Pressure hull wall assembly and method and system for making a pressure hull wall assembly

Abstract

A method of making a pressure cabin wall assembly for an aircraft includes determining optimized positions of splice angles such that splice surfaces of the splice angles will form a circumferential splice surface of the pressure cabin wall assembly in an optimized shape. The method further includes performing a virtual fit between the plurality of splice angles in the optimized positions and a rear pressure cabin wall. The method also includes determining splice angle hole positions of splice angle holes to be drilled in each of the splice angles such that the splice angle holes will correspond with rear pressure cabin wall holes pre-drilled in the rear pressure cabin wall. The method further includes drilling the splice angle holes in each of the splice angles at the splice angle hole positions. The method also includes joining each of the splice angles with the rear pressure cabin wall such that the splice surfaces form the circumferential splice surface in the optimized shape.

Description

Technical Field

[0001] This disclosure generally relates to methods and systems for joining structural components, and more specifically, to methods and systems for mating structural components associated with pressure bulkhead assemblies of an aircraft. Background Technology

[0002] Pressure bulkheads are commonly used on aircraft to separate pressurized and unpressurized sections of the fuselage. In some applications, pressure bulkheads can be installed inside the fuselage and attached to the outer skin of one or more sections of the fuselage. In some cases, multiple angled members, known as splice angles, are used to install pressure bulkheads onto the aircraft.

[0003] Complex and expensive assembly fixtures are typically used to assemble splice angle steel and pressure bulkheads onto drill press fixtures. For example, the pressure bulkhead is initially joined to the splice angle steel. Subsequently, holes are drilled through the pressure bulkhead and splice angle steel while they are temporarily joined to each other. However, drilling holes in such major structural joints using drill press fixtures can result in oversized holes, may require multiple measurement and alignment steps, and / or necessitate repeated placement and removal of the pressure bulkhead and splice angle steel from the fixture, any or all of which can lead to production delays. Using drill press fixtures can also result in non-conformal joint surfaces of the pressure bulkhead and / or gasket designs that are larger than intended. Furthermore, the flexibility of the carbon fiber material constituting some of the pressure bulkhead components can make machining the surfaces and holes of the pressure bulkhead more difficult when it is attached to the fixture.

[0004] Therefore, there is a need for an assembly method for pressure bulkheads that shortens installation time, improves the accuracy of hole size and position, improves the positioning accuracy of splicing angle steel, reduces labor, is easily automated, and minimizes parts waste. Consequently, those skilled in the art continue their efforts in the research and development of pressure bulkhead components. Summary of the Invention

[0005] Methods for manufacturing pressure bulkhead assemblies, systems for manufacturing pressure bulkhead assemblies, and examples of pressure bulkhead assemblies for aircraft are disclosed. The following is a non-exhaustive list of examples that may be claimed or may not be claimed under the subject matter of this disclosure.

[0006] In an example, the disclosed method includes the following steps: (1) determining an optimized position for a plurality of splicing angle steels such that a plurality of splicing surfaces of the plurality of splicing angle steels will form the circumferential splicing surface of the pressure bulkhead assembly in an optimized shape; (2) performing a virtual fit between the plurality of splicing angle steels at the optimized position and the rear pressure bulkhead; (3) determining the splicing angle steel hole position for drilling splicing angle steel holes in each of the plurality of splicing angle steels such that such splicing angle steel holes will correspond to pre-drilled rear pressure bulkhead holes in the rear pressure bulkhead; (4) drilling such splicing angle steel holes in each of the plurality of splicing angle steels at such splicing angle steel hole positions; and (5) joining each of the plurality of splicing angle steels to the rear pressure bulkhead such that the plurality of splicing surfaces form the circumferential splicing surface in the optimized shape.

[0007] In the example, the disclosed system includes a measuring machine configured to measure an aft pressure bulkhead and a plurality of spliced ​​angle steels. The system includes a computer system having a memory and a processor, wherein the memory stores a program. The processor is configured to execute the program to: (1) determine an optimal position for the plurality of spliced ​​angle steels such that a plurality of splicing surfaces of the plurality of spliced ​​angle steels will form a circumferential splicing surface in an optimized shape; (2) perform a virtual fit between the plurality of spliced ​​angle steels in the optimized position and the aft pressure bulkhead; and (3) with the plurality of spliced ​​angle steels in the optimized position, determine the spliced ​​angle steel hole positions for drilling spliced ​​angle steel holes in each of the plurality of spliced ​​angle steels such that such spliced ​​angle steel holes correspond to pre-drilled aft pressure bulkhead holes in the aft pressure bulkhead. The system includes a computer numerical control (CNC) machine tool configured to drill holes in each of the plurality of splicing angle steels at the locations of the splicing angle steel holes. When the plurality of splicing angle steels are joined to the rear pressure bulkhead at the optimized location, the plurality of splicing surfaces form the circumferential splicing surface in the optimized shape.

[0008] In the example, the disclosed pressure bulkhead assembly includes: an aft pressure bulkhead including a bulkhead interface surface and a pre-drilled aft pressure bulkhead hole through the bulkhead interface surface; and a plurality of splicing angle steels configured to connect to the aft pressure bulkhead. Each of the plurality of splicing angle steels includes: a flange surface configured to mate with the bulkhead interface surface; splicing angle steel holes drilled through the flange surface; and a splicing surface extending from the flange surface. With the splicing angle steel holes aligned with the aft pressure bulkhead holes, the plurality of splicing surfaces form a circumferential splicing surface with an optimized shape.

[0009] Other examples of the disclosed methods, systems, and structural components will become apparent from the following detailed description, accompanying drawings, and appended claims. Attached Figure Description

[0010] Figure 1 This is a schematic perspective view of an example of a pressure bulkhead assembly;

[0011] Figure 2 This is a schematic example of an aircraft that includes pressure bulkhead components;

[0012] Figure 3 A schematic cutaway perspective view of an example of a pressure bulkhead assembly attached to the fuselage of an aircraft.

[0013] Figure 4 This is a flowchart illustrating an example of a method for manufacturing pressure bulkhead components;

[0014] Figure 5 This is a schematic block diagram of an example of a system used to manufacture pressure bulkhead components;

[0015] Figure 6 A schematic cutaway perspective view of an example of a portion of the first bulkhead surface of the rear pressure bulkhead assembly;

[0016] Figure 7 A schematic cutaway perspective view of an example of a portion of the second bulkhead surface of the rear pressure bulkhead assembly;

[0017] Figure 8 This is a schematic perspective view of an example of splicing angle steel configured to be mounted on the aft pressure bulkhead to form a pressure bulkhead assembly;

[0018] Figure 9 This is a schematic perspective view of an example of splicing angle steel configured to be mounted on the aft pressure bulkhead to form a pressure bulkhead assembly;

[0019] Figure 10 This is a schematic example of multiple spliced ​​angle steels in their initial positions, wherein the circumferential splicing surfaces of the pressure bulkhead assembly have an initial shape;

[0020] Figure 11 Is Figure 10 A schematic perspective view of a portion of the scanned spliced ​​angle steel shown in the image;

[0021] Figure 12 Is Figure 10 A schematic perspective view of a portion of the spliced ​​angle steel scan, showing it being adjusted from its initial position to an optimized position;

[0022] Figure 13This is a schematic example of multiple spliced ​​angle steel scans in optimized positions, wherein the circumferential splicing surfaces of the pressure bulkhead assembly have optimized shapes;

[0023] Figure 14 Is Figure 13 A schematic perspective view of a portion of the scanned spliced ​​angle steel shown in the image;

[0024] Figure 15 This is a schematic example of a three-dimensional virtual overlay of a scan of the aft pressure bulkhead and one of the multiple scans of the spliced ​​angle steel;

[0025] Figure 16 Is Figure 8 and 9 A schematic perspective view of an example of spliced ​​angle steel is shown, in which multiple spliced ​​angle steel holes are drilled in the spliced ​​angle steel;

[0026] Figure 17 This is a schematic cross-sectional view of an example of a pressure bulkhead assembly;

[0027] Figure 18 This is a schematic plan view of an example of a gasket for a pressure bulkhead assembly, wherein gasket holes are drilled in the gasket; and

[0028] Figure 19 It is a flowchart of aircraft manufacturing and maintenance methods. Detailed Implementation

[0029] The following detailed description refers to the accompanying drawings, which illustrate specific examples described in this disclosure. Other examples with different structures and operations do not depart from the scope of this disclosure. Similar reference numerals may refer to the same feature, element, or component in different figures. Throughout this disclosure, any one of a plurality of entries may be referred to individually as that entry, and the plurality of entries may be collectively referred to as those entries and may be referred to by similar reference numerals. Furthermore, as used herein, a feature, element, component, or step preceded by the word "a (or an)" should be understood to not exclude multiple features, elements, components, or steps, unless such exclusion is expressly stated.

[0030] The following provides exemplary, non-exhaustive examples of the subject matter of this disclosure that may be claimed, but are not necessarily claimed. The term "example" as used herein means that one or more features, structures, elements, components, characteristics, and / or operations described in connection with the example are included in at least one aspect, embodiment, and / or implementation of the subject matter of this disclosure. Therefore, throughout this disclosure, the phrases "an example," "another example," "one or more examples," and similar language may refer to the same example, but not necessarily the same example. Furthermore, the subject matter characterizing any example may include, but does not necessarily include, the subject matter characterizing any other example. Moreover, the subject matter characterizing any example may, but does not necessarily, be combined with the subject matter characterizing any other example.

[0031] refer to Figure 1 By way of example, this disclosure relates to a pressure bulkhead assembly 100 comprising a rear pressure bulkhead 108 and a plurality of splice angles 102. Generally, reference is made to... Figure 4 By way of example, this disclosure relates to a method 1000 for preparing a pressure bulkhead assembly 100 by matching (indexing) and mounting a plurality of splicing angle steels 102 onto a rear pressure bulkhead 108. Generally referenced Figure 5 By way of example, this disclosure also relates to a system 200 for preparing a pressure bulkhead assembly 100. In one or more instances, method 1000 is implemented using system 200.

[0032] Examples of system 200 and method 1000 use measurements of the aft pressure bulkhead 108 to determine the surface profile of the aft pressure bulkhead 108 and to determine the location of pre-drilled full-size holes in the aft pressure bulkhead 108. Examples of system 200 and method 1000 use measurements of a plurality of splicing angle bars 102 to determine the surface profile of each of the plurality of splicing angle bars 102. Examples of system 200 and method 1000 use the determined surface profiles of the aft pressure bulkhead 108 and the determined surface profiles of the plurality of splicing angle bars 102 to virtually mate the plurality of splicing angle bars 102 around the aft pressure bulkhead 108 at optimized locations to achieve the assembly of the pressure bulkhead assembly 100. Examples of system 200 and method 1000 use virtual mating and the determined positions of pre-drilled full-size holes in the aft pressure bulkhead 108 to determine the positions of full-size holes to be drilled in each of the plurality of splice angle bars 102, such that the plurality of splice angle bars 102 are mated in optimized positions when joined to the aft pressure bulkhead 108.

[0033] Examples of system 200 and method 1000 facilitate drilling full-size holes at defined locations in each of a plurality of splicing angle steels 102, such that the full-size holes drilled in the splicing angle steels 102 correspond to pre-drilled full-size holes in the aft pressure bulkhead 108. Examples of system 200 and method 1000 also facilitate mounting the splicing angle steels 102 onto the aft pressure bulkhead 108 using a plurality of fasteners inserted through the aligned pairs of full-size holes in the splicing angle steels 102 and the full-size holes in the aft pressure bulkhead 108, thereby engaging the plurality of splicing angle steels 102 to the aft pressure bulkhead 108 at optimized locations.

[0034] Examples of system 200 and method 1000 facilitate the identification of the dimensions of the gaps formed between the aft pressure bulkhead 108 and the plurality of splicing angle steels 102, and the formation of a plurality of gaskets 128 based on these gap dimensions. Examples of system 200 and method 1000 also facilitate the determination of the locations of full-size holes to be drilled in the gaskets 128 and facilitate the drilling of full-size holes in the gaskets 128 at the determined locations. Examples of system 200 and method 1000 further facilitate the installation of the plurality of gaskets 128 between the aft pressure bulkhead 108 and the plurality of splicing angle steels 102, such that the plurality of splicing angle steels 102 are joined to the aft pressure bulkhead 108 at optimized locations.

[0035] Now for reference Figure 1 This schematically illustrates an example of a pressure bulkhead assembly 100. The pressure bulkhead assembly 100 includes, or is formed of, a rear pressure bulkhead 108 and splicing angle steel 102. The splicing angle steels 102 are positioned adjacent to each other and engaged with the rear pressure bulkhead 108. The splicing angle steels 102 form a circumferential splicing surface 106. The circumferential splicing surface 106 has an optimized shape 136.

[0036] For the purposes of this disclosure, given manufacturing tolerances, the optimized shape 136 of the circumferential splice surface 106 refers to a shape that is optimized to be as close to a circle as possible. As will be described in more detail herein, the optimized shape 136 of the circumferential splice surface 106 is achieved by determining the optimized position of each splice angle in the splice angle 102 in order to minimize the step or offset between the mating edges of directly adjacent splice angles in the splice angle 102. In one or more instances, the optimized shape 136 is generally circular, wherein the step size 116 between the mating edge 118 of each splice angle in the plurality of splice angles 102 and the mating edge 118 of one directly adjacent splice angle in the plurality of splice angles 102 (e.g., in Figure 12 The result shown is minimized (e.g., in Figure 13 and 14 (as shown in the image).

[0037] In one or more instances, the aft pressure bulkhead 108 includes a bulkhead interface surface 126 (e.g., in...). Figure 7 and 9 (as shown) and multiple rear pressure bulkhead holes 114 (e.g., in) Figures 6 to 9 (As shown in the diagram). The rear pressure bulkhead hole 114 is pre-drilled through the bulkhead interface surface 126.

