Method of assembling a structure

Abstract

The present invention relates to methods of assembling structures. Systems and methods for assembling structures are provided. The systems and methods include micro-pulsing a structure along a track in a process direction for less than the length of the structure. The structure is indexed to a station by pairing an indexing feature in a manufacturing allowance of the structure with a complementary indexing feature at the station. The station performs a job on the structure at the station as the structure is indexed to the station. Micro-pulsing and indexing and performing jobs on the structure are iteratively repeated until the structure is ready to advance to a next assembly process.

Description

Technical Field

[0001] This disclosure relates to the field of assembly, and more particularly to airframe assembly. Background Technology

[0002] The frame defines the mechanical structure of an aircraft. A frame is made up of multiple components that provide desired structural characteristics. For example, a portion of the frame for an aircraft fuselage may include frames, skins, and stringers that are mechanically joined together according to design parameters (e.g., via co-bonding, co-curing, or fasteners). As currently practiced, frame components are manufactured and assembled in predetermined units on a factory floor. For example, components may be laid, cured, or otherwise manufactured in one unit and then transported as a whole to a new unit where operations are performed.

[0003] While the manufacturing processes discussed above are reliable, these processes encounter delays when work at specific parts of a component is completed more slowly than expected. For example, if a specific section of a fuselage segment takes longer to fasten or lay than expected, the entire section typically remains at the unit until all delayed work is completed. Furthermore, significant time is spent cataloging the component's configuration after it has been moved. This time is not value-added. Moreover, frequent moves between units add a substantial amount of non-value-added time. That is, each movement of a component between units (and therefore between the individual units used in the manufacturing process) results in setup time, which should be minimized to enhance efficiency. Current designs utilize automated optical inspection techniques and / or probes to inspect the position of these components along six degrees of freedom across their dimensions, but these are particularly time-consuming and expensive processes.

[0004] Patent document WO 03 / 037564A2, according to its abstract, describes a production system for manufacturing workpieces, comprising: an indexing system including a plurality of indexing devices and a longitudinally extending indexing member, the plurality of indexing devices being detachably mounted on the workpiece at known longitudinally spaced locations along the indexing system; the longitudinally extending indexing member being releasably engaged with at least two of the indexing devices such that the indexing devices fix their position and orientation relative to the workpiece; the indexing member having position indicating features distributed along the indexing devices. The production system also includes a machine module mounted for longitudinal movement along the indexing member and operable to perform operations; the machine module is operable to detect the position indicating features on the indexing member and thereby determine its position relative to the workpiece.

[0005] Patent document EP 3 287 247A1, according to its abstract, describes an apparatus and method for manufacturing fiber-reinforced plastic molded articles, whereby two components can be positioned relative to each other when integrally molded by the VaRTM method. An apparatus for manufacturing fiber-reinforced plastic molded articles includes: a skin mold in which a skin, as a cured fiber-reinforced composite component, is mounted; a longitudinal beam mold configured to receive a longitudinal beam, which is a fabric to be joined to the skin; and a folding plate configured to receive the longitudinal beam mold and including a positioning portion for positioning relative to a positioning portion disposed on the skin.

[0006] Patent document US2013 / 019446A1, according to its abstract, describes a system and method for assembling 360-degree segments of an aircraft fuselage or engine nacelle by means of the following steps: positioning multiple assembly panels relative to a machine reference indicating an assembly-level datum pattern; drilling full-size holes in the panels at their closest second skin edges using a machine; trimming the second edges of the panels using a machine; and then using the full-size holes closest to the second skin edges as alignment features to properly orient and attach the panel pairs together on opposite sides of the second skin edges, closest to the first skin edge, using an auxiliary machine, thereby forming a panel pair. A control system can be individually and independently installed into the panel pairs, and the panel pairs can then be joined together by means of the following steps: aligning the full-size holes closest to the second edges, and inserting fasteners through the aligned full-size holes closest to the second skin edges.

[0007] Patent document US2011 / 301735A1, according to its abstract, describes a method for controlling a paced production line for processing aircraft structural components, wherein the production line includes at least one station having at least one processing machine. The method involves determining the processing sequence at the station for a production step by: determining the expected or actual occupancy of a work area by the structural component or structural component segment of the production step, and based on the occupancy, determining all operations to be performed at the station in the production step, and optimizing the processing sequence of these operations.

[0008] Therefore, it is desirable to have a method and apparatus that takes into account at least some of the problems discussed above, as well as other possible problems. Summary of the Invention

[0009] According to an aspect of this disclosure, a method for assembling a structure is provided, the method comprising the steps of: micropulsing a structure along a track in a process direction to a length less than that of the structure; transposing the structure toward a work station by pairing a transposition feature in the structure's manufacturing excess with a complementary transposition feature at a work station; performing work on the structure at the work station while transposing the structure toward the work station; and iteratively repeating the steps of micropulsing the structure, transposing the structure, and performing work on the structure.

[0010] Advantageously, in the method, the step of transferring the structure to the workstation is performed in such a way that multiple workstations are transferred to the structure at one time.

[0011] Preferably, in the method, the step of transferring the structure to a workstation simultaneously transmits multiple instructions to one or more workstations.

[0012] Preferably, in the method, the step of transferring the structure to the workstation involves transmitting a 3D representation of the structure within the purview of the workstation and / or IML lofting and / or OML lofting.

[0013] Preferably, in the method, the step of transferring the structure to the workstation transmits the digitization of the structure within the workstation's field of view.

[0014] Preferably, in the method, the step of transferring the structure to the workstation transmits assembly instructions to the workstation for the structure within the workstation's field of vision.

[0015] Preferably, in the method, the workstation performs operations during the pauses between micro-pulsations of the structure.

[0016] Preferably, in the method, the workstation performs the operation during the micro-pulsation of the structure.

[0017] Preferably, in the method, the step of shifting the structure to the work station includes: inserting pins into holes that have been placed in or on the structure at predetermined intervals.

[0018] Preferably, in the method, the step of shifting the structure to the work station includes: inserting a pin into a hole that has been machined into the structure at predetermined intervals.

[0019] Preferably, in the method, the step of transferring the structure to the workstation includes: scanning RFID tags or barcodes placed on the structure at predetermined intervals.

[0020] Preferably, in the method, a displacement feature is provided in the manufacturing allowance of the structure, and the method further includes the step of trimming the manufacturing allowance and the displacement feature from the structure.

[0021] Preferably, in the method, the step of micro-pulsating structure exposes new parts of the structure for the station to receive operations.

[0022] Preferably, in the method, the workstations are arranged along the track and separated by a length less than that of the structure.

[0023] Preferably, the method further includes the step of: adding a micro-pulsating structure along the track up to a length less than that of the structure.

[0024] Preferably, in the method, when the structure is rotated, work is performed on the structure at a workstation, the work being performed by the workstation during pauses between micro-pulses of the structure.

[0025] Preferably, in the method, the structure is operated on at a station between rotations, the operation being performed by the station during the micro-pulsation of the structure.

[0026] Preferably, in the method, the step of micropulsating the additional structure includes: micropulsating the additional structure immediately upstream and / or downstream of the structure.

[0027] Preferably, in the method, the micropulsations are continuously arranged along the track and separated by gaps in the additional structure.

[0028] Preferably, in the method, the step of adding micro-pulsating structures includes maintaining a gap between the added structures.

[0029] Preferably, the method further includes the following step: periodically standing down the workstation when it is not necessary to perform work on the structure from the workstation within its field of vision.

[0030] Preferably, the method further includes the step of performing maintenance at a workstation set with one of the gaps during the pause between micropulses of the additional structure.

[0031] Preferably, in the method, each gap in the gap comprises a multiple of the micropulsation length of the structure.

[0032] Preferably, in the method, the structure is micro-pulsated to a distance equal to a multiple of the frame pitch distance.

[0033] Preferably, in the method, the step of the micro-pulsating structure includes: iteratively advancing the structure to a length less than that of the structure, and then pausing.

[0034] Preferably, in the method, different messages are transmitted to the workstation via a shifting feature, at least based on the shape, type, or location of the shifting feature at the structure, which is customized to provide instructions regarding operations to be performed within the workstation's field of vision.

[0035] Preferably, in the method, multiple instructions are transmitted simultaneously to multiple workstations via one or more indexing features.

[0036] Preferably, in the method, the workstations are simultaneously rotated to the structure, and the workstations simultaneously perform operations to modify the structure.

[0037] Preferably, in the method, the complementary features are positioned relative to the workstation.

[0038] A portion of the aircraft assembled according to the above method is part of this disclosure.

[0039] According to an aspect of this disclosure, a system for assembling structures is provided, the system comprising: a track for transporting structures including indexing features; a row of workstations arranged along the track, the workstations performing operations on the structures and being spaced apart from each other in a process direction by a length less than that of the individual structures in the structure; and an indexing unit arranged along the track relative to the workstations with a known offset from corresponding workstations in the row of workstations, and including complementary indexing features positioned relative to the track, the complementary indexing features being sized to mate with the indexing features.

[0040] Advantageously, in this system, an indexing feature is set in the manufacturing allowance of the structure, and the manufacturing allowance is removed at the work station.

[0041] Preferably, in this system, the indexing feature transmits to the station a 3D representation of the structure within the station's field of view and / or an inner mold line (IML) loft and / or an outer mold line (OML) loft.

[0042] Preferably, in this system, the indexing feature transmits the digitization of the structure within the workstation's field of view to the workstation.

[0043] Preferably, in this system, the indexing feature transmits assembly instructions to the workstation for the structure within the workstation's field of view.

[0044] Preferably, in this system, the track includes a series of statures, which include rollers positioned at predetermined locations for receiving structures.

[0045] Preferably, in this system, the transposition feature is selected from the group consisting of: through holes, blind holes, slots, pins, RFID tags and / or barcodes that have been coupled to the structure at predetermined intervals.

[0046] Preferably, in this system, each workstation performs a type of operation selected from the group consisting of: installing frames, installing longitudinal beams, installing door surrounds, installing window surrounds, cutting window holes, and cutting door holes.

[0047] Preferably, in this system, different messages are transmitted to the workstation based at least on the shape or position of the rotation feature.

[0048] Preferably, in this system, the workstation simultaneously performs operations on the structure.

[0049] Preferably, in this system, the structure is separated by gaps, each of which includes a multiple of the micropulse length.

[0050] Preferably, in this system, the structure is micro-pulsated to a distance equal to a multiple of the frame pitch distance.

[0051] The manufacture of an aircraft using the system described above is part of this disclosure.

[0052] According to an aspect of this disclosure, an apparatus for assembling a structure is provided, the apparatus comprising: a track for advancing the structure in a process direction; at least one station disposed along the track; and a shifting unit disposed relative to the at least one station.

[0053] Advantageously, in this device, the indexing unit is set with an offset from at least one corresponding station.

[0054] Preferably, in the device, the indexing unit includes a complementary indexing feature that is coupled to an indexing feature at the structure, thereby receiving work from the workstation.

[0055] Preferably, in this device, the complementary indexing feature is formed to the required size to match the indexing feature in the manufacturing allowance of the structure.

[0056] Preferably, in the device, the at least one workstation comprises multiple workstations, and the multiple workstations are arranged continuously along a structure that progresses along a track.

[0057] The manufacture of an aircraft using the equipment described above is part of this disclosure.

[0058] According to an aspect of this disclosure, a method for assembling a structure is provided, the method comprising the steps of: micropulsing a structure along a track in a process direction to a length less than that of the structure; transposing the structure to a work station by pairing a transposition feature in the structure’s manufacturing allowance with a complementary transposition feature at the work station; and iteratively repeating the steps of micropulsing the structure and transposing the structure.

[0059] Advantageously, in the method, when the structure is rotated to a work station, the structure at that work station is operated on; and the steps of micro-pulsation, rotation, and operation on the structure are iteratively repeated.

[0060] Preferably, in the method, the structure is operated on by at least one of the workstations before being transferred to the plurality of workstations; and the steps of micro-pulsating structure, transferring structure, and operating on structure are iteratively repeated.

[0061] Preferably, in the method, without transferring the structure to a workstation, operations can be performed on the structure by at least one of the workstations; and the steps of iteratively repeating the micro-pulsating structure and performing operations on the structure can be carried out.

[0062] A portion of the aircraft assembled according to the above method is part of this disclosure.

[0063] According to an aspect of this disclosure, a method for manufacturing a structure for an aircraft is provided, the method comprising the steps of: micro-pulsating the structures along a track by iteratively advancing and pausing a series of structures; performing work on the series of structures via a row of workstations during multiple pauses between micro-pulsations; identifying the arranged micro-pulsations; and performing an interruption during the arranged micro-pulsations, wherein work is stopped at at least one of the workstations in the row of workstations.

[0064] Advantageously, in the method, the micro-pulsation step includes: iteratively advancing the structure to a length less than that of each individual structure, and then pausing.

[0065] Preferably, in the method, the operation includes mounting the frame onto the structure.

[0066] Preferably, in the method, the step of micro-pulsating the series structure includes: operating the power roller at the track.

[0067] Preferably, in the method, the step of micro-pulsating the series structure includes: advancing the half-barrel section of the fuselage along the track.

[0068] Preferably, the method further includes the step of performing maintenance on at least one of the workstations during the interruption.

[0069] Preferably, the method further includes the step of removing personnel from the work site during the interruption.

[0070] A portion of the aircraft assembled according to the above method is part of this disclosure.

[0071] According to an aspect of this disclosure, a system for assembling a structure is provided, the system comprising: a track, the track transporting the structure; and

[0072] A row of workstations, arranged along the track, performs operations on the structure according to a common cycle time.

[0073] Advantageously, the system also includes an indexing unit disposed in the row of stations and including a complementary feature formed to the required dimensions to match the indexing feature in the manufacturing allowance of the structure.

[0074] Preferably, in this system, the cycle time is equal to the duration of pausing the structure between micropulses plus the duration of advancing the structure between micropulses.

[0075] Preferably, in this system, the cycle time is based on the number of aircraft manufactured per month and the number of aircraft required to be assembled.

[0076] Preferably, the system also includes a feeder line that feeds into the track based on cycle time.

[0077] Preferably, in this system, the workstation performs the operation based on instructions transmitted by the rotation features at the structure.

[0078] According to an aspect of this disclosure, a method is provided for transposing a preform after each of a plurality of micropulses along a process direction, the method comprising the steps of: placing the preform on a conveying device that holds the preform in a layout; moving the preform along the process direction to a station without altering the layout of the preform; and locking a transposing unit to one of a plurality of transposing features in the preform.

[0079] Advantageously, in the method, the conveying device keeps the preform aligned with the outer mold line (OML).

[0080] Preferably, in the method, the conveying device keeps the preform aligned with the inner mold line (IML).

[0081] Preferably, in the method, messages are transmitted to the workstation based at least on the shape, type, or position of the rotation feature.

[0082] Preferably, in the method, a message is transmitted from a transposition feature to the workstation, wherein the transposition feature is selected from the group consisting of: through holes, blind holes, slots, pins, radio frequency identifier (RFID) tags and / or barcodes.

[0083] Preferably, in the method, the workstation simultaneously performs operations on the preform.

[0084] Preferably, in the method, the workstation is simultaneously rotated to multiple rotation features.

[0085] A portion of the aircraft assembled according to the above method is part of this disclosure.

[0086] According to an aspect of this disclosure, a method is provided for transpositioning a structure after each of a plurality of micropulses along a process direction, the method comprising the steps of: micropulsating the structure being assembled from one station to the next station via a track; locking transposition features of the structure to complementary features of the station; and determining the digitization of the structure at the moment of transposition.

[0087] Advantageously, in the method, the track retaining structure is laid out in accordance with the outer mold line (OML).

[0088] Preferably, in the method, the track retaining structure is laid out in accordance with the inner mold line (IML).

[0089] Preferably, in the method, messages are transmitted to the workstation and the next workstation based at least on the shape or position of the rotation feature.

[0090] Preferably, in the method, a message is transmitted from a transposition feature to the workstation, wherein the transposition feature is selected from the group consisting of: through holes, blind holes, slots, pins, radio frequency identifier (RFID) tags and / or barcodes.

[0091] Preferably, in the method, the workstation simultaneously performs operations on the structure.

[0092] Preferably, in the method, the workstation is simultaneously rotated to multiple rotation features.

[0093] A portion of the aircraft assembled according to the above method is part of this disclosure.

[0094] According to an aspect of this disclosure, a method for assembling a structure is provided, the method comprising the steps of: advancing the structure along a track in a process direction; rotating the structure toward a workstation set along the track; and performing operations on the structure via the workstation according to a cycle time.

[0095] Advantageously, in the method, the work is performed at the workstation during the same pause between micro-pulsations of the structure.

[0096] Preferably, in the method, the cycle time is equal to the duration of pausing the structure between micropulses plus the duration of advancing the structure within the micropulses.

[0097] Preferably, in the method, the workstation performs the operation during the same micro-pulse between pauses in the structure.

