 of structure 120 downstream of the trimming station 140 is carried along a second structural conveyor 104 including an additional second track 112 having a different height than track 110. That is, the second structural conveyor 104 has a second height that allows structure 120 to move in the processing direction 199 and is greater than a first height, and the second structural conveyor 104 is positioned downstream of structural conveyor 102. The height difference corresponds to the height of the excess manufacturing portion 124 after it has been cut off. For example, the second track 112 may include a post sized to support the structure 120 at the trimmed final cut edge 129. Thus, the trimming station 140 leaves the final cut edge 129, which accommodates the splice and contacts the second structure conveyor 104. Therefore, track 110 operates as a first track, supporting the structure 120 while carrying the excess manufacturing portion 124 of the structure 120 (e.g., including the carrying edge 125), and allowing the structure 120 to move in the processing direction 199. The second track 112 operates to support the structure 120 while carrying the cut edge of the structure 120 (e.g., another carrying edge or the final cut edge 129), and allowing the structure 120 to move in the processing direction 199 after the excess manufacturing portion 124 has been removed. In these exemplary examples, the method includes positioning the final cut edge 129 of structure 120 in contact with the track 112 of structure conveyor 104, such that track 112 supports structure 120 from the final cut edge 129. The second track 112 is higher than track 110 by the height of the manufacturing excess 124. Furthermore, when structure 120 includes a half-tube section of the fuselage, the first track 110 supports the manufacturing excess 124 on each side of the half-tube section, and the second track 112 supports the final cut edge 129 on each side of the half-tube section.

[0051] The operation of the trimming station 140 is managed by a controller 144. In one embodiment, the controller 144 determines the advance of the structure 120 along the track 110 (e.g., based on input from a technician or sensor 146) and the position / orientation of the structure 120 relative to the trimming station 140 (e.g., using the same indexing system as an upstream manufacturing station), and uses this input to manage the operation of the trimming station 140 according to instructions stored in a numerical control (NC) program. For example, the controller 144 may modify the instructions in the NC program for the trimming station 140 to accommodate any deviation of the position of the structure 120 from its nominal position and orientation. The controller 144 may be implemented as, for example, custom circuitry, a hardware processor executing program instructions, or some combination thereof.

[0052] exist Figure 1 The diagram also depicts an edge sealing station 170. Edge sealing station 170 applies edge sealant 172 to the newly cut final cut edge 129. Sealant 172 protects the final cut edge 129 from abrasion and prevents the propagation of inconsistencies from the final cut edge 129. Non-destructive testing (NDI) station 180 operates ultrasonic, visual, or laser sensors to scan the final cut edge 129 for out-of-tolerance conditions (e.g., voids, debris, etc.). NDI station 180 is located upstream of edge sealing station 170 to inspect the final cut edge 129 before it is sealed.

[0053] Will target Figure 2 The following are exemplary details of the operation of the assembly line system 100. It is assumed that, for this embodiment, structure 120 has begun to pulsate less than its length in the processing direction 199.

[0054] Figure 2 This is a flowchart illustrating a method 200 for trimming a structure (e.g., structure 120) in an exemplary embodiment. (See reference...) Figure 1 The steps in method 200 are described in the context of a streamlined assembly system 100, but those skilled in the art will understand that method 200 can be performed in other systems. Not all steps in the flowcharts described herein are included, and other steps not shown may be included. The steps described herein may also be performed in an alternative order.

[0055] In step 202, the carrier edge 125 is cut into a manufacturing excess 124 of the structure 120. This may include demolding the structure 120 from a laying mandrel (not shown) after cutting to remove burrs, including resin and / or excess fibers, from the structure 120. As manufacturing continues, the carrier edge 125 is carried by the track 110, and the structure 120 is transported in the processing direction 199. Utilizing the manufacturing excess 124 as the carrier edge 125 (and / or retaining the indexing feature 126 or carrying an RFID chip for instructions to downstream stations) allows the manufacturing excess 124 to provide value during the manufacturing process. That is, unlike existing systems that trim the manufacturing excess 124 into non-value-adding waste, this technology provides a valuable manufacturing excess 124 by facilitating processing and manufacturing in a post-curing environment. This technology provides the additional benefit of protecting the final cut edge 129 of the composite part from damage during transport.

[0056] In step 204, the manufacturing excess portion 124 of structure 120 is positioned to contact structure conveyor 102 (e.g., track 110). Thus, track 110 supports and guides structure 120 by carrying the manufacturing excess portion 124. The manufacturing excess portion 124 may be placed within a notch or groove defined by a support at track 110 and may be positioned on a roller at track 110 that facilitates movement of structure 120 in the processing direction 199.

[0057] In step 206, structure 120 is advanced toward trimming station 140 along structure conveyor 102 (e.g., track 110) in processing direction 199. This may include operating a system that drives track 110 or operating a system that pushes or pulls structure 120 along track 110. In some exemplary examples, advancing structure 120 along track 110 in processing direction 199 includes pulsating structure 120 in processing direction 199. In some exemplary examples, advancing structure 120 along track 110 in processing direction 199 includes moving structure 120 continuously in processing direction 199. Structure 120 may be pulsated (e.g., “micro-pulsations” less than its length) for a predefined distance (e.g., frame pitch indicating the distance between mounted frames) and then paused, or it may be moved continuously along track 110. During the process, the track 110 can hold the structure 120 at a specific height (e.g., within a tolerance such as 25 micrometers (thousandths of an inch), or the trimming station 140 can operate the sensor 146 to detect the height of the structure 120 and then adjust the height of the cutter head 142 to align the cutter to the desired position to form the final trim 129, or even utilize the indexing feature 126.

[0058] In step 208, for each side of structure 120, the trimming station 140 operates to remove manufacturing excess 124 (including the bearing edge 125) from one side of structure 120. Thus, during the same pause or advance of structure 120, the manufacturing excess 124 on both the left and right sides of structure 120 is trimmed. In one embodiment, trimming occurs during the movement of structure 120 over a tool in place, while in another embodiment, trimming is performed by a tool that moves longitudinally relative to structure 120 during a pause. In one embodiment, the sides are trimmed by two different tools (one on each side), which is an improvement over the prior art, which uses a single tool to work the entire edge in a dedicated unit after scanning and transposing structure 120 to the tool.

[0059] Step 208 may include driving the cutter head 142 against the processing direction 199 or driving the cutter head 142 back and forth along the processing direction 199 during cutter movement at the cutter head 142. The trimming operation may be performed during pauses between pulses, during movement of the structure 120 between pauses (e.g., micro-pulsating movement), or during pulsation or during continuous movement of the structure 120. That is, one embodiment utilizes a stationary cutter head 142, wherein the cutting step occurs during pulsating movement in the processing direction 199. When the cutter head 142 is stationary, excess material 124 is removed by a fixed cutter as the structure 120 is pulsated forward. The pulsation may be performed as a “micro-pulsation” at the frame pitch length, so that each cut portion is cut into segments (or cut multiple times to a length less than the micro-pulsation length, or even cut once up to the full pulsation length) at the end of the pulsation and then falls into the chute 160. The trimming station 140 removes manufacturing excess 124 by moving relative to structure 120 in the processing direction 199, moving relative to structure 120 in the opposite direction of processing direction 199, or remaining stationary as structure 120 advances along structure conveyor 102 in the processing direction 199. The segments can be cut using a separate vertical cutter, or the same cutter can be used. Cutting can begin during each pulse, wherein, during the rest period between pulses, the cutter head 142 circulates in the opposite direction to processing direction 199 in a manner similar to a typewriter carriage. In other embodiments, sealing can be performed at the edge sealing station 170 during pauses in the pulses, or via an integrated mechanism located at the trimming station 140.

[0060] In other embodiments, the non-destructive testing (NDI) station 180 and / or the edge sealing station 170 are integrated into the cutter head 142, such that a single scan of the cutter head 142 performs cutting, inspection, and sealing as desired. In other embodiments, the NDI scan and / or sealing are performed when the structure 120 is pulsated (e.g., micro-pulsated), during a pause, or during continuous movement of the structure 120, and the cutter head used to perform the NDI scan and / or sealing is held in place.

[0061] In one embodiment, the cutter head 142 advances vertically after a predefined distance (e.g., after a multiple or a portion of the pulsation length, such as the length corresponding to a micropulsation) to cut the chip 150 into multiple segments of manageable length. In other embodiments, the cutter head 142 vertically cuts the chip 150 from the manufacturing excess portion 124 using a separate cutter, or breaks off fragments of the manufacturing excess portion 124 using a clamping tool (not shown). In other embodiments, the weight of the chip 150 due to gravity causes the chip 150 to separate from the manufacturing excess portion 124. The chip 150 falls into a chute 160 for removal. The chute 160 is located below the trimming station 140.