[0038] In one or more instances, the splice angle steel 102 is configured to be coupled to the aft pressure bulkhead 108 (e.g., mounted on or otherwise secured to the aft pressure bulkhead 108). Each splice angle steel 102 includes a flange surface 130, a plurality of splice angle steel holes 112, and a splice surface 104 (e.g., in...). Figure 8 , 9 (As shown in Figure 16). The flange surface 130 is configured to mate with the bulkhead interface surface 126. The splice angle hole 112 is drilled through the flange surface 130. The splice surface 104 extends from the flange surface 130. With the splice angle hole 112 aligned with the aft pressure bulkhead hole 114, the plurality of splice surfaces 104 form a circumferential splice surface 106 in an optimized shape 136.

[0039] In one or more instances, the splicing angle steel hole position 110 of the splicing angle steel hole 112 is determined based on the following (e.g., in...). Figure 16 As shown in the diagram): (1) the virtual fit between the spliced ​​angle steel 102 in the optimized position and the aft pressure bulkhead 108; and (2) the measured aft pressure bulkhead hole position 132 of the aft pressure bulkhead hole 114 (e.g., in...). Figure 6 and 7 (as shown in the image).

[0040] For the purposes of this disclosure, the “position” of a hole refers to its location in three-dimensional space (e.g., along the X, Y, and Z axes) and its angular orientation (e.g., around the X, Y, and Z axes) (e.g., relative to a three-dimensional coordinate system).

[0041] In one or more instances, the pressure bulkhead assembly 100 includes a plurality of fasteners 134 (e.g., in...). Figure 5 and 17 (As shown in the diagram). Fasteners 134 are inserted through the splicing angle steel holes 112 and the rear pressure bulkhead holes 114 to secure the plurality of splicing angle steels 102 to the rear pressure bulkhead 108.

[0042] In one or more instances, the pressure bulkhead assembly 100 includes a gasket 128 (e.g., in...). Figure 17 and 18As shown in the diagram). Gasket 128 is positioned between the flange surface 130 of one of the splicing angle steels 102 and the bulkhead interface surface 126 of the aft pressure bulkhead 108 (e.g., in...). Figure 17 (as shown in the image).

[0043] In one or more instances, the aft pressure bulkhead 108 takes the form of a panel, disc, or dome (e.g., dome-shaped). Therefore, the aft pressure bulkhead 108 is also referred to as an aft pressure bulkhead dome or an aft pressure bulkhead panel. For simplicity, the aft pressure bulkhead may be referred to herein or in the accompanying drawings as "APB". Generally, the size and shape of the pressure bulkhead assembly 100 are configured to be placed inside the fuselage 1202 of the aircraft 1200 (e.g., in...). Figure 2 As shown in the diagram), the rear pressure bulkhead 108 protects the interior 1204 of the aircraft 1200. Figure 2 The pressurized portion (e.g., a pressurized chamber) of the fuselage 1204 is separated from the unpressurized portion of the interior 1204, and the splicing angle steel 102 forms a pressure seal. In one or more instances, the pressure bulkhead assembly 100 is attached to the skin 1206 of the fuselage 1202 via the splicing angle steel 102. Figure 2 ).

[0044] The aft pressure bulkhead 108 and the splicing angle steel 102 are formed of any suitable material. In one or more embodiments, the aft pressure bulkhead 108 and the splicing angle steel 102 are formed of a composite material. In one or more embodiments, the aft pressure bulkhead 108 and the splicing angle steel 102 are formed of a metallic material, a polymeric material, another suitable material, or a combination of materials. The materials of the aft pressure bulkhead 108 and the splicing angle steel 102 can be the same or different.

[0045] Now for reference Figure 2 This schematically illustrates an example of an aircraft 1200 using a pressure bulkhead assembly 100. The pressure bulkhead assembly 100 separates the pressurized side of the aircraft 1200 from the unpressurized side of the aircraft 1200. Angle steel 102 ( Figure 1 ) Installed on the pressurized side of the rear pressure bulkhead 108 ( Figure 1 As an example, aircraft 1200 includes a fuselage 1202 and a wing 1208 attached to and extending outward from the fuselage 1202. The fuselage 1202 includes multiple fuselage sections (e.g., barrel sections). Each fuselage section (e.g., each fuselage section) has a skin 1206 connected to a frame 1210, which forms the exterior of the aircraft 1200. A pressure bulkhead assembly 100 separates a first fuselage section 1212 (e.g., pressurized side) from a second fuselage section 1214 (e.g., unpressurized side) in the rear portion of the fuselage 1202. For example, in... Figure 3In the middle, arrow 1216 indicates the direction of the front (e.g., pressurized) section of the aircraft 1200.

[0046] Now for reference Figure 3 This schematically illustrates an example of a portion of the pressure bulkhead assembly 100 attached to the first fuselage section 1212 and the second fuselage section 1214, viewed from inside the fuselage 1202. The splicing angle steel 102 overlaps with the first skin portion 1218 of the skin 1206 of the first fuselage section 1212 and the second skin portion 1220 of the skin 1206 of the second fuselage section 1214. The splicing angle steel 102 is attached (e.g., fastened by a plurality of fasteners) to the first skin portion 1218 and to the second skin portion 1220. In this manner, the splicing angle steel 102 joins the aft pressure bulkhead 108, the first fuselage section 1212, and the second fuselage section 1214 together. Therefore, the splicing angle steel 102 is also referred to as the skin splicing angle steel.

[0047] As an example, during the fabrication of aircraft 1200, the pressure bulkhead assembly 100 is attached to the second fuselage section 1214 by fastening the splicing angle steel 102 to the second skin portion 1220. The first fuselage section 1212 is then positioned adjacent to the second fuselage section 1214 such that the splicing angle steel 102 overlaps with the first skin portion 1218. The pressure bulkhead assembly 100 is attached to the first fuselage section 1212 by fastening the splicing angle steel 102 to the first skin portion 1218. The optimized shape 136 of the circumferential splicing surface 106 formed by the splicing angle steel 102 (… Figure 1 The barrel (e.g., circular) shape of the skin 1206 of the first fuselage section 1212 and the second fuselage section 1214 is substantially complementary to that of the second fuselage section 1206. Therefore, the splicing angle steel 102 is positioned on the pressurized side of the aft pressure bulkhead 108 and is configured to form the fuselage 1202 between the first fuselage section 1212 (e.g., the pressurized section) and the second fuselage section 1214 (e.g., the unpressurized section). Figure 2 Pressure seals.

[0048] In one or more instances, one or more splice components and skin spacers ( Figure 3 (Not shown) Positioned between the circumferential splicing surface 106 of the splicing angle steel 102 and the skin 1206 to fill any gaps present between the splicing angle steel 102 and the first skin portion 1218 and / or the second skin portion 1220, for example, where the circumferential splicing surface 106 does not contact the skin 1206 of the first fuselage section 1212 and / or the second fuselage section 1214 (e.g., the optimized shape 136 of the circumferential splicing surface 106). Figure 1 In areas where the barrel shape does not match that of the first fuselage section 1212 and / or the second fuselage section 1214.

[0049] Now for reference Figure 4 Examples of method 1000 are illustrated below. In one or more examples, method 1000 includes (box 1002) the step of preparing or forming a rear pressure bulkhead 108. In one or more examples, method 1000 includes (box 1004) the step of drilling a rear pressure bulkhead hole 114 through the rear pressure bulkhead 108.

[0050] Now for reference Figure 6 and 7 Examples are schematically illustrated, showing a portion of the first bulkhead surface 138 and a portion of the second bulkhead surface 140 of the aft bulkhead 108. In one or more examples, the aft bulkhead 108 having a plurality of aft bulkhead holes 114 is initially prepared or otherwise manufactured. For example, the aft bulkhead 108 may be attached to an assembly jig or support tool for drilling the aft bulkhead holes 114.

[0051] The aft pressure bulkhead hole 114 is pre-drilled in the aft pressure bulkhead 108 and is configured to receive the corresponding fastener 134 (e.g., in...). Figure 17 The rear pressure bulkhead hole 114 is a full-size hole (shown in the diagram). Therefore, the rear pressure bulkhead hole 114 is also referred to as a pre-drilled full-size hole or a rear pressure bulkhead fastener hole. The rear pressure bulkhead hole 114 is drilled at a predetermined location on the rear pressure bulkhead 108. The predetermined location of each rear pressure bulkhead hole 114 refers to the predetermined actual (e.g., physical, real-world) location of the rear pressure bulkhead hole 114 drilled on the rear pressure bulkhead 108.

[0052] In one or more instances, the aft pressure bulkhead 108 includes a first bulkhead surface 138 (e.g., in...). Figure 6 (as shown in the diagram) and the second bulkhead surface 140 opposite the first bulkhead surface 138 (e.g., in... Figure 7 (As shown in the diagram). The aft pressure bulkhead 108 also has a thickness 142 defined between the first bulkhead surface 138 and the second bulkhead surface 140. Figure 6 ).

[0053] In one or more instances, the first bulkhead surface 138 is or forms the outer mold line (OML) of the aft pressure bulkhead 108, and the second bulkhead surface 140 is or forms the inner mold line (IML) of the aft pressure bulkhead 108. Therefore, the first bulkhead surface 138 is also referred to as the outer surface, and the second bulkhead surface 140 is also referred to as the inner surface. The pressure bulkhead assembly 100 is installed within the fuselage 1202 of the aircraft 1200 (e.g., in…). Figure 3In the case shown, the first bulkhead surface 138 is on the unpressurized side of the aft pressure bulkhead 108, and the second bulkhead surface 140 is on the pressurized side of the aft pressure bulkhead 108.

[0054] The second bulkhead surface 140 includes (e.g., a portion of the second bulkhead surface 140 is formed) a bulkhead interface surface 126 (e.g., the aft pressure bulkhead interface surface). The bulkhead interface surface 126 is positioned adjacent to the outer peripheral edge of the aft pressure bulkhead 108 and extends along a generally circular path. The bulkhead interface surface 126 is configured to mate with the splice angle steel 102 during the installation of the splice angle steel 102 onto the aft pressure bulkhead 108. In other words, the bulkhead interface surface 126 serves as a mating surface during the assembly of the pressure bulkhead assembly 100 ( Figure 1 During this period, the splicing angle steel 102 is in contact with the joint between the splicing angle steel 102 and the rear pressure bulkhead 108.

[0055] The aft pressure bulkhead hole 114 is drilled through the thickness 142 of the aft pressure bulkhead 108 (e.g., extending between the first bulkhead surface 138 and the second bulkhead surface 140). The predetermined position of the aft pressure bulkhead hole 114 is located through the bulkhead interface surface 126, for example along a generally circular path close to the outer peripheral edge of the aft pressure bulkhead 108 (e.g., at or near the outer peripheral edge).

[0056] For the purpose of clarity, in Figure 6 and 7 Only some of the aft pressure bulkhead holes 114 are shown in the diagram (e.g., aft pressure bulkhead holes 114 in sections of aft pressure bulkhead 108). Although not shown in Figure 6 and 7 As explicitly illustrated, but should be understood, the aft pressure bulkhead opening 114 extends around the entire aft pressure bulkhead 108 (e.g., in...). Figure 1 (as shown in the image).

[0057] Refer again Figure 4 In one or more instances, method 1000 includes (box 1006) preparing spliced ​​angle steel 102 ( Figure 8 and 9 The steps are as follows: Initially prepare or otherwise manufacture spliced ​​angle steel 102 that does not have multiple holes (e.g., pre-drilled full-size holes).

[0058] Now for reference Figure 8 and 9 The examples illustrate, schematically, instances of the first splicing angle steel surface 144 and the second splicing angle steel surface 146 of one of the splicing angle steels 102 relative to the aft pressure bulkhead 108. Figure 8 and9 The spliced ​​angle steel 102 shown in the example represents any one of the multiple spliced ​​angle steels 102.

[0059] In one or more instances, the splicing angle steel 102 includes a first splicing angle steel surface 144 (e.g., in...). Figure 8 (as shown) and the second splicing angle steel surface 146 opposite to the first splicing angle steel surface 144 (e.g., in) Figure 9 (As shown in the diagram). The splicing angle steel 102 also has a thickness defined between the first splicing angle steel surface 144 and the second splicing angle steel surface 146.

[0060] In one or more instances, the first splicing angle steel surface 144 is or forms the outer mold line (OML) of the splicing angle steel 102, and the second splicing angle steel surface 146 is or forms the inner mold line (IML) of the splicing angle steel. Therefore, the first splicing angle steel surface 144 is also referred to as the outer surface, and the second splicing angle steel surface 146 is also referred to as the inner surface. The pressure bulkhead assembly 100 is installed on the fuselage 1202 of the aircraft 1200 (e.g., in...). Figure 3 In the case shown in the figure, the first splicing angle steel surface 144 generally faces outward radially, and the second splicing angle steel surface 146 generally faces inward radially.

[0061] In one or more instances, the splice angle 102 includes a flange 148. The flange 148 includes (e.g., a portion of a first splice angle surface 144 formed) a flange surface 130 (e.g., a splice angle interface surface). The flange surface 130 is configured to mate with the bulkhead interface surface 126 of the aft pressure bulkhead 108 during the mounting of the splice angle 102 onto the aft pressure bulkhead 108. In other words, the flange surface 130 serves as a mating surface that is used during the assembly of the pressure bulkhead assembly 100 (…). Figure 1 During this period, the interface surface 126 of the bulkhead is in contact with the joint between the splicing angle steel 102 and the rear pressure bulkhead 108.

[0062] In one or more instances, the splicing angle steel 102 includes a skin splice 150 extending from the flange 148 at an inclined angle. The skin splice 150 includes a splicing surface 104 (e.g., formed by a portion of the first splicing angle steel surface 144). The splicing surface 104 forms a circumferential splicing surface 106 (e.g., in…). Figure 1 The arc-shaped segment shown in the figure.

[0063] The splicing angle steel 102 includes a pair of opposing mating edges 118 (e.g., in...). Figure 1 , 8In (and 9, identified as the first mating edge 118a and the second mating edge 118b). During the installation of the splicing angle steel 102 onto the aft pressure bulkhead 108, one mating edge (e.g., the first mating edge 118a) of one of the splicing angle steels 102 is adjacent to one mating edge (e.g., the second mating edge 118b) of a directly adjacent splicing angle steel 102 (e.g., in Figure 1 (as shown in the image).