[0098] Preferably, in the method, the cycle time is based on the number of aircraft manufactured per month.

[0099] Preferably, in the method, the cycle time is defined for a row of workstations assigned to perform the task.

[0100] Preferably, in the method, the step of the track micro-pulsation structure includes: driving a series of rollers along a series of rollers mounted to a support.

[0101] Preferably, in the method, material is supplied from the feeder line according to the cycle time of the half-barrel assembly line and the cycle time of the feeder line.

[0102] Preferably, the method further includes the following steps: removing waste material from the workstation via the outgoing conveyor line based on the cycle time of the half-barrel assembly line and the cycle time of the outgoing conveyor line.

[0103] A portion of the aircraft assembled according to the above method is part of this disclosure.

[0104] According to an aspect of this disclosure, a system for assembling structures is provided, the system comprising: a track; a structure disposed along the track, the structure including an indexing feature; a row of workstations disposed along the track for indexing the structure and performing operations on the structure according to a cycle time, and being spaced apart from each other in the process direction by a length less than that of the individual structures in the structure; and a feeder assembly line that supplies material to the workstations.

[0105] Advantageously, the system also includes an outflow line that removes waste from the workstation.

[0106] Preferably, in this system, the workstation performs operations during pauses between micro-pulsations of the structure.

[0107] Preferably, in this system, the cycle time is equal to the duration of the pause between micropulses plus the duration of the micropulses.

[0108] Preferably, in this system, the track follows a series of roller drive structures mounted to the support.

[0109] Preferably, in this system, the feeder assembly line supplies materials according to the common cycle time of the half-barrel assembly line and the cycle time of the feeder assembly line.

[0110] Preferably, the system further includes an outflow feed chute that removes waste material from the workstation.

[0111] The manufacture of an aircraft using the system described above is part of this disclosure.

[0112] According to an aspect of this disclosure, a system for assembling structures is provided, the system comprising: a track; a row of workstations arranged along the track, which are configured to rotate toward indexing features of the structure arranged along the track and perform operations on the structure according to a cycle time, and are spaced apart from each other in the process direction by a length less than that of the individual structures in the structure; and a feeder assembly line that supplies materials to the workstations.

[0113] Advantageously, the system also includes an outflow line for removing waste.

[0114] Preferably, in this system, the outflow line operates according to the cycle time of the half-barrel assembly line and the cycle time of the outflow line.

[0115] Preferably, in this system, the workstation performs operations on the structure during pauses between micro-pulses.

[0116] Preferably, in this system, the workstation performs operations on the structure during the micro-pulse between pauses.

[0117] Preferably, in this system, the cycle time is equal to the duration of the pause between micropulses plus the duration of the micropulses.

[0118] Preferably, in this system, the track comprises a series of roller drive structures mounted to a support.

[0119] Preferably, in this system, the feeder assembly line supplies materials to the half-drum assembly line.

[0120] Preferably, in this system, the feeder assembly line supplies materials to the workstations in a Just-In-Time (JIT) manner.

[0121] Preferably, in this system, the feeder assembly line progresses according to the cycle time of the half-barrel assembly line and the cycle time of the feeder assembly line.

[0122] Preferably, in this system, the feeder assembly line provides components selected from the group consisting of: frame, longitudinal beams, fuselage sections, and door frames.

[0123] Preferably, the system further includes an outflow feed chute that removes waste material from the workstation.

[0124] The manufacture of an aircraft using the system described above is part of this disclosure.

[0125] According to an aspect of this disclosure, a method for assembling a structure is provided, the method comprising the steps of: advancing the structure along a track in a process direction; implementing a predetermined shape onto the structure; and performing operations on the structure via a workstation according to a cycle time.

[0126] Advantageously, in the method, the work is performed at the workstation during the same pause between micro-pulsations of the structure.

[0127] Preferably, in the method, the cycle time is equal to the duration of pausing the structure between micropulses plus the duration of advancing the structure during the micropulses.

[0128] Preferably, in the method, the cycle time is based on the number of aircraft produced per month.

[0129] Preferably, in the method, the step of the track micro-pulsation structure includes: driving a series of rollers along a series of rollers mounted to a support.

[0130] Preferably, in the method, material is supplied from the feeder assembly line according to the cycle time.

[0131] Preferably, the method further includes the following step: removing waste material from the workstation according to the cycle time.

[0132] A portion of the aircraft assembled according to the above method is part of this disclosure.

[0133] According to an aspect of this disclosure, a system for assembling structures is provided, the system comprising: a track; a structure disposed along the track, the structure including an indexing feature; a row of workstations disposed along the track, the row of workstations being indexed toward the structure and performing operations on the structure according to a cycle time, and being spaced apart from each other in the process direction by a length less than that of the individual structures in the structure; and a feeder assembly line supplying materials to the workstations.

[0134] Advantageously, in this system, the workstation performs operations during pauses between micro-pulses of the structure.

[0135] Preferably, in this system, the cycle time is equal to the duration of the pause between micropulses plus the duration of the micropulses.

[0136] Preferably, in this system, the track follows a series of roller drive structures mounted to the support.

[0137] Preferably, in this system, the feeder assembly line supplies material according to the cycle time.

[0138] Preferably, in this system, the feeder assembly line delivers materials to the workstation in a Just-In-Time (JIT) manner.

[0139] Preferably, in this system, the feeder production line progresses according to the cycle time.

[0140] Preferably, in this system, each feeder production line progresses according to its own cycle time.

[0141] Preferably, the system further includes an outflow feed chute that removes waste material from the workstation.

[0142] The manufacture of an aircraft using the system described above is part of this disclosure.

[0143] According to an aspect of this disclosure, a system for assembling a structure is provided, the system comprising: a track; a row of stations arranged along the track, which are positioned to rotate onto indexing features of the structure arranged along the track and perform operations on the structure according to a cycle time, and are spaced apart from each other in the process direction by a length less than that of the individual structures in the structure; and a feeder assembly line that supplies material to the structure.

[0144] Advantageously, in this system, the workstation performs operations during pauses between micro-pulses of the structure.

[0145] Preferably, in this system, the workstation performs operations during micro-pulsations between pauses in the structure.

[0146] Preferably, in this system, the cycle time is equal to the duration of the pause between micropulses plus the duration of the micropulses.

[0147] Preferably, in this system, the track follows a series of roller drive structures mounted to the support.

[0148] Preferably, in this system, the transposition features at the structure are paired with complementary features at the transposition units located at the track.

[0149] Preferably, in this system, the feeder assembly line supplies materials according to the cycle time of the feeder assembly line and the half-drum assembly line.

[0150] Preferably, the system also includes a chute that removes waste material from the workstation.

[0151] The manufacture of an aircraft using the system described above is part of this disclosure.

[0152] Other exemplary embodiments (e.g., methods and computer-readable media related to the foregoing embodiments) may be described below. The features, functions, and advantages already discussed may be implemented independently in different embodiments or may be combined in other embodiments, and further details of these features, functions, and advantages may be understood with reference to the following description and drawings. Attached Figure Description

[0153] Now, some embodiments of this disclosure will be described by way of example only and with reference to the accompanying drawings. In all the drawings, the same reference numerals denote the same elements or elements of the same type.

[0154] Figure 1 An example of an assembled aircraft, including a fuselage section, is depicted in an exemplary embodiment.

[0155] Figure 1A This is a block diagram of a line assembly system in an exemplary embodiment.

[0156] Figure 1B This is a diagram of an assembly line in a manufacturing environment as described in an exemplary embodiment.

[0157] Figure 2 This is a flowchart illustrating a method for operating a production line assembly system in an exemplary embodiment.

[0158] Figure 3 This is a perspective view of an assembly line system in an exemplary embodiment, showing the frame mounted on a half-barrel fuselage section.

[0159] Figure 4A This is a perspective view of the indexing unit of the assembly line system in an exemplary embodiment.

[0160] Figures 4B to 4D This is a front view of a support column including rollers in an exemplary embodiment of a production line assembly system.

[0161] Figure 5A This is a side view of a feature machined into the fuselage section in an exemplary embodiment.

[0162] Figure 5B This is a side view of the recess in the fuselage section of an exemplary embodiment.

[0163] Figures 6 to 10 This is a cut-through front view of a feature in the fuselage section of an exemplary embodiment.

[0164] Figure 11This is a perspective view of the shape implementation system for maintaining the shape of the semi-barrel section of the aircraft in an exemplary embodiment.

[0165] Figures 12 to 13 This is a flowchart illustrating another method for operating a production line assembly system in an exemplary embodiment.

[0166] Figure 14 This is a diagram illustrating a layup mandrel for applying a displacement feature to a preform in an exemplary embodiment.

[0167] Figure 15 This is a flowchart illustrating a method for applying a displacement feature to a preform in an exemplary embodiment.

[0168] Figure 16 This is an end view of the track in the illustrative embodiment of the support structure.

[0169] Figure 17 This is a flowchart illustrating a method for transporting the structure by means of manufacturing allowance in an exemplary embodiment.

[0170] Figure 18 This is a flowchart illustrating a method of implementing a shape at the structure, which is maintained by the manufacturing allowance of the structure, in an exemplary embodiment.

[0171] Figure 19 This is a block diagram of an assembly line in an exemplary embodiment.

[0172] Figure 20 This is a flowchart illustrating a method for operating a production line assembly system in an exemplary embodiment.

[0173] Figure 21 This is a flowchart illustrating another method of operating a production line assembly system in an exemplary embodiment.

[0174] Figure 22 This is a flowchart illustrating another method of operating a production line assembly system in an exemplary embodiment.

[0175] Figure 23 This is a flowchart of an aircraft manufacturing and maintenance method in an exemplary embodiment.

[0176] Figure 24 This is a block diagram of an aircraft in an exemplary embodiment. Detailed Implementation

[0177] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. Therefore, it should be appreciated that, although not explicitly described or shown herein, those skilled in the art will be able to design various arrangements that embody the principles of this disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and are to be construed as not being limited to such specific examples and conditions. Consequently, this disclosure is not limited to the specific embodiments or examples described below, but is limited by the claims and their equivalents.

[0178] The fuselage can be made of metal or can be realized as a composite component. Composite components (such as carbon fiber reinforced polymer (CFRP) components) are initially laid out in multiple layers, collectively referred to as preforms. Individual fibers within each layer of the preform are aligned parallel to each other, but different layers can exhibit different fiber orientations to increase the strength of the resulting composite part along different dimensions. The preform may include a viscous resin that solidifies to harden the preform into the composite part. Carbon fibers that have been impregnated with uncured thermosetting or thermoplastic resins are called "prepregs." Other types of carbon fibers include "dry fibers" that are not impregnated with thermosetting resins but may include tackifiers or adhesives. Dry fibers are foamed with resin before curing. For thermosetting resins, curing is a one-way process called curing, while for thermoplastic resins, if the resin is reheated, it can reach a viscous form.

[0179] Now, turn to Figure 1 The illustration depicts an example diagram of an aircraft that can implement an exemplary embodiment. The aircraft 10 can be constructed from... Figure 1A An example of an aircraft formed from a half-barrel section 24 of a fuselage 12. In this exemplary example, aircraft 10 has wings 15 and 16 attached to the fuselage 12. Aircraft 10 includes an engine 14 attached to the wing 15 and an engine 16 attached to the wing 16. The fuselage 12 has a tail section 18 and a nose section 38. Horizontal stabilizers 20, 21, and 22 are attached to the tail section 18 of the fuselage 12. The fuselage 12 is manufactured from the finalized half-barrel section 24, wherein the upper half-barrel section 126 ( Figure 1A The segments are joined to the lower half-barrel segment 128 to form full barrel segments 29-1, 29-2, 29-3, 29-4, and 29-5. Full barrel segment 146 corresponds to view AA, and full barrel segment 136 corresponds to view BB, and these full barrel segments are continuously fastened to the fuselage 12. Wings 15 and 16 are formed by wing panels 30 including upper wing panel 32 and lower wing panel 34 joined together.

[0180] Figure 1AThis is a block diagram of a production line assembly system 100 in an exemplary embodiment. The production line assembly system 100 includes any system, device, or component operable to iteratively micro-pulse 181 a structure 120 along track 110 to a distance less than the length of the structure. While the structure 120 pauses or moves continuously between pulsations 182 and micro-pulsations 181, work (e.g., modification of the structure) is performed on the structure 120 via one or more workstations 140 by the production line assembly system 100. The structure 120 includes a portion of a frame approximately forty feet long, or has any suitable length, such as a length including multiple frame pitches (i.e., multiple times the distance between frames at the fuselage). The structure 120 is a half-barrel segment 320 plus a manufacturing allowance 125, a window manufacturing allowance 170, and a door manufacturing allowance 180 prior to separation during assembly. In such embodiments, the fuselage segment may include any suitable arcuate portion of the fuselage, such as one-third, one-quarter, or one-sixth barrel sections of the fuselage (as desired and not shown). In some embodiments, structure 120 includes hardened composite or metallic components, such as the aircraft's awaiting longitudinal beams and / or frame skin panels for enhanced rigidity.

[0181] In this embodiment, the assembly line system 100 includes a track 110 on which the structure 120 moves along a process direction 199. The track 110 includes one or more powered rollers 152 mounted to the ends of supports 154 or spring-loaded pogo sticks, and / or rails, rollers, or other components that facilitate movement (e.g., rolling or sliding) of the structure 120 along the track 110. In other embodiments, the track 110 includes a chain drive, electric trolley, or other power system capable of moving the structure 120 in the process direction 199.

[0182] The assembly line system 100 also includes indexing units 130. Each indexing unit 130 is designed to be physically connected to indexing features 124 in the surface 122 of the structure 120. The indexing features 124 are positioned along the structure 120, and in one embodiment, the indexing features 124 are spaced equidistant along the structure 120. In some embodiments, the indexing features 124 are applied as part of a precure process or placed on a coating mandrel 1400. Figure 14 The transposition feature 124 is created on or above the shape of the structure 120. In other embodiments, the transposition feature 124 is created and / or placed after a post-cure manufacturing process such as machining or drilling. In other embodiments, the transposition feature 124 is created by placing an RFID tag 562 and / or a barcode 564 on the structure 120. Figure 5A (This is) created after being solidified, wherein the RFID tag and / or barcode are both associated with a transmittable message. In other embodiments, although... Figure 1A The indexing feature 124 is shown in a straight alignment, but it is positioned at various intervals. In other embodiments, different messages guiding assembly instructions are transmitted to workstation 140 via the indexing feature 124, based on the shape, type, or position of the indexing feature 124 relative to the structure 120 (e.g., the shape, height, type, or position of the indexing feature 124 relative to the structure 120). Thus, the indexing feature 124 is customized to provide messages including instructions regarding operations to be performed within the field of view 183 of workstation 140, and multiple instructions are transmitted simultaneously to multiple workstations 140 via one or more indexing features 124. Workstation 140 performs operations based on the instructions transmitted via messages from the indexing feature 124 at structure 120. Figure 1AThe view 183 of station 140 is shown, the length of which is greater than the lengthwise portion 127, but in various embodiments, the length of view 183 varies from the frame pitch 184 to a multiple or fraction of that pitch. In various embodiments, the lengthwise portion 127 varies from the frame pitch 184 to a multiple or fraction of that pitch. For example, placing the indexing feature 124 at different vertical or lateral positions adjacent to the manufacturing allowance 125 of the bearing edge 113, or the window manufacturing allowance 170, or the door manufacturing allowance 180 can indicate the performance of different types of operations. The bearing edge 113 and structure 120 are used to form part of the tooling process during manufacturing. This message can indicate the operation to be performed on structure 120 at a particular station 140. This message can be transmitted based on the pairing of the indexing feature 124 with the complementary feature 134 at the particular station 140. In some embodiments, there are more than one indexing feature 124 per pulse 182 or micro-pulse 181 distance on structure 120. Therefore, one or more transposition features 124 for transmitting messages can engage / pair complementary features 134 at a specific station 140 with each pulse 181 or micro-pulse 182. Detection of message pairing and transmission can be enabled at a specific station 140, for example, to add a window frame, add a specific frame arrangement, cut off window manufacturing allowance 170 or door manufacturing allowance 180, or prevent the execution of a specific operation. Pairing can occur at any location of the transposition feature 124, such as in the window manufacturing allowance 170 or door manufacturing allowance 180. In other embodiments, the transposition feature 124 is provided in the manufacturing allowance 125, window manufacturing allowance 170, and / or door manufacturing allowance 180 of structure 120. The manufacturing allowance 125, window manufacturing allowance 170, and / or door manufacturing allowance 180 are trimmed from structure 120 to facilitate engagement of the half-barrel segment 320 to another half-barrel segment 320 and / or attachment to additional components. Although two workstations 140 are shown, it is conceivable that one workstation 140 or more than two workstations 140 may be positioned along track 110.