[0062] In step 210, structure 120 is advanced along structure conveyor 102 in processing direction 199. That is, structure 120 downstream of a cutting station (e.g., trimming station 140) is conveyed at the required height to bear the final trimmed edge 129, while structure upstream of a cutting station (e.g., trimming station 140) is conveyed at the required height to bear the manufacturing excess 124. For example, structure 120 can be pulsed a distance equal to the frame pitch or other distance. Advancing structure 120 in processing direction 199 exposes additional manufacturing excess 124 to trimming station 140, and / or to any NDI station 180 and sealant application station. Steps 206-208 can be performed iteratively until the excess 124 is completely removed, the final trim 129 is fully inspected by non-destructive testing (NDI) and the edge is sealed, and the structure 120 advances its entire length through trimming station 140 and any NDI station 180 and sealant application station (e.g., edge sealing station 170).

[0063] Method 200 offers technological advantages over existing technologies because it makes the transport time of large composite parts a value-added time, where manufacturing and / or assembly continue while the parts are being transported. Therefore, manufacturing and transport actions are integrated, meaning transport time is also operation time. Furthermore, because the operations of the workstations are synchronized according to takt time (i.e., their timing is based on the expected manufacturing rate of the aircraft or a part thereof) in one or more embodiments, the workstations can be chained together to increase work density. This reduces the overall production time of the aircraft, thereby reducing costs. In addition, Method 200 provides a unique technique by which trimming of aircraft components can be performed in a moving assembly line.

[0064] Figures 3 to 4 A trimming station 140 for removing material from structure 120 is illustrated in an exemplary embodiment. Trimming station 140 may cut one side of structure 120, while another trimming station 140 simultaneously cuts the other side of structure 120. In this embodiment, structure 120 includes a semi-cylindrical section of the fuselage, which has been reinforced by stringers, frames, and window surrounds. Structure 120 includes a surface 312 in which excess manufacturing material 124 for window 314 has been removed (e.g., ...). Figure 1 The structure 120 also includes a window cutout 128 in the structure 120. The structure 120 also includes a transposition feature 126 (e.g., a hole, slot, RFID chip, etc.) disposed within the manufacturing excess portion 124.

[0065] Structure 120 is supported on track 110 at floor 360. Track 110 includes a first-height support 332 (also referred to herein as a "spring stilt"), and a second track 112 includes a second-height support 334, which allows structure 120 to move in the processing direction 199. Support 334 is higher than support 332 by the height of the manufacturing excess portion 124. That is, the spring stilt / support 334 located downstream of the trimming station 140 is higher than the spring stilt / support 332 located upstream of the trimming station 140. Although not depicted in the figures, in some exemplary examples, track 112 includes: supports 334, each including a support member holding structure 120 in place; and rollers that allow structure 120 to move in the processing direction 199 while being held by the support member.

[0066] During the advancement of structure 120, or during pauses between pulses of structure 120, individual workstations will transpose themselves to one or more transposition features 126, such as multiple transposition features 126, at the location of structure 120. This allows the workstations to determine their precise position relative to structure 120 and to characterize the structure 120 within the range of the workstation. Figure 1The portion 127 is depicted in the diagram. In this way, by referring to the indexing feature 126, the workstation can perform operations accurately and precisely at the structure 120.

[0067] The trimming station 140 includes a tool path 342 along which the cutter head 142 moves. In another embodiment, a stationary cutter performs the cutting step during the pulsating movement of the structure 120 in the processing direction 199. The pulsation can be performed at a frame pitch length or other distance, such that each cut portion is segmented at the end of the pulsation and falls into the chute 160. A pulsation equal to the length of the structure 120 is called a “full pulsation,” while a pulsation smaller than the length of the structure 120 (e.g., the frame pitch distance) is called a “micro pulsation.” The cutter head 142 advances back and forth by sliding along the tool path 342 in the processing direction 199. In some exemplary examples, movement in or parallel to the processing direction 199 is referred to as horizontal movement. In some exemplary examples, the cutter head 142 operates horizontally to remove manufacturing excess 124 from the structure 120. The cutter head 142 cuts the manufacturing residue 124 into multiple chips 150, which accumulate in the chute 160. After advancing through the trimming station 140, the structure 120 presents a final trimmed edge 129. The final trimmed edge 129 can provide the structure 120 with the desired dimensions for integration with another structure 120 (e.g., another section of the fuselage). That is, the final trimmed edge 129 can be trimmed to the final manufacturing dimensions. In one embodiment, during pauses in the advancement of the structure 120, multiple stations (e.g., for trimming, cleaning, non-destructive testing (NDI) inspection, and / or edge sealing) perform operations or otherwise operate on the structure 120 (e.g., at different portions 127 of its length).

[0068] Figure 4 This is the rear view of the trimming station 140, and... Figure 3 The view arrow 4 corresponds to this. Figure 4 The cutting station 140 includes a blade 400 protruding from the cutter head 142. The blade 400 is positioned at the desired height of the cut edge of the structure 120 being cut. Although in Figure 4 The blade 400 is exemplified as a reciprocating blade, but in other embodiments, the blade 400 includes a circular blade, a laser cutter, a pressurized waterjet cutter, or other cutting tools. Figure 4It is also shown that each support 332 includes a support 410 defining a groove for receiving the manufacturing excess portion 124 and a roller 420 for carrying the manufacturing excess portion 124. The structure conveyor 102 is a track 110, which includes supports 332, each support 332 including: a support 410 that holds the structure 120 in place; and a roller 420 that allows the structure 120 to move in the processing direction 199 while being held by the support. Although Figure 4 The track 110 is depicted with struts 332, but in some exemplary examples, the track 112 also includes struts 334, each strut 334 including: a support member that holds the structure 120 in place; and a roller that allows the structure 120 to move in the processing direction 199 while being held by the support member.

[0069] Figure 5 This is a perspective view of the edge-cutting station 140 in the exemplary embodiment, and is related to... Figure 4 The view arrow 5 corresponds to this. Figure 5 A frame 510 supporting the tool track 342 is illustrated, and a groove 520 is also illustrated, along which the tool head 142 slides at the tool track 342. Figure 5 A vacuum groove 550 at the cutter head 142 is also illustrated, which applies suction to remove dust and debris during cutting via the blade 400. Figure 5 The image also depicts a vertical cutter head 530. The vertical cutter head 530 is positioned downstream of the cutter head 142 and moves vertically upwards to cut the excess manufacturing portion 124 of the hanging amount into... Figure 1 The vertical cutter head 530 segments the manufacturing surplus 124 to be removed into chips 150 of predetermined lengths. The vertical cutter head 530 includes a blade 540 positioned below the edge of the manufacturing surplus 124 and advances vertically until it reaches the edge being cut by the cutter head 142. Thus, the vertical cutter head 530 applies a vertical cut to the manufacturing surplus 124 so that the manufacturing surplus 124 can be removed to a predetermined length. These vertical cuts can be applied before or after the operation of the cutter head 142. The cutter head 142 and the vertical cutter head 530 operate cooperatively (i.e., cutting segments without interfering with each other) to remove the manufacturing surplus 124.

[0070] Having discussed the specific implementation of the edge trimming station 140 above, Figure 6 This illustrates the arrangement of the trimming station 140 relative to other stations in the assembly environment. Specifically, Figure 6 This is a top view illustrating a series of stations that facilitate trimming, inspection, cleaning, and sealing in an exemplary embodiment. Figure 6In this process, structure 120 is pulsated along structure conveyor 102 (e.g., track 110) in processing direction 199. In the illustrated example, trimming station 140 may include a coarse trimming station 620 and a fine trimming station 630. Coarse trimming station 620 performs an initial cut within a first tolerance (e.g., 25 mm (tenth of an inch)) to remove manufacturing excess 124 from the side of structure 120. All coarse trimming can be completed in one station or even in a single pass of coarse trimming station 620. Fine trimming station 630 performs a fine cut to bring the edges to a predetermined tolerance (e.g., more stringent than the tolerance used for coarse trimming, such as within a 2.5 cm (1 inch) section). In some illustrated examples, the method includes operating fine trimming station 630 to cut off additional material from the edge of structure 120. In some exemplary examples, a fine-trimming station 630 operates to trim structure 120 to a final cut edge 129. A non-destructive testing (NDI) station 180 includes means for performing ultrasonic, laser, or visual inspection on the cut edge to detect delamination or other out-of-tolerance conditions. A cleaning station 660 removes dust and debris from structure 120, for example, by brushing, blowing, or rinsing with a liquid cleaning solution. The cleaning station 660 cleans the final cut edge 129. This can include operating elements 662 in the form of air knives, sprayers, brushes, etc. An example of an edge-sealing station 170 is illustrated as a chemical edge-sealing station 650. The cleaned portion of structure 120 reaches the chemical edge-sealing station 650, which seals the edges with a chemical sealant such as sealant 172. That is, the chemical edge-sealing station 650 seals the final cut edge 129 of structure 120. Other stations, such as a spraying station, may follow the stations discussed above.