[0064] In one or more instances, the splicing angle steel 102 is fabricated with guide holes 152 drilled through the skin splice 150. The guide holes 152 are drilled at several locations, such as during the installation of the pressure bulkhead assembly 100 into the fuselage 1202 (e.g., in...). Figure 3 As shown in the figure, the positions of the full-size holes drilled through the splicing angle steel 102, the skin splicing piece 150, the first skin portion 1218, and the second skin portion 1220 roughly correspond to each other.

[0065] Refer again Figure 4 In one or more instances, method 1000 includes (box 1008) the step of measuring the aft pressure bulkhead 108. In one or more instances, the step of (box 1008) measuring the aft pressure bulkhead 108 provides (e.g., generates) three-dimensional (3D) measurement data representing the 3D geometry of the aft pressure bulkhead 108.

[0066] In one or more instances, (box 1008) the step of measuring the aft pressure bulkhead 108 includes measuring the bulkhead interface surface 126 and measuring the aft pressure bulkhead bore 114. It is understood that all or other portions of the aft pressure bulkhead 108, such as the entirety of the first bulkhead surface 138, the entirety of the second bulkhead surface 140, and / or the outer peripheral edge of the aft pressure bulkhead 108, may also be measured.

[0067] In one or more instances, method 1000 includes (box 1010) the step of measuring spliced ​​angle steel 102 (e.g., each spliced ​​angle steel in spliced ​​angle steel 102). In one or more instances, the step of (box 1010) measuring spliced ​​angle steel 102 provides (e.g., generates) 3D measurement data representing the 3D geometry of each spliced ​​angle steel in spliced ​​angle steel 102.

[0068] In one or more instances, (box 1010) the step of measuring the splice angle 102 includes measuring the first splice angle surface 144 of the splice angle 102 (e.g., measuring the flange surface 130 and measuring the splice surface 104). In one or more instances, (box 1010) the step of measuring the splice angle 102 includes measuring the guide hole 152. It is understood that all or other portions of the splice angle 102, such as all of the first splice angle surface 144, all of the second splice angle surface 146, and / or a pair of mating edges 118, may also be measured.

[0069] In one or more instances, method 1000 includes (box 1012) generating multiple spliced ​​angle steel scans 120 (e.g., in...). Figure 5 The steps are shown in the diagram. In one or more instances, a spliced ​​angle steel scan 120 is generated using 3D measurement data obtained during the measurement step (e.g., box 1010). Therefore, the spliced ​​angle steel scan 120 is a virtual model or 3D digital representation of the spliced ​​angle steel 102, such as the surface of the spliced ​​angle steel 102 (e.g., a 3D surface profile) and optionally other geometric features of the spliced ​​angle steel 102. Each spliced ​​angle steel scan in the spliced ​​angle steel scan 120 represents a corresponding spliced ​​angle steel in the spliced ​​angle steel 102 (e.g., a 3D digital representation of that corresponding spliced ​​angle steel).

[0070] In one or more instances, the spliced ​​angle steel scan 120 represents the first spliced ​​angle steel surface 144 ( Figure 8 At least a portion of the splicing angle steel 102. Optionally, the splicing angle steel scan 120 represents at least a portion of the second splicing angle steel surface 146 of the splicing angle steel 102. In one or more instances, the splicing angle steel scan 120 includes a representation of the splicing surface 104 ( Figure 8 ) splicing surface scan 158 (e.g., in Figures 10 to 14 As shown in the illustration). In one or more instances, the spliced ​​angle steel scan 120 includes a representation of the flange surface 130 (shown in the illustration). Figure 8 ) flange surface scan 162 (e.g., in Figure 11 , 12 (as shown in Figure 14). In one or more instances, the splicing angle steel scan 120 includes a mating edge 118 representing the splicing angle steel 102 (as shown in Figure 14). Figure 8 and 9 ) mating edge scan 160 (e.g., in Figure 11 , 12 (as shown in Figure 14). In one or more instances, the splicing angle steel scan 120 includes a guide hole scan 164 representing a guide hole 152 of the splicing angle steel 102 (e.g., in...). Figure 11 and 14 (as shown in the image).

[0071] In one or more instances, method 1000 includes (box 1014) aligning (e.g., virtually aligning) the splicing angle steel scan 120 to the nominal model 122 of the pressure bulkhead assembly 100. Figure 5 The steps are as follows. The nominal model 122 is a 3D design model, such as a computer-aided design (CAD) model, representing a pressure bulkhead assembly 100 having a circumferential splicing surface 106 with a nominal shape (e.g., a design shape). (Box 1014) The step of aligning the splicing angle steel scans 120 to the nominal model 122 involves arranging a plurality of splicing angle steel scans 120 in an initial position in which the splicing angle steel scans 120 are positioned adjacent to each other and the plurality of splicing surface scans 158 of the splicing angle steel scans 120 represent the circumferential splicing surface 106 having an initial shape 154 (e.g., in…). Figure 10 and 11 (as shown in the image).

[0072] Therefore, the initial position of the splicing angle steel scan 120 is the position of the splicing angle steel scan 120 after it is aligned with the nominal model 122. The initial shape 154 of the circumferential splicing surface 106 is the shape of the circumferential splicing surface 106 represented by the splicing surface scan 158 after the splicing angle steel scan 120 is aligned with the nominal model 122.

[0073] For the purposes of this disclosure, the “position” (e.g., initial position, adjusted position, optimized position, etc.) of the splicing angle steel 102 or the splicing angle steel scan 120 refers to the position (e.g., along the X-axis, Y-axis, and Z-axis) and angular orientation (e.g., around the X-axis, Y-axis, and Z-axis) of the splicing angle steel 102 or the splicing angle steel scan 120 in three-dimensional space (e.g., relative to a three-dimensional coordinate system).

[0074] In one or more instances, (box 1014) the step of aligning the splice angle steel scan 120 to the nominal model 122 includes performing a best-fit step between each of the plurality of splice angle steel scans 120 and the nominal model 122. For example, alignment parameters are calculated by performing an optimized best-fit on a plurality of points of the splice angle steel scan 120 with a portion of the nominal model 122 representing the splice angle steel 102 of the pressure bulkhead assembly 100.

[0075] In one or more instances, method 1000 includes, during the step of aligning the splice angle steel scan 120 to the nominal model 122 (such as while performing a best fit), (box 1016) the step of restricting the degrees of freedom of each splice angle steel scan 120 relative to the nominal model 122 within predetermined tolerances. The predetermined tolerances restrict the magnitude of the movement (e.g., linearly along the X, Y, and Z axes and / or angularly about the X, Y, and Z axes) of the splice angle steel scan 120 relative to the nominal model 122 during the best fit analysis. In one or more instances, the degrees of freedom are restricted using features of the splice angle steel 102 represented by the splice angle steel scan 120. For example, the movement (e.g., linear and / or angular movement) of the guide hole scan 164 of the splice angle steel scan 120 relative to a fixed coordinate system shared by the splice angle steel scan 120 and the nominal model 122 is constrained to predefined linear and / or angular dimensions.

[0076] Now for reference Figure 10 and 11 This is schematically illustrated in (box 1014) as the nominal model 122 of the splicing angle steel scan 120 is aligned with the pressure bulkhead assembly 100. Figure 5 Following the steps, instances of splicing angle steel scans 120 are arranged (e.g., virtually positioned) at the initial position. With the splicing angle steel scans 120 in the initial position, the mating edge scans 160 of each splicing angle steel scan in the splicing angle steel scans 120 are adjacent to the mating edge scans 160 of one directly adjacent splicing angle steel scan in the splicing angle steel scans 120. The splicing surface scans 158 (e.g., 3D surface profiles) representing the splicing surface 104 of the splicing angle steel scans 120 form a virtual representation of the circumferential splicing surface 106 having an initial shape 154.

[0077] Refer again Figure 4 In one or more instances, method 1000 includes (box 1018) determining a step size 116 between a mating edge scan 160 of each splicing angle steel scan 120 and a mating edge scan 160 of a directly adjacent splicing angle steel scan 120 (e.g., in...). Figure 12 The steps are shown in the diagram. The step size 116 is determined with the splicing angle steel scan 120 in the initial position.

[0078] Now for reference Figure 12 This schematically illustrates an example of a portion of a spliced ​​angle steel scan 120 arranged adjacent to each other in its initial position. For example... Figure 12As illustrated, when the spliced ​​angle steel scan 120 is fitted to the nominal model 122 (e.g., in the initial position), stepping can occur between the splicing surface scans 158 of adjacent spliced ​​angle steel scans in the spliced ​​angle steel scan 120. The offset distance (e.g., step) between the splicing surface scans 158 of directly adjacent spliced ​​angle steel scans in the spliced ​​angle steel scan 120 is defined (e.g., calculated) by the step size 116 between adjacent mating edge scans 160 of directly adjacent spliced ​​angle steel scans in the spliced ​​angle steel scan 120. For example, in the initial position, the first mating edge scan 160a of the first spliced ​​angle steel scan 120a is offset relative to the second mating edge scan 160b of the second spliced ​​angle steel scan 120b directly adjacent to the first spliced ​​angle steel scan 120a. The second mating edge scan 160b of the first splicing angle steel scan 120a is offset relative to the first mating edge scan 160a of the third splicing angle steel scan 120c. The third splicing angle steel scan is directly adjacent to the first splicing angle steel scan 120a and opposite to the second splicing angle steel scan 120b.

[0079] Accordingly, if the splicing angle steel 102 is to be joined to the aft pressure bulkhead 108 at the initial position, this step will create one or more interruptions along the circumferential splicing surface 106 between the splicing surfaces 104 of directly adjacent splicing angle steels in the splicing angle steel 102 (e.g., in...). Figures 10 to 12 (As shown in the diagram). This step can present challenges when installing the pressure bulkhead assembly 100 within the fuselage 1202 of the aircraft 1200. For example, the initial shape 154 of the circumferential splice surface 106 may not properly mate with the surface of the skin 1206 of the fuselage 1202. As another example, splice-to-skin spacers (not shown) positioned between the circumferential splice surface 106 formed by the splice angles 102 and the skin 1206 typically extend across the splice surface 104 across two or more of the splice angles 102. Thus, when this step is present, fabricating the splice-to-skin spacers to properly fill the gap between the splice angles 102 and the skin 1206 can be challenging.

[0080] Refer again Figure 4 In one or more instances, method 1000 includes (box 1020) determining the angular displacement of each splicing angle steel scan in the splicing angle steel scan 120 to minimize the step size 116 and (box 1022) adjusting (e.g., repositioning) each splicing angle steel scan in the splicing angle steel scan 120 by the angular displacement. Adjusting the splicing angle steel scan 120 by the angular displacement moves the plurality of splicing angle steel scans 120 from an initial position to an optimized position.

[0081] The angular displacement of each splice angle scan in the splice angle scan 120 (which minimizes the step size 116) is used to determine the optimal position of the splice angle scan 120, and thus determine the optimal position of the splice angle 102 when it engages with the rear pressure bulkhead 108 to form the pressure bulkhead assembly 100. In one or more instances, method 1000 includes (block 1024) determining the optimal positions of a plurality of splice angles 102 such that a plurality of splice surfaces 104 of the plurality of splice angles 102 will form a circumferential splice surface 106 in an optimized shape 136 (e.g., in...). Figure 13 and 14 The steps shown in the figure are as follows. The step of determining the optimal position of the splicing angle steel 102 is achieved by adjusting the splicing angle steel scan 120 according to the angular displacement between directly adjacent splicing angle steels in the splicing angle steel scan 120 to minimize the step size 116.

[0082] Therefore, the optimized position of the splicing angle steel 102 is represented by the optimized position of the splicing angle steel scan 120. The optimized position of the splicing angle steel scan 120 is the position of the splicing angle steel scan 120 where the step size 116 is minimized. The optimized positions of the multiple splicing angle steels 102 are such positions for each of the splicing angle steels 102, where the step size 116 is minimized and the optimized shape 136 of the circumferential splicing surface 106 formed by the splicing surface 104 of the splicing angle steel 102 is achieved. The optimized shape 136 of the circumferential splicing surface 106 is the shape of the circumferential splicing surface 106 after the position optimization of the splicing angle steel scan 120 and the minimization of the step size between the splicing angle steel scan 120 (e.g., in...). Figure 13 and 14 (as shown in the image).

[0083] Refer again Figure 12 In one or more instances, the angular displacement of the splicing angle steel scan 120 represents the rotation angle applied to the splicing angle steel scan 120 about the rotation axis 156, which is required to minimize the step size 116 between the splicing angle steel scan 120 and the directly adjacent splicing angle steel scan 120. For example, in Figure 12 As illustrated, based on the angular displacement, the first splicing angle steel scan 120a is adjusted by applying an axial rotation about the rotation axis 156 to the first splicing angle steel scan 120a (e.g., angular repositioning of the first splicing angle steel scan 120a) so as to: (1) minimize the step size 116 between the first mating edge scan 160a of the first splicing angle steel scan 120a and the second mating edge scan 160b of the second splicing angle steel scan 120b; and (2) minimize the step size 116 between the second mating edge scan 160b of the first splicing angle steel scan 120a and the first mating edge scan 160a of the third splicing angle steel scan 120c.

[0084] Then, an axial rotation about the corresponding rotation axis 156 and according to the corresponding angular displacement is applied to each of the remaining splicing angle steel scans 120 to minimize the step size 116 between each splicing angle steel scan 120 and its directly adjacent splicing angle steel scan. In other words, the angular displacement of each splicing angle steel scan 120 is determined to “compromise” between the relative mating edge scan 160 of each splicing angle steel scan 120 and the corresponding mating edge scan 160 of a directly adjacent pair of relative splicing angle steel scans 120 (e.g., neighboring splicing angle steel scans 120).