[0183] In this embodiment, each indexing unit in indexing unit 130 includes a complementary feature 134 for inserting, clamping, or otherwise mating with or pairing with indexing features 124 created before or after curing. In another embodiment, each indexing unit in indexing unit 130 includes a complementary feature 134 to extract messages by reading RFID tags 562 and / or barcodes 564. Indexing units 130 are positioned relative to a row of 141 workstations 140 and track 110. During assembly, structure 120 is micro-pulsated by a certain distance / pulse length (P) (e.g., at least equal to the shortest distance between indexing features 124, frame pitch distance 184). Figure 3The structure is rotated to the indexing unit 130 (or the distance 185 between stations 140) by a single or multiple times, and the work is performed by station 140. Whenever the indexing feature 124 in structure 120 is paired with the complementary indexing feature 134 in indexing unit 130, the position of structure 120 is rotated to a known position in the coordinate space shared by track 110, indexing unit 130, and station 140. Moreover, in some embodiments, the indexing 129 also carries the force transmitted from one side to the other through structure 120, thereby performing lofting in structure 120 and maintaining structure 120 with the desired outer mold line (OML) and / or inner mold line (IML). When structure 120 is pulsated 182 or micro-pulsated 181 to a specific station 140, the message characterizes structure 120 within the field of view 183 of that station 140 without performing a characterization scan of structure 120 being worked on by that station 140. The indexing feature 124 is used to transmit characterization messages about the structure 120 within the viewport 183 to station 140 via complementary feature 134. That is, micro-pulsations 181 do not alter the configuration of the structure 120 determined before demolding or after scanning upstream 198 of station 140 via non-destructive inspection (NDI) technology. In this way, the indexing feature 129 transmits the configuration / characterization (including IML lofting 177 and / or OML lofting 175) of the work-to-work portion of the structure 120 to station 140, instead of running a scan / re-scan of the entire structure 120 as part of individual pulses 181 or micro-pulsations 182, to save time and labor while maintaining quality. Furthermore, any forces applied to structure 120 to cause outward or inward bending are resisted via track 110 with the aid of rollers mounted on a spring-loaded stilt, resulting in the desired outer mold line (OML) and inner mold line (IML) at the desired loft position (e.g., maintaining an arched shape), allowing track 110 to implement compliance with the desired IML loft 177 and / or OML loft 175. In other embodiments, structure 120 maintains the desired IML loft 177 and / or OML loft 175 shape without applying forming forces and / or equipment. In any case, when structure 120 receives work from station 140, the structure is aligned with the desired IML loft 177 and / or OML loft 175. Specifically, each indexing unit 130 is positioned at a known offset (O) from the station 140 (e.g., along the three axes), which means that the action of indexing structure 120 toward indexing unit 130 129 makes the position of structure 120 within the field of view 183 of each station 140 known.The width of the track, together with the IML layout 177 and / or OML layout 175e of structure 120, and the delayed execution of cutting off window manufacturing allowance 170 and door manufacturing allowance 180 until after the installation of the frame, window frame and door frame, and possibly other means of maintaining the desired IML layout 177 and / or OML layout 175, all help to ensure that the configuration of structure 120 is maintained as desired when the work is rotated at a particular station 140.

[0184] In one embodiment, the transposition 129 is performed at least according to the following description. The structure 120 is transported via a track 110, which comprises a rail system embedded in the ground and bolted to the ground, etc. The rails (e.g., tandemly arranged supports 154 / spring stilts) are positioned in known locations. The structure 120 has been manufactured to precise dimensions on a lamination mandrel 1400. Moreover, the mandrel has precise features that facilitate the positioning of the transposition feature 124 within the manufacturing allowances 125, 170, and / or 180 of the structure 120, and this precise lamination allows the transposition feature 124 to be precisely positioned within the manufacturing allowances 125, 170, and / or 180 of the structure 120. Therefore, once the half-barrel segment 320 is positioned on the precisely positioned track 110 (and possibly with additional inner mold line (IML) or outer mold line (OML) forced tooling set upstream 198 or downstream 197 of station 140), the 3D position of the half-barrel segment 320 and the IML lofting 177 and / or OML lofting 175 are precisely known when engaging the indexing feature 124, without the need for a full scan via probe or optical technology at each station 140 with pauses between individual pulses 182 or micro-pulses 181.

[0185] In this implementation, the inherent stiffness of the demolded or otherwise formed structure 120, along with the precisely positioned track 110, can be relied upon to maintain the desired IML loft 177 and / or OML loft 175 without any joining shape-defining tooling during pulsation 182 or micropulsation 181 assembly. With this arrangement, the indexing feature 124 is precisely positioned within the structure 120 relative to the IML loft 177 and / or OML loft 175, and the precisely positioned track 110 facilitates the transfer of the structure 120 from station 140 to station 140 without any deformation of the IML loft 177 and / or OML loft 175 beyond tolerance. Therefore, the 3D features / positions, IML lofts 177 and / or OML lofts 175, and orientation and / or digitization of the structure 120 are quickly and accurately known (i.e., indexed) after each pulsation 181 or micropulsation 182 without requiring a rescan of the structure 120 each time.

[0186] Because precise indexing 129 is performed, the position of each tool at each station 140 can be precisely determined relative to structure 120 when structure 120 is positioned at station 140 via indexing unit 130. The 3D position and orientation of structure 120, and / or IML lofting 177 and / or OML lofting 175 are then established or indexed to any CNC programming or automation system used at station 140. Therefore, no time or scan is required after or during the individual pulses 182 or micro-pulses 181 of structure 120. Moreover, structures added to or removed from existing station 140 can be added to any structure 120 model or representation within the system without requiring a scan of structure 120 for modification.

[0187] In other embodiments, the spacing and vertical position of the indexing features 124 within the manufacturing allowance 125 vary along the length of the structure 120, as does their distance from the bearing edge 113 of the contact track 110. When paired with complementary features 134, the shape, arrangement, and / or size of each indexing feature 124 can be changed as needed to convey specific messages to station 140. For example, placement of an indexing feature 124 with a first shape in a first position may indicate a desire to install a first type of frame, while placement of an indexing feature 124 with a second shape in a second position may indicate a desire to install a second type of frame. When indexing unit 130 is paired with indexing features 124, 3D representations and / or digitizations of the portion of the structure within the field of view 183 of station 140 are obtained, as in the operations to be performed by station 140. In other embodiments, a shifting feature 124 is provided in the manufacturing allowance 125 of structure 120, which is trimmed off before structure 120 is put into service.

[0188] In other embodiments, manufacturing allowances exist in the form of window manufacturing allowance 170 and door manufacturing allowance 180, which are trimmed from structure 120 after frame installation has occurred. Frames, window frames, and door frames are installed to reinforce structure 120 before removing window manufacturing allowance 170 or door manufacturing allowance 180. In this embodiment, each indexing unit in indexing unit 130 includes a complementary feature 134 for inserting, clamping, or otherwise engaging indexing feature 124. Indexing unit 130 is positioned relative to station 140 and track 110. During assembly, structure 120 is pulsated 182 or micro-pulsated 181 a certain distance (e.g., at least equal to the shortest distance between indexing features 124) to indexing unit 130, and this is performed by station 140. That is, structure 120 is pulsated 182 or micro-pulsated 181 to the indexed position. Whenever the indexing feature 124 in structure 120 is paired with the complementary indexing feature 134 in indexing unit 130, the position of structure 120 is indexed to a known position in the coordinate space shared by track 110, indexing unit 130, and station 140. Specifically, each indexing unit 130 is positioned at a known offset (O) from station 140 (e.g., along the three axes), meaning that the action of indexing structure 120 toward indexing unit 130 129 makes the position of structure 120 relative to station 140 known. When the complementary indexing feature 134 is paired with indexing feature 124, the 3D representation and / or digitization of the portion of structure 120 within the field of view 183 of station 140, including IML lofting 177 and / or OML lofting 175, is obtained, along with the operations to be performed by station 140. In one embodiment, this knowledge is derived from a prior scan of the retrieved structure 120 (or a portion thereof) and aligned with positional information obtained from the shifting unit 130. In another embodiment, this knowledge is obtained by reading a radio frequency identifier (RFID) tag 562 attached to the structure 120 closest to the shifting unit 130. The shifting unit 130 may also be positioned at a specific shifting station 140. In this way, different messages are transmitted to station 140 based on the RFID tag 562. To reiterate, the shifting process 129 transmits a digital and / or 3D representation of the portion of structure 120 within the field of view 183 of the specific station 140, including IML lofting 177 and / or OML lofting 175, and the operations to be performed by station 140. In some embodiments, the shifting process 129 transmits a message that no operation will be performed on that portion of structure 120 at station 140. Shifting and instructions can be performed simultaneously on multiple stations 140 before operations are simultaneously performed on structure 120.

[0189] Workstation 140 performs operations on structure 120. Workstation 140 is arranged along track 110 and is spaced apart by a length 196 shorter than that of structure 120. The operations may include installing new components (such as frames) onto structure 120 via fasteners, material removal (e.g., drilling or trimming), material addition, etc. In one embodiment, each workstation in workstation 140 performs a single type of operation, such as installing frames, installing intercostal ribs, installing door frames, installing window frames, trimming door frame manufacturing allowance 180, trimming manufacturing allowance 125, or cutting window manufacturing allowance 170.

[0190] In embodiments where structure 120 includes the semi-barrel segment 320 of the aircraft fuselage, some stations in station 140 include a pair of rings (e.g., fixed arches) through which structure 120 travels during pulsations 182 or micro-pulsations 181. In other embodiments, structure 120 travels above or inside station 140 during pulsations 182 or micro-pulsations 181 (particularly in stations entirely within structure 120 during pulsations 182 or micro-pulsations 181). This exposes both the outer mold line (OML) and inner mold line (IML) of structure 120 to station 140, which facilitates clamping and other tasks for fastener installation. OML machine 142 and IML machine 144 are clamped together to perform fastener installation when the frame is installed into structure 120. In still other embodiments, the physical fit formed between indexing unit 130 and structure 120 makes structure 120 resistant to forces applied as described above. That is, the force applied to structure 120 is at least partially resisted by the physical fit / connection between structure 120 and indexing unit 130, and is transmitted to indexing unit 130. This enables station 140 to perform a One-Time Assembly (OUA) process. OUA involves assembling using machining operations (such as drilling), followed by applying sealant to the mating surfaces without disassembly to clean drill chips, deburr, and install fasteners after reassembly. The OUA process applies sealant appropriately to the mating surfaces and performs fastening without disassembly to deburr and clean drill chips between the structures being fastened together. This allows the clamping force between structure 120 and the machine to reach a desired level as the machine performs its work. In other embodiments, station 140 may perform operations such as nondestructive imaging (NDI), window and door cutting, trimming operations, edge sealing, and other tasks.

[0191] The operation of station 140 is managed by controller 112. In one embodiment, controller 112 determines the progress of structure 120 along track 110 (e.g., based on input from a technician) and uses that input to manage the operation of station 140 according to instructions stored in a numerical control (NC) program and any messages transmitted via indexer 129. Controller 112 can be implemented, for example, as custom circuitry, a hardware processor that executes programmed instructions, or a combination thereof.

[0192] To put it another way, Figure 1A An apparatus for assembling a structure is described, comprising at least one station 140 disposed along a track 110, and a shifting unit 130 disposed relative to the at least one station 140. The shifting unit 130 is disposed with a known offset from a corresponding station among the at least one station 140. Furthermore, the shifting unit 130 includes a complementary shifting feature 134 that engages with a shifting feature 124 at a structure 120 to receive work from the station 140. In some embodiments, the complementary shifting feature 134 is sized to mate with shifting features 124 in manufacturing allowances 125, window manufacturing allowances 170, and / or door manufacturing allowances 180 of the structure 120. In other embodiments, the at least one station 140 comprises a plurality of stations 140, and the plurality of stations 140 are arranged sequentially along the track and the structure 120 advancing along the track 110.

[0193] Figure 1BThis is a diagram 190 of an assembly line in a manufacturing environment according to an exemplary embodiment. In this embodiment, feeder lines 191-1 to 191-3 supply raw materials to the layup line and can feed into a track (e.g., track 110) based on cycle time. Specifically, feeder line 191-1 supplies layup material (e.g., CFRP tow, wide stock, etc.) to layup line 192-1 of structure 120, feeder line 191-2 supplies layup material to frame layup and forming line 192-2, and feeder line 191-3 supplies material for surrounding layup and forming line 192-3. The continuous lamination line 192-1 of the half-barrel segment 320 lays preforms of structure 120 for hardening into composite components such as structure 120, and receives longitudinal beam preforms from feeder line 191-4. Feeder line 191-4 manufactures longitudinal beam preforms by any suitable means, and receives lamination material from feeder line 191-5. Frame lamination and forming line 192-2 manufactures preforms for frames and supplies these preforms to frame feeder line 193-2. Frame lamination and forming line 192-3 manufactures preforms for frames (e.g., window frames, door frames, etc.) to be placed onto structure 120 of the fuselage.

[0194] The preforms of the structure 120 of the machine body are provided to the half-barrel assembly line 193-3. The half-barrel assembly line 193-3 also receives frames via frame feeder line 193-2 and packing frames via packing feeder line 193-1. The half-barrel assembly line 193-3 also hardens one or more of these components together, receives fasteners via fastener feeder line 194-1 and sealant via sealant feeder line 194-2 to facilitate the installation of hardened parts (e.g., hardened frames), and removes trimmed material, waste, and / or debris via an outflow line 194-3, which operates according to common or different cycle times. An additional scrap feeder line 194-4 provides various components of the structure 120 under manufacture to facilitate further fabrication. Furthermore, the various pipeline operations discussed above can be made to continuously advance the components that are performing the work, to micro-pulse these components by iteratively advancing the components to a length less than their own and pausing, or to pulsate these components by iteratively advancing the components to the length between each advance and pausing.

[0195] Figure 1BEach production line in the various described assembly lines can operate at the same or different cycle times as the other production lines to provide just-in-time delivery of components as needed. For example, it can be... Figure 1B The various numbered takts are set to a common interval (e.g., 20 minutes) or different intervals. Multiple production lines utilize a unique or shared takt and provide just-in-time (JIT) delivery to the next production line. In one implementation, the feeder production lines have takts different from the takts of the production lines they feed. Each feeder production line may have a unique takt or may have a takt similar to the other feeder production lines they feed.

[0196] Figure 1B Figure 190 shows an assembly line 189 in an exemplary manufacturing environment. In this embodiment, feeder lines 191-1 to 191-3 supply raw materials to the lamination line. Specifically, feeder line 191-1 supplies lamination material (e.g., CFRP tow, wide stock, etc.) to the half-barrel continuous lamination line 192-1, feeder line 191-2 supplies lamination material to the frame lamination and forming line 192-2, and feeder line 191-3 supplies material for the frame lamination and forming line 192-3. The half-barrel continuous lamination line 192-1 lays half-barrel preforms for hardening into composite components and receives longitudinal beam preforms from feeder line 191-4. Feeder line 191-4 manufactures longitudinal beam preforms by any suitable means and receives cladding material from feeder line 191-5. Frame cladding and forming line 192-2 manufactures preforms for the frame and supplies these preforms to frame feeder line 193-2. Cladding cladding and forming line 192-3 manufactures preforms for cladding (e.g., window frames, door frames, etc.) to be placed on the fuselage section.

[0197] The pre-formed body sections are fed to the half-barrel assembly line 193-3. The half-barrel assembly line 193-3 also receives frames via frame feeder line 193-2 and frames via frame feeder line 193-1. The half-barrel assembly line 193-3 also fastens one or more of these components together, receives fasteners via fastener feeder line 194-1 and sealant via sealant feeder line 194-2 to facilitate component installation (e.g., frames), and removes trimmed material, such as manufacturing allowance 125, window manufacturing allowance 170, or door manufacturing allowance 180, via the outflow line 194-3. Depending on the cycle time of the half-barrel assembly line 193-3 and the cycle time of the outflow line 194-3, waste material is removed from station 140 via the outflow line 194-3. The additional scrap feeder line 194-4 provides various components for further manufacturing of the half-barrel segments being manufactured. Material is supplied from the feeder lines (191-1, 191-2, 191-3, 192-1, 193-1, 193-2, 194-1, 194-2, 194-4) based on the cycle time of the half-barrel assembly line (193-3). Furthermore, the various lines discussed above can be operated to continuously advance the components they are working on, to "micro-pulse" these components by iteratively advancing them to a length less than their own and pausing, or to "fully pulsate" these components by iteratively advancing them to at least their own length and pausing.