[0071] Figure 7 This is a flowchart illustrating a method 700 for cleaning structure 120 in an exemplary embodiment, and the following is specifically for... Figure 8The method 700 includes advancing structure 120 along track 830 in a processing direction 199 in step 702. This can be performed continuously or in a pulsating manner. In some exemplary examples, advancing structure 120 along track 830 in the processing direction 199 includes pulsating structure 120 in the processing direction 199. In some exemplary examples, advancing structure 120 along track 830 in the processing direction 199 includes moving structure 120 continuously in the processing direction 199. The method 700 also includes aligning a cleaning station 660 at track 830 with an edge, such as a final cut edge 129 of structure 120 trimmed upstream of cleaning station 660, in step 704, and removing debris from the edge via cleaning station 660 in step 706. Debris removal may include applying fluid to the edge carrying debris from the edge, or may include brushing the edge. In one embodiment, cleaning station 660 removes debris from the entire contour of structure 120 (e.g., the entire cross-section, including the IML and / or OML) or within a threshold distance of the final cut edge 129 (e.g., within 2.5 cm (1 inch), 30.5 cm (12 inches), etc.). For example, cleaning station 660 may include annular clamps positioned at the IML and / or OML of structure 120, which scrub the entire structure 120 via brushes and / or jets. Debris removal may be performed via a large-scale application of pressurized air or pressurized liquid, and / or via abrasion with a scrubbing head. In step 708, structure 120 is further advanced along track 830 in the processing direction 199. In other embodiments, fluid is sprayed at an upstream angle (e.g., at 45 degrees into structure 120) so that dust does not accumulate downstream of cleaning station 660. The applied fluid may be captured via drain pipe 852.

[0072] In other embodiments, structure 120 is pulsed in the processing direction 199, and debris removal is performed during pauses between pulses or during the pulse. In other embodiments, structure 120 is continuously moved in the processing direction 199, and debris removal is performed as structure 120 continuously moves.

[0073] Figures 8 to 9 The illustration shows a cleaning station 660 at the edge of the cleaning structure in the exemplary embodiment. Figure 8 An exemplary embodiment illustrates a cleaning station 660 for cleaning the final cut edge 129 of a structure 120 having a contour 812 and a window cutout 128. The structure 120 is supported by its final cut edge 129 on a track 830 (e.g., ...). Figure 1On the additional or second track 112, track 830 includes a plurality of supports 334 at floor 360. During the advancement of structure 120 (e.g., during pulsations), or during pauses between pulsations of structure 120, cleaning station 660 transposes itself to one or more transposition features 126 at structure 120. This allows cleaning station 660 to determine its precise position relative to structure 120 and to characterize structure 120. In this way, by referring to transposition features 126, cleaning station 660 is able to perform work accurately and precisely at structure 120. In other embodiments, cleaning station 660 performs work based on transposition performed by an upstream station.

[0074] Figure 9 Corresponding to Figure 8 View arrow 9 illustrates that the cleaning station 660 includes a base 910 and a fork 920 supporting the cleaning head 930. The cleaning head 930 may include brushes for wiping edges (e.g., passive brushes, actively driven brushes, etc.), air knives that apply pressurized air to clean the final cut edge 129 with air, injectors / nozzles that apply fluids such as cleaning fluids to the edges, and any suitable combination thereof. Fluids such as pressurized air or liquids are drawn from a reservoir 950 and applied to the final cut edge 129. Excess fluid is captured and removed via a reservoir 940. Figure 10 Is with Figure 9 The 3D view of the cleaning station corresponding to arrow 10 in the view.

[0075] like Figures 8 to 10 As shown, the cleaning station 660 includes a track 830 that contacts and supports the final cut edge 129 of the structure 120, and allows the structure 120 to move in the processing direction 199. As the structure 120 advances in the processing direction 199 via the track 830, the cleaning station 660 removes debris from the final cut edge 129 of the structure 120.

[0076] Figure 11This is a flowchart illustrating a method 1100 for inspecting structure 120 in an exemplary embodiment. Step 1102 includes advancing structure 120 along track 112 in a processing direction 199. In some exemplary examples, advancing structure 120 along track 112 in the processing direction 199 includes pulsating structure 120 in the processing direction 199. In some exemplary examples, advancing structure 120 along track 112 in the processing direction 199 includes moving structure 120 continuously in the processing direction 199. During the advancement of structure 120 (e.g., during pulsation), or during pauses between pulsations of structure 120, nondestructive testing (NDI) station 180 and edge sealing station 170 independently and / or together rotate themselves to one or more rotation features 126 at structure 120. This allows the stations to determine their precise position relative to structure 120 and to characterize structure 120. In this way, by referencing the indexing feature 126, the workstation can perform the work accurately and precisely at structure 120. In other embodiments, the workstation performs the work based on an indexing performed by an upstream workstation. In other embodiments, other means are used to locate the edges of structure 120 (e.g., final cut edge 129 or bearing edge 125) of the structure 120 to which these workstations perform the work. Step 1104 includes aligning the nondestructive testing (NDI) workstation 180 at track 112 with the edge of structure 120 that was trimmed upstream of the NDI workstation 180. This can be performed via the indexing techniques discussed above. Step 1106 includes imaging the edge (e.g., final cut edge 129 or bearing edge 125) via the NDI workstation 180. This can include acquiring images via a camera, via an ultrasonic transducer, or via a laser. In one embodiment, imaging the edge includes applying ultrasonic energy to the edge. In other embodiments, imaging the edge includes acquiring a photographic image of the edge.

[0077] In embodiments using ultrasonic transducers, the image depicts the interior of structure 120 without damaging structure 120. Step 1108 includes characterizing edges based on the imaging. For example, a non-destructive testing (NDI) station 180 can characterize edges by identifying out-of-tolerance conditions at the edges. Step 1110 includes further advancing structure 120 in the processing direction 199.

[0078] In other embodiments, structure 120 is pulsed in the processing direction 199, and edge imaging is performed during pauses between pulses or during pulses. In other embodiments, structure 120 is continuously moved in the processing direction 199, and edge imaging is performed as structure 120 continuously moves.

[0079] Figures 12 to 13The non-destructive testing (NDI) station 180 for structural edges in the exemplary embodiment is shown. Figure 12 A non-destructive testing (NDI) station 180 for the final cut edge 129 of a characterizing structure 120 is illustrated in an exemplary embodiment. The structure 120 has a profile 1212 and a window surround 1214. The structure 120 is supported by its edges on a track 830, which includes a plurality of supports 334 at a floor 360. The track 830 contacts the final cut edge 129 of the structure 120 while simultaneously supporting the structure 120 from the final cut edge 129, and allows the structure 120 to move in the processing direction 199.

[0080] Figure 13 Corresponding to Figure 12 View arrow 13 illustrates a non-destructive testing (NDI) station 180 including sensors 1310 and 1320 (e.g., cameras, ultrasonic transducers that apply ultrasonic energy to the edge, lasers, etc.) that generate images of the final trimmed edge 129. A NDI controller 1330 characterizes the final trimmed edge 129 based on the images acquired by sensors 1310 and / or 1320. For example, the NDI controller 1330 can identify the presence of out-of-tolerance conditions at the final trimmed edge 129 based on the images. In these illustrative examples, the NDI station 180 includes an NDI controller 1330 that identifies out-of-tolerance conditions at the final trimmed edge 129 based on images acquired by the NDI station 180. The location of the edge sealing station 170 along the edge can be determined using input regarding the location and size of the out-of-tolerance condition. Figure 14 Is with Figure 13 The perspective view of the non-destructive testing (NDI) station (180) corresponding to arrow 14 in the view. Figure 14 As illustrated, sensors 1320 and 1310 may be accompanied by one or more rollers 1410 that support the final cut edge 129 as it advances.

[0081] Figure 15This is a flowchart illustrating a method 1500 for sealing the edge (e.g., final cut edge 129) of a sealing structure 120 in an exemplary embodiment. Step 1502 includes advancing the structure 120 along track 830 in a processing direction 199. During the advancement of the structure 120 (e.g., during pulsation), or during pauses between pulsations of the structure 120, a non-destructive testing (NDI) station (180) and an edge sealing station 170 independently and / or together rotate themselves to one or more rotation features 126 at the structure 120. In some exemplary examples, advancing track 830 in the processing direction 199 includes pulsating the structure 120 in the processing direction 199. In some exemplary examples, advancing the structure 120 along track 830 in the processing direction 199 includes continuously moving the structure 120 in the processing direction 199. This allows the workstations to determine their precise positions relative to structure 120 and to characterize portions 127 of structure 120 within the range of the workstation. In this way, by referencing the indexing feature 126, the workstations can perform work accurately and precisely at structure 120. In other embodiments, the workstations perform work based on indexing performed by upstream workstations. In other embodiments, other means are used to index the edges of structure 120 (e.g., final cut edge 129) operated on by these workstations. Step 1504 includes aligning the edge sealing workstation 170 at track 830 with the edge of structure 120 (e.g., final cut edge 129) trimmed upstream of the edge sealing workstation 170. This can be performed via the indexing techniques discussed above. Step 1506 includes applying an edge sealant 172 to the edge of structure 120 (e.g., final cut edge 129) via the edge sealing workstation 170. This can include rolling or spraying a liquid edge sealant 172, such as an epoxide, onto the edge, such that the edge sealant 172 fills any areas exceeding tolerances. In various implementations, the edge sealant 172 is applied by an automated device or manually during pulsation, during continuous propulsion, or during a period of stillness after pulsation.