[0085] In one or more instances, adjustment steps (e.g., angle repositioning via axial rotation) are performed sequentially along the circumferential splicing surface 106 for each splicing angle steel scan 120. For example, after adjusting the first splicing angle steel scan 120a, the second splicing angle steel scan 120b is adjusted (e.g., angle repositioning of the second splicing angle steel scan 120b) to minimize its step size 116. Then, the splicing angle steel scan 120 directly adjacent to the second splicing angle steel scan 120b and opposite to the first splicing angle steel scan 120a is adjusted (e.g., angle repositioning of the splicing angle steel scan 120) to minimize its step size 116. This process is repeated for each subsequent splicing angle steel scan 120 along a circular path corresponding to the circumferential splicing surface 106 until the third splicing angle steel scan 120c is adjusted (e.g., angle repositioning of the third splicing angle steel scan 120c) to minimize its step size 116.

[0086] Refer again Figure 4 In one or more instances, method 1000 includes the following steps: iteratively repeating (box 1018) the step of determining the step size 116, (box 1020) the step of determining the angular displacement of each splicing angle steel in a plurality of splicing angle steels 102, and (box 1022) the step of adjusting each splicing angle steel scan in the splicing angle steel scan 120 by the angular displacement, until the step size 116 between each splicing angle steel scan in the splicing angle steel scan 120 and its neighboring splicing angle steel scan (e.g., a directly adjacent splicing angle steel scan in the splicing angle steel scan 120) is less than a predetermined threshold. Iteratively repeating the aforementioned optimization steps for each splicing angle steel scan in the splicing angle steel scan 120 further optimizes the position of each splicing angle steel scan in the splicing angle steel scan 120 to achieve a shape of the circumferential splicing surface 106 that is closer to a circle.

[0087] The predetermined threshold can be any suitable predefined value. In one or more instances, the predetermined threshold is the maximum dimensional value of the step (e.g., step size 116) between adjacent spliced ​​angle steel scans in the spliced ​​angle steel scan 120, which is within manufacturing tolerances. In one or more instances, the predetermined threshold is a point beyond which there is no discernible angular displacement that would further minimize the step size 116.

[0088] Now for reference Figure 13 and 14 This schematically illustrates an example of splicing angle steel scans 120 arranged adjacent to each other at the optimized position after optimization steps (e.g., boxes 1018, 1020, and 1022). When the splicing angle steel scans 120 are in the optimized position, the mating edge scan 160 of each splicing angle steel scan 120 is adjacent to the mating edge scan 160 of a directly adjacent splicing angle steel scan 120. The splicing surface scan 158 representing the splicing surface 104 of the splicing angle steel scans 120 forms a virtual representation of a circumferential splicing surface 106 having an optimized shape 136.

[0089] With the splicing angle steel scan 120 in the optimized position, the step between the splicing surface scans 158 of adjacent splicing angle steel scans in the splicing angle steel scan 120 is minimized. Accordingly, when the splicing angle steel 102 is joined to the rear pressure bulkhead 108 in the optimized position, this minimized step will reduce or eliminate the interruption along the circumferential splicing surface 106 between the splicing surfaces 104 of directly adjacent splicing angle steels in the splicing angle steel 102 (e.g., in...). Figure 13 and 14 (As shown in the diagram). When installing the pressure bulkhead assembly 100 within the fuselage 1202 of the aircraft 1200, it is advantageous to minimize this step. As an example, an optimized shape 136 of the circumferential splice surface 106 will more appropriately mate with the surface of the skin 1206 of the fuselage 1202. As another example, splice and skin spacers (not shown) positioned between the circumferential splice surface 106 formed by the splice angles 102 and the skin 1206 typically extend across the splice surface 104 across two or more of the splice angles 102. Accordingly, when minimizing this step, it is less challenging to fabricate the splice and skin spacers to properly fill the gap between the splice angles 102 and the skin 1206.

[0090] Refer again Figure 4In one or more instances, method 1000 includes (box 1026) the step of performing a virtual mating between a plurality of splice angle steels 102 in an optimized position and a rear pressure bulkhead 108. Virtual mating is essentially the virtual engagement of the splice angle steels 102 with the rear pressure bulkhead 108 using splice angle steel scan 120 and rear pressure bulkhead scan 124 (e.g., in…). Figure 15 (As shown in the diagram). For example, (box 1026) the step of performing virtual fitting includes virtually overlapping or aligning the aft pressure bulkhead scan 124 with the splicing angle steel scan 120.

[0091] In one or more instances, method 1000 includes virtually arranging the spliced ​​angle steel scan 120 in an optimized location (e.g., in [location]) before performing virtual mating (box 1026). Figure 13 and 14 The steps are shown in the figure.

[0092] In one or more instances, method 1000 includes (box 1028) generating an aft pressure bulkhead scan 124 representing the aft pressure bulkhead 108 (e.g., in...). Figure 15 The steps are shown in the diagram. In one or more instances, a rear pressure bulkhead scan 124 is generated using 3D measurement data obtained during the measurement step (e.g., box 1008). Thus, the rear pressure bulkhead scan 124 is a virtual model or 3D digital representation of the rear pressure bulkhead 108, such as the surfaces of the rear pressure bulkhead 108 (e.g., 3D surface profiles) and optionally other geometric features of the rear pressure bulkhead 108.

[0093] For example, the aft pressure bulkhead scan 124 represents the first bulkhead surface 138 of the aft pressure bulkhead 108. Figure 8 At least a portion of the second bulkhead surface 140 Figure 9 At least a portion of ). In one or more instances, the aft pressure bulkhead scan 124 includes a first bulkhead surface scan 166 representing the first bulkhead surface 138 (e.g., in Figure 15 (As shown in the illustration). In one or more instances, the aft pressure bulkhead scan 124 includes a second bulkhead surface scan 168 representing the second bulkhead surface 140 (e.g., in...). Figure 15 (As shown in the illustration). In one or more instances, the aft pressure bulkhead scan 124 includes a representation of the bulkhead interface surface 126 (as shown in the illustration). Figure 9 ) Surface scan of the bulkhead interface 170 (e.g., in Figure 15 (As shown in the illustration). In one or more instances, the bulkhead interface surface scan 170 forms part of the second bulkhead surface scan 168. In one or more instances, the aft pressure bulkhead scan 124 includes an aft pressure bulkhead aperture 114 representing the aft pressure bulkhead 108. Figure 8 and 9 Scanning of the rear pressure bulkhead holes (e.g., not shown).

[0094] In one or more instances, method 1000 includes (box 1030) aligning the rear pressure bulkhead scan 124 to the nominal model 122 to virtually fit the rear pressure bulkhead 108 (e.g., box 1026) to the splice angle steel 102 at an optimized location. For example, aligning the rear pressure bulkhead scan 124 to the nominal model 122 such that the rear pressure bulkhead scan 124 virtually overlays the splice angle steel scan 120, which has been positioned and optimized relative to the nominal model 122.

[0095] In one or more instances, according to method 1000 (box 1030), the step of aligning the aft pressure bulkhead scan 124 to the nominal model 122 includes performing a best-fit between the aft pressure bulkhead scan 124 and the nominal model 122. For example, alignment parameters are calculated by performing an optimized best-fit on multiple points of the second bulkhead surface scan 168 with a portion of the nominal model 122 representing the second bulkhead surface 140 of the pressure bulkhead assembly 100.

[0096] In one or more instances, method 1000 includes the following steps: (box 1032) determining the splicing angle steel hole positions 110 for the splicing angle steel holes 112 to be drilled in each of the splicing angle steels 102, such that the splicing angle steel holes 112 (e.g., in...) Figure 16 (As shown) will be connected to the aft pressure bulkhead hole 114 pre-drilled in the aft pressure bulkhead 108 (e.g., in Figure 8 and 9 (As shown in the diagram). The splicing angle steel hole position 110 indicates the determined position and orientation of the splicing angle steel hole 112 to be drilled in each splicing angle steel 102, such that when the splicing angle steel 102 is joined to the aft pressure bulkhead 108 at the optimized position, the splicing angle steel hole 112 will be axially aligned with the corresponding aft pressure bulkhead hole 114. The alignment of the splicing angle steel hole 112 with the aft pressure bulkhead hole 114 fundamentally matches the splicing angle steel 102 at the optimized position relative to the aft pressure bulkhead 108.

[0097] The splicing angle steel hole position 110 of the splicing angle steel hole 112 is determined based on the measured 3D surface profile of the flange surface 130 of the splicing angle steel 102, the measured 3D surface profile of the bulkhead interface surface 126, and the measured position of the rear pressure bulkhead hole 114. In one or more instances, (box 1032) the step of determining the splicing angle steel hole position 110 of the splicing angle steel hole 112 includes the following steps: determining the position and orientation of the drill axis for drilling each splicing angle steel hole in the splicing angle steel hole 112 relative to the 3D profile of the flange surface 130, such that the drill axis is axially aligned with the center drill axis of the corresponding rear pressure bulkhead hole in the rear pressure bulkhead hole 114.

[0098] In one or more instances, the bulkhead interface surface 126 to be used with the aft pressure bulkhead 108 is determined by measuring the splicing angle steel 102 (e.g., frame 1010) (such as measuring the flange surface 130). Figure 9 The flange surface 130 of the spliced ​​angle steel 102 is joined. Figure 8 The 3D surface profile of the spliced ​​angle steel scan 120 is scanned by the flange surface scan 162 (e.g., in the...). Figure 15 The diagram shows the 3D surface profile. As described above, the splicing angle steel 102 is initially manufactured without full-size pre-drilled holes (e.g., without multiple splicing angle steel holes 112), as shown in... Figure 8 and 9 Examples are provided.

[0099] In one or more instances, the flange surface 130 to be joined with the splicing angle steel 102 is determined by measuring the rear pressure bulkhead 108 (e.g., frame 1008) (such as measuring the bulkhead interface surface 126 (e.g., second bulkhead surface 140)). Figure 8 The bulkhead interface surface 126 of the rear pressure bulkhead 108 is joined. Figure 9 The 3D surface profile of the pressure bulkhead, and the bulkhead interface surface scan 170 of the rear pressure bulkhead scan 124 (e.g., in the... Figure 15 The diagram shows the 3D surface profile. As described above, the aft pressure bulkhead 108 is initially fabricated with full-size pre-drilled holes (e.g., multiple aft pressure bulkhead holes 114), as shown in... Figure 8 and 9 Examples are provided.

[0100] In one or more instances, method 1000 includes (block 1034) the step of determining the aft pressure bulkhead hole location 132 of the aft pressure bulkhead hole 114. In one or more instances, the aft pressure bulkhead hole location 132 of the aft pressure bulkhead hole 114 is determined by measuring the aft pressure bulkhead 108 (e.g., block 1008) (such as measuring the bulkhead interface surface 126 and the aft pressure bulkhead hole 114). In one or more instances, the step of (block 1034) determining the aft pressure bulkhead hole location 132 of the aft pressure bulkhead hole 114 includes the steps of determining the position and orientation of the aft pressure bulkhead hole 114.

[0101] Now for reference Figure 6 and 7 In one or more instances, based on the first hole center 172 of the rear pressure bulkhead hole 114 formed in the first bulkhead surface 138 (e.g., in... Figure 6 The first measuring position 178 (as shown) and based on the second hole center 174 of the rear pressure bulkhead hole 114 formed in the second bulkhead surface 140 (e.g., in... Figure 7 The second measurement position 180 (shown in the diagram) determines the position of each aft pressure bulkhead hole 114. For example, the center 172 of the first hole and the center 174 of the second hole are measured relative to the origin O in an exemplary three-dimensional Cartesian coordinate system XYZ (e.g., box 1008). As an example, the first measurement position 178 of the center 172 of the first hole of the aft pressure bulkhead hole 114 is measured as x1, y1, z1 in the XYZ coordinate system (e.g., in...). Figure 6 As shown in the figure), and in the XYZ coordinate system, the second measuring position 180 of the second hole center 174 of the rear pressure bulkhead hole 114 is measured as x2, y2, z2 (e.g., in Figure 7 (as shown in the image).

[0102] It's understandable that the origin O can be chosen for convenience (for example, in...). Figure 6 and 7 As shown in the diagram, the origin may be selected as the outer perimeter edge of the aft pressure bulkhead 108. In other cases, the origin O may be selected at a different location, or in other cases, different coordinate systems (such as polar or spherical coordinates) may be used for measurement, without departing from the scope of this disclosure.

[0103] In one or more instances, the orientation of each rear pressure bulkhead hole 114 is determined based on a first measurement position 178 of the first hole center 172 and a second measurement position 180 of the second hole center 174. Based on the first measurement position 178 of the first hole center 172 and the second measurement position 180 of the second hole center 174, the measurement orientation 182 of the rear pressure bulkhead hole 114 is determined by an angle θ formed between a plane 176 and a reference plane of the XYZ coordinate system (e.g., the XY plane). The plane 176 contains a central borehole axis (e.g., in the plane) extending through the thickness 142 of the rear pressure bulkhead 108 between the first hole center 172 and the second hole center 174. Figure 6 (as shown in the image).

[0104] In one or more instances, after the step of performing virtual mating (box 1026) by overlapping the aft pressure bulkhead scan 124 with the splice angle steel scan 120 at the optimized position, the step of determining the splice angle steel hole position 110 of the splice angle steel hole 112 is performed (box 1032). For example, the splice angle steel scans 120 are configured to be adjacent to each other and fixed at the optimized position, such that the splice surface scan 158 forms a virtual representation of the circumferential splice surface 106 having an optimized shape 136. The aft pressure bulkhead scan 124 can be translated and / or rotated relative to the splice angle steel scan 120 to optimize the mating interface between the bulkhead interface surface scan 170 and the flange surface scan 162. The virtual overlap 184 of the aft pressure bulkhead scan 124 with the splice angle steel scan 120 (e.g., in Figure 15 (as shown in the figure) is fixed, and the splicing angle steel hole position 110 is determined (e.g., calculated) based on the determined rear pressure bulkhead hole position 132 of the rear pressure bulkhead hole 114.

[0105] Refer again Figure 4 In one or more instances, method 1000 includes (box 1034) the step of drilling a splicing angle steel hole 112 at splicing angle steel hole location 110 in each splicing angle steel 102.