[0198] Figure 1B The depicted feeder line arrangement illustrates how sub-assemblies are manufactured and combined to form larger assemblies by delivering them via JIT to the next assembly stage. This is made possible by designing / customizing the cycle times of various feeder lines based on the cycle times of other feeder lines. For example, the cycle time of a feeder line for a sub-assembly (e.g., a wing) can be a portion of the cycle time of a feeder line for an assembly (e.g., an entire frame). Alternatively, the cycle time of an assembly can be an integer multiple of the cycle times of the sub-assemblies that are used multiple times within that assembly. In one embodiment, the cycle time is based on the number of aircraft manufactured per month. In another embodiment, the cycle time is based on the number of aircraft manufactured per month and the number of assemblies required per aircraft. In yet another embodiment, the cycle time is defined for a row of workstations 140 performing job assignments (e.g., a scheduled workload repeated across multiple assemblies).

[0199] Reference Figure 2The following are illustrative details of the operation of the assembly line system 100. For this embodiment, it is assumed that one or more structures of structure 120 have been placed sequentially on track 110 and are ready for assembly via fastening attachments.

[0200] Figure 2 This is a flowchart illustrating a method 200 for operating a production line assembly system 100 in an exemplary embodiment. (Refer to...) Figure 1 The steps of method 200 are described using a production line assembly system 100 as an example; however, those skilled in the art will recognize that method 200 can be performed in other ways. The steps in the flowcharts described herein are not exhaustive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0201] In step 202, structure 120 is micro-pulsed 181 or 182 along track 110 (e.g., along the length of track 110) in the process direction 199 to a length less than or equal to that of structure 120. This occurs at a common station 140 cycle time, meaning that all stations 140 can perform work during the same time period (e.g., during the same pause between micro-pulses 181 or 182, or during micro-pulses 181). That is, multiple stations 140 can perform work on the same or different structures 120 during the same pause between micro-pulses 181 or 182, or during the same micro-pulse 181 or 182 between pauses. Continuously, structure 120 is operated on by at least one of the stations 140 before being rotated to station 140. Additionally, without shifting the structure 120 to station 140 (such as during NDI inspection), operations can be performed on the structure 120 by at least one of the stations 140.

[0202] The micro-pulsation 181 structure 120 exposes a new longitudinal portion 127 for the station 140 to receive work. This new longitudinal portion 127 of the structure 120 is brought into the field of view 183 of the station 140. In embodiments, the longitudinal portion 127 is equal to the micro-pulsation 181, a multiple of the micro-pulsation 181, or a portion of the micro-pulsation 181. Although the micro-pulsation 181 is shown as equal to the field of view 183, other lengths, such as frame pitch 184, are also contemplated. In embodiments where the track 110 is powered, this includes driving one or more components of the track 110 (e.g., powered and unpowered rollers 152) to move the structure along the process direction 199. Figure 1AIn the depicted example, powered and unpowered rollers 152 are used for this purpose. Powered roller 152 is mounted to support 154 (which is mounted to the factory floor) and drives the structure synchronously with micro-pulsations 181, or causes the structure to advance continuously along the process direction 199. In other embodiments, this includes operating a self-driving gantry (AGV), operating a powered trolley mounted to track 110, or operating another component to micro-pulsate structure 120 along track 110 to a desired position. In embodiments where an additional structure 120 is positioned on track 110, the additional structure 120 is... Figure 1A The micro-pulsations 181 of the depicted structure 120 are also synchronously micro-pulsated to a length less than that of the structure 120. During the same pause, the additional structure 120 is operated on via multiple stations 140 arranged consecutively along the process direction 199, and occupies the following portion of the track 110: this portion is immediately adjacent to the structure 120 with a gap 1990 ( Figure 19 ) Separate upstream 198 or downstream 197.

[0203] In step 204, the structure is indexed toward station 140, positioned along track 110, by pairing indexing feature 124 in the manufacturing allowance of structure 120 with complementary feature 134, the complementary feature being positioned relative to track 110 with a known offset from station 140 at track 110. The structure 120 is indexed toward track 110 and / or station 140 by pairing indexing feature 124 in structure 120 with complementary indexing feature 134, the complementary indexing feature being positioned relative to track 110 with a known offset from station 140 at track 110. This makes the position of station 140 known relative to a portion of the work received from station 140 by structure 120. In one embodiment, complementary indexing feature 134 (such as a pin disposed at track 110 and / or station 140) is engaged into indexing feature 124 (such as a hole placed in structure 120 at predetermined intervals, such as by machining). After structure 120 has been indexed, the position of structure 120 relative to station 140 is known (i.e., at least in part because the offset from indexing unit 130 to station 140 is known). Therefore, even for very large structures, operations can be performed with the desired level of accuracy (e.g., within fractions of an inch). In an embodiment where multiple structures 120 travel along track 110 at a time, the indexing 129 of structures 120 can be performed synchronously, such that multiple indexing features 124 of each structure in these structures 120 are synchronously paired with multiple stations 140. In one embodiment, the step of indexing structure 120 to station 140 129 is performed in a manner that multiple stations 140 are indexed to structure 120 at a time, and the multiple stations 140 perform operations during pauses between micro-pulses 181 of structure 120.

[0204] In step 206, when structure 120 is rotated toward track 110 and / or station 140, station 140 performs operations on structure 120. The operations may include any of the operations discussed above regarding station 140. In one embodiment, the operation includes installing a frame by fastening it to structure 120. In embodiments where multiple structures 120 travel along track 110 simultaneously, the operations on structure 120 can be performed synchronously. That is, rotation 129 is synchronized across stations 140, and station 140 performs operations on different longitudinal portions 127 of structure 120 during pauses between micro-pulses 181.

[0205] In step 208, steps 202 through 206 (i.e., micro-pulsation 181, rotation 129, and operation) are repeated until structure 120 has moved a distance at least equal to its length. That is, structure 120 continues to move in small increments and receive operations from stations 140 (e.g., from multiple stations 140 at a time, with each station performing operations on different longitudinal sections 127 of the structure at a common beat time during pauses between micro-pulsations 181 of structure 120) until structure 120 has passed all stations 140. This incremental process continues, and depending on the number and type of operations to be performed on structure 120, structure 120 eventually advances a distance longer than its length. Furthermore, structure 120 can be routed via switching technology to other tracks 110 with different combinations of stations 140 to receive additional or alternative types of operations.

[0206] Method 200 offers technical benefits superior to existing technologies because it enables assembly line-based technology on large structures such as aircraft fuselages. Specifically, multiple longitudinal sections 127 of the same structure 120 are operated simultaneously by multiple workstations 140 arranged in series with a common beat. Because this technology moves large structures in small increments (referred to herein as “micro-pulses 181”) smaller than the length of structure 120, it also reduces the amount of work that needs to be completed in each work interval, thus reducing the risk of delays and the potential length of such delays. The workload can be more evenly distributed among the micro-pulses passing through workstations 140. The micro-pulses of all workstations 140 at track 110 are performed with respect to each of the multiple micro-pulses 181 in a common beat. The magnitude of the workload performed by each workstation 140 allows work to be completed at each workstation 140 during pauses between micro-pulses 181. If the beat cannot be met, the workload is adjusted in a particular workstation 140. For example, another workstation 140 can be added to perform some of the workload of workstation 140 that cannot complete its tasks within the current cycle time. The use of the second workstation 140 provides twice the time to perform the same amount of work.

[0207] Figure 3 This is a perspective view of a production line assembly system 300, in an exemplary embodiment, in which frames are mounted onto one or more structures of the structure 120 during other assembly operations. Production line assembly system 300 corresponds to production line assembly system 100. (As...) Figure 3 As shown, the assembly line system 300 includes stations 330 and 340 (which perform operations by securing frames 302 into place and / or cutting windows, respectively), and stations 360 and 370 (which perform NDI inspection and window frame installation, respectively). Stations 330 and 340, as well as stations 360 and 370, correspond to station 140. Between operation periods, structure 120 moves along track 310, which has been divided into a series of posts 312 (also referred to as struts or spring stilts) including rollers 314 for receiving structure 120. Track 310 corresponds to track 110. During each pulse, structure 120 moves a distance P. Distance P may include a frame pitch 184 less than 24 inches or a multiple thereof, which may be the frame pitch 184 distance between the frames of the assembled fuselage. Furthermore, after the non-destructive imaging (NDI) inspection station 360, there may be multiple frame installation stations 330 and window frame installation stations 360, followed by door and window cutting stations 140, final panel finishing stations 140, and / or any other number of stations 140. Stations 140 are configured to mate within and / or centered on the length of structure 120, which is pulsed through during assembly. Shift features 322 corresponding to shift features 124 within structure 120 are separated at intervals I, which are less than P or multiples of P. At the end of each micro-pulse 181, during the pause between micro-pulses 181, the shift features 322 are paired with shift units 350 at station 140. Thus, shifting 129 is synchronized at station 140. During micro-pulsation 181, some stations 140 (such as those performing NDI) perform operations, while other stations (such as frame installation station 140) perform operations during pauses between micro-pulsations 181. Figure 3 It also depicts the cutout 324 used for the window.

[0208] In one embodiment, each of the workstations 140 is separated from its adjacent workstations by a distance equal to the frame pitch (or a multiple or fraction thereof). For example, a non-destructive inspection (NDI) workstation may be separated from the first frame installation workstation 140 by a distance of one frame pitch 184, and a frame installation workstation 140 may be one of a series of frame installation workstations 140, each separated from the others by a single frame pitch 184. Following the last frame installation workstation 140 may be one or more window frame installation workstations 140 in series, followed by one or more door frame installation workstations 140, one or more cutting workstations 140, one or more trimming workstations 140, one or more edge sealing workstations 140, etc. Each workstation 140 is separated from its adjacent workstation by one frame pitch (or a multiple or fraction thereof). In embodiments where structure 120 extends forty or more feet along the assembly line and the frame pitch 184 is eighteen to twenty-two inches, this arrangement advantageously generates technical benefits by saving space on the factory floor. Instead of having a single unit performing one operation at a time with the length of structure 120, the work density is significantly increased if various job assignments are performed in a space of the same size. That is, the work is performed by workstations 140 arranged continuously along the current footprint of at least one structure 120, instead of being defined as multiple fixed units, each sized to encompass the entire length of structure 120.

[0209] Figure 4A This is a perspective view of the indexing unit 130 of the assembly line system 300 in the exemplary embodiment, and is related to... Figure 3 The view arrow 4A corresponds to this. According to... Figure 4A The indexing unit 350 includes a pin 410 having a cylindrical shape and a diameter D for insertion into an indexing feature 124 on the structure 120, and the pin 410 is rotatable along the joint 420 and / or retracted into the recess 412 to move in alignment and misalignment with the indexing feature 124. The indexing unit 350 also includes a body 430 having a cylindrical shape 411, which is positioned relative to the track 110. However, in other embodiments, multiple indexing units 130 and indexing features 124 may be utilized as needed.

[0210] Figures 4B to 4D This is a front view of the support column 456, including roller 452, of the assembly line system 300 in the exemplary embodiment. These figures are consistent with... Figure 3 The view arrow 4B corresponds to this. In some embodiments, the supports are extendable, while in others they are fixed. Figure 4BIn this embodiment, a system 450 comprising three rollers 452 and 454 is used to support the support edge 451 (e.g., the lower edge) of the structure 120. The rollers 452 roll freely and prevent lateral displacement 458 of the support edge 451. The support edge 451 corresponds to the support edge 113. Power is supplied to the rollers 454, driving the support edge 451 along the process direction 199 of the page entry / exit. In another embodiment, power is supplied to the rollers 452 while the rollers 454 roll freely. Figure 4C In this configuration, a system 460, including a "barbell-shaped" roller 461, is used to support the load-bearing edge 451 (e.g., the lower edge) of the structure. Power is supplied to the roller 461, and a bell plate 462 is included to prevent lateral displacement 458 of the load-bearing edge 451. Meanwhile, a central shaft 464 transports the load-bearing edge 451. Figure 4D In this system, a "slant barbell" roller 471 is included for supporting the load-bearing edge 451 (e.g., the lower edge) of the structure. Power is supplied to the roller 471, and a barbell plate 472 includes an inclined surface 473 to prevent lateral displacement 458 of the load-bearing edge 451. Meanwhile, a central shaft 474 transports the load-bearing edge 451. (The above refers to...) Figures 4B to 4D The rollers and barbell plates described are independently operated, and even if they act synchronously to drive the structure in the process direction, they can move independently or even be powered independently.

[0211] Figure 5A This is a side view of the transposition feature 322 in structure 120 (or other structures) in the exemplary embodiment, and is related to... Figure 3 The view arrow 5 corresponds to this. Any one or a combination of these pivoting features 322 (e.g., through-hole 530, blind hole 540, slot 550, pin 560, RFID tag 562 and / or barcode 564, etc.) can be implemented at a given structure in the form of structure 120. In this embodiment, structure 120 remains integral with the flash edge portion 510 along the bearing edge 512 and the manufacturing allowance 520 corresponding to the manufacturing allowance 125, which corresponds to the bearing edge 113 (also referred to as the "lower edge") of structure 120. Structure 120 also includes a window manufacturing allowance 522 located at the material area 523 corresponding to the window manufacturing allowance 170, which will be at the window cutting station (e.g., Figure 1After one of the workstations 140, it is cut from the structure 120. Indexing features 322 (e.g., through holes 530, blind holes 540, slots 550, pins 560, RFID tags 562, and / or barcodes 564, etc.) are placed in manufacturing allowances 520 and / or manufacturing allowances 522, and these indexing features 322 (e.g., through holes 530, blind holes 540, slots 550, pins 560, RFID tags 562, and / or barcodes 564, etc.) can be installed during post-curing processes before demolding. Furthermore, the flash portion 510 is roughly trimmed to establish the load-bearing edge 512 of the structure 120. Along the track (e.g., Figure 1 Before moving structure 120 on track 110, the flash portion 510 is trimmed to form a bearing edge 514 to eliminate any sharp edges formed during the curing process. The bearing edge 514 is used to transport structure 120 on rollers. Finally, when manufacturing allowance 520 and / or manufacturing allowance 522 are no longer needed for indexing 129, the manufacturing allowance 520 is trimmed away. This provides an advantage because any protrusions or gaps added to the bearing edge 514 during pulsation can be trimmed away with the manufacturing allowance 520 and / or manufacturing allowance 522 without rework. In one embodiment, if trimming is performed on a portion of the structure that is not integrated into the finished aircraft (i.e., if that portion of the structure is not a "flyaway" component integrally made with the aircraft), less precise rework is required. Such rework can be limited to requiring micro-pulsation of structure 120 through station 140 while providing the desired accuracy / precision for the manufacturing operation.

[0212] In other embodiments, the two arched edges 592 and 594 of structure 120 may also have roughened manufacturing edges that are trimmed on the coating mandrel 1400 and optionally finalized near the end of the micropulsation 181 fabrication. This provides a similar benefit because any resulting protrusions or gaps can be trimmed away before final assembly. That is, protrusions or gaps are trimmed as trimmed portions to achieve the desired fly-away edge dimensions.

[0213] like Figure 5A As shown, the indexing feature 124 is installed in the manufacturing allowance 520 and / or installed as an indexing feature 524 at the manufacturing allowance 522, and corresponds to the indexing feature 124 and the manufacturing allowance 125, respectively. For example, this manufacturing allowance 125, 170, 180 is trimmed / removed just before fastening half-barrel segment 320 to another half-barrel segment 320 (e.g., when two half-barrel segments 320 are joined longitudinally to form a full barrel segment), or during a window cutting operation. The indexing feature 524 includes: a through hole 530, terminating at... Figure 7The blind hole 540 at 700 of the backing terminates at Figure 8 The groove 550 at 800 of the backing, and the drive through Figure 9 A 900mm through hole and a 560mm pin. Therefore, these features can include different types of holes, countersunk holes, notches, or even pins. Figure 9 In one figure, the pin itself is a mating feature that the indexing station or other station 140 will engage with, while in other figures, a hole or notch engages with station 140.

[0214] Therefore, various features among these different characteristics can be utilized to facilitate indexing 129 or other operations at various stations 140. For example, some stations 140 may use one type of feature (e.g., a blind hole that facilitates placement of the structure relative to the station), while other stations 140 may use another type of feature (e.g., a pin that facilitates clamping the part). The possibility of using convex features (e.g., pins) and / or concave features (e.g., holes) means that low-profile stations (e.g., NDI inspection stations) can interact with concave features of the part without physical interference. These are examples of some of the many geometries that can be implemented to achieve indexing mating in a desired manner.

[0215] The spacing of the shifting feature 524 provided herein is not shown to scale, and the micropulse 181 can be set as frame pitch 184 or other distances. Therefore, the spacing can be much smaller than the spacing currently shown, and can be smaller than the spacing between windows. In another embodiment, more than one feature per pulse exists on structure 120. The shifting feature 124 can engage / pair complementary features 134 at a specific station 140 with each micropulse 181. This pairing activates the specific station 140 to add a specific frame arrangement, or window frame, or trim window manufacturing allowance 522, or trim manufacturing allowance 520, or door manufacturing allowance 180, or indicate that station 140 will not perform a specific operation within view 183.