[0082] Step 1508 includes further advancing structure 120 along track 830 in the processing direction 199.

[0083] In other embodiments, structure 120 is pulsed in the processing direction 199, and edge sealant 172 is applied during pauses between pulses or during pulses. In other embodiments, structure 120 is continuously moved in the processing direction 199, and edge sealant 172 is applied as structure 120 continuously moves. In other embodiments, edge sealant 172 is sprayed onto the edge of structure 120 (e.g., final cut edge 129). In other embodiments, applying edge sealant 172 prevents inconsistencies from propagating through the edge into structure 120. In other embodiments, applying edge sealant 172 includes applying an epoxide.

[0084] Figures 16 to 17 An edge sealing station 170 of the final cut edge 129 of the sealing structure 120 in the exemplary embodiment is shown. Figure 16 An edge sealing station 170 is illustrated in an exemplary embodiment, sealing the final cut edge 129 of a structure 120 having a contour 812 and a window surround 1214. The structure 120 is supported by its final cut edge 129 on a track 830 in the processing direction 199. The track 830 includes a plurality of supports 334 at a floor 360. The track 830 contacts the edge of the structure 120 while supporting it from the final cut edge 129, and allows the structure 120 to move in the processing direction 199. A heater 1652 at the edge sealing station 170 heats and cures the applied edge sealant 172 before the final cut edge 129 contacts / is supported by the next support 334.

[0085] Figure 17 Corresponding to Figure 16 View arrow 17 illustrates that the edge sealing station 170 includes an applicator 1710 (e.g., a sprayer / nozzle, a roller for applying edge sealant 172 from a reservoir, etc.) that applies edge sealant 172 (e.g., epoxide) from a reservoir 1730 to the final cut edge 129. A roller 1720 is also depicted, which is powered to facilitate the advancement of the structure 120.

[0086] Figure 18 It is the edge sealing station and Figure 17 The 3D view corresponding to view arrow 18. Figure 18 The applicator 1710 is depicted as being positioned on either side of the edge; however, in other embodiments, the applicator 1710 is positioned below the edge.

[0087] Now pay attention Figure 19 , Figure 19 The control components of a production system that performs ultrasonic inspection are extensively illustrated. Figure 19This is a block diagram of a control system for facilitating a mobile assembly line process, as illustrated in an exemplary embodiment. A controller 1900 coordinates and controls the operation of a trimmer cutter 1920 and the movement of one or more mobile platforms 1970 along a track 1960 having powered supports 1962. In one embodiment, the mobile platform 1970 includes multiple body sections having one or more bearing edges 1978 that contact the supports 1962. The controller 1900 may include a processor 1910 coupled to a memory 1912 storing a program 1914. In one example, the mobile platform 1970 is driven along the track 1960 (controlled by the controller 1900), which is continuously driven by the powered supports 1962. In this example, the mobile platform 1970 includes a facility connector 1972, which may include an electrical, pneumatic, and / or hydraulic quick-disconnect link connecting the mobile platform 1970 to a facility 1940 from an external source. In other examples, the mobile platform 1970 includes an automated guided vehicle (AGV) carrying the desired components and including onboard facilities, as well as a GPS / automatic guidance system 1974. In other examples, the movement of the mobile platform 1970 is controlled using a laser tracker 1950 and a shifting unit 1952. The shifting unit 1952 may physically interact with shifting features 1976 at the mobile platform 1970 to characterize the mobile platform 1970, or it may do so using radio frequency identification (RFID) technology. The position of the mobile platform 1970 and the support column 1962 are determined using a position and / or motion sensor 1930 coupled to a controller 1900.

[0088] The principle of the aforementioned moving production line may include other types of operations that are normally performed when producing composite material parts. Figure 20 This is a flowchart illustrating the processing flow for components in a moving assembly line in an exemplary embodiment. Figure 20An example of a mobile production line 2000 is illustrated, which incorporates various operations that may be necessary in the production of composite parts. For example, the mobile production line may include stations, areas, or supports for tool preparation 2002, which involves cleaning or applying a coating to tools. After tool preparation, the tools are transported on a platform to one or more locations where a preform is formed in lamination 2004. The fully laid preform can then be conveyed on the mobile production line to downstream locations where compaction 2006 and pressing 2008 of the preform are performed. Additionally, the preform can be processed at further locations where molding 2010, hardening the preform into a composite part 2012, trimming 2014, inspection 2016, rework 2018, and / or surface treatment 2020 operations are performed. Therefore, the various trimming operations described above and throughout this specification can be performed as desired at trimmer 2014.

[0089] Example

[0090] For more details, please refer to the accompanying drawings, as shown in... Figure 21 The aircraft manufacturing and maintenance method 2100 shown and as Figure 22 Embodiments of this disclosure are described within the context of the aircraft 2102 shown. In the early production phase, method 2100 may include the specification and design 2104 and material procurement 2106 of the aircraft 2102. During production, the manufacturing of components and sub-assemblies of the aircraft 2102 and system integration 2110 are carried out. Thereafter, the aircraft 2102 may be inspected and delivered 2112 for entry into service 2114. During its service by the customer, the aircraft 2102 is scheduled for routine maintenance and overhaul 2116 (which may also include modifications, refits, refurbishments, etc.). The equipment and methods implemented herein may be used during any or more suitable phases of production and maintenance described in method 2100 (e.g., specification and design 2104, material procurement 2106, component and sub-assembly manufacturing 2108, system integration 2110, verification and delivery 2112, service 2114, maintenance and overhaul 2116) and / or in any suitable component of aircraft 2102 (e.g., airframe 2118, system 2120, interior 2122, propulsion system 2124, electrical system 2126, hydraulic system 2128, environmental system 2130).

[0091] Each of the processes in method 2100 may be performed or executed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0092] like Figure 22 As shown, an aircraft 2102 produced using method 2100 may include an airframe 2118 and an interior 2122 having multiple advanced systems 2120. Examples of systems 2120 include one or more of a propulsion system 2124, an electrical system 2126, a hydraulic system 2128, and an environmental system 2130. Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention can be applied to other industries such as the automotive industry.

[0093] As mentioned above, the equipment and methods implemented herein can be employed during any one or more phases of production and maintenance described in method 2100. For example, components or sub-assemblies corresponding to component and sub-assembly manufacturing 2108 can be made or manufactured in a manner similar to the production of components or sub-assemblies when aircraft 2102 is in service 2114. Additionally, one or more equipment implementations, method implementations, or combinations thereof can be utilized during sub-assembly manufacturing 2108 and system integration 2110, for example, by significantly accelerating the assembly of aircraft 2102 or reducing the cost of aircraft 1302. Similarly, one or more equipment implementations, method implementations, or combinations thereof can be utilized when aircraft 2102 is in service 2114 (e.g., but not limited to maintenance and overhaul 2116). Therefore, the invention can be used in any stage or any combination thereof discussed herein, such as specifications and design 2104, material procurement 2106, component and sub-component manufacturing 2108, system integration 2110, verification and delivery 2112, service 2114, maintenance and overhaul 2116, and / or any suitable component of aircraft 2102 (e.g., airframe 2118, system 2120, interior 2122, propulsion system 2124, electrical system 2126, hydraulic system 2128, and / or environmental system 2130).

[0094] In one embodiment, the part comprises a portion of the airframe 2118 and is manufactured during component and subassembly manufacturing 2108. The part can then be assembled onto the aircraft during system integration 2110 and utilized in service 2114 until wear renders it unusable. The part can then be discarded and replaced with a newly manufactured part during maintenance and overhaul 2116. To manufacture new parts, the components and methods of the present invention can be utilized throughout component and subassembly manufacturing 2108.

[0095] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein can be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination thereof. For example, an element can 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, these functions may be provided by a single dedicated processor, a single shared processor, or 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 circuits, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic devices, or some other physical hardware component or module.

[0096] Additionally, control elements can be implemented as instructions executable by a processor or computer to perform the functions of that element. Some examples of instructions are software, program code, and firmware. Instructions are operable when executed by a processor to instruct the processor to perform the functions of the element. Instructions can be stored on a processor-readable storage device. Some examples of storage devices are digital or solid-state memories, magnetic storage media such as disks and magnetic tapes, hard drives, or optically readable digital data storage media.