[0106] Now for reference Figure 16 This schematically illustrates an example of splicing angle steel 102 after drilling splicing angle steel holes 112 through flange 148. As determined according to method 1000, at the corresponding splicing angle steel hole position 110 (e.g., in... Figure 16 Drill each splicing angle steel hole in the splicing angle steel hole 112 at the location indicated by x3, y3, z3.

[0107] In one or more instances, such as Figure 16As shown, additional splicing angle steel holes are drilled through the skin splice 150 at appropriate locations for use when the pressure bulkhead assembly 100 is installed within the fuselage 1202 (e.g., in...). Figure 3 As shown in the diagram, the skin splice 150 is joined to the skin 1206 of the fuselage 1202. In one or more instances, additional splice angle steel holes are located in the guide holes 152 ( Figure 8 and 9 A full-size hole drilled through the skin splice at ) location.

[0108] In one or more instances, method 1000 includes (box 1036) the step of assembling the pressure bulkhead assembly 100. In one or more instances, according to method 1000, the step of (box 1036) assembling the pressure bulkhead assembly 100 includes the step of (box 1038) engaging each of the splice angles 102 with the rear pressure bulkhead 108 such that the splice surfaces 104 of the splice angles 102 form the circumferential splice surfaces 106 of the pressure bulkhead assembly 100 in an optimized shape 136 (e.g., in...). Figure 1 (as shown in the image).

[0109] Now for reference Figure 17 This schematically illustrates an example of a portion of a pressure bulkhead assembly 100. In one or more examples, when the pressure bulkhead assembly 100 is assembled, gaps may exist between the bulkhead interface surface 126 of the aft pressure bulkhead 108 and the flange surfaces 130 of one or more splicing angles 102. It is understood that such gaps may be formed due to manufacturing tolerances of the aft pressure bulkhead 108 and the splicing angles 102. Gaskets 128 are used to fill the gaps between the bulkhead interface surface 126 and the flange surfaces 130.

[0110] Refer again Figure 4 In one or more instances, method 1000 includes (box 1040) the step of determining the shim size of a shim 128 to be positioned between a bulkhead interface surface 126 of a rear pressure bulkhead 108 and a flange surface 130 of one of the splicing angles 102.

[0111] In one or more instances, based on virtual overlap 184 ( Figure 15 The gap between the bulkhead interface surface scan 170 and the flange surface scan 162 identified in the method is used to determine the gasket size of the gasket 128. In one or more instances, the method 1000 includes the step of determining (e.g., detecting or estimating) the gap between the bulkhead interface surface scan 170 and the flange surface scan 162, which, when the pressure bulkhead assembly 100 is assembled, will correspond to the gap formed between the bulkhead interface surface 126 of the aft pressure bulkhead 108 and the flange surface 130 of the splicing angle steel 102.

[0112] refer to Figure 15 It schematically illustrates an example of a portion of the virtual overlap 184 between the aft pressure bulkhead scan 124 and the splicing angle steel scan 120 (in Figure 15 For clarity, only one splicing angle steel scan 120 is shown. In one or more instances, when the aft pressure bulkhead scan 124 virtually overlaps with the splicing angle steel scan 120, any deviation between the bulkhead interface surface scan 170 and the flange surface scan 162 is identified as a gap. Calculated deviations exceeding design tolerances are identified as requiring the use of shims 128 (e.g., in...). Figure 16 The gaps (shown in the diagram) are filled and used to determine the gasket size.

[0113] In one or more instances, the deviation is used to determine the gasket profile 186 and 3D gasket surface profile 188 of the gasket 128 to be used to fill the gap between the bulkhead interface surface 126 and the flange surface 130. The gasket profile 186 and the gasket surface profile 188 represent the gasket dimensions.

[0114] Refer again Figure 4 In one or more instances, method 1000 includes (block 1042) the step of fabricating (e.g., preparing) a shim 128 for filling the gap between the aft pressure bulkhead 108 and the splice angle steel 102, based on shim dimensions. The shim shape 186 and shim surface profile 188 of the shim 128 are determined based on dimensional data of the deviation between the bulkhead interface surface scan 170 and the flange surface scan 162 (e.g., in…). Figure 15 (As shown in the figure). Gasket outline 186 and gasket surface profile 188 represent the length, width, thickness and surface geometry of gasket 128.

[0115] In one or more instances, (box 1042) the step of fabricating gasket 128 includes machining gasket 128 from a stock gasket (not shown) to have a defined gasket size (e.g., forming gasket outline 186 and gasket surface profile 188). Gasket 128 is machined according to the gasket size to fill the gap between the rear pressure bulkhead 108 and the splicing angle steel 102 (e.g., in…). Figure 17 (as shown in the image).

[0116] In one or more instances, method 1000 includes determining a plurality of gasket holes 190 to be drilled in each of the gaskets 128 (e.g., in...). Figure 18 The step of multiple gasket hole positions 192 (shown in the figure). In one or more instances, based on virtual overlap 184 ( Figure 15The gasket hole position 192 of the gasket hole 190 is determined based on the determined gasket size. For example, when the rear pressure bulkhead scan 124 is fixed with the splicing angle steel scan 120 in a virtual overlap 184, the gasket hole position 192 is determined (e.g., calculated) based on the determined rear pressure bulkhead hole position 132 of the rear pressure bulkhead hole 114 and the splicing angle steel hole position 110 of the splicing angle steel hole 112.

[0117] In one or more instances, (box 1042) the step of fabricating the gasket 128 includes drilling a gasket hole 190 through the gasket 128 at the determined gasket hole location 192. At the corresponding gasket hole location 192 (e.g., at...) Figure 18 Drill each gasket hole in gasket hole 190 at the location indicated by x4, y4.

[0118] In one or more instances, a gasket hole 190 is drilled in the gasket 128 before the gasket 128 is machined to the gasket dimensions. For example, the gasket hole 190 is drilled in a stock gasket with a generally flat configuration (e.g., a flat stock gasket). In these instances, the gasket surface profile 188 is transformed into a virtual (e.g., flat or planar) profile corresponding to the flat surface of the stock gasket, and the gasket hole position 192 is transformed into a corresponding virtual position on the stock gasket. After the stock gasket is machined to the gasket dimensions, the gasket hole 190 is drilled in the stock gasket at the virtual position such that the gasket hole 190 is in the appropriate gasket hole position 192.

[0119] In one or more instances, a gasket hole 190 is drilled in the gasket 128 after the gasket 128 is machined to the gasket dimensions. In these instances, the gasket hole 190 is drilled in the gasket 128 at a predetermined gasket hole location 192.

[0120] Now for reference Figure 18 This schematically illustrates an example of a gasket 128. The gasket hole position 192 of the gasket hole 190 corresponds to the rear pressure bulkhead hole position 132 of the rear pressure bulkhead hole 114 in the rear pressure bulkhead 108 and the splicing angle steel hole position 110 of the splicing angle steel hole 112 in the splicing angle steel 102. When the gasket 128 is positioned between the bulkhead interface surface 126 and the flange surface 130, and the splicing angle steel 102 is engaged with the rear pressure bulkhead 108 at an optimized position (e.g., in…), Figure 17 As shown in the diagram, the shim hole 190 will be axially aligned with the corresponding rear pressure bulkhead hole 114 and the corresponding splicing angle steel hole 112. The gap between the rear pressure bulkhead 108 and the flange 148 is filled with shims 128 so that the splicing angle steel 102 is maintained in an optimized position relative to the rear pressure bulkhead 108.

[0121] Refer again Figure 4In one or more instances, according to method 1000, step (box 1036) includes the following steps: prior to step (1038) of joining the splice angle steel 102 to the rear pressure bulkhead 108, (box 1044) positioning a gasket 128 between the bulkhead interface surface 126 and the flange surface 130 such that the gasket hole 190 is axially aligned with the corresponding rear pressure bulkhead hole 114 and the corresponding splice angle steel hole 112.

[0122] In one or more instances, method 1000 includes the following steps: (box 1046) moving a rear pressure bulkhead scan 124 relative to a plurality of splice angle scans 120 such that the gasket size of gasket 128 is larger than a minimum manufacturing size. In one or more instances, when the rear pressure bulkhead scan 124 virtually overlaps with the splice angle scans 120, the calculated deviation between the bulkhead interface surface scan 170 and the flange surface scan 162 exceeds the design tolerance but defines a gap smaller than the minimum manufacturing size of gasket 128. In one or more instances, after performing the virtual mating step (box 1026), the rear pressure bulkhead scan 124 is moved away from the splice angle scans 120 along an axis circumscribed by the circumferential splice surface 106 to space the bulkhead interface surface scan 170 and the flange surface scan 162 until the gasket size of gasket 128 is larger than the minimum manufacturing size of gasket 128. In these examples, after moving the rear pressure bulkhead scan 124 away from the splice angle scan 120 (e.g., spaced apart from the splice angle scan 120), the splice angle hole position 110, the gasket hole position 192, and the gasket size are determined.

[0123] refer to Figure 1 and 17 In one or more instances, after drilling splicing angle steel holes 112 in the splicing angle steel 102, each splicing angle steel in the splicing angle steel 102 is joined to the rear pressure bulkhead 108 such that the splicing angle steel holes 112 are aligned with the corresponding rear pressure bulkhead holes 114 in the rear pressure bulkhead holes. Fasteners 134 are installed through the aligned rear pressure bulkhead holes 114 in the rear pressure bulkhead 108 and the splicing angle steel holes 112 in the splicing angle steel 102. Figure 17 The splice angle 102 is fastened to the aft pressure bulkhead 108 at an optimized position. As described herein, splice angle holes 112 are drilled at splice angle hole locations 110 so that fasteners 134 can mate the splice angle 102 at the optimized position. Assembling the pressure bulkhead assembly 100 according to method 1000 also reduces or eliminates the amount of assembly tooling required to mate and hold the splice angle 102 in place relative to the aft pressure bulkhead 108 during assembly of the pressure bulkhead assembly 100, which advantageously shortens cycle time and reduces manufacturing costs.

[0124] In one or more instances, as needed, the gasket 128 is used to fill the gap between the bulkhead interface surface 126 and the flange surface 130. After machining the gasket 128 to the gasket dimensions and drilling gasket holes 190 in the gasket 128, the splice angle steel 102 and the gasket 128 are joined to the aft pressure bulkhead 108 such that the gasket holes 190 and the splice angle steel holes 112 are aligned with the corresponding aft pressure bulkhead holes 114 in the aft pressure bulkhead 108. Fasteners 134 are installed through the aligned aft pressure bulkhead holes 114 in the aft pressure bulkhead 108, the gasket holes 190 in the gasket 128, and the splice angle steel holes 112 in the splice angle steel 102. Figure 17 ), to fix the splicing angle steel 102 and the gasket 128 to the rear pressure bulkhead 108, wherein the splicing angle steel 102 is in an optimized position.

[0125] As described above, each of the splicing angle steels 102 is joined to the aft pressure bulkhead 108 at the optimized location, such that the flange surface 130 mates with the corresponding portion (e.g., segment) of the bulkhead interface surface 126, thereby achieving an optimized shape 136. Figure 1 A circumferential splicing surface 106 is formed for the pressure bulkhead assembly 100. A gasket 128 is used to fill the gap between the flange surface 130 and the bulkhead interface surface 126, if necessary. Fasteners 134 are provided through a set of aligned holes to engage the rear pressure bulkhead 108, splicing angle steel 102, and gasket 128 together as needed, thereby forming the pressure bulkhead assembly 100. The fasteners 134 can take any desired form, such as permanent fasteners.

[0126] When the splice angle steel 102 is joined to the aft pressure bulkhead 108, the fasteners 134 and gaskets 128 maintain an optimized shape 136. The pressure bulkhead assembly 100 may include any number of splice angle steels 102 required to form the circumferential splice surface 106 and to attach the pressure bulkhead assembly 100 to the fuselage 1202. In this example, thirty-two splice angle steels 102 are joined to the aft pressure bulkhead 108 to form the pressure bulkhead assembly 100.

[0127] Now for reference Figure 5The diagram schematically illustrates an example of system 200. In one or more instances, system 200 is configured to accurately measure and process the aft pressure bulkhead 108 and splice angle steel 102, for example, to generate aft pressure bulkhead scan 124 and splice angle steel scan 120. System 200 is also configured to determine an optimal position for splice angle steel 102 based on measurements of the aft pressure bulkhead 108 and splice angle steel 102. System 200 is further configured to determine splice angle steel hole positions 110 of splice angle steel holes 112 such that the optimal position of splice angle steel 102 is maintained when the splice angle steel 102 is engaged with the aft pressure bulkhead 108. System 200 is additionally configured to machine the splice angle steel 102 (e.g., drill splice angle steel holes 112 in the splice angle steel 102). System 200 is further configured to machine gaskets 128 to the required tolerances as needed.

[0128] In one or more instances, system 200 includes a measuring machine 202 configured to measure the aft pressure bulkhead 108 and a plurality of spliced ​​angle steels 102. In one or more instances, the measuring machine 202 is a coordinate measuring machine (CMM).

[0129] In one or more instances, the measuring machine 202 (e.g., CMM) is configured to measure an object in a three-dimensional (3D) coordinate system, typically compared to a computer-aided design (CAD) model of that object. For example, the measuring machine 202 measures the aft pressure bulkhead 108 and the splice angle steel 102 to drill splice angle steel holes 112 in the splice angle steel 102, and optionally, if necessary, adds shims 128 and drills shim holes 190 in the shims 128 to fill the gap between the aft pressure bulkhead 108 and the splice angle steel 102.

[0130] The measuring machine 202 is any suitable measuring machine. In one or more instances, the measuring machine 202 is a portable coordinate measuring machine. In one or more instances, the measuring machine 202 includes an articulated measuring arm, such as a ROMER arm (e.g., not shown). For example, the measuring machine 202 includes a robotic arm with six or seven joints in 3D space, which has six degrees of freedom, meaning that the robotic arm can move forward / backward, up / down, left / right in three-dimensional space and rotate about three vertical axes (roll, yaw, pitch). The movement along each of the three axes is independent of each other and independent of the rotation about any of these axes, thus having six degrees of freedom.