[0216] Figure 5B This is a side view of the recess 570 in the fuselage structure 120 of the exemplary embodiment, and is consistent with... Figure 3 Corresponding to arrow 5 in the view. The notch 570 is trapezoidal, including the recess 572. In this embodiment, the notch 570 does not extend completely through the thickness T of the manufacturing allowance 520 (e.g., ...). Figure 10 (As shown). In other embodiments, a through notch or a notch accessible only from one side (not shown) is possible. Figure 5BAnother notch in the form of a square notch 580 is also shown. Additional shapes and / or sizes of the notch can facilitate locking / alignment / placement at different workstations. For example, a window cutting workstation may utilize a square notch 580, while a frame installation workstation may utilize a trapezoidal notch 570.

[0217] Figure 11 This is a perspective view of a shape implementation system for maintaining the shape of the semi-cylinder fuselage section 1110 of an aircraft in an exemplary embodiment (specifically, an embodiment prior to the mounting frame and / or door / window frames). The shape implementation system 1100 is particularly advantageous for implementing IML lofting 177 and / or OML lofting 175 onto the skin of the semi-cylinder fuselage section 1110 before and after the frame is installed into the semi-cylinder fuselage section 1110. The semi-cylinder fuselage section 1110 corresponds to structure 120. According to... Figure 11 The shape implementation system 1100 includes a structural ring 1120 located on the leading edge 1132 or the trailing edge 1131 or both of the semi-barrel fuselage section 1110. Figure 11 In this embodiment, the shape implementation system 1100 illustrates a structural ring 1120 located only on the leading edge 1132. The structural ring can be secured to the inner mold line (IML) surface 1133 or the outer mold line (OML) surface 1134, or complementaryly coupled to the leading edge 1132 or the trailing edge 1131, and / or overlap with both the inner mold line (IML) surface 1133 or the outer mold line (OML) surface 1134. The ring can be attached via clamps or fasteners and removed after the semi-barrel fuselage section 1110 is placed on a track (e.g., along micro-pulses 181 or pulsations 182 of track 110) and before the installation of the frame and / or window or door frame providing mechanical support. After the frame and / or window or door frame or other reinforcements are installed, the semi-barrel fuselage section 1110 is reinforced sufficiently to eliminate the need for the shape implementation system 1100. Another implementation does not use the shape implementation system 1100 before installing the frame and / or window frame or door frame or other reinforcements.

[0218] The shape implementation system 1100 forms a semi-circular shape and includes multiple clamps 1130 that attach the structural ring 1120 to the semi-barrel body section to implement the desired level of curvature. In some embodiments, various implementation systems are used to ensure compliance with the desired positioning along the six degrees of freedom, such as IML lofting 177 and / or OML lofting 175. In other embodiments, the desired implementation parameters change between stations 140, or multiple stations 140 share a single implementation mechanism. The implementation system may even contact and / or interact with the indexing feature 124 to provide the desired amount and type of implementation. Moreover, compliance with the desired loft level or shape implementation can be detected via an NDI inspection station or other components.

[0219] Figures 12 to 13This is a flowchart illustrating another method for operating the assembly line system 100 in an exemplary embodiment. Figure 12 A method 1200 is illustrated for indexing structure 120 129 after each of a plurality of micropulses 181 along a process direction 199. Method 1200 includes the following steps: In step 1202, an indexing feature 124 is added to preform 1440 (…). Figure 14 (e.g., untreated or pre-hardened structure 120), while the preform 1440 is positioned on the coating mandrel (e.g., Figure 14 The preform 1440 is placed on a mandrel 1400. In step 1204, the hardened preform 1440 is placed on a conveying device 111 (e.g., track 110) that maintains the layout and / or shape of the preform 1440. Then, in step 1206, the preform 1440 is moved to station 140 in the process direction without changing the layout of the preform 1440. Method 1200 further includes the step of: in step 1208, connecting a shifting unit 130 to one of a plurality of shifting features 124 in the preform 1440. In one embodiment, this step involves connecting more than one shifting unit 130 to a corresponding shifting feature 124 so that during pauses between micropulses 181, multiple stations 140 can operate on the structure 120 within their field of view 183.

[0220] Figure 13A method 1300 is illustrated for inverting structure 120 129 after each of a plurality of micropulses 181 along a process direction 199. Specifically, method 1300 is less than the length of structure 120 with respect to the micropulses 181. Step 1302 includes: micropulsating the structure 1200 being assembled from one station 140 to the next station in station 140 via micropulses 181. Step 1304 includes: locking the inversion feature 124 of structure 120 into complementary feature 134 at station 140 (e.g., at inversion unit 130 located at station 140). Step 1306 includes: determining the precise 3D position of structure 120 at the moment of inversion 129. As used herein, precise 3D positioning can refer to the location of a component at least twenty feet long relative to each of the three vertical axes along the desired tolerances, and / or the configuration / characterization (including IML lofting 177 and / or OML lofting 175) of structure 120 within the field of view 183 of transfer station 140. The precise 3D position of structure 120 is known because the precise position of indexing feature 124 relative to structure 120 is known, and because structure 120 has already been characterized upstream 198 via NDI scanning, optical techniques, or other means (such as relying on the accuracy of the plating mandrel transferred to the hardened structure 120). In another embodiment, the 3D IML lofting 177 and / or OML lofting 175 characterization of structure 120 is known without scanning, based on the accuracy of the plating mandrel used to form structure 120. Shape-defining features such as wheels and arches can also be used to implement profile and / or IML lofting 177 and / or OML lofting 175, thereby eliminating the need for scanning.

[0221] A representation of a portion of structure 120 within the field of view 183 of station 140 is linked to an indexing feature 124 placed in or above the manufacturing allowance 125 of structure 120. When indexing feature 124 is paired with complementary indexing feature 134, a representation of the portion of structure 120 to be operated by station 140 is transferred to station 140. Similar operations are performed simultaneously at all stations 140 for the corresponding portions of structure 120 to be operated.

[0222] Figure 14 This is a diagram illustrating a coating mandrel 1400 for applying a displacement feature to a preform in an exemplary embodiment.

[0223] according to Figure 14The lamination mandrel 1400 includes a structure 120 having a conformed surface 1412 for receiving a preform 1440. The preform 1440 is conformed against the conformed surface 1412, which defines the shape of the preform 1440. The conformed surface 1412 also includes surface features 1430 disposed at predetermined locations. Some of these surface features 1430 may include holes, protrusions, indentations, etc., covered by the preform 1440 (although other surface features may have preforms laid around them), such that the forming of the preform 1440 at the contoured surface 1412 of the lamination mandrel 1400 applies the indexing feature 1431 (corresponding to indexing feature 124) to the preform 1440, which is formed to the required dimensions to index 129 the resulting composite component 1411 corresponding to structure 120 toward a station 140 provided along the track 110 that the composite component 1411 travels during manufacturing. Surface features 1430 can be disposed on / near any longitudinal edge 1405 of the coagulation mandrel 1400 such that, on the resulting composite part 1411, the indexing features 1431 (generated by surface features 1430 at predetermined locations) are separated by the width W of the coagulation mandrel 1400, and are found at manufacturing allowances 1442 of the resulting composite part 1411 near each of the longitudinal edges 1405. Manufacturing allowances 1442 can define edges that are less precise (e.g., more irregular) compared to edges produced after final finishing operations. That is, after hardening, the composite part 1411 includes manufacturing allowances 1442 that can have roughened coagulation crenulation forming flash portions 510. Manufacturing allowances 1442 are then trimmed off before demolding to reveal the bearing edge 1444. After manufacturing and final finishing, a final cut edge is produced that will be used when joined to another structure 120.

[0224] During transport on track 110 (e.g., along power rollers mounted to the supports in track 110, which includes a series of supports), manufacturing allowance 1442 operates as a tooling / transport surface / edge. This arrangement, allowing material to pass under the supports, enables efficient and rapid just-in-time transport of material to station 140. The manufacturing allowance 1442 present after this transport process is trimmed during final finishing. The bearing edge is already within tolerance because it was trimmed before demolding and is part of structure 120. The lamination mandrel 1400 operates as a tooling surface during preform 1440 formation and as a hardened fixation during indexing feature 1431 installation and flash portion 510 separation. The window manufacturing allowance 1460 and door manufacturing allowance 1470 are removed by downstream station 197 while still on track 110. Then, a final finishing process removes manufacturing allowance 1442 to give the edges of structure 120 the desired final characteristics before joining half-barrel segments 320 to another half-barrel segment 320 to bring the upper and lower parts together to form a full barrel segment. Therefore, no special tooling is required to be added to the half-barrel edges for easy transport via rollers. Thus, manufacturing allowance 1442 is used as a consumable tooling surface in the form of a transport component via a carrying edge 1444 (which corresponds to carrying edge 113). In this embodiment, the carrying edge 1444 in manufacturing allowance 1442 is cut within a first tolerance smaller than the tolerance used for the final separation of manufacturing allowance 1442 from half-barrel segments 320, which is part of the longitudinal joining of half-barrel segments 320. The finishing process for the first tolerance forms a bearing edge 1444 with the desired straightness at the desired location, so that when the structure 120 moves through the production line at station 140d via micro-pulsations 181, the structure 120 remains within the desired tolerance until the structure 120 is fully manufactured and finally finished to form an edge for joining to another half-barrel segment 320. An NDI scanning station, set before demolding or configured at station 140 as part of the micro-pulsation 181 process, determines the configuration of the structure 120 during pauses between micro-pulsations 181. The NDI scan can be performed on the entire half-barrel segment 320 during pauses between micro-pulsations 181 and / or during micro-pulsations 181, or it can be implemented as a series of scans of only a portion or all of the half-barrel segment before or after demolding. After each micropulse 181, the 3D representation of structure 120 is assumed to be in a scan state, and the indexing 129 engages to transfer the digitized and / or 3D representation to a specific station 140, which docks with the segment of structure 120 located within the field of view 183 of the specific station 140.If structure 120 is added or subtracted at upstream station 140 198, the theoretical form of these changes is incorporated into the digital and / or 3D representation transmitted in downstream station 129 197.

[0225] Figure 14 The example also illustrates that the coating mandrel 1400 has an arched shape 1420, and the contoured surface 1412 defines the shape of the arched fuselage section of the aircraft. The coating mandrel 1400 also includes brackets 1480 and 1482, which are part of a trolley 1490 located below the coating mandrel 1400, supporting the coating mandrel from its lower surface. Wheels 1450 transport the trolley 1490 along the process direction 199, and thus transport the coating mandrel 1400. In other embodiments, the trolley 1490 is integrally formed with the coating mandrel 1400 or implemented as an AGV. However, in other embodiments, the coating mandrel 1400 does not utilize a separate trolley but instead has built-in mobility. Figure 14 The document also depicts window manufacturing allowance 1460 and door manufacturing allowance 1470, in which the indexing feature 1431 can be mounted into the preform 1440.

[0226] In other embodiments, surface feature 1430 includes holes drilled into the coating mandrel 1400, and indexing feature 1431 applied to the preform 1440 includes notches covering or surrounding these holes. Still in other embodiments, surface feature 1430 includes protrusions from the coating mandrel 1400, and indexing feature 1431 applied to the preform 1440 includes notches covering these protrusions. In still other embodiments, features include recesses filled with potting compound in the coating mandrel 1400 to create a consumable coating surface, allowing for drilling or trimming on the mandrel after hardening without directly drilling or cutting into unpotted portions of the contoured surface 1412 of the coating mandrel 1400. That is, over-drilling or over-cutting can be formed in the potting compound. The potting compound can then be used to resurface the coating surface before the next use of the coating mandrel 1400. The potting compound helps to create a smooth coating surface at possible trimming or drilling locations. Surface feature 1430 is positioned on each side of structure 120, and within manufacturing allowance 1442 on each of the left and right sides 1414 and 1416. However, surface feature 1430 need not be identical or mirror images of each other from left 1414 to right 1416. Although surface feature 1430 is shown as cylindrical, other shapes are possible.

[0227] While most surface features 1430 are shown arranged in a straight, continuous line, surface features 1430 may have varying spacing from the bearing edge 1444 (as shown in surface feature 1430), or varying positions within the window manufacturing allowance 1460 or door manufacturing allowance 1470 (as shown in surface feature 1432). The type and position of surface features 1430, 1432 can convey different messages for a specific station 140 for a particular operation. If an operation is to be performed at a specific station 140, the station 140 performing that particular operation may have paired features. For example, a station 140 for installing a window will be paired with surface features 1430, 1432 to which a window is intended to be installed, but not with features not required for window installation. In some embodiments, this concept is broken down into specific surface features 1430, 1432 for specific frame installations, since each frame installation station 140 can install various frames. A portion of structure 120 may have surface features for mating at a frame installation station, another surface feature for mating at a window frame installation station, another surface feature for mating at a window cutting station, and another surface feature for mating at a trimming station. All of these occur simultaneously at multiple stations 140 based on the matching of multiple rotated features 1431.

[0228] Figure 15 This is a flowchart illustrating a method 1500 for applying a transposition feature 1431 to a preform 1440 in an exemplary embodiment. According to method 1500, step 1502 includes: obtaining a lamination mandrel including a contoured surface 1412 defining the shape of the preform 1440, which will be hardened into a composite component (such as structure 120). Step 1504 includes: identifying a surface feature 1430 disposed at a predetermined location on the contoured surface 1412, the contoured surface being located on the preform 1440 (e.g., covered or surrounded by the preform 1440). Step 1506 includes: adhering the preform 1440 to the contoured surface 1412. In one embodiment, this adhering operation causes the surface feature 1430 to apply the transposition feature 1431 to the preform 1440. This may include pressing the preform 1440 onto the surface feature 1430, which may be in the form of a protrusion or a hole. In other embodiments, the transposition feature 1431 is applied to the preform 1440 in other ways. This may include laying the preform 1440 in such a way that the preform 1440 has holes, indentations, or protrusions corresponding to the surface feature 1430 of the lamination mandrel 1400.

[0229] Step 1508 includes: for example, curing the preform 1440 into structure 120 via curing structure 120. Then, the structure 120 is demolded from the coating mandrel, and the coating mandrel is returned for cleaning and receiving of the preform 1440 for another structure 120.

[0230] Step 1509 includes applying the indexing feature 1431 to the structure 120. In one embodiment, this includes drilling, milling, or finishing a filler hole in the mandrel. The filler hole accommodates manufacturing allowances through the structure 120 and into the drilled and / or milled filler mandrel without damaging the mandrel. The filler hole is surface-finished prior to any subsequent use at the mandrel. The structure 120 may also be finished to expose bearing edges (e.g., before or after demolding) and to allow demolding of the structure 120.

[0231] Step 1510 includes demolding structure 120 from the coating mandrel 1400.

[0232] Step 1511 includes conveying the structure 1200 along its bearing edge on the track. In one embodiment, the structure 120 advances past an NDI inspection station characterizing the component. The scan can be acquired using the micro-pulsation technique described above, or it can be performed during a full pulsation in which the structure 120 advances in the process direction by at least the length of the structure.

[0233] Step 1512 includes: indexing the indexing feature 1432 of structure 120 to station 140 along track 110 by indexing 129, and can be performed via any of the techniques discussed above. In one embodiment, these operations are performed simultaneously across multiple stations 140 to pair with multiple indexing features 1431. After the structure 120 has been indexed, step 1514 includes: transferring the representation of structure 120 to station 140 based on indexing 129. This operation can be performed by obtaining prior scan information of said portion of structure 120 after the station 140 has been indexed to a portion of structure 120. In one embodiment, the lofting of structure 120 is determined based on indexing 129, and the position of the inner mold line (IML) or outer mold line (OML) of structure 120 can be determined based on indexing 129. Furthermore, the position on structure 120 can be determined based on indexing 129. That is, the representation of the component can be determined within tolerances. Structure 120 is known to be constructed on a lamination mandrel within specific tolerances using a lamination process within tolerances. Therefore, when the final structure 120 is demolded and maintains its shape during transport through the pulsating station 140, structure 120 is within tolerances and has the desired loft. Thus, indexing 129 is possible, assuming the schematic or representation of the part is within tolerances and structure 120 is within tolerances at station 140. Transporting structure 120 along the track does not change the shape of structure 120, nor does it undesirably alter the loft.

[0234] Figure 16 This is an end view of the track in the illustrative embodiment of the support structure. According to... Figure 16 The structure 120, which adopts a half-barrel segment form of the fuselage, is supported by the bearing edge 113 at the manufacturing allowance 125 on the left side 1652 and the right side 1654 of the structure.