[0097] Although 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 and any equivalents thereof.

[0098] This disclosure also includes the following sets of provisions, which should not be confused with the appended claims that define the scope of protection.

[0099] Group 1 Clause:

[0100] 1. A method for manufacturing a structure (120), the method comprising:

[0101] The manufacturing excess portion (124) of the structure (120) is placed in contact with the structure conveyor (102);

[0102] The structure (120) is advanced toward the cutting station (140) in the processing direction (199); and

[0103] The trimming station (140) is operated to remove the manufacturing excess (124) by moving the trimming station (140) relative to the structure (120) in the processing direction (199).

[0104] 2. The method according to Clause 1, further comprising:

[0105] The chips (150) fall into the chute (160) located below the cutting station (140).

[0106] 3. The method according to Clause 2, wherein:

[0107] The chips (150) include some of the removed portions of the manufacturing excess (124).

[0108] 4. The method according to any one of the preceding clauses, wherein:

[0109] Advancing the structure (120) in the processing direction (199) exposes the additional manufacturing excess portion (124) to the trimming station (140).

[0110] 5. The method according to any one of the preceding clauses, wherein:

[0111] Removing the excess manufacturing portion (124) separates the indexing feature (126) from the structure (120), the indexing feature (126) being utilized by an upstream station performing work on the structure (120).

[0112] 6. The method according to any one of the preceding clauses, the method further comprising:

[0113] The structure (120) is carried on a second structure conveyor (104) downstream of the trimming station (140), the height of the second structure conveyor (104) being greater than the height of the structure conveyor (102) by the height of the removed manufacturing excess portion (124).

[0114] 7. The method according to any one of the preceding clauses, further comprising:

[0115] The structure (120) is advanced along the structure conveyor (102) toward the fine edge trimming station (630) in the processing direction (199); and

[0116] Operate the fine edge trimming station (630) to trim off additional material from the edge of the structure (120).

[0117] 8. The method according to any one of the preceding clauses, wherein:

[0118] Advancing the structure (120) includes making the pulsation of the structure (120) smaller than the length of the structure (120); and

[0119] Operating the trimming station (140) includes sliding the cutting head (142) of the trimming station (140) in the processing direction (199).

[0120] 9. The method described in Clause 8, wherein:

[0121] During the pauses between the pulses of the structure (120), the operation of the cutting station (140) is performed.

[0122] 10. The method according to clause 8 or 9, wherein:

[0123] During the pulsation between pauses in the structure (120), the operation on the cutting station (140) is performed.

[0124] 11. The method according to any one of the preceding clauses, wherein:

[0125] As the structure (120) pulses forward, the excess manufacturing portion (124) is removed using a fixed tool.

[0126] 12. The method according to any one of the preceding clauses, wherein:

[0127] The manufacturing excess (124) is removed by a vertical cutter head (530) and a cutter head (142) operating in a horizontal manner.

[0128] 13. The method according to any one of the preceding clauses, further comprising:

[0129] A vertical cut is applied to the excess manufacturing portion (124) so ​​that the excess manufacturing portion (124) can be removed to a predetermined length.

[0130] 14. The method according to any one of the preceding clauses, the method further comprising:

[0131] Before placing the excess manufacturing portion (124) onto the structure conveyor (102), a bearing edge (125) is cut into the excess manufacturing portion (124) of the structure (120), wherein the bearing edge (125) is carried by the structure conveyor (102).

[0132] 15. The method according to any one of the preceding clauses, further comprising:

[0133] During the pauses in advancing the structure (120), multiple workstations are operated on the structure (120).

[0134] 16. The method according to any one of the preceding clauses, the method further comprising:

[0135] During the process of advancing the structure (120) through the trimming station (140), the multiple trimming stations (140) perform operations on the structure (120).

[0136] 17. A part of an aircraft assembled according to any one of the preceding clauses.

[0137] 18. A non-transitory computer-readable medium comprising program instructions that, when executed by a processor, are operable to perform a method of manufacturing a structure (120), optionally, the method being a method according to any of the preceding clauses, the method comprising:

[0138] The manufacturing excess portion (124) of the structure (120) is placed in contact with the structure conveyor (102);

[0139] The structure (120) is advanced along the structure conveyor (102) toward the edge-cutting station (140) in the processing direction (199); and

[0140] The trimming station (140) is operated to remove the manufacturing excess (124) by moving the trimming station (140) relative to the structure (120) in the processing direction (199).

[0141] 19. The medium according to Clause 18, wherein the method further comprises:

[0142] The chips (150) fall into the chute (160) located below the cutting station (140).

[0143] 20. The medium as described in Clause 18 or 19, wherein:

[0144] The chips (150) include the removed excess manufacturing material (124).

[0145] 21. The medium according to any one of clauses 18 to 20, wherein:

[0146] Advancing the structure (120) in the processing direction (199) exposes the additional manufacturing excess portion (124) to the trimming station (140).

[0147] 22. The medium according to any one of clauses 18 to 21, wherein:

[0148] Removing the excess manufacturing portion (124) separates the indexing feature (126) from the structure (120), the indexing feature (126) being utilized by an upstream station performing work on the structure (120).

[0149] 23. The medium according to any one of clauses 18 to 22, wherein the method further comprises:

[0150] The structure (120) is carried on a second structure conveyor (104) downstream of the trimming station (140), the height of the second structure conveyor (104) being greater than the height of the structure conveyor (102) by the height of the removed manufacturing excess portion (124).

[0151] 24. The medium according to any one of clauses 18 to 23, wherein the method further comprises: advancing the structure (120) along the structure conveyor (102) toward the fine edge trimming station (630) in the processing direction (199); and

[0152] Operate the fine edge trimming station (630) to trim off additional material from the edge of the structure (120).

[0153] 25. The medium according to any one of clauses 18 to 24, wherein the method further comprises:

[0154] Advancing the structure (120) includes making the pulsation of the structure (120) smaller than the length of the structure (120); and

[0155] Operating the trimming station (140) includes sliding the cutting head (142) of the trimming station (140) in the processing direction (199).

[0156] 26. The medium as described in Clause 25, wherein:

[0157] During the pauses between the pulses of the structure (120), the operation of the cutting station (140) is performed.

[0158] 27. The medium as described in Clause 25 or 26, wherein:

[0159] During the pulsation between pauses in the structure (120), the operation on the cutting station (140) is performed.

[0160] 28. The medium according to any one of clauses 18 to 27, wherein:

[0161] As the structure (120) pulses forward, the excess manufacturing portion (124) is removed using a fixed tool.

[0162] 29. The medium according to any one of clauses 18 to 28, wherein:

[0163] The manufacturing excess (124) is removed by a vertical cutter head (530) and a cutter head (142) operating in a horizontal manner.

[0164] 30. The medium according to any one of clauses 18 to 29, wherein the method further comprises:

[0165] A vertical cut is applied to the excess manufacturing portion (124) so ​​that the excess manufacturing portion (124) can be removed to a predetermined length.

[0166] 31. The medium according to any one of clauses 18 to 30, wherein the method further comprises:

[0167] Before placing the excess manufacturing portion (124) onto the structure conveyor (102), a bearing edge (125) is cut into the excess manufacturing portion (124) of the structure (120), wherein the bearing edge (125) is carried by the structure conveyor (102).

[0168] 32. The medium according to any one of clauses 18 to 31, wherein the method further comprises:

[0169] During the pauses in advancing the structure (120), multiple workstations are operated on the structure (120).

[0170] 33. A part of an aircraft assembled by a method defined by program instructions stored on a computer-readable medium according to any one of clauses 18 to 32.

[0171] 34. A system (100) for manufacturing a structure (120), the system (100) comprising:

[0172] A structural conveyor (102) that supports the structure (120) at its bearing edge (125) while contacting the manufacturing excess portion (124) of the structure (120), and the structural conveyor (102) enables the structure (120) to move in a processing direction (199); and

[0173] The trimming station (140) removes the manufacturing excess (124) by moving relative to the structure (120) in the processing direction (199).

[0174] 35. The system (100) according to clause 34, the system (100) further includes:

[0175] A non-destructive testing (NDI) station (180), located downstream of the edge trimming station (140) in the processing direction (199), checks whether the edge is delaminated.

[0176] 36. The system (100) described in accordance with clause 34 or 35, wherein:

[0177] The structural conveyors (102, 104) are tracks (110, 112), which include:

[0178] Pillars (332, 334), each of which includes:

[0179] Support members that hold the structure (120) in place; and

[0180] The rollers enable the structure (120) to move in the processing direction (199) while being held by the support.

[0181] 37. The system (100) according to any one of clauses 34 to 36, said system (100) further comprising:

[0182] The second track (112) includes a support (334) disposed downstream of the cutting station (140), wherein the support (334) of the second track (112) is sized to support the structure (120) at the final cut edge (129) of the structure (120).