[0131] In one or more embodiments, the measuring machine 202 is configured to measure selected areas (e.g., aft pressure bulkhead bore 114 and bulkhead interface surface 126) on the aft pressure bulkhead 108. In one or more embodiments, the measuring machine 202 is positioned adjacent to the aft pressure bulkhead 108 to be measured, such that an articulated measuring arm can measure the position and orientation of the aft pressure bulkhead bore 114 and bulkhead interface surface 126. In one or more embodiments, the aft pressure bulkhead 108 is mounted on an assembly fixture or support tool for measurement by the measuring machine 202.

[0132] In one or more embodiments, the measuring machine 202 is configured to measure selected areas (e.g., flange surface 130 and splice surface 104) on the splice angle steel 102. In one or more embodiments, the measuring machine 202 is positioned adjacent to the splice angle steel 102 to be measured, such that an articulated measuring arm can measure both flange surface 130 and splice surface 104. In one or more embodiments, one or more splice angle steels of the splice angle steel 102 may be mounted on an assembly fixture or support tool for measurement of each splice angle steel of the splice angle steel 102 by the measuring machine 202.

[0133] It should be understood that other suitable types of coordinate measuring machines with sufficient accuracy can also be used to measure selected areas of the structure being measured (e.g., the aft pressure bulkhead 108 and the splicing angle steel 102), such as handheld measuring devices or laser scanners. Furthermore, it should be understood that the system 200 can use different coordinate measuring machines to measure the aft pressure bulkhead 108 and the splicing angle steel 102.

[0134] In one or more instances, system 200 includes computer system 204. In one or more instances, system 200 includes measuring device 220. In one or more instances, measuring device 220 includes a spatial relationship device or takes the form of a spatial relationship device. Measuring device 220 includes measuring machine 202 and computer system 204 (e.g., controller). Measurements performed by measuring machine 202 are sent to computer system 204. Computer system 204 provides users with an interface for executing measurement plans, processes measurements performed by measuring machine 202, and provides the processed measurements to On-Demand Emergency Manufacturing (ODEM) application 222 in .XML format.

[0135] Computer system 204 includes processor 210 and memory 206. Memory 206 stores one or more programs 208. In one or more instances, computer system 204 includes a measurement software platform. The measurement software platform is any suitable type that includes programs 208 adapted to perform and process measurements. An exemplary measurement software platform (e.g., program 208) is a spatial analyzer program 224. In one or more instances, computer system 204 includes an optimization software platform. The optimization software platform is any suitable type that includes programs 208 adapted to process measurement data and perform optimization algorithms on the data. An exemplary optimization software platform (e.g., program 208) is a best-fit optimizer program 226.

[0136] In one or more instances, processor 210 is configured to execute program 208 to determine optimized positions of a plurality of splicing angle steels 102, such that a plurality of splicing surfaces 104 of the plurality of splicing angle steels 102 will form a circumferential splicing surface 106 in an optimized shape 136. Processor 210 is configured to execute program 208 to perform a virtual mating between the plurality of splicing angle steels 102 in the optimized positions and the aft pressure bulkhead 108. Processor 210 is configured to execute program 208 to determine splicing angle steel hole positions 110 for drilling splicing angle steel holes 112 in each of the plurality of splicing angle steels 102, such that the splicing angle steel holes 112 will correspond to a pre-drilled aft pressure bulkhead hole 114 in the aft pressure bulkhead 108.

[0137] In one or more instances, processor 210 is configured to execute program 208 to generate a plurality of splice angle steel scans 120 representing a plurality of splice surfaces 104 based on measurements taken by measuring machine 202 of a plurality of splice angle steels 102. Processor 210 is configured to execute program 208 to align the plurality of splice angle steel scans 120 to a nominal model 122 representing a pressure bulkhead assembly 100, thereby arranging the plurality of splice angle steel scans 120 in an initial position in which a plurality of splice surface scans 158 of the plurality of splice angle steel scans 120 represent circumferential splice surfaces 106 having an initial shape 154.

[0138] In one or more instances, processor 210 is configured to execute program 208 to determine a step size 116 between a mating edge scan 160 of each of the plurality of spliced ​​angle steel scans 120 and a mating edge scan 160 of one directly adjacent spliced ​​angle steel scan 120. Processor 210 is configured to execute program 208 to determine an angular displacement of each of the spliced ​​angle steel scans 120 to minimize the step size 116. Processor 210 is configured to execute program 208 to adjust each of the plurality of spliced ​​angle steel scans 120 by the angular displacement to move the plurality of spliced ​​angle steel scans 120 to an optimized position.

[0139] In one or more instances, processor 210 is configured to execute program 208 to virtually arrange multiple splice angle steel scans 120 in optimized positions prior to performing virtual mating. Processor 210 is configured to execute program 208 to generate a rear pressure bulkhead scan 124 representing the bulkhead interface surface 126 of the rear pressure bulkhead 108 based on measurements taken by measuring machine 202 of the rear pressure bulkhead 108. Processor 210 is configured to execute program 208 to align the rear pressure bulkhead scan 124 to the nominal model 122, virtually overlaying the rear pressure bulkhead scan 124 onto the multiple splice angle steel scans 120 at the optimized positions.

[0140] In one or more instances, system 200 includes a computer numerical control (CNC) machine tool 212 or equivalent. The CNC machine tool 212 is configured to drill splice angle steel holes 112 at splice angle steel hole locations 110 in each of the plurality of splice angle steels 102 (e.g., Figure 16 For example, each splicing angle steel in splicing angle steel 102 is fixed and matched on the drill string.

[0141] In one or more instances, computer system 204 executes a software application to create a program for drilling splice angle steel holes 112 in splice angle steel 102 based on the determined splice angle steel hole positions 110, such splice angle steel hole positions being aligned with the measured aft pressure bulkhead hole positions 132 of aft pressure bulkhead holes 114 in aft pressure bulkhead 108. In one or more instances, CNC machine tool 212 drills splice angle steel holes 112 in splice angle steel 102 based on the created program. In one or more instances, CNC machine tool 212 drills splice angle steel holes 112 in each splice angle steel in splice angle steel 102 based on NC program 228.

[0142] In one or more instances, the CNC machine tool 212 includes a network computer (NC) controller 232 that receives an NC program 228. The system 200 performs measurements, processing these measurements according to a requirements document in .XML format. The ODEM application 222 then updates the NC seed model with the data in .XML format and then automatically creates the necessary validated NC program 230.

[0143] In one or more instances, system 200 includes assembly fixture 214 configured to restrict aft pressure bulkhead 108 for engaging each of a plurality of splice angles 102 with aft pressure bulkhead 108 such that a plurality of splice surfaces 104 form circumferential splice surfaces 106 in an optimized shape 136.

[0144] In one or more instances, processor 210 executes program 208 (e.g., spatial analyzer program 224) to facilitate the measurement device 220 in providing an interface to a user for executing measurement plans, processing such measurements, and providing such processed measurements to the ODEM application 222 as described in method 1000. In one or more instances, processor 210 executes program 208 (e.g., spatial analyzer program 224) to instruct the measuring machine 202 to perform the operational measurement steps of method 1000 (e.g., blocks 1008 and 1010).

[0145] In one or more instances, processor 210 executes space analyzer program 224 to perform operational steps that implement: a first measurement model (e.g., a 3D seed model) of the aft pressure bulkhead 108, the first measurement model including multiple first measurement points for each aft pressure bulkhead hole 114 and for portions of the bulkhead interface surface 126 adjacent to the aft pressure bulkhead hole 114; and a second measurement model (e.g., a 3D seed model) of each splice angle steel 102, the second measurement model including multiple second measurement points for portions of the flange surface 130. Processor 210 then executes space analyzer program 224 to perform other operational steps of method 1000 (e.g., blocks 1012 to 1020, 1026 to 1032 and 1040).

[0146] In one or more instances, the measuring machine 202 measures (e.g., frame 1008) the rear pressure bulkhead hole 114 along the first bulkhead surface 138 of the rear pressure bulkhead 108 relative to the origin O in an exemplary three-dimensional Cartesian coordinate system XYZ. Figure 6The center 172 of the first hole of each aft pressure bulkhead hole in the aft pressure bulkhead 108. The aft pressure bulkhead hole 114 is measured by measuring machine 202 relative to the origin O in an exemplary three-dimensional Cartesian coordinate system XYZ (e.g., frame 1006) along the second bulkhead surface 140 of the aft pressure bulkhead 108. Figure 7 The center of the second hole 174 of each rear pressure bulkhead hole in the )

[0147] In one or more instances, computer system 204 processes measurements to determine aft pressure bulkhead hole positions 132 (e.g., relative positions and orientations) for aft pressure bulkhead holes 114. In one or more instances, computer system 204 processes measurements to determine aft pressure bulkhead hole positions 132 for each of the aft pressure bulkhead holes 114 in the aft pressure bulkhead 108.

[0148] In one or more instances, the bulkhead interface surface 126 of the aft pressure bulkhead 108 is scanned by a measuring machine 202. A three-dimensional (3D) scan of the aft pressure bulkhead 108 is generated and stored by a computer system 204 (e.g., aft pressure bulkhead scan 124). In one or more instances, the 3D scan produces 3D point cloud surface contour data of the aft pressure bulkhead 108.

[0149] In one or more instances, a 3D scan of the aft pressure bulkhead 108 is compared with the corresponding 3D seed model, the nominal model of the aft pressure bulkhead 108, or the design dimensions derived from a drawing associated with the aft pressure bulkhead 108 to identify the measurement capability of the measuring machine 202 in performing the 3D scan, ensure that the measurement process is error-free, ensure that proper alignment has been achieved, and / or confirm that no anomalies exist.

[0150] In one or more instances, a measuring machine 202 scans the flange surface 130 and the splicing surface 104 of the spliced ​​angle steel 102. A three-dimensional (3D) scan of the spliced ​​angle steel 102 is generated and stored by a computer system 204 (e.g., spliced ​​angle steel scan 120). In one or more instances, the 3D scan produces 3D point cloud surface profile data of the spliced ​​angle steel 102.

[0151] In one or more instances, the 3D scan of the spliced ​​angle steel 102 is compared with the corresponding 3D seed model, the nominal model of the spliced ​​angle steel 102, or the design dimensions derived from the drawings associated with the spliced ​​angle steel 102 to identify the measurement capability of the measuring machine 202 to perform the 3D scan, ensure that the measurement process does not produce errors, ensure that proper alignment has been achieved, and / or confirm that there are no anomalies.

[0152] In one or more instances, computer system 204 executes a software application (e.g., space analyzer program 224) to generate aft pressure bulkhead scan 124 and splice angle steel scan 120. For example, aft pressure bulkhead scan 124 is generated using 3D scans (e.g., measurement data and / or 3D cloud surface profile data) of aft pressure bulkhead hole location 132 of aft pressure bulkhead hole 114, first bulkhead surface 138, second bulkhead surface 140, and bulkhead interface surface 126. Splice angle steel scan 120 is generated using 3D scans (e.g., measurement data and / or 3D cloud surface profile data) of first splice angle steel surface 144 and second splice angle steel surface 146.

[0153] In one or more instances, processor 210 executes program 208 (e.g., best-fit optimizer program 226) to process measurements of step size 116 and angular displacement and to help optimize circumferentially stitched surface 106, as described in method 1000. In one or more instances, processor 210 executes program 208 (e.g., best-fit optimizer program 226) to instruct computer system 204 to perform operational optimization steps of method 1000 (e.g., blocks 1018 to 1024).

[0154] In one or more instances, the best-fit optimizer program 226 performs position optimization operations on each spliced ​​angle steel scan in the spliced ​​angle steel scan 120 by rotatably adjusting the angular orientation of each spliced ​​angle steel scan in the spliced ​​angle steel scan 120 according to the determined angular displacement, so as to minimize the step size 116 (e.g., in...). Figure 12 (as shown in the diagram) and scan the splicing angle steel 120 from the initial position (e.g., in the diagram). Figure 10 and 11 (as shown) move to the optimized position (e.g., in) Figure 13 and 14 (as shown in the image).

[0155] In one or more instances, the space analyzer program 224 performs virtual mating by, for example, virtually aligning the aft pressure bulkhead scan 124 (representing the bulkhead interface surface 126 of the aft pressure bulkhead 108) with the splice angle steel scan 120 (representing the corresponding flange surface 130 of the splice angle steel 102) at an optimized location relative to the nominal model 122, for example, generating a virtual overlap 184 (e.g., in...). Figure 15 (As shown in the diagram). Based on the virtual overlap 184 between the aft pressure bulkhead scan 124 and the splicing angle steel scan 120 at the optimized location, the space analyzer program 224 determines the splicing angle steel hole position 110 of the splicing angle steel hole 112 to be drilled in each splicing angle steel in the splicing angle steel 102, corresponding to the aft pressure bulkhead hole 114 in the aft pressure bulkhead 108.

[0156] Therefore, the splicing angle steel hole position 110 of each splicing angle steel hole 112 determined by the space analyzer program 224 provides the position and orientation of the drilling axis for drilling the splicing angle steel hole 112. In the fabrication (e.g., assembly) of the pressure bulkhead assembly 100 ( Figure 1 During this process, the splicing angle steel hole 112 is coaxially aligned with the rear pressure bulkhead hole 114, so that the splicing angle steel 102 is matched in the optimized position.

[0157] In one or more instances, when a compatible .XML measurement file and a 3D seed model are provided from the spatial analyzer program 224, the ODEM application 222 generates a network computer (NC) program 228, then verifies the NC program and generates a verified NC program 230 to enable drilling full-size holes in the splice angle steel 102, machining or fabricating necessary shims 128, and drilling full-size holes (e.g., frames 1034 and 1042) in the shims 128. Each hole to be drilled will have the XYZ points to be drilled and the associated planes, thus determining the orientation of the hole to be drilled. Therefore, the system 200 is configured to generate multiple NC programs based on the obtained measurements for drilling splice angle steel holes 112 in the splice angle steel 102.