[0235] Each manufacturing allowance 125 includes a boundary 1616 and a load-bearing edge 113 positioned in direct contact with the track 110 (specifically, a roller 1634 of the track 110 that facilitates movement in the process direction 199) and bears the weight of the structure 120. The manufacturing allowance 125 also includes an indexing feature 1612. In this embodiment, the track includes a series of supports 1630. Each support 1630 includes a fork 1632 defining a recess 1636 in which the load-bearing edge 113 of the manufacturing allowance 125 is placed. The recess 1636 facilitates the implementation of IML lofting 177 and / or OML lofting 175 onto the structure 120, such that the center 1602 of the structure 120 remains above the track 110. Specifically, the recess implements IML lofting 177 and / or OML lofting 175 by implementing a predetermined spacing width between the load-bearing edges 113 on the left side 1652 and the right side 1654. In other embodiments, the groove 1636 is defined by a roller 1638 (e.g., a pinch roller) in a fork 1632 mounted on either side of the bearing edge 113. The roller 1634 directly contacts the manufacturing allowance 125 and can be driven by a drive unit 1640 (e.g., a motor, chain drive, etc., driving the rollers 1634 and / or 1638) to advance the structure 120 forward. The operation of the drive unit 1640 can be controlled via a controller 1642 according to programmed instructions to micro-pulse the structure 181 or pulsate it 182 along the process direction 199 of the page entry, or to move them continuously. In this way, the roller 1638 drives the bearing edge 113 through the track 110, the left side 1652 of the structure 120 remains in direct contact with the track, the right side 1654 of the structure 120 remains in direct contact with the track, and the center 1602 of the structure 120 remains above the track. In one embodiment, the controller 1642 advances the structure 120 uniformly to prevent it from tilting out of the IML loft 177 and / or OML loft 175. In another embodiment, the indexing unit 130 monitors the progress of the left side 1652 and right side 1654 of the structure 120 to ensure that it is advancing uniformly without tilting or tilting.

[0236] Figure 17This is a flowchart illustrating a method 1700 for transporting the structure 120 via a manufacturing allowance 125 in an exemplary embodiment. According to method 1700, step 1702 includes: advancing the structure 120 along track 110 in a process direction 199, while passing through indexing 129, micro-pulsation 181, and the manufacturing process, defining that the manufacturing allowance 125 of the bearing edge 113 remains in contact with rollers 1634 and / or 1638. The bearing edge 113 of the structure 120 directly contacts track 110 and bears the weight of the structure 120. In one embodiment, advancing the structure 120 includes driving the bearing edge 113 along rollers 1634 at track 110. In another embodiment, advancing the structure 120 applies abrasion to the bearing edge 113 as it is ground or scraped by the rollers. Subsequently, the bearing edge 113 and manufacturing allowance 125, which will be ground or scraped, are separated by finishing as part of forming the half-barrel segment 320, rather than transporting the finished edge half-barrel segment 320 through the micro-pulsation assembly process 181. Therefore, by separating the manufacturing allowance during the formation of the half-barrel segment 320, any wear that occurs during transport of the structure 120 is eliminated, leaving precise part edges for later assembly. Furthermore, if the bearing edge 113 becomes excessively worn during transport, it can be repaired to the extent necessary to restore the desired tolerance / indexing accuracy level of the bearing edge 113. This may include gluing or bolting a patch to the bearing edge 113. Later, after final finishing, the manufacturing allowance 125 is removed, and the part achieves the desired dimensions for final finishing at the joint edge where it will be further assembled.

[0237] Step 1704 includes: rotating the structure 129 towards station 140 at track 110 by referencing the indexing feature 124 in the manufacturing allowance of structure 125. The manufacturing allowance can be positioned along the left side 1652 and right side 1654 of structure 120. In the area to be cut out for a window or door, window manufacturing allowance 170, and door manufacturing allowance 180, the indexing feature 124 (if present) transmits instructions to the station performing window frame installation, door frame installation, and / or separation of window manufacturing allowance 170 and / or door manufacturing allowance 180. In some embodiments, the indexing feature 124 is also used to engage with trimming devices, or even to help guide the separation of window manufacturing allowance 170 and / or door manufacturing allowance 180. In such embodiments, the operation of separating window manufacturing allowance 170 and / or door manufacturing allowance 180 can even be performed after the manufacturing allowance 125 has been trimmed. This can be performed in a manner similar to the indexing steps provided above for the earlier method.

[0238] Step 1706 includes performing operations on structure 120 at station 140 while rotating structure 120 toward station 140. This can be performed in a manner similar to the steps provided above for the earlier method.

[0239] Step 1708 includes removing manufacturing allowance 125 from structure 120 to form half-barrel segment 320 before it is joined to the fuselage of the aircraft. This includes trimming off the bearing edge 113 and any remaining indexing features 124. This may include trimming off the manufacturing allowance 125 from structure 120 via a cutter or saw, via a laser tool or water tool, etc. Removing the manufacturing allowance 125 leaves clean part edges for use during further assembly.

[0240] Method 1700 offers technological benefits over existing systems and techniques because it enables the large structure 120 to be moved during manufacturing without the need for specialized support tools that must be installed, managed, and / or removed. It also allows the structure 120 to be indexed 129 at various stations 140 using indexing features 124 on the structure 120 itself, without additional tooling or jigs. This improves overall manufacturing efficiency and reduces labor costs.

[0241] Figure 18This is a flowchart illustrating a method 1800 for shaping a structure 120 held by a support edge 113 of a manufacturing allowance 125, as exemplified in an exemplary embodiment. Step 1802 includes advancing the structure 120 along a track 110 in a process direction 199 while maintaining the manufacturing allowance 125 on the left side 1652 and the manufacturing allowance 125 on the right side 1654 of the structure 120 in contact with the track 110. This can be performed by any of the processes discussed above. Step 1804 includes shaping the predetermined shape at the structure 120 by maintaining the manufacturing allowance 125 on the left side 1652 and the manufacturing allowance 125 on the right side 1654 separated by a predetermined distance via the track 110. In other words, the bearing edge 113 on the left side 1652 is held by the track 110 at a distance away from the bearing edge 113 on the right side 1654, while the structure 120 is pulsated 182 or micro-pulsated 181 through the station 140 to maintain the desired IML layout 177 and / or OML layout 175. The desired IML layout 177 and / or OML layout 175 is established on the lamination mandrel 1400, and the track 110 is set to maintain the structure as the micro-pulsated structure 120 passes through the station 140. Moreover, since the IML layout 177 and / or OML layout 175 are performed by the track 110 without deformation, the shape of the structure 120 (e.g., from the lamination mandrel 1400) is conveyed through the station 140. The predetermined shape may include the layout of the structure 120, or other desired shapes. The step of shaping the structure 120 before demolding after demolding and passing through station 140 micro-pulsation 181 may include placing manufacturing allowances 125 on the left side 1652 and right side 1654 of the structure 120 within grooves 1636 at track 110. Therefore, the shape resulting from the transport mandrel of structure 120 includes maintaining an arched or other shape as micro-pulsation passes through station 140. That is, maintaining a desired spacing between the two sides without causing twisting, warping, or other possible deformation.

[0242] In step 1806, when shaping is performed, structure 120 is rotated to station 140 along track 110, and in step 1808, when performing the desired IML lofting 177 and / or OML lofting 175, work is performed on structure 120 along station 140 along track 110. The work performed can be any of the operations discussed above.

[0243] Method 1800 offers advantages over the prior art because it allows the large, lightweight structure 120 to be processed during transport while maintaining the desired shape of the structure 120. This ensures that work is performed at the desired locations on the structure and that the structure does not bend or strain in an undesirable manner.

[0244] Figure 19 This is a block diagram of an assembly line 1900 in an exemplary embodiment. Assembly line 1900 is a system for assembling structures such as fuselage half-sections or wing panels, and includes: a track 110, and a structure 120 arranged along the track 110, the structure including a pivoting feature 124. A row of stations 140 is arranged along the track 110, pivoting the row of stations toward the structure 120 and performing operations on the structure 120 according to a common takt time. That is, stations 140 operate during the same time period associated with the start of production of one work unit of a longitudinal portion L of structure 120 and the start of production of the next work unit of another longitudinal portion L of structure 120. In one embodiment, feeder line 1940 also progresses / manufacturing components according to the common takt time and / or removes scrap 1952 from stations 140 according to the common takt time. The longitudinal portion L of structure 120 corresponds to a pulsation distance P (e.g., a micro-pulsation distance 181 smaller than the total length of structure 120). In this embodiment, stations 140 are separated from each other in the process direction 199 by a distance smaller than the length (“length”) 196 of each structure in structure 120, so that multiple operations can be performed on structure 120 simultaneously. Feeder lines 1940 supply material to stations 140 on time according to the cycle time of structure 120 along track 110 in assembly line 1900. Feeder lines 1940 may have a cycle time different from or the same as that of assembly line 1900. Moreover, each feeder line 1940 may have a unique cycle time, or may have a cycle time similar to that of other feeder lines at assembly line 1900. Meanwhile, as waste accumulates, chute 1950 removes waste 1952 from station 140.

[0245] In another embodiment, workstation 140 performs operations during pauses between micro-pulses 181 of structure 120. In another embodiment, the cycle time is equal to the duration of the pause between micro-pulses 181 plus the duration of the advance of structure 120 within a single micro-pulse 181 (i.e., the duration of the pause between micro-pulses 181 plus the duration of the micro-pulse 181). In a further embodiment, track 110 drives structure 120 along a series of rollers 152 mounted to support column 1630.

[0246] Figure 20This is a flowchart illustrating a method 2000 for operating a production line assembly system 1900 in an exemplary embodiment. Production line assembly system 1900 corresponds to production line assembly system 100 and / or production line assembly system 300. Step 2002 includes: advancing structure 120 along track 110 in a process direction 199 (e.g., micro-pulsation 181). In one embodiment, the step of micro-pulsating structure 120 along track 110 181 includes: driving structure 120 along a series of rollers 152 mounted to support column 154.

[0247] Step 2004 includes: rotating structure 120 129 towards station 140 positioned along track 110. The rotation 129 step includes: rotating at least a portion 127 of the structure within the field of view 183 of station 140, and may include rotating a single structure 120 or more structures 120 towards multiple stations 140 during the same rotation 129 cycle (e.g., during the same micro-pulse 181). Step 2006 includes: supplying material to station 140 via material feeder line 191-1 (e.g., according to a common cycle time). Outflow line 194-3 may also remove material from station 140 (e.g., according to a common cycle time). Step 2008 includes: performing work during pauses between micro-pulses 181 of the structure in step 2008 (e.g., according to a common or individual cycle time, such as the structure cycle time or the feeder line cycle time). In the micro-pulsation 181 embodiment, the cycle time is equal to the duration of the pause in structure 120 between micro-pulses 181. The cycle time can vary between different components being manufactured, and the length of the cycle time for one component can be defined as a known fraction of the cycle time for another component. For example, the cycle time of frame feeder line 193-2 can be set equal to the cycle time of segmental continuous component 193-3 divided by the number of frames to be installed at the frame mounting station. In this way, frames are delivered on time to accommodate the manufacture of structure 120. More broadly, the cycle time of any sub-component feeder line can be defined as the cycle time for installing sub-components into structure 120 divided by the number of sub-components to be installed into structure 120 at a particular station 140. This concept also applies to multiple levels. For example, the wing beat can be based on the aircraft's beat for supplying the right and left wings, the wing spars beat can be based on the wing beat, and the beat for supplying coating material to the wing spars assembly line can be based on the wing spars beat, etc. In other embodiments, the beat time is applied not only to the feeder assembly line that supplies material to the workstations on a just-in-time basis, but also to the outflow assembly line to ensure that material is removed on a just-in-time basis. Method 2000 provides technical benefits by enabling the manufacturing technology to be applied in a way that increases manufacturing speed, wherein individual feeder assembly lines can operate with the same or different beat times. Moreover, in some embodiments, each workstation has a structural input position and a structural output position, as well as a feeder assembly line input end and / or a material output end / outlet (e.g., a chute) that may be trimmed.

[0248] Figure 21This is a flowchart illustrating another method 2100 for manufacturing an aircraft using an operational assembly line system 100 in an exemplary embodiment. Method 2100 includes the following steps: in step 2102, pulsating the series of structures 120 along a track 110 by iteratively advancing and pausing the structures 120. In one embodiment, the pulsating step includes iteratively advancing the structures 120 to a length 196 less than that of each individual structure 120 and pausing. In another embodiment, the pulsating step of the series of structures 120 includes operating a power roller 152 at the track 110. In yet another embodiment, the micro-pulsating step of the series of structures 120 includes advancing the series of structures 120 along the track 110.

[0249] Step 2104 includes the following steps: During pauses between multiple micro-pulses 181, work is performed on the series of structures 120 via a row of 141 workstations 140. Work can also be performed by multiple workstations 140 on the same structure 120 during the same pause. In one embodiment, the work includes installing a frame onto the structure 120, but any suitable work can be performed, such as trimming manufacturing allowances, installing window or door frames, etc. Furthermore, multiple workstations 140 can simultaneously and continuously perform work on multiple structures 120.

[0250] Step 2106 includes: identifying the arranged micro-pulse 181, which can be performed based on a schedule stored in the controller's memory. Step 2108 includes: performing a job interruption at station 140 during the arranged micro-pulse 181, wherein at least one of the stations 140 in the row of stations 140 stops work within the field of view 183. The station is periodically stopped when it is not necessary to perform work on structure 120 by that station within the field of view 183. In one embodiment, the method further includes the steps of: performing maintenance (e.g., cleaning, replacing parts, etc.) on the stopped station 140 during the interruption, and / or removing personnel from station 140 during the interruption. In one embodiment, the job interruption occurs at the station 140 level, rather than for all stations 140 that currently have a portion of structure 120 within their field of view 183. A gap 1990 is maintained between structures 120 to allow stations 141 ( Figure 19The workstation 141 can be stopped, allowing workers at the workstation time to perform maintenance on the workstation 141 and / or take a break from working on the structure 120. In one embodiment, each gap 1990 between the structures 120 includes the length of one or more micro-pulses 181. Similarly, when the workstation 140 is not being used to perform work on the structure (e.g., in a window or door workstation opposite a portion of the structure without a window or door installed), the use of the workstation 140 can be paused, allowing workers at the workstation 141 time to perform maintenance on the workstation 141 and / or take a break from working on the structure 120.

[0251] Figure 22 This is a flowchart illustrating another method of the operational assembly line system 100 in the exemplary embodiment. Step 2202 includes: micro-pulsating 181 of the structure 120 being assembled from one station 140 to the next station 140 via a conveyor 111 (e.g., track 110). Step 2204 includes: attaching the indexing feature 124 of the structure 120 to the complementary feature 134 at station 140. Step 2206 includes: at the time of indexing 129, transferring the digitized and / or 3D configuration / characterization (including IML lofting 177 and / or OML lofting 175) of the work-to-be portion of the structure 120 (within the field of view 183) to station 140, without running a scan / re-scan of the entire structure 120 as part of the individual pulses 181 or micro-pulsations 182, in order to save time and labor while maintaining quality.

[0252] Example

[0253] In the following examples, additional processes, systems, and methods are described in the context of a pipeline component system 100 for structural components.

[0254] Referring more specifically to the accompanying drawings, embodiments of this disclosure can be implemented as follows: Figure 23 The aircraft manufacturing and maintenance methods 2300 shown, and such as Figure 24The description is presented within the context of the aircraft 2302. During pre-production, method 2300 may include the specification and design 2304 of the aircraft 2302 and the procurement of materials 2306. During production, the manufacturing 2308 of components and sub-components of the aircraft 2302 and system integration 2310 may be performed. Subsequently, the aircraft 2302 may undergo certification and delivery 2312 for use 2314. When in use by the customer, routine maintenance and upkeep 2316 (which may also include modifications, reconfigurations, refurbishments, etc.) are performed on the aircraft 2302. The equipment and methods specifically implemented herein may be employed during any one or more suitable stages of production and use as described in method 2300 (e.g., specification and design 2304, material procurement 2306, component and sub-component manufacturing 2308, system integration 2310, certification and delivery 2312, in use 2314, maintenance and servicing 2316) and / or any suitable component of aircraft 2302 (e.g., frame 2318, system 2320, interior 2322, propulsion system 2324, electrical system 2326, hydraulic system 2328, environment 2330).

[0255] Each process in method 2300 can be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator can include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party can include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator can be an airline, leasing company, military entity, service organization, etc.

[0256] like Figure 24 As shown, an aircraft 2302 produced according to method 2300 may include a frame 2318 having multiple systems 2320 and an interior 2322. Examples of systems 2320 include one or more of the following: a propulsion system 2324, an electrical system 2326, a hydraulic system 2328, and an environmental system 2330. 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.

[0257] As mentioned above, the equipment and methods specifically implemented herein can be used during any or more suitable stages of the production and maintenance phases described in method 2300. For example, components or sub-components corresponding to component and sub-component manufacturing 2308 can be made or manufactured in a manner similar to that of components or sub-components produced when aircraft 2302 is in use. Moreover, during sub-component manufacturing 2308 and system integration 2310, one or more equipment implementations, method implementations, or combinations thereof can be utilized, for example, by significantly accelerating the assembly of aircraft 2302 or reducing the cost of the aircraft. Similarly, when aircraft 2302 is in use (e.g., and without limitation, during maintenance and servicing 2316), one or more equipment implementations, method implementations, or combinations thereof can be utilized. For example, the techniques and systems described herein can be used for material procurement 2306, component and sub-component manufacturing 2308, system integration 2310, in use 2314 and / or maintenance and servicing 2316, and / or can be used for rack 2318 and / or interior 2322. These technologies and systems can even be used in system 2320, such as propulsion system 2324, electrical system 2326, hydraulic system 2328 and / or environmental system 2330.