[0183] 38. The system (100) according to any one of clauses 34 to 37, wherein:

[0184] The support column (334) located upstream of the cutting station (140) is higher than the support column (332) located downstream of the cutting station (140).

[0185] 39. To manufacture a part of an aircraft using the system (100) pursuant to any one of clauses 34 to 38.

[0186] 40. An apparatus for manufacturing a structure (120), the apparatus comprising:

[0187] A first structural conveyor (102) having a first height, which enables the structure (120) to move in the processing direction (199);

[0188] A trimming station (140) removes excess manufacturing material (124) from the structure (120); and

[0189] A second structural conveyor (104) having a second height, which enables the structure (120) to move in the processing direction (199), and the second structural conveyor (104) being disposed downstream of the first structural conveyor (102), the second height being greater than the first height.

[0190] 41. The device according to clause 40, wherein:

[0191] The first structural conveyor (102) includes a track (110); and

[0192] The second structure conveyor (104) includes a second track (112).

[0193] 42. The device according to clause 40 or 41, wherein:

[0194] Each track (110, 112) includes a support (332, 334) arranged in the processing direction (199).

[0195] 43. The device according to clause 41, wherein:

[0196] The support (334) is arranged at a height to engage the final cut edge (129) of the structure (120).

[0197] 44. The device as described in clause 42 or 43, wherein:

[0198] The support pillars (332, 334) include powered rollers.

[0199] 45. To manufacture a part of an aircraft using the equipment pursuant to any one of clauses 40 to 44.

[0200] 46. ​​An apparatus for conveying a structure (120) being manufactured, the apparatus comprising:

[0201] A first track (110) supports the structure (120) while carrying the manufacturing excess portion (124) of the structure (120), and allows the structure (120) to move in the processing direction (199); and

[0202] The second track (112) supports the structure (120) while carrying the final cut edge of the structure (120) and allows the structure (120) to move in the processing direction (199) after the excess manufacturing portion (124) is removed.

[0203] 47. The device according to clause 46, wherein:

[0204] The second track (112) is higher than the track (110) than the height of the manufacturing excess portion (124).

[0205] 48. The device as described in clause 46 or 47, wherein:

[0206] The structure (120) includes a half-cylinder section of the fuselage, and different instances of the first track (100) support a manufacturing excess portion (124) on each side of the half-cylinder section.

[0207] 49. To manufacture a part of an aircraft using the equipment pursuant to any one of clauses 46 to 48.

[0208] 50. A device for trimming the edge of a structure (120), the device comprising:

[0209] The edge trimming station (140) includes:

[0210] A cutting head (142), which operates horizontally, to remove manufacturing excess (124) from the structure (120); and

[0211] A vertical cutter head (530) operates vertically to remove the manufacturing excess portion (124) from the structure (120).

[0212] 51. The device according to clause 50, wherein:

[0213] The edge trimming station (140) also includes:

[0214] The cutter head (142) slides along the groove (520).

[0215] 52. The device according to clause 50 or 51, wherein:

[0216] The cutter head (142) also includes a vacuum groove (550) to apply suction to remove dust and debris when cutting the manufacturing excess portion (124).

[0217] 53. The equipment according to any one of clauses 50 to 52, wherein:

[0218] The vertical cutter head (530) segments the manufacturing residue (124) that has been removed into chips (150) of predetermined length.

[0219] 54. The equipment according to any one of clauses 50 to 53, wherein the edge-cutting station (140) comprises:

[0220] Roughing edge trimming station (620); and

[0221] A fine trimming station (630) is operated to trim the structure (120) to the final trimmed edge (129).

[0222] 55. To manufacture a part of an aircraft using the equipment pursuant to any one of the preceding clauses 50 to 54.

[0223] Group 2 Clause:

[0224] 1. A method for inspecting a structure (120), the method comprising:

[0225] The structure (120) is advanced along the track (122) in the processing direction (199);

[0226] Align the non-destructive testing (NDI) station (180) at the track (112) with the final cut edge (129) of the structure (120) trimmed upstream of the NDI station (180);

[0227] The final cut edge (129) is imaged via the NDI station (180);

[0228] The final cut edge (129) is characterized based on the imaging steps; and

[0229] The structure (120) is further advanced in the processing direction (199) via the track (112).

[0230] 2. The method according to Clause 1, wherein:

[0231] The structure (120) pulsates in the processing direction (199); and

[0232] During the pauses between pulses, the step of imaging the final cut edge (129) is performed.

[0233] 3. The method according to Clause 1, wherein:

[0234] The structure (120) pulsates in the processing direction (199); and

[0235] During the pulsation, the step of imaging the final cut edge (129) is performed.

[0236] 4. The method according to any one of clauses 1 to 3, wherein:

[0237] The structure (120) moves continuously in the processing direction (199); and

[0238] As the structure (120) moves continuously, the step of imaging the final cut edge (129) is performed.

[0239] 5. The method according to any one of clauses 1 to 4, wherein:

[0240] Imaging the final cut edge (129) involves applying ultrasonic energy to the edge.

[0241] 6. The method according to any one of clauses 1 to 5, wherein:

[0242] Imaging the final cut edge (129) includes acquiring a captured image of the edge.

[0243] 7. The method according to any one of clauses 1 to 6, wherein:

[0244] The NDI station (180) characterizes the final cut edge (129) by identifying cases where the final cut edge (129) exceeds the tolerance.

[0245] 8. A part of an aircraft assembled in accordance with any one of Clauses 1 to 7.

[0246] 9. A non-transitory computer-readable medium comprising program instructions that, when executed by a processor, are operable to perform a method for checking a structure (120), optionally, the method being a method according to any of the preceding clauses, the method comprising:

[0247] The structure (120) is advanced along the track (112) in the processing direction (199);

[0248] Align the non-destructive testing (NDI) station at the track (112) with the final cut edge (129) of the structure (120) trimmed upstream of the NDI station (180);

[0249] The final cut edge (129) is imaged via the NDI station (180);

[0250] The final cut edge (129) is characterized based on the imaging steps; and

[0251] The structure (120) is further advanced in the processing direction (199) via the track (112).

[0252] 10. The medium as described in Clause 9, wherein:

[0253] The structure (120) pulsates in the processing direction (199); and

[0254] During the pauses between pulses, the step of imaging the final cut edge (129) is performed.

[0255] 11. The medium as described in Clause 9 or 10, wherein:

[0256] The structure (120) pulsates in the processing direction (199); and

[0257] During the pulsation, the step of imaging the final cut edge (129) is performed.

[0258] 12. The medium according to any one of clauses 9 to 11, wherein:

[0259] The structure (120) moves continuously in the processing direction (199); and

[0260] As the structure (120) moves continuously, the step of imaging the final cut edge (129) is performed.

[0261] 13. The medium according to any one of clauses 9 to 12, wherein:

[0262] Imaging the final cut edge (129) includes applying ultrasonic energy to the final cut edge (129).

[0263] 14. The medium according to any one of clauses 9 to 13, wherein:

[0264] Imaging the final cut edge (129) includes acquiring a captured image of the final cut edge.

[0265] 15. The medium according to any one of clauses 9 to 14, wherein:

[0266] The NDI station (180) characterizes the final cut edge (129) by identifying cases where the final cut edge (129) exceeds the tolerance.

[0267] 16. A part of an aircraft assembled by a method defined by program instructions stored on a computer-readable medium according to any one of clauses 9 to 15.

[0268] 17. A system (100) for inspecting a structure (120), the system (100) comprising:

[0269] A track (112) that supports the structure (120) from its final cut edge (129) while contacting the final cut edge (129), and enabling the structure (120) to move in the processing direction (199); and

[0270] A non-destructive testing (NDI) station (180) characterizes the final cut edge (129) of the structure (120) as the structure (120) is advanced in the processing direction (199) via the track (112).

[0271] 18. The system (100) according to Clause 17, wherein:

[0272] The NDI station (180) includes a sensor (1310) that applies ultrasonic energy to the final cut edge (129).

[0273] 19. The system (100) described in Clause 17 or 18, wherein:

[0274] The track (112) includes support pillars (334), each of which comprises:

[0275] Support members that hold the structure (120) in place; and

[0276] The rollers enable the structure (120) to move in the processing direction (199) while being held by the support.

[0277] 20. The system (100) according to any one of clauses 17 to 19, wherein:

[0278] The NDI station (180) includes a camera-type sensor (1320).

[0279] 21. The system (100) according to any one of clauses 17 to 20, wherein:

[0280] The NDI station (180) includes an NDI controller (1330) that identifies out-of-tolerance situations at the final cut edge (129) based on images acquired by the NDI station (180).

[0281] 22. To manufacture a part of an aircraft using the system (100) pursuant to any one of clauses 17 to 21.