[0158] In one or more instances, the space analyzer program 224 is adapted (e.g., programmed to) link three-dimensional (3D) measurement seed models. For example, system 200 includes 3D measurement seed models corresponding to a nominally configured aft pressure bulkhead 108 and splice angle steel 102, such nominal configurations including interface surfaces, nominal full-size holes, and surface geometries. As an example, for aft pressure bulkhead 108, the corresponding measurement seed model identifies a first bulkhead surface 138, a second bulkhead surface 140, a bulkhead interface surface 126, and aft pressure bulkhead holes 114 (e.g., in…). Figures 6 to 9 (As shown in the diagram). As an example, for each spliced ​​angle steel in the spliced ​​angle steel 102, the corresponding measurement seed model can identify the flange 148, the skin splice 150, the flange surface 130, and the splice surface 104 (e.g., in...). Figure 8 and 9 (as shown in the image).

[0159] In one or more instances, for each selected area to be measured, the spatial analyzer program 224 operates to guide the measuring machine 202 (e.g., under automated computer control or operator control) to complete the required measurement and processing steps, thereby causing a coordinate system transformation from the CMM coordinate system at installation time to the 3D NC seed model in the nominal coordinate system for each of the aft pressure bulkhead 108 and the spliced ​​angle steel 102.

[0160] In one or more instances, system 200 provides processed measurements to ODEM application 222 in .XML format. When a compatible .XML measurement file and an NC seed model are provided, ODEM application 222 generates a network computer program (e.g., NC program 228 or a validated NC program 230), and then validates the network computer program for drilling splice angle steel holes 112 (e.g., full-size holes) in splice angle steel 102, and optionally fabricates shims 128 as needed (e.g., machining shims 128 and drilling full-size holes in shims 128). Each hole to be drilled will have the XYZ points to be drilled and the associated planes, thereby determining the location and orientation of the hole to be drilled. ODEM application 222 also monitors the fabrication status of the drilled or machined parts.

[0161] In one or more instances, the ODEM application 222 also transmits network computer programs to a server that includes quality assurance provisions reflecting the tolerances for boreholes and gaskets, as well as settings documents for measurement plans, locking plans, and installation plans for each product definition data.

[0162] In one or more instances, processor 210 is configured to execute program 208 to determine the shim size of shim 128 for positioning between bulkhead interface surface 126 and the flange surface 130 of one of the plurality of splice angles 102. Shim 128 is positioned between bulkhead interface surface 126 and flange surface 130 before one of the splice angles 102 is engaged with the aft pressure bulkhead 108.

[0163] In one or more instances, when the space analyzer program 224 overlaps the aft pressure bulkhead scan 124 with the splice angle steel scan 120, the space analyzer program 224 further estimates the gap between the bulkhead interface surface scan 170 and the flange surface scan 162. The estimated gap represents the gap between the bulkhead interface surface 126 of the aft pressure bulkhead 108 and the flange surface 130 of the splice angle steel 102. The estimated gap is used to determine the fill required to fill any gaps between the bulkhead interface surface 126 and the flange surface 130 during the assembly of the pressure bulkhead assembly 100.

[0164] In one or more instances, the space analyzer program 224 minimizes the gap by adjusting the position of the rear pressure bulkhead scan 124 relative to the splice angle scan 120 during the virtual overlap and alignment as described above, and thus minimizes the gap filling requirements. This gap minimization step is performed prior to the step of determining the splice angle hole position 110 of the splice angle hole 112 in (box 1032).

[0165] In one or more instances, to determine gap and / or spacing requirements, the space analyzer program 224 determines a set of deviations (defining gaps) between the bulkhead interface surface scan 170 and the corresponding flange surface scan 162 during overlap, and compares this set of deviations with deviation tolerances for the design or nominal 3D profile of the aft pressure bulkhead 108 and the splice angle 102. This set of deviations between the bulkhead interface surface scan 170 and the flange surface scan 162 includes, for example, dimensional and 3D surface profile data. This set of deviations exceeding (e.g., greater than) the design tolerances determines the mating surfaces and profiles of the gasket 128 to be positioned between the aft pressure bulkhead 108 and the splice angle 102.

[0166] In one or more instances, processor 210 is configured to execute program 208 to move the rear pressure bulkhead scan 124 relative to a plurality of splice angle steel scans 120 such that the shim size of shim 128 is larger than the minimum manufacturing size. In one or more instances, space analyzer program 224 determines the clearance size by adjusting the position of the rear pressure bulkhead scan 124 relative to the splice angle steel scans 120 during virtual overlap and alignment, and thus determines the camber requirement such that the shim size meets the minimum manufacturing size. This clearance size setting is performed before determining the splice angle steel hole positions 110 of the splice angle steel holes 112.

[0167] In one or more instances, CNC machine tool 212 is configured to fabricate (e.g., machine) shim 128 based on shim dimensions. CNC machine tool 212 is configured to drill shim holes 190 in shim 128 (e.g., ...). Figure 18 For example, each of the gaskets in 128 is fixed and matched on the drill string.

[0168] In one or more instances, computer system 204 executes a software application to create a program for machining shims 128 according to determined shim dimensions and drilling shim holes 190 in shims 128 based on determined shim hole positions 192, which are aligned with measured rear pressure bulkhead hole positions 132 of rear pressure bulkhead holes 114 and determined splicing angle steel hole positions 110 of splicing angle steel holes 112. In one or more instances, CNC machine tool 212 machines shims 128 and drills shim holes 190 in shims 128 based on the created program. In one or more instances, CNC machine tool 212 drills shim holes 190 in each shim of shims 128 based on NC program 228.

[0169] In one or more instances, a set of .XML measurement files is generated, including the determination of the splice angle steel hole position 110 for the splice angle steel hole 112 to be drilled in the splice angle steel 102, the shim dimensions of the shim 128 to be machined (e.g., shim shape 186 and shim surface profile 188), and the determination of the shim hole position 192 for the shim hole 190 to be drilled in the shim 128. In one or more instances, the space analyzer program 224 generates this set of .XML files and transfers the set of .XML files to the ODEM application 222. The ODEM application 222 then generates multiple NC programs 228 for drilling the splice angle steel hole 112 in the splice angle steel 102, machining the shim 128 to fill the gap, and drilling the shim hole 190 in the shim 128. The NC programs 228 are then verified, and the ODEM application 222 then transfers a set of verified NC programs 230 to the CNC machine tool 212 or equivalent. The NC controller 232 receives the verified NC program 230 and the CNC machine tool 212 drills splicing angle steel holes 112 in the splicing angle steel 102, machines shims 128, and drills shim holes 190 in the shims 128 based on the verified NC program 230.

[0170] Now for reference Figure 2 and 19 Examples of method 1000, system 200, and pressure bulkhead assembly 100 can be compared with those in... Figure 19 The flowchart illustrates the aircraft manufacturing and maintenance method 1100 and in Figure 2 The aircraft 1200 is schematically illustrated in connection with, or used in the context of, aircraft manufacturing and maintenance method 1100 and aircraft 1200. For example, aircraft 1200 and / or aircraft manufacturing and maintenance method 1100 may utilize, according to method 1000 and / or using, information about Figure 1 and Figures 3 to 18 The system 200 described describes the pressure bulkhead assembly 100.

[0171] refer to Figure 2 An example of aircraft 1200 may include a frame 1210 forming a wing 1208 and a fuselage 1202 having an interior 1204. Aircraft 1200 also includes multiple higher-order systems 1222. Examples of higher-order systems 1222 include one or more of a propulsion system 1224, an electrical system 1226, a hydraulic system 1228, and an environmental system 1230 (e.g., an environmental control system). In other examples, aircraft 1200 may include any number of other types of systems, such as communication systems, flight control systems, guidance systems, weapon systems, etc.

[0172] refer to Figure 19During pre-production, method 1100 includes the specification and design of aircraft 1200 (box 1102) and material procurement (box 1104). During the production of aircraft 1200, the manufacturing of aircraft 1200 parts and sub-assemblies (box 1106) and system integration (box 1108) occur. Subsequently, aircraft 1200 is certified and delivered (box 1110) for service (box 1112). Routine maintenance and repair (box 1114) includes modification, reconfiguration, refurbishment, etc., of one or more systems of aircraft 1200.

[0173] This can be performed or implemented by system integrators, third parties, and / or operators (e.g., customers). Figure 19 Each process in the method 1100 illustrated herein. For the purposes of this description, the system integrator may include any number of spacecraft manufacturers and main system subcontractors without limitation; the third party may include any number of vendors, subcontractors, and suppliers without limitation; and the operator may be an airline, leasing company, military entity, service organization, etc.

[0174] It is possible Figure 19 Examples of the pressure bulkhead assembly 100, system 200, and method 1000 shown and described herein are employed during any one or more stages of the manufacturing and maintenance method 1100 illustrated in the flowcharts. In these examples, embodiments of the pressure bulkhead assembly 100, system 200, and method 1000 may form part of component and sub-component manufacturing (box 1106) and / or system integration (box 1108). For example, the production of the pressure bulkhead assembly 100 using system 200 or prepared according to method 1000, or the production of an aircraft 1200 including the pressure bulkhead assembly 100, may correspond to component and sub-component manufacturing (box 1106). Furthermore, the pressure bulkhead assembly 100 prepared using system 200 or according to method 1000 may be utilized in a manner similar to that of a component or sub-component prepared when the aircraft 1200 is in service (box 1112). Furthermore, the pressure bulkhead assembly 100 prepared using system 200 or according to method 1000 can be utilized during system integration (box 1108) and certification and delivery (box 1110). Similarly, for example and without limitation, embodiments using system 200 or prepared according to method 1000 can be utilized when the aircraft 1200 is in service (box 1112) and during maintenance and repair (box 1114).

[0175] Furthermore, this disclosure includes embodiments pursuant to the following provisions:

[0176] Clause 1. A method (1000) for preparing a pressure bulkhead assembly (100), the method (1000) comprising the following steps:

[0177] Determine the optimal positions of multiple splicing angle steels (102) such that multiple splicing surfaces (104) of the multiple splicing angle steels (102) will form the circumferential splicing surface (106) of the pressure bulkhead assembly (100) in an optimized shape (136);

[0178] A virtual fit is performed between the multiple spliced ​​angle steels (102) in the optimized position and the rear pressure bulkhead (108);

[0179] Determine the splicing angle hole position (110) of the splicing angle hole (112) to be drilled in each of the plurality of splicing angle steels (102) such that the splicing angle steel holes (112) will correspond to the rear pressure bulkhead holes (114) pre-drilled in the rear pressure bulkhead (108);

[0180] In each of the plurality of splicing angle steels (102), a hole (112) is drilled at the location (110) of the splicing angle steel hole; and

[0181] Each of the plurality of splicing angle steels (102) is joined to the rear pressure bulkhead (108) such that the plurality of splicing surfaces (104) form the circumferential splicing surface (106) in the optimized shape (136).

[0182] Clause 2. The method (1000) according to Clause 1 further includes the following steps:

[0183] Generate multiple splicing angle steel scans (120) representing the multiple splicing surfaces (104); and

[0184] The plurality of splicing angle steel scans (120) are aligned with the nominal model (122) representing the pressure bulkhead assembly (100) to arrange the plurality of splicing angle steel scans (120) in an initial position in which the plurality of splicing surface scans (158) of the plurality of splicing angle steel scans (120) represent the circumferential splicing surface (106) having an initial shape (154).

[0185] Clause 3. The method (1000) according to Clause 2, wherein the step of aligning the plurality of spliced ​​angle steel scans (120) to the nominal model (122) includes performing a best fit between the plurality of spliced ​​angle steel scans (120) and the nominal model (122).

[0186] Clause 4. The method (1000) according to Clause 3 further includes, while performing the best fit, limiting the degrees of freedom of each of the plurality of spliced ​​angle steel scans (120) relative to the nominal model (122) within a predetermined tolerance.

[0187] Clause 5. The method (1000) according to Clause 2 further includes the following steps:

[0188] Determine the step size (116) between the mating edge scan (160) of each of the plurality of spliced ​​angle steel scans (120) and the mating edge scan (160) of one of the directly adjacent spliced ​​angle steel scans (120);

[0189] Determine the angular displacement of each spliced ​​angle steel scan in the spliced ​​angle steel scans (120) to minimize the step size (116); and

[0190] Each of the multiple spliced ​​angle steel scans (120) is adjusted by the angular displacement to move the multiple spliced ​​angle steel scans (120) to an optimized position.

[0191] Clause 6. The method (1000) according to Clause 5 further includes iteratively repeating the steps of determining the step size (116), determining the angular displacement of each of the plurality of spliced ​​angle steel scans (102), and adjusting each of the plurality of spliced ​​angle steel scans (120) by the angular displacement, until the step size (116) is below a predetermined threshold.

[0192] Clause 7. The method (1000) according to Clause 5 further includes virtually arranging the plurality of spliced ​​angle steel scans (120) in the optimized position prior to performing the virtual fit.

[0193] Clause 8. The method (1000) described in Clause 5 further includes the following steps:

[0194] Generate a rear pressure bulkhead scan (124) representing the rear pressure bulkhead (108); and

[0195] Align the rear pressure bulkhead scan (124) with the nominal model (122) to virtually overlay the rear pressure bulkhead scan (124) onto the plurality of spliced ​​angle steel scans (120) at the optimized position.

[0196] Clause 9. The method (1000) according to Clause 8, wherein the step of aligning the aft pressure bulkhead scan (124) to the nominal model (122) includes performing a best fit between the aft pressure bulkhead scan (124) and the nominal model (122).

[0197] Clause 10. The method (1000) according to Clause 8 further includes the following steps:

[0198] Determine the size of the gasket (128) to be positioned between the bulkhead interface surface (126) of the rear pressure bulkhead (108) and the flange surface (130) of one of the splicing angle steels (102);

[0199] The gasket (128) is manufactured based on these gasket dimensions; and

[0200] Before joining one of the multiple spliced ​​angle steels (102) to the rear pressure bulkhead (108), the gasket (128) is positioned between the bulkhead interface surface (126) and the flange surface (130).