[0258] In one embodiment, the component includes a portion of frame 2318 and is manufactured during component and sub-component manufacturing 2308. The component can then be assembled into the aircraft during system integration 2310 and utilized during use 2314 until wear renders it unusable. Then, during maintenance and servicing 2316, the component can be discarded and replaced with a newly manufactured component. The inventive components and methods can be utilized immediately throughout component and sub-component manufacturing 2308 to manufacture new components.

[0259] 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 executing software, a processor executing firmware, or a combination thereof. For example, an element can be implemented as dedicated hardware. The dedicated hardware element can be referred to as a “processor,” a “controller,” or a similar term. When provided by a processor, the functionality can be provided by a single dedicated processor, a single shared processor, or multiple individual processors, some of which may share the functionality. Furthermore, the terms “processor” or “controller” as explicitly used should not be construed as referring specifically to hardware capable of executing software, but may implicitly include, but are not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) storing software, random access memory (RAM), non-volatile memory, logic, or some other physical hardware component or module.

[0260] Furthermore, control elements can be implemented as instructions executable by a processor or computer to perform the function of that element. Some examples of instructions are software, program code, and firmware. The instructions are operable when executed by a processor to instruct the processor to perform the function of the element. The instructions can be stored on a storage device that can be read by a processor. Some examples of storage devices are digital or solid-state memories, magnetic storage media such as disks and tapes, hard disk drives, or optically readable digital data storage media.

[0261] Furthermore, this document provides the following provisions, which will not be confused with the appended claims that define the scope of protection, and relate to:

[0262] 1. A method for assembling a structure (120), the method comprising the steps of: micro-pulsating (181) the structure (120) along a track (110) in a process direction (199) to a length (196) smaller than that of the structure (120); shifting the structure (120) toward the station (140) by pairing a shifting feature (124) in the manufacturing allowance (125, 170, 180) of the structure (120) with a complementary shifting feature (134) at a station (140); performing work on the structure (120) at the station (140) while shifting the structure (120) toward the station (140); and iteratively repeating the steps of micro-pulsating (181) the structure (120), shifting the structure (120) (129), and performing work on the structure (120).

[0263] 2. The method according to Clause 1, wherein the step of rotating the structure (120) to the workstation (140) (129) is performed in such a manner as rotating multiple workstations (140) to the structure (120) (129) at one time.

[0264] 3. The method according to clause 1 or 2, wherein the step of causing the structure (120) to be rotated (129) to a workstation (140) transmits multiple instructions to one or more workstations (140) simultaneously.

[0265] 4. The method according to any one of the clauses 1 to 3, wherein the step of transposing the structure (120) to the workstation (140) (129) transmits the 3D representation and / or IML lofting (177) and / or OML lofting (175) of the structure (120) within the field of view (183) of the workstation (140).

[0266] 5. The method according to any one of the clauses 1 to 4, wherein the step of transferring (129) the structure (120) to the workstation (140) transmits the digitization of the structure (120) within the field of view (183) of the workstation (140).

[0267] 6. The method according to any one of the clauses 1 to 5, wherein the step of transposing the structure (120) to the workstation (140) (129) transmits to the workstation (140) an assembly instruction for the structure (120) within the field of view (183) of the workstation (140).

[0268] 7. The method according to any one of the clauses 1 to 6, wherein: the workstation (140) performs work during the pause between micro-pulses (181) of the structure (120).

[0269] 8. The method according to any one of the clauses 1 to 7, wherein: the workstation (140) performs the operation during the micro-pulsation (181) of the structure (120).

[0270] 9. The method according to any one of the clauses 1 to 8, wherein the step of rotating the structure (120) to the work station (140) (129) comprises inserting a pin into a hole (530) that has been placed in or on the structure (120) at a predetermined interval.

[0271] 10. The method according to any one of the clauses 1 to 9, wherein the step of shifting the structure (120) to the work station (140) (129) comprises: inserting a pin (410) into a hole (530) machined into the structure (120) at predetermined intervals.

[0272] 11. The method according to any one of the clauses 1 to 10, wherein the step of transferring the structure (120) to the workstation (140) (129) comprises scanning an RFID tag (562) or barcode (564) placed on the structure (120) at predetermined intervals.

[0273] 12. The method according to any one of the clauses 1 to 11, wherein: the indexing feature (124) is provided in the manufacturing allowance (125, 170, 180) of the structure (120), and the method further comprises the step of: trimming the manufacturing allowance (125, 170, 180) and the indexing feature (124) from the structure (120).

[0274] 13. The method according to any one of clauses 1 to 12, wherein: the step of micropulsating (181) the structure (120) exposes a new portion of the structure (120) for the station (140) to receive work.

[0275] 14. The method according to any one of the clauses 1 to 13, wherein: the workstation (140) is arranged along the track (110) and is separated by a length (196) less than that of the structure (120).

[0276] 15. The method according to any one of the clauses 1 to 14, the method further comprising the step of: micropulsating (181) along the track (110) an additional structure (120) to a length (196) smaller than that of the structure (120).

[0277] 16. The method according to any one of the clauses 1 to 15, the method further comprising the step of performing work on the structure (120) at the station (140) when the structure (120) is rotated (129), the work being performed by the station (140) during pauses between micropulses (181) of the structure (120).

[0278] 17. The method according to any one of the clauses 1 to 16, the method further comprising the step of: performing work on the structure (120) at the station (140) between indexing (181), the work being performed by the station (140) during micropulsations (181) of the structure (120).

[0279] 18. The method according to any one of the clauses 15 to 17, wherein the step of micropulsating (181) the additional structure (120) comprises: micropulsating (181) the additional structure (120) immediately upstream (198) and / or downstream (197) of the structure (120).

[0280] 19. The method according to any one of clauses 15 to 18, wherein: the micropulsations (181) are continuously arranged along the track (110) and separated by gaps (1990) of the additional structure (120).

[0281] 20. The method according to any one of the clauses 15 to 19, wherein the step of micropulsating (181) the additional structure (120) includes maintaining a gap (1990) between the additional structures (120).

[0282] 21. The method according to any one of the clauses 1 to 20, the method further comprising the step of periodically stopping the workstation when it is not necessary for the workstation to perform work on the structure (120) within the field of view (183) of the workstation (140).

[0283] Clause 22. The method according to Clause 20 or Clause 21 further includes the step of performing maintenance at a station (140) set with a gap in one of the gaps (1990) during a pause between micropulses (181) of the additional structure (120).

[0284] 23. The method according to any one of clauses 20 to 22, wherein: each gap in the gap (1990) comprises a multiple of the length (196) of the micropulse (181) of the structure (120).

[0285] 24. The method according to any one of clauses 1 to 23, wherein: the structure (120) is micropulsated (181) to a distance equal to a multiple of the frame pitch (184).

[0286] 25. The method according to any one of the clauses 1 to 24, wherein the step of micropulsating (181) the structure (120) comprises: iteratively advancing the structure to a length (196) less than that of the structure (120), and pausing.

[0287] 26. The method according to any one of the clauses 1 to 25, wherein: different messages are transmitted to the workstation (140 via the indexing feature (124) at least based on the shape, type or position of the indexing feature (124) at the structure (120), the indexing feature (124) being customized to provide instructions regarding an operation to be performed within the field of view (183) of the workstation (140).

[0288] 27. The method according to any one of the clauses 1 to 26, wherein: multiple instructions are transmitted simultaneously to multiple workstations (140) via one or more indexing features (124).

[0289] 28. The method according to any one of clauses 1 to 27, wherein: the workstation (140) is simultaneously rotated to the structure (120), and the workstation (140) simultaneously performs an operation to modify the structure (120).

[0290] 29. The method according to any one of the clauses 1 to 28, wherein: the complementary feature (134) is positioned relative to the workstation (140).

[0291] 30. A part of an aircraft assembled in accordance with the method described in any one of the provisions 1 to 29.

[0292] 31. A system for assembling a structure (120), the system comprising: a track (110) for transporting the structure (120) including a shifting feature (124); a row of workstations (140) arranged along the track (110) for performing operations on the structure (120) and spaced apart from each other in a process direction (199) by a length (196) less than that of the individual structures in the structure (120); and a shifting unit (130) arranged along the track (110) relative to the workstations (140) with a known offset from the corresponding workstations (140) in the row of workstations, and including a complementary shifting feature (134) positioned relative to the track (110), the complementary shifting feature (134) being sized to mate with the shifting feature (124).

[0293] 32. The system according to Clause 31, wherein: the indexing feature (124) is placed in the manufacturing allowance (125, 170, 180) of the structure (120), and the station (140) removes the manufacturing allowance (125, 170, 180).

[0294] 33. The system according to clause 31 or 32, wherein: the transposition feature (124) transmits to the station (140) a 3D representation and / or IML lofting (177) and / or OML lofting (175) of the structure (120) within the field of view (183) of the station (140).

[0295] 34. The system according to any one of clauses 31 to 33, wherein: the transposition feature (124) transmits the digitization of the structure (120) within the field of view (183) of the workstation (140) to the workstation (140).

[0296] 35. The system according to any one of clauses 31 to 34, wherein: the indexing feature (124) transmits to the workstation (140) assembly instructions for the structure (120) within the field of view (183) of the workstation (140).

[0297] 36. The system according to any one of clauses 31 to 35, wherein: the track (110) includes a series of supports (154), the series of supports including rollers (152) at predetermined positions for receiving the structure (120).

[0298] 37. The system according to any one of clauses 31 to 36, wherein: the transposition feature (124) is selected from the group consisting of: through hole (530), blind hole (540), slot (550), pin (560), RFID tag (562) and / or barcode (564) connected to the structure (120) at predetermined intervals.

[0299] 38. The system according to any of the clauses 31 to 37, wherein each of the workstations (140) performs a type of operation selected from the group consisting of: installing frames, installing longitudinal beams, installing door frames, installing window frames, cutting window holes, and cutting door holes.

[0300] 39. The system described in any of clauses 31 to 38, wherein:

[0301] Different messages are transmitted to the workstation (140) based at least on the shape or position of the rotation feature (124).

[0302] 40. The system according to any one of clauses 31 to 39, wherein: the workstation (140) simultaneously performs operations on the structure (120).

[0303] 41. The system according to any one of clauses 31 to 40, wherein: the structure (120) is separated by gaps (1990), each gap comprising a multiple of the length of the micropulse (181).

[0304] 42. The system according to any one of clauses 31 to 41, wherein: the structure (120) is micropulsated (181) to a distance equal to a multiple of the frame pitch (184).

[0305] 43. To manufacture a part of an aircraft using the system described in any of the provisions 31 to 42.

[0306] 44. An apparatus for assembling a structure (120), the apparatus comprising: a track (110) for advancing the structure (120) along a process direction (199); at least one station (140) disposed along the track (110); and a shifting unit (130) disposed relative to the at least one station (140).

[0307] 45. The device according to clause 44, wherein the indexing unit (130) is set with an offset from at least one corresponding workstation (140).

[0308] 46. ​​The device according to clause 44 or 45, wherein: the indexing unit (130) includes a complementary indexing feature (134) connected to an indexing feature (124) at the structure (120) to receive work from the workstation (140).

[0309] 47. The device according to any one of clauses 44 to 46, wherein: the complementary indexing feature (134) is formed to the required size to mate with the indexing feature (124) in the manufacturing allowance (125, 170, 180) of the structure (120).

[0310] 48. The equipment according to any one of the clauses 44 to 47, wherein: the at least one station (140) comprises a plurality of stations (140), and the plurality of stations (140) are arranged sequentially along a structure (120) that progresses along the track (110).

[0311] 49. To manufacture a part of an aircraft using the equipment described in any of the provisions 44 to 48.

[0312] 50. A method for assembling a structure (120), the method comprising the steps of:

[0313] Along the track (110) in the process direction (199), the micro-pulsation (181) structure (120) reaches a length (196) smaller than that of the structure (120); the structure (120) is rotated (129) toward the station (140) by pairing the indexing feature (124) in the manufacturing allowance (125, 170, 180) of the structure (120) with the complementary indexing feature (134) at the station (140); and

[0314] The steps of micropulsation (181) of the structure (120) and transposition (129) of the structure are repeated iteratively.

[0315] 51. The method according to Clause 50, the method further comprising the steps of: performing work on the structure (120) at the workstation (140) while the structure (120) is rotated (129) to the workstation (140); and iteratively repeating the steps of micropulsating (181) the structure (120), rotating the structure (120) (129) and performing work on the structure (120).

[0316] Clause 52. The method according to Clause 50 or 51, the method further comprising the steps of: performing operations on the structure (120) by at least one of the stations (140) before transposing the structure (120) to the plurality of stations (140) (129); and iteratively repeating the steps of micropulsating (181) the structure (120), transposing the structure (120) (129), and performing operations on the structure (120).

[0317] 53. The method according to any one of clauses 50 to 52, wherein: without shifting the structure (120) to the workstation (140), work can be performed on the structure (120) by at least one of the workstations (140); and the steps of iteratively repeating the micropulsation (181) on the structure (120) and performing work on the structure (120).

[0318] 54. A part of an aircraft assembled in accordance with the method described in any of the provisions of 50 to 53.

[0319] 55. A method for manufacturing a structure (120) of an aircraft, the method comprising the steps of: micro-pulsating (181) the series of structures (120) along a track (110) by iteratively advancing and pausing the structures (120); performing work on the series of structures (120) via a row of stations (140) during a plurality of pauses between micro-pulsations (181); identifying the arranged micro-pulsations (181); and performing an interruption during the arranged micro-pulsations (181), wherein work is stopped at at least one of the stations (140) in the row of stations (140).

[0320] 56. The method according to Clause 55, wherein the step of micropulsation (181) includes: iteratively advancing the structure (120) to a length less than that of each structure (120), and pausing.

[0321] 57. The method according to clause 55 or 56, wherein: the operation includes mounting the frame onto the structure (120).

[0322] 58. The method according to any one of clauses 55 to 57, wherein the step of micro-pulsating (181) the series structure (120) includes operating the power roller (152) at the track (110).

[0323] 59. The method according to any one of clauses 55 to 58, wherein the step of micropulsating (181) the series structure (120) includes advancing the half-barrel section (24) of the fuselage along the track (110).

[0324] 60. The method according to any one of the provisions 55 to 59, the method further comprising the step of performing maintenance on at least one of the workstations (140) during the interruption.

[0325] 61. The method according to any one of the provisions 55 to 60, the method further comprising the step of removing personnel from the workstation (140) during the interruption.

[0326] 62. A part of an aircraft assembled in accordance with the method described in any of the provisions 55 to 61.

[0327] 63. A system for assembling a structure (120), the system comprising: a track (110), the track transport structure (120); and a row (141) of workstations (140) arranged along the track (110), the row of workstations performing operations on the structure (120) according to a common cycle time.

[0328] 64. The system according to Clause 63, the system further comprising: an indexing unit (130) disposed in the row of workstations and including a complementary feature (134) formed to the required dimensions to mate with the indexing feature (124) in the manufacturing allowances (125, 170, 180) of the structure (120).

[0329] 65. The system according to any one of clauses 63 to 64, wherein: the clock cycle time is equal to the duration of pausing the structure (120) between micropulses (181) plus the duration of advancing the structure (120) between micropulses (181).

[0330] 66. The system according to any one of clauses 63 to 65, wherein: the cycle time is based on the number of aircraft manufactured per month and the number of assemblies required per aircraft.

[0331] 67. The system according to any one of clauses 63 to 66, the system further comprising: a feeder assembly line (191-1) that feeds into the track (110) based on the cycle time.

[0332] 68. The system according to any one of clauses 63 to 67, wherein: the workstation (140) performs the operation based on instructions transmitted by the indexing feature (124) at the structure (120).

[0333] 69. A method for indexing a preform (1440) after each of a plurality of micro-pulses (181) along a process direction, the method comprising the steps of: placing the preform (1440) on a conveying device for maintaining the layout of the preform (1440); moving the preform (1440) along the process direction to a station (140) without altering the layout of the preform (1440); and locking an indexing unit to one of a plurality of indexing features (124) in the preform (1440).

[0334] 70. The method according to Clause 69, wherein: the conveying device keeps the preform (1440) aligned with the outer mold line (OML).

[0335] 71. The method according to clause 69 or 70, wherein: the conveying device keeps the preform (1440) aligned with the inner mold line (IML).

[0336] 72. The method according to any one of the clauses 69 to 71, the method further comprising the step of: transmitting a message to the workstation (140) based at least on the shape, type or position of the indexing feature (124).