[0282] 23. A system (100) for inspecting a structure (120), the system (100) comprising:

[0283] A structure conveyor (102) is used to contact the manufacturing excess portion (124) of the structure (120);

[0284] A second structural conveyor (104) for supporting the structure (120) at the final cut edge (129) of the structure (120) after the excess manufacturing portion (124) has been removed, the structural conveyor (102) and the second structural conveyor (104) enabling the mechanism (120) to move in the processing direction (199); and

[0285] A non-destructive inspection (NDI) station (180), located at the second structure conveyor (104), inspects the final cut edge (129) of the structure (120).

[0286] 24. The system (100) as described in Clause 23, wherein:

[0287] The structural conveyor (102) includes a first track (110); and

[0288] The second structure conveyor (104) includes a second track (112).

[0289] 25. The system (100) described in accordance with clause 23 or 24, wherein:

[0290] The NDI station (180) is located at the second structure conveyor (104), downstream of the edge cutting station (140).

[0291] 26. The system (100) according to any one of clauses 23 to 25, said system (100) further comprising:

[0292] Cleaning station (660) cleans the final cut edge (129).

[0293] 27. The system (100) according to any one of clauses 23 to 26, wherein the system (100) further comprises:

[0294] An edge sealing station (170) applies edge sealant (172) to the final cut edge (129).

[0295] 28. To manufacture a part of an aircraft using the system (100) pursuant to any one of clauses 23 to 27.

[0296] Group 3 Clause:

[0297] 1. A method for sealing the edge of a structure (120), the method comprising:

[0298] The structure (120) is advanced along the track (112) in the processing direction (199);

[0299] Align the edge sealing station (170) at the track (112) with the final cut edge (129) of the structure (120) trimmed upstream of the edge sealing station (170);

[0300] An edge sealant (172) is applied to the final cut edge (129) of the structure (120); and

[0301] The structure (120) is further advanced in the processing direction (199) via the track (112).

[0302] 2. The method according to Clause 1, wherein:

[0303] The structure (120) pulsates in the processing direction (199); and

[0304] During the pauses between the pulses, the step of applying the edge sealant (172) is performed.

[0305] 3. The method according to clause 1 or 2, wherein:

[0306] The structure (120) pulsates in the processing direction (199); and

[0307] During the pulsation, the step of applying the edge sealant (172) is performed.

[0308] 4. The method according to any one of clauses 1 to 3, wherein:

[0309] The structure (120) moves continuously in the processing direction (199); and

[0310] As the structure (120) moves continuously, the step of applying the edge sealant (172) is performed.

[0311] 5. The method according to any one of clauses 1 to 4, wherein:

[0312] The edge sealant (172) is sprayed onto the final cut edge (129) of the structure (120).

[0313] 6. The method according to any one of clauses 1 to 5, wherein:

[0314] Applying the edge sealant (172) prevents inconsistencies from propagating through the final cut edge (129).

[0315] 7. The method according to any one of clauses 1 to 6, wherein:

[0316] Applying the edge sealant (172) includes applying an epoxide.

[0317] 8. A part of an aircraft assembled in accordance with any one of Clauses 1 to 7.

[0318] 9. A non-transitory computer-readable medium comprising program instructions that, when executed by a processor, are operable to perform a method for executing an edge of a sealing structure (120), optionally, the method being a method according to any of the preceding claims, the method comprising:

[0319] The structure (120) is advanced along the track (112) in the processing direction (199);

[0320] Align the edge sealing station (170) at the track (112) with the final cut edge (129) of the structure (120) trimmed upstream of the edge sealing station (170);

[0321] An edge sealant (172) is applied to the final cut edge (129) of the structure (120); and

[0322] The structure (120) is further advanced in the processing direction (199) via the track (112).

[0323] 10. The medium as described in Clause 9, wherein:

[0324] The structure (120) pulsates in the processing direction (199); and

[0325] During the pauses between pulses, the step of applying the edge sealant (172) is performed.

[0326] 11. The medium as described in Clause 9 or 10, wherein:

[0327] The structure (120) pulsates in the processing direction (199); and

[0328] During the pulsation, the step of applying the edge sealant (172) is performed.

[0329] 12. The medium according to any one of clauses 9 to 11, wherein:

[0330] The structure (120) moves continuously in the processing direction (199); and

[0331] As the structure (120) moves continuously, the step of applying the edge sealant (172) is performed.

[0332] 13. The medium according to any one of clauses 9 to 12, wherein:

[0333] The edge sealant (172) is sprayed onto the final cut edge (129) of the structure (120).

[0334] 14. The medium according to any one of clauses 9 to 13, wherein:

[0335] Applying the edge sealant (172) prevents inconsistencies from propagating through the final cut edge (129).

[0336] 15. The medium according to any one of clauses 9 to 14, wherein:

[0337] Applying the edge sealant (172) includes applying an epoxide.

[0338] 16. A part of an aircraft assembled by a method defined by program instructions stored on a computer-readable medium according to any one of clauses 9 to 15.

[0339] 17. A system (100) for the final cut edge (129) of a sealing structure (120), the system (100) comprising:

[0340] A track (112) that supports the structure (120) from its final cut edge (129) while contacting the final cut edge (129), and enabling the structure (120) to move in the processing direction (199); and

[0341] An edge sealing station (170) applies an edge sealant (172) to the final cut edge (129) of the structure (120) as the structure (120) is advanced in the processing direction (199) via the track (112).

[0342] 18. The system (100) according to Clause 17, wherein the system (100) further comprises:

[0343] An applicator, located at the edge sealing station (170), applies the edge sealant (172) to the final cut edge (129).

[0344] 19. The system (100) described in Clause 17 or 18, wherein:

[0345] The track (112) includes supports, each of which comprises:

[0346] Support members that hold the structure (120) in place; and

[0347] The rollers enable the structure (120) to move in the processing direction (199) while being held by the support.

[0348] 20. The system (100) according to any one of clauses 17 to 19, said system (100) further comprising:

[0349] A heater, located at the edge sealing station (170), cures the edge sealant (172).

[0350] 21. The system (100) according to any one of clauses 17 to 20, wherein:

[0351] The edge sealing station (170) also applies edge sealant (172) from the reservoir (1730) at the edge sealing station (170).

[0352] 22. To manufacture a part of an aircraft using the system (100) pursuant to any one of clauses 17 to 21.

[0353] 23. A system (100) of a sealing structure (120), the system (100) comprising:

[0354] A structural conveyor (104) supports the structure (120) at its final cut edge (129) while contacting the final cut edge (129), and enables the structure (120) to move in the processing direction (199); and

[0355] An edge sealing station (170), located at the structure conveyor (104), seals the final cut edge (129) of the structure (120).

[0356] 24. The system (100) as described in Clause 23, wherein:

[0357] The structural conveyor (104) includes a track (112).

[0358] 25. The system (100) described in accordance with clause 23 or 24, wherein:

[0359] The edge sealing station (170) is located at the structural conveyor (104), downstream of the edge cutting station (140).

[0360] 26. To manufacture a part of an aircraft using the system (100) pursuant to any one of clauses 23 to 25.

[0361] Group 4 Clause:

[0362] 1. A method for cleaning a structure (120), the method comprising the following steps:

[0363] The structure (120) is advanced along the track (112) in the processing direction (199);

[0364] Align the cleaning station at the track (112) with the final cut edge (129) of the structure (120) trimmed upstream of the cleaning station (660);

[0365] Debris is removed from the final cut edge (129) via the cleaning station (660); and

[0366] The structure (120) is further advanced in the processing direction (199) via the track (112).

[0367] 2. The method according to Clause 1, wherein:

[0368] The structure (120) pulsates in the processing direction (199); and

[0369] During the pauses between pulses, the step of removing the fragments is performed.

[0370] 3. The method according to Clause 1, wherein:

[0371] The structure (120) pulsates in the processing direction (199); and

[0372] During the pulsation, the step of removing the debris is performed.

[0373] 4. The method according to any one of clauses 1 to 3, wherein:

[0374] The structure (120) moves continuously in the processing direction (199); and

[0375] As the structure (120) moves continuously, the step of removing the fragments is performed.

[0376] 5. The method according to any one of clauses 1 to 4, wherein:

[0377] Removing the debris includes applying fluid to the final cut edge (129) that carries the debris from the final cut edge (129).

[0378] 6. The method according to any one of clauses 1 to 5, wherein:

[0379] Removing the debris includes brushing the final cut edge (129).

[0380] 7. The method according to any one of clauses 1 to 6, wherein:

[0381] The cleaning station (660) removes debris from the entire outline (812) of the structure (120).

[0382] 8. A portion of an aircraft cleaned in accordance with any one of Clauses 1 to 7.