[0201] Clause 11. The method (1000) according to Clause 10 further includes moving the rear pressure bulkhead scan (124) relative to the plurality of spliced ​​angle steel scans (120) such that the gasket dimensions of the gasket (128) are greater than the minimum manufacturing dimensions.

[0202] Clause 12. A system (200) for manufacturing a pressure bulkhead assembly (100), the system (200) comprising:

[0203] A measuring machine (202) is configured to measure the aft pressure bulkhead (108) and multiple spliced ​​angle steels (102);

[0204] A computer system (204) having a memory (206) and a processor (210), wherein the memory stores a program (208) and the processor (210) is configured to execute the program (208) to: determine an optimal position for the plurality of splicing angle steels (102) such that a plurality of splicing surfaces (104) of the plurality of splicing angle steels (102) will form a circumferential splicing surface (106) in an optimized shape (136); perform a virtual fit between the plurality of splicing angle steels (102) in the optimized position and the rear pressure bulkhead (108); and determine the splicing angle steel hole position (110) of the splicing angle steel hole (112) to be drilled in each of the plurality of splicing angle steels (102) such that the splicing angle steel hole (112) will correspond to a pre-drilled rear pressure bulkhead hole (114) in the rear pressure bulkhead (108);

[0205] A computer numerical control machine tool (212) configured to drill holes (112) in each of the plurality of splicing angle steels (102) at the locations (110) of the splicing angle steel holes; and

[0206] An assembly fixture (214) is configured to constrain the rear pressure bulkhead (108) for engaging each of the plurality of splice angles (102) with the rear pressure bulkhead (108) such that the plurality of splice surfaces (104) form the circumferential splice surface (106) in the optimized shape (136).

[0207] Clause 13. The system (200) according to Clause 12, wherein the processor (210) is further configured to execute the program (208) so as to:

[0208] Based on the measurements performed by the measuring machine (202) on the plurality of spliced ​​angle steels (102), a plurality of spliced ​​angle steel scans (120) representing the plurality of spliced ​​surfaces (104) are generated; and

[0209] The plurality of splicing angle steel scans (120) are aligned with a nominal model (122) representing the pressure bulkhead assembly (100) to arrange the plurality of splicing angle steel scans (120) in an initial position in which the plurality of splicing surface scans (158) of the plurality of splicing angle steel scans (120) represent the circumferential splicing surface (106) having an initial shape (154).

[0210] Clause 14. The system (200) according to Clause 13, wherein the processor (210) is further configured to execute the program (208) so as to:

[0211] Determine the step size (116) between the mating edge scan (160) of each of the plurality of spliced ​​angle steel scans (120) and the mating edge scan (160) of one of the directly adjacent spliced ​​angle steel scans (120);

[0212] Determine the angular displacement of each spliced ​​angle steel scan in the spliced ​​angle steel scan (120) to minimize the step size (116); and

[0213] Each of the multiple spliced ​​angle steel scans (120) is adjusted by the angular displacement to move the multiple spliced ​​angle steel scans (120) to an optimized position.

[0214] Clause 15. The system (200) according to Clause 14, wherein the processor (210) is further configured to execute the program (208) to virtually arrange the plurality of spliced ​​angle steel scans (120) in the optimized position prior to performing the virtual mating, wherein the processor (210) is further configured to execute the program (208) so as to:

[0215] Based on measurements taken by the measuring machine (202) of the rear pressure bulkhead (108), a rear pressure bulkhead scan (124) representing the bulkhead interface surface (126) of the rear pressure bulkhead (108) is generated; and

[0216] Align the rear pressure bulkhead scan (124) with the nominal model (122) to virtually overlay the rear pressure bulkhead scan (124) onto the plurality of spliced ​​angle steel scans (120) at the optimized position.

[0217] Clause 16. The system (200) pursuant to Clause 15, wherein:

[0218] The processor (210) is further configured to execute the program (208) to determine the shim size of the shim (128) to be positioned between the bulkhead interface surface (126) and the flange surface (130) of one of the splice angles (102);

[0219] The computer numerical control machine tool (212) is further configured to manufacture the shim (128) based on the shim dimensions; and

[0220] Before joining one of the multiple spliced ​​angle steels (102) to the rear pressure bulkhead (108), the gasket (128) is positioned between the bulkhead interface surface (126) and the flange surface (130).

[0221] Clause 17. The system (200) according to Clause 16, wherein the processor (210) is further configured to execute the program (208) to move the rear pressure bulkhead scan (124) relative to the plurality of splice angle steel scans (120) such that the gasket dimensions of the gasket (128) are greater than the minimum manufacturing dimensions.

[0222] Clause 18. A pressure bulkhead assembly (100) for an aircraft (1200), the pressure bulkhead assembly (100) comprising:

[0223] A rear pressure bulkhead (108), comprising a bulkhead interface surface (126) and a pre-drilled rear pressure bulkhead bore (114) through the bulkhead interface surface (126); and

[0224] Multiple spliced ​​angle steels (102) are configured to connect to the aft pressure bulkhead (108).

[0225] in:

[0226] Each of the plurality of spliced ​​angle steels (102) includes:

[0227] A flange surface (130) configured to mate with the bulkhead interface surface (126);

[0228] The splicing angle steel holes (112) are drilled through the flange surface (130); and

[0229] A splicing surface (104) extends from the flange surface (130); and

[0230] With the splicing angle steel holes (112) aligned with the rear pressure bulkhead holes (114), a plurality of splicing surfaces (104) form a circumferential splicing surface (106) in an optimized shape (136).

[0231] Clause 19. The pressure bulkhead assembly (100) according to Clause 18, wherein the optimized shape (136) is generally circular, wherein the step size (116) between the mating edge (118) of each of the plurality of splicing angles (102) and the mating edge (118) of one of the directly adjacent splicing angles (102) is minimized.

[0232] Clause 20. The pressure bulkhead assembly (100) as described in Clause 19, wherein the splicing angle hole positions (110) of such splicing angle holes (112) are determined based on the following:

[0233] The virtual fit between the plurality of spliced ​​angle steels (102) in the optimized position and the rear pressure bulkhead (108); and

[0234] The measured location (132) of the rear pressure bulkhead holes (114).

[0235] Clause 21. The pressure bulkhead assembly (100) according to Clause 19 further includes fasteners (134) inserted through the splice angle steel holes (112) and the rear pressure bulkhead holes (114) to secure the plurality of splice angle steels (102) to the rear pressure bulkhead (108).

[0236] Clause 22. The pressure bulkhead assembly (100) according to Clause 21 further includes a gasket (128) positioned between the flange surface (130) of one of the plurality of splice angles (102) and the bulkhead interface surface (126) of the rear pressure bulkhead (108).

[0237] The described features, advantages, and characteristics of an example can be combined in one or more other examples in any suitable manner. Those skilled in the art will recognize that the examples described herein can be practiced without having one or more of the specific features or advantages of a particular example. In other cases, additional features and advantages that may not be present in all examples may be recognized in some examples. Furthermore, although various examples of the pressure bulkhead assembly 100, system 200, and method 1000 have been shown and described, modifications may occur to those skilled in the art upon reading this specification. This application includes such modifications and is limited only by the scope of the claims.

Claims

1. A method (1000) for preparing a pressure bulkhead assembly (100), the method (1000) comprising the following steps: Generate (1012) multiple splicing angle steel scans (120) representing multiple splicing surfaces (104) of multiple splicing angle steels (102); The plurality of splicing angle steel scans (120) are aligned (1014) with a nominal model (122) representing the pressure bulkhead assembly (100) to arrange the plurality of splicing angle steel scans (120) in an initial position in which the plurality of splicing surface scans (158) of the plurality of splicing angle steel scans (120) represent circumferential splicing surfaces (106) having an initial shape (154); Determine (1024) the optimized positions of the plurality of splicing angle steels (102) such that the plurality of splicing surfaces (104) of the plurality of splicing angle steels (102) will form the circumferential splicing surface (106) of the pressure bulkhead assembly (100) in an optimized shape (136), wherein the circumferential splicing surface is optimized to be as close to a circle as possible, and the step size between the mating edge of each of the plurality of splicing angle steels and the mating edge of one of the plurality of splicing angle steels directly adjacent to the mating angle steel is minimized; A virtual fit (1026) is performed between the plurality of spliced ​​angle steels (102) in the optimized position and the rear pressure bulkhead (108); Determine (1032) the location (110) of the splicing angle steel hole (112) to be drilled in each of the plurality of splicing angle steels (102) such that the splicing angle steel hole (112) will correspond to the rear pressure bulkhead hole (114) pre-drilled in the rear pressure bulkhead (108); In each of the plurality of splicing angle steels (102), a splicing angle steel hole (1034) is drilled at the splicing angle steel hole position (110); and Each of the plurality of splicing angle steels (102) is joined (1038) to the rear pressure bulkhead (108) such that the plurality of splicing surfaces (104) form the circumferential splicing surface (106) in the optimized shape (136).

2. The method (1000) according to claim 1, wherein the step of aligning (1014) the plurality of spliced ​​angle steel scans (120) to the nominal model (122) comprises: A best fit is performed between the plurality of spliced ​​angle steel scans (120) and the nominal model (122), and while performing the best fit, the degrees of freedom of each spliced ​​angle steel scan (120) relative to the nominal model (122) are restricted within a predetermined tolerance.

3. The method (1000) according to claim 1, further comprising the following steps: Determine (1018) the step size (116) between the mating edge scan (160) of each of the plurality of splicing angle steel scans (120) and the mating edge scan (160) of one of the directly adjacent splicing angle steel scans (120). Determine (1020) the angular displacement of each of the plurality of spliced ​​angle steel scans (120) to minimize the step size (116); as well as Each of the plurality of spliced ​​angle steel scans (120) is adjusted by the angular displacement (1022) to move the plurality of spliced ​​angle steel scans (120) to an optimized position.

4. The method (1000) according to claim 3, further comprising the steps of iteratively and sequentially determining (1018) the step size (116), determining (1020) the angular displacement of each of the plurality of spliced ​​angle steel scans (120), and adjusting (1022) each of the plurality of spliced ​​angle steel scans (120) by the angular displacement until the step size (116) is below a predetermined threshold, and virtually arranging the plurality of spliced ​​angle steel scans (120) in the optimized position before performing the virtual fit.

5. The method (1000) according to claim 4, further comprising the following steps: Generate (1028) a rear pressure bulkhead scan (124) representing the rear pressure bulkhead (108). as well as Aligning (1030) the rear pressure bulkhead scan (124) to the nominal model (122) to virtually overlay the rear pressure bulkhead scan (124) onto the plurality of spliced ​​angle steel scans (120) at the optimized position, wherein the step of aligning (1030) the rear pressure bulkhead scan (124) to the nominal model (122) includes performing a best fit between the rear pressure bulkhead scan (124) and the nominal model (122).

6. The method (1000) according to claim 5, further comprising the following steps: Determine (1040) the size of the gasket (128) to be positioned between the bulkhead interface surface (126) of the rear pressure bulkhead (108) and the flange surface (130) of one of the splicing angle steels (102); The gasket (128) is manufactured (1042) based on the gasket size. as well as Before joining one of the plurality of spliced ​​angle steels (102) to the rear pressure bulkhead (108), the gasket (128) is positioned (1044) between the bulkhead interface surface (126) and the flange surface (130).

7. A system (200) for fabricating a pressure bulkhead assembly (100), the system (200) comprising: The measuring machine (202) is configured to measure the rear pressure bulkhead (108) and multiple spliced ​​angle steels (102); A computer system (204) has a memory (206) and a processor (210), the memory storing a program (208), and the processor (210) being configured to execute the program (208) so as to: Based on the measurements performed by the measuring machine (202) on the plurality of spliced ​​angle steels (102), a plurality of spliced ​​angle steel scans (120) representing the plurality of spliced ​​angle steels (104) are generated. The plurality of splicing angle steel scans (120) are aligned with a nominal model (122) representing the pressure bulkhead assembly (100) to arrange the plurality of splicing angle steel scans (120) in an initial position in which the plurality of splicing surface scans (158) of the plurality of splicing angle steel scans (120) represent circumferential splicing surfaces (106) having an initial shape (154). The optimized positions of the plurality of splicing angle steels (102) are determined such that the plurality of splicing surfaces (104) of the plurality of splicing angle steels (102) will form the circumferential splicing surface (106) in an optimized shape (136), wherein the circumferential splicing surface is optimized to be as close to a circle as possible, and the step size between the mating edge of each of the plurality of splicing angle steels and the mating edge of one of the plurality of splicing angle steels directly adjacent to the mating angle steel is minimized; A virtual fit is performed between the plurality of spliced ​​angle steels (102) in the optimized position and the rear pressure bulkhead (108); and Determine the splicing angle hole position (110) of the splicing angle hole (112) to be drilled in each of the plurality of splicing angle steels (102) such that the splicing angle hole (112) will correspond to the rear pressure bulkhead hole (114) pre-drilled in the rear pressure bulkhead (108); A computer numerical control machine tool (212) is configured to drill a hole (112) in each of the plurality of splicing angle steels (102) at the splicing angle steel hole location (110); and Assembly fixture (214) is configured to constrain the rear pressure bulkhead (108) for engaging each of the plurality of splice angles (102) with the rear pressure bulkhead (108) such that the plurality of splice surfaces (104) form the circumferential splice surface (106) in the optimized shape (136).

8. The system (200) of claim 7, wherein the processor (210) is further configured to execute the program (208) so as to: Determine the step size (116) between the mating edge scan (160) of each of the plurality of splicing angle steel scans (120) and the mating edge scan (160) of one of the plurality of splicing angle steel scans (120). Determine the angular displacement of each of the plurality of spliced ​​angle steel scans (120) to minimize the step size (116); and Each of the plurality of spliced ​​angle steel scans (120) is adjusted by the angular displacement to move the plurality of spliced ​​angle steel scans (120) to an optimized position.

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