[0337] 73. The method according to Clause 72, wherein: a message is transmitted from a transposition feature (124) to a workstation (140), wherein the transposition feature is selected from the group consisting of: through-hole (530), blind hole (540), slot (550), pin (560), radio frequency identifier (RFID) tag (562) and / or barcode (564).

[0338] 74. The method according to any one of clauses 69 to 73, wherein: the workstation (140) simultaneously performs operations on the preform (1440).

[0339] 75. The method described pursuant to any of the provisions 69 to 74, wherein:

[0340] The station (140) is simultaneously rotated to multiple rotation features (124).

[0341] 76. A part of an aircraft assembled in accordance with the method described in any of the provisions 69 to 75.

[0342] 77. A method for transposing a structure (120) after each of a plurality of micro-pulses (181) along a process direction, the method comprising the steps of: micro-pulsating (181) the structure (120) being assembled from one station (140) to the next station (140) via a track (110); locking a transposition feature (124) of the structure (120) to a complementary feature (134) of the station (140); and determining the digitization of the structure (120) at the time of the transposition (129).

[0343] 78. The method according to Clause 77, wherein: the track (110) keeps the structure (120) consistent with the outer mold line (OML) layout (175).

[0344] 79. The method according to clause 77 or 78, wherein: the track (110) keeps the structure (120) consistent with the inner mold line (IML) layout (177).

[0345] 80. The method according to any one of the clauses 77 to 79, wherein: messages are transmitted to station (140) and the next station (140) based at least on the shape or position of the transposition feature (124).

[0346] 81. The method according to Clause 80, wherein: a message is transmitted from a transposition feature (124) to a workstation (140), wherein the transposition feature is selected from the group consisting of: through-hole (530), blind hole (540), slot (550), pin (560), radio frequency identifier (RFID) tag (562) and / or barcode (564).

[0347] 82. The method according to any one of clauses 77 to 81, wherein: the workstation (140) simultaneously performs work on the structure (120).

[0348] 83. The method according to any one of clauses 77 to 82, wherein: the workstation (140) simultaneously rotates (129) to a plurality of rotation features (124).

[0349] 84. A part of an aircraft assembled in accordance with the method described in any of the provisions 77 to 83.

[0350] 85. A method for assembling a structure (120), the method comprising the steps of: advancing the structure (120) along a track (110) in a process direction; rotating the structure (120) toward a station (140) arranged along the track (110); and performing operations on the structure (120) via the station (140) according to a cycle time.

[0351] 86. The method according to Clause 85, wherein the workstation (140) performs work during the same pause between micro-pulses (181) of the structure (120).

[0352] 87. The method according to Clause 86, wherein: the beat time is equal to the duration of pausing the structure (120) between micropulses (181) plus the duration of advancing the structure (120) in the micropulses (181).

[0353] 88. The method according to any one of clauses 85 to 87, wherein: the workstation (140) performs the operation during the same micro-pulse (181) between pauses in the structure (120).

[0354] 89. The method described under any of Clauses 85 to 88, wherein: the takt time is based on the number of aircraft manufactured per month.

[0355] 90. The method described in any of the clauses 85 to 89, wherein: the cycle time is defined for a row of workstations (140) assigned to perform the operation.

[0356] 91. The method according to any one of the clauses 85 to 90, wherein the step of micro-pulsating (181) the structure (120) along the track (110) comprises driving the structure (120) along a series of rollers (152) mounted to the support (154).

[0357] 92. The method according to any one of clauses 85 to 91, the method further comprising the step of: supplying material from the feeder lines (191-1, 191-2, 191-3, 192-1, 193-1, 193-2, 194-1, 194-2, 194-4) according to the cycle time of the half-barrel assembly line (193-3).

[0358] 93. The method according to any one of clauses 85 to 92, the method further comprising the step of removing waste from the station (140) via the outflow line (194-3) according to the cycle time of the half-barrel assembly line (193-3) and the cycle time of the outflow line (194-3).

[0359] 94. A part of an aircraft assembled in accordance with the method described in any of the provisions 85 to 93.

[0360] 95. A system for assembling a structure (120), the system comprising: a track (110); a structure (120) disposed along the track (110), the structure (120) including an indexing feature (124); a row (141) of workstations (140) disposed along the track (110), the row of workstations being indexed (129) toward the structure (120) and performing operations on the structure (120) according to a cycle time, and being separated from each other in a process direction (199) by a length (196) less than that of each structure in the structure (120); and a feeder assembly line (191-1) supplying materials to the workstations (140).

[0361] 96. The system according to Clause 95, the system further comprising: an outflow line (194-3) that removes material from the workstation (140).

[0362] 97. The system according to clause 95 or 96, wherein the workstation (140) performs work during pauses between micro-pulses (181) of the structure (120).

[0363] 98. The system according to clause 96 or 97, wherein: the clock cycle time is equal to the duration of pausing the structure (120) between micropulses (181) plus the duration of the micropulses (181).

[0364] 99. The system according to any one of clauses 95 to 98, wherein: the track (110) drives the structure (120) along a series of rollers (152) mounted to the support (154).

[0365] 100. The system according to any one of clauses 95 to 99, wherein: the feeder lines (191-1, 191-2, 191-3, 192-1, 193-1, 193-2, 194-1, 194-2, 194-4) supply material according to the common cycle time of the half-barrel assembly line (193-3) and the cycle time of the feeder lines (191-1, 191-2, 191-3, 192-1, 193-1, 193-2, 194-1, 194-2, 194-4).

[0366] 101. The system according to any one of the clauses 95 to 100, the system further comprising: an outflow line (194-3) feed chute (1950) that removes waste (1952) from the station (140).

[0367] 102. To manufacture a part of an aircraft using the system described in any of the provisions 95 to 101.

[0368] 103. A system for assembling a structure (120), the system comprising: a track (110); a row (141) of workstations (140) arranged along the track (110) for indexing (129) of the structure (120) arranged along the track (110) and performing operations on the structure (120) according to a cycle time, and being separated from each other in a process direction (199) by a length (196) less than that of each structure in the structure (120); and feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) that supply materials to the workstations (140).

[0369] 104. The system according to Clause 103, the system further comprising: an outflow line (194-3) for removing waste.

[0370] 105. The system according to Clause 104, wherein: the outflow line (194-3) operates according to the cycle time of the half-barrel assembly line (193-3) and the cycle time of the outflow line (194-3).

[0371] 106. The system according to any one of clauses 103 to 105, wherein: the workstation (140) performs work on the (120) structure during pauses between micro-pulses (181).

[0372] 107. The system according to any one of clauses 103 to 106, wherein: the workstation (140) performs work on the structure (120) during micro-pulses (181) between pauses.

[0373] 108. The system according to any one of clauses 103 to 107, wherein: the clock cycle time is equal to the duration of pausing the structure (120) between micropulses (181) plus the duration of the micropulses (181).

[0374] 109. The system according to any one of the clauses 103 to 108, wherein: the track (110) comprises a series of rollers (152) mounted to the support (154) to drive the structure (120).

[0375] 110. The system according to any one of clauses 103 to 109, wherein: the feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) supply materials to the half-barrel assembly line (193-3).

[0376] 111. The system according to any one of clauses 103 to 110, wherein: the feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) supply materials to the workstation (140) in a just-in-time (JIT) manner.

[0377] 112. The system according to any one of clauses 103 to 110, wherein: the feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) progress according to the cycle time of the half-barrel assembly line (193-3) and the cycle time of the feeder lines (193-1, 193-2, 194-1, 194-2, 194-4).

[0378] 113. The system according to any one of clauses 103 to 112, wherein: the feeder production line (193-1, 193-2, 194-1, 194-2, 194-4) provides components selected from the group consisting of: frame, longitudinal beams, fuselage sections, and door frames.

[0379] 114. The system according to any one of clauses 103 to 113, wherein: the outflow line (194-3) feeds a chute (1950) that removes waste from the station (140).

[0380] 115. To manufacture a part of an aircraft using the system described in any of the provisions 103 to 114.

[0381] 116. A method for assembling a structure (120), the method comprising the steps of: advancing the structure (120) along a track (110) in a process direction (199); applying a predetermined shape to the structure (120); and performing operations on the structure (120) via the station (140) according to a cycle time.

[0382] 117. The method according to Clause 116, wherein the workstation (140) performs work during the same pause between micro-pulses (181) of the structure (120).

[0383] 118. The method according to Clause 117, wherein: the beat time is equal to the duration of pausing the structure (120) between micropulses (181) plus the duration of advancing the structure (120) during the micropulses (181).

[0384] 119. The method according to any one of the provisions 116 to 118, wherein: the takt time is based on the number of aircraft produced per month.

[0385] 120. The method according to any one of the clauses 116 to 119, wherein the step of micro-pulsating (181) the structure (120) along the track (110) comprises driving the structure (120) along a series of rollers (152) mounted to the support (154).

[0386] 121. The method according to any one of clauses 116 to 120, wherein: material is supplied from the feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) according to the cycle time.

[0387] 122. The method according to any one of the clauses 116 to 121, the method further comprising the step of: removing waste from the workstation (140) according to the cycle time.

[0388] 123. A part of an aircraft assembled according to the method described in any of the provisions 116 to 122.

[0389] 124. A system for assembling a structure (120), the system comprising: a track (110); a structure (120) disposed along the track (110), the structure (120) including a pivoting feature (124); a row (141) of workstations (140) disposed along the track (110), the row of workstations pivoting toward the structure (120) and performing operations on the structure (120) according to a cycle time, and being separated from each other in a process direction (199) by a length (196) less than that of each structure in the structure (120); and a feeder assembly line (191-3) supplying materials to the workstations (140).

[0390] 125. The system according to Clause 124, wherein the workstation (140) performs work during pauses between micro-pulses (181) of the structure (120).

[0391] 126. The system according to clause 124 or 125, wherein: the clock cycle time is equal to the duration of pausing the structure (120) between micropulses (181) plus the duration of the micropulse (181).

[0392] 127. The system according to any one of clauses 124 to 126, wherein: the track (110) drives the structure (120) along a series of rollers (152) mounted to the support (154).

[0393] 128. The system according to any one of clauses 124 to 127, wherein: the feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) supply material according to the said cycle time.

[0394] 129. The system according to any one of clauses 124 to 128, wherein: the feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) deliver materials to the workstation (140) in a just-in-time (JIT) manner.

[0395] 130. The system according to any one of clauses 124 to 129, wherein: the feeder pipeline (193-1, 193-2, 194-1, 194-2, 194-4) progresses according to the cycle time.

[0396] 131. The system described in any of Clauses 124 to 130, wherein each feeder pipeline (193-1, 193-2, 194-1, 194-2, 194-4) progresses according to its own cycle time.

[0397] 132. The system according to any of the clauses 124 to 131, wherein: the outflow line (194-3) feeds a chute (1950) that removes waste from the station (140).

[0398] 133. To manufacture a part of an aircraft using the system described in any of the provisions 124 to 132.

[0399] 134. A system for assembling a structure (120), the system comprising: a track (110); a row (141) of workstations (140) arranged along the track (110) for indexing (129) of the structure (120) arranged along the track (110) and performing operations on the structure (120) according to a cycle time, and being separated from each other in a process direction (199) by a length (196) less than that of each structure in the structure (120); and feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) that supply material to the structure (120).

[0400] 135. The system according to Clause 134, wherein the workstation (140) performs work during pauses between micro-pulses (181) of the structure (120).

[0401] 136. The system according to clause 134 or 135, wherein: the workstation (140) performs work during micro-pulses (181) between pauses in the structure (120).

[0402] 137. The system according to clause 135 or 136, wherein: the clock cycle time is equal to the duration of pausing the structure (120) between micropulses (181) plus the duration of the micropulses (181).

[0403] 138. The system according to any one of clauses 134 to 137, wherein: the track (110) drives the structure (120) along a series of rollers (152) mounted to the support (154).

[0404] 139. The system according to any one of clauses 134 to 138, wherein: the transposition feature (124) at the structure (120) is paired with a complementary feature (134) at the transposition unit (130) located at the track (110).

[0405] 140. The system according to any one of clauses 134 to 138, wherein: the feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) supply materials according to the cycle time of the feeder lines (193-1, 193-2, 194-1, 194-2, 194-4) and the half-drum assembly line (193-3).

[0406] 141. The system according to any one of clauses 134 to 140, the system further comprising: a chute (1950) that removes waste (1952) from the workstation (140).

[0407] 142. To manufacture a part of an aircraft using the system described in any of the provisions 134 to 141.

[0408] 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.

Claims

1. A method for assembling a structure, the method comprising the following steps: The length of the micro-pulsating structure along the track in the process direction is less than that of the structure. By pairing the indexing feature in the manufacturing allowance of the structure with the complementary indexing feature at the work station, the structure is indexed to the work station, and the indexing feature can be physically connected to the complementary indexing feature. as well as The steps of iteratively repeating the micropulsation of the structure and transposing the structure are performed. The structure includes the aircraft fuselage.

2. The method according to claim 1, further comprising the following steps: When the structure is rotated to the work station, the structure is operated at the work station; as well as The steps of iteratively repeating the micropulsation of the structure, transposing the structure, and performing operations on the structure are carried out.

3. The method according to claim 2, wherein, The step of transferring the structure to the workstation is performed by transferring multiple workstations to the structure at a time.

4. The method according to claim 3, further comprising the following step: Before the structure is transferred to the plurality of workstations, the structure is operated on by at least one of the workstations. The steps include iteratively repeating the micropulsation of the structure, transposing the structure, and performing operations on the structure.

5. The method according to claim 1 or 2, further comprising the following step: Without shifting the structure to the workstation, the structure is operated on by at least one of the workstations. The steps of iteratively repeating the micropulsation of the structure and operating on the structure.

6. The method according to claim 2, wherein: The step of transferring the structure to a workstation simultaneously transmits multiple instructions to one or more workstations.

7. The method according to claim 6, wherein: The step of transferring the structure to the workstation involves transmitting the 3D representation and / or IML lofting and / or OML lofting of the structure within the workstation's field of view, and / or The step of transferring the structure to the workstation involves transmitting the digitization of the structure within the workstation's field of view, and / or The step of transferring the structure to the workstation transmits assembly instructions for the structure within the workstation's field of view to the workstation.

8. The method according to claim 2, wherein: During the pauses between the micro-pulsations of the structure, the workstation performs operations, and / or During the micro-pulsation of the structure, the workstation performs operations.

9. The method according to claim 2, wherein: The step of shifting the structure to the workstation includes: inserting pins into holes that have been placed in or on the structure at predetermined intervals, and / or The step of shifting the structure to the workstation includes: inserting a pin into a hole machined into the structure at predetermined intervals, and / or The step of moving the structure to the workstation includes scanning RFID tags or barcodes placed on the structure at predetermined intervals.

10. The method according to claim 2, wherein: The indexing feature is provided in the manufacturing allowance of the structure, and the method further includes the following steps: The manufacturing allowance and the rotation feature are trimmed from the structure.

11. The method according to claim 2, wherein: The micro-pulsation process exposes new portions of the structure for the station to receive operations.

12. The method according to claim 2, wherein: The workstations are arranged along the track and separated by a length less than that of the structure.

13. The method according to claim 2, further comprising the following steps: The micro-pulsating additional structure along the track reaches a length smaller than that of the structure.

14. The method of claim 13, wherein: The additional structures, with micro-pulsations continuously arranged along the track and spaced apart at intervals, and / or The steps of micro-pulsating the additional structures include: maintaining a gap between the additional structures, and / or The step of micropulsating the additional structure includes micropulsating the additional structure immediately upstream and / or downstream of the structure.

15. The method according to claim 13, further comprising the following step: The structure is manipulated at the workstation during the rotation of the structure, the manipulation being performed by the workstation during pauses between micro-pulses of the structure; and / or The structure is operated on at the station between rotations, the operation being performed by the station during the micro-pulsation of the structure.

16. The method of claim 14, further comprising the step of: During the pauses between the micro-pulsations of the additional structure, maintenance is performed at a workstation set according to one of the gaps, and / or Each gap in the gap comprises a multiple of the micropulsation length of the structure.

17. The method according to claim 2, wherein: The structure is micro-pulsated to a distance equal to a multiple of the frame pitch distance, and / or The steps of micropulsating the structure include: iteratively advancing the structure to a length less than that of the structure, and then pausing.

18. The method according to claim 2, wherein: At least based on the shape, type, or location of the indexing feature at the structure, different messages are transmitted from the indexing feature to the workstation, the indexing feature being customized to provide instructions regarding operations to be performed within the workstation's field of view, and / or Multiple instructions can be transmitted simultaneously to multiple workstations via one or more indexing features.

19. The method according to claim 2, wherein: The workstation is simultaneously rotated toward the structure, and the workstation simultaneously performs operations to modify the structure, wherein the complementary rotation feature is positioned relative to the workstation.

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