[0383] 9. A non-transitory computer-readable medium comprising program instructions operable, when executed by a processor, to perform a method of executing a clean structure (120), optionally, the method being a method according to any of the preceding clauses, the method comprising:

[0384] The structure (120) is advanced along the track (112) in the processing direction (199);

[0385] Align the cleaning station (660) at the track (112) with the final cut edge (129) of the structure (120) trimmed upstream of the cleaning station (660);

[0386] Debris is removed from the final cut edge (129) via the cleaning station (660); and

[0387] The structure (120) is further advanced in the processing direction (199) via the track (112).

[0388] 10. The medium as described in Clause 9, wherein:

[0389] The structure (120) pulsates in the processing direction (199); and

[0390] During the pauses between pulses, the step of removing the fragments is performed.

[0391] 11. The medium as described in Clause 9, wherein:

[0392] The structure (120) pulsates in the processing direction (199); and

[0393] During the pulsation, the step of removing the debris is performed.

[0394] 12. The medium according to any one of clauses 9 to 11, wherein:

[0395] The structure (120) moves continuously in the processing direction (199); and

[0396] As the structure (120) moves continuously, the step of removing the fragments is performed.

[0397] 13. The medium according to any one of clauses 9 to 12, wherein:

[0398] Removing the debris includes applying fluid to the final cut edge (129) that carries the debris from the final cut edge (129).

[0399] 14. The medium according to any one of clauses 9 to 13, wherein:

[0400] Removing the debris includes brushing the final cut edge (129).

[0401] 15. The medium according to any one of clauses 9 to 14, wherein:

[0402] The cleaning station (660) removes debris from the entire outline of the structure (120).

[0403] 16. A part of an aircraft cleaned by a method defined by program instructions stored on a computer-readable medium according to any one of clauses 9 to 15.

[0404] 17. A system (100) for a cleaning structure (120), the system (100) comprising:

[0405] A track (112) that supports the structure (120) from its final cut edge (129) while contacting the final cut edge (129), and enabling the structure (120) to move in the processing direction (199); and

[0406] A cleaning station (660) removes debris from the final cut edge (129) of the structure (120) as the structure (120) advances in the processing direction (199) via the track (112).

[0407] 18. The system (100) according to Clause 17, wherein:

[0408] The cleaning station (660) applies pressurized air to the final cut edge (129).

[0409] 19. The system (100) described in Clause 17 or 18, wherein:

[0410] The track (112) includes support pillars (334), each of which comprises:

[0411] Support members that hold the structure (120) in place; and

[0412] The rollers enable the structure (120) to move in the processing direction (199) while being held by the support.

[0413] 20. The system (100) according to any one of clauses 17 to 19, wherein:

[0414] The cleaning station (660) includes an element for wiping the final cut edge (129).

[0415] 21. The system (100) according to any one of clauses 17 to 20, wherein:

[0416] The cleaning station (660) includes elements for applying fluid to the final cut edge (129).

[0417] 22. Clean a portion of the aircraft using the system (100) pursuant to any one of clauses 17 to 21.

[0418] 23. A system (100) for a cleaning structure (120), the system (100) comprising:

[0419] A structural conveyor (104) that, while supporting the structure (120), contacts the final cut edge (129) of the structure (120) and enables the structure (120) to move in the processing direction (199); and

[0420] A cleaning station (660) is located at the structure conveyor (104) to remove debris from the structure (120).

[0421] 24. The system (100) as described in Clause 23, wherein:

[0422] The structural conveyor (104) includes a track (112).

[0423] 25. The system (100) described in accordance with clause 23 or 24, wherein:

[0424] The cleaning station (660) is located at the structural conveyor (104), downstream of the edge-cutting station (140).

[0425] 26. The system (100) according to any one of clauses 23 to 25, wherein:

[0426] The cleaning station (660) performs at least one activity selected from the group consisting of: applying pressurized air, applying pressurized liquid, performing abrasion, and wiping.

[0427] 27. Clean a portion of the aircraft using the system (100) pursuant to any one of clauses 23 to 26.

Claims

1. A method for manufacturing a structure (120), the method comprising the following steps: The manufacturing excess portion (124) of the structure (120) is placed in contact with the structure conveyor (102); The structure (120) is advanced toward the cutting station (140) in the processing direction (199). The trimming station (140) is operated to remove the manufacturing excess (124) by moving the trimming station (140) relative to the structure (120) in the processing direction (199); and The structure (120) is carried on a second structure conveyor (104) downstream of the trimming station (140), the height of the second structure conveyor (104) being greater than the height of the structure conveyor (102) than the height of the removed manufacturing excess (124).

2. The method according to claim 1, wherein: The step of advancing the structure (120) in the processing direction (199) exposes the additional manufacturing excess (124) to the trimming station (140).

3. The method according to claim 1 or 2, wherein: The step of removing the manufacturing excess (124) separates the indexing feature (126) from the structure (120), the indexing feature (126) being utilized by an upstream station performing work on the structure (120).

4. The method according to claim 1 or 2, further comprising: The structure (120) is advanced along the structure conveyor (102) toward the fine edge trimming station (630) in the processing direction (199); and Operate the fine edge trimming station (630) to trim off additional material from the edge of the structure (120).

5. The method according to claim 1 or 2, wherein: The step of advancing the structure (120) includes making the pulsation of the structure (120) smaller than the length of the structure (120); and The steps of operating the trimming station (140) include sliding the cutting head (142) of the trimming station (140) in the processing direction (199).

6. The method according to claim 5, wherein: During the pauses between the pulses of the structure (120), the steps of operating the cutting station (140) are performed, and / or During the pulsation between pauses in the structure (120), the steps of operating the cutting station (140) are performed.

7. The method according to claim 1 or 2, wherein: As the structure (120) pulses forward, the excess manufacturing portion (124) is removed using a fixed tool, and / or The manufacturing excess (124) is removed by a vertical cutter head (530) and a cutter head (142) operating in a horizontal manner.

8. The method according to claim 1 or 2, further comprising: Before placing the excess manufacturing portion (124) onto the structure conveyor (102), a bearing edge (125) is cut into the excess manufacturing portion (124) of the structure (120), wherein the bearing edge (125) is carried by the structure conveyor (102).

9. The method according to claim 1 or 2, further comprising: During the pauses in advancing the structure (120), multiple workstations are operated on the structure (120), and / or During the process of advancing the structure (120) through multiple cutting stations (140), the multiple cutting stations (140) are operated on the structure (120).

10. A system (100) for manufacturing a structure (120), the system (100) comprising: A structural conveyor (102) supports the structure (120) at its bearing edge (125) while contacting the manufacturing excess portion (124) of the structure (120) and enabling the structure (120) to move in the processing direction (199); The trimming station (140) removes the manufacturing excess (124) by moving relative to the structure (120) in the processing direction (199). The structural conveyor (102, 104) is a track (110, 112), which includes supports (332, 334), each support (332, 334) comprising: Support members that hold the structure (120) in place; and Rollers allow the structure (120) to move in the processing direction (199) while being held by the support; and The system also includes a second track (112) including a support (334) disposed downstream of the cutting station (140), wherein the support (334) of the second track (112) is sized to support the structure (120) at the final cut edge (129) of the structure (120), wherein the support (334) disposed upstream of the cutting station (140) is higher than the support (332) disposed downstream of the cutting station (140).

11. The system (100) according to claim 10, further comprising: A non-destructive inspection station (180), located downstream of the edge trimming station (140) in the processing direction (199), inspects whether the final edge trimming is delaminated.

12. An apparatus for manufacturing a structure (120), the apparatus comprising: A first structural conveyor (102) having a first height, the first structural conveyor (102) enabling the structure (120) to move in the processing direction (199); A trimming station (140) removes excess manufacturing material (124) from the structure (120). as well as A second structural conveyor (104) having a second height, the second structural conveyor (104) enabling the structure (120) to move in the processing direction (199), the second height being greater than the first height, and the second structural conveyor (104) being disposed downstream of the first structural conveyor (102).

13. The device according to claim 12, wherein: The first structural conveyor (102) includes a track (110); and The second structure conveyor (104) includes a second track (112).

14. The device according to claim 13, wherein: Each track (110, 112) includes supports (332, 334) arranged in the processing direction (199); and / or The support (334) is arranged at a height to engage the final cut edge (129) of the structure (120).

15. The device according to claim 14, wherein, The support pillars (332, 334) include powered rollers.

16. An apparatus for conveying a structure (120) being manufactured, the apparatus comprising: The first track (110) supports the structure (120) while carrying the manufacturing excess portion (124) of the structure (120) and enables the structure (120) to move in the processing direction (199); as well as The second track (112) supports the structure (120) while carrying the final cut edge of the structure (120) and allows the structure (120) to move in the processing direction (199) after the excess manufacturing portion (124) is removed, wherein the second track (112) is higher than the height of the excess manufacturing portion (124) than the first track (110).

17. The apparatus according to claim 16, wherein: The structure (120) includes a half-cylinder section of the fuselage, and a first track (110) supports the manufacturing excess portion (124) on each side of the half-cylinder section.

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