Improved systems, methods, and apparatus for robotic airship manufacturing

Abstract

Systems, methods, and apparatus are proposed to assist in assembling frames, attaching skins, and performing other tasks in the manufacture of airships and building other structures that are otherwise difficult, inefficient, or inappropriate for humans to perform and / or that traditionally require significant investment in capital-intensive manufacturing facilities. Several embodiments are proposed that allow these and other repetitive manufacturing operations to be performed safely and efficiently with the assistance of autonomous, semi-autonomous, and / or human-directed robots operating independently and in robot swarms.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 63 / 280,368, entitled “SYSTEM, METHOD AND APPARATUS FOR AIRSHIP MANUFACTURE USING ROBOTICS,” filed November 17, 2021, the entire contents of which are incorporated herein by reference. [Background technology]

[0002] Technical field of the subject technology The present technology relates to the construction of lighter-than-air vehicles and other large aviation and aerospace structures that are tall, long, wide, and / or extremely heavy, and therefore tend to be difficult, inefficient, or generally unsuitable for human construction by conventional systems and methods, and / or require large investments in highly capital-intensive manufacturing facilities and equipment.

[0003] Description of the Prior Art Airships are well known in the art. A rigid or semi-rigid airship or dirigible is a steerable airship with a structural framework that maintains the airship's shape and carries its structural loads, and provides buoyancy by inflating one or more internal bags or compartments with a lighter-than-air gas such as hydrogen or helium. To benefit sufficiently from such buoyancy to carry commercial payloads, airships have traditionally been very large. For example, the Graf Zeppelin, which operated commercially from 1928 to 1937, was 776 feet long and over 100 feet in diameter. To be able to carry meaningful payloads, future commercial airships are likely to be significantly larger, presenting significant manufacturing challenges using traditional methods.

[0004] Historically, airships have been built around a keel, but Applicant's prior patent applications, including Application No. 13 / 855,923, filed April 3, 2013, now U.S. Patent No. 9,102,391 (the '391 patent), and Application No. 17 / 005,628, filed August 28, 2020, now U.S. Patent No. 11,066,145 (the '145 patent), disclose an exoskeleton comprised of a series of triangular structures formed from hubs and spokes. The relevant content from such prior '391 and '145 patents is incorporated herein in its entirety by this reference.

[0005] As shown in the '145 patent, applicants envision that a commercial size airship could be approximately 1,000 feet long and 200 feet in diameter. In such a case, the exoskeleton and skin surface material alone of the airship would weigh in excess of 250,000 pounds. Such structural systems and skins would require extensive assembly and layup, which, if pursued by conventional methods, would result in high capital demands to build specialized manufacturing facilities and equipment, creating challenges, inefficiencies, and safety risks for workers, and would significantly limit the ability to rapidly expand, replicate, or scale up such facilities to manufacture many such airships.

[0006] For illustrative purposes, this application focuses on airships, particularly airships such as those disclosed in the '145 patent, however, the principles disclosed herein are relevant to large aviation and aerospace structures, including but not limited to the bodies of commercial fixed-wing aircraft and commercial rockets, other airships, and fuselages, which face similar problems during construction due to their height, length, diameter, and mass. For example, SpaceX's Falcon Heavy rocket is reported to be 230 feet tall, 40 feet in diameter, and weighs over 60,000 pounds without fuel. Even larger rockets may be required in the future for interplanetary missions, the manufacturing challenges of which will inevitably become more difficult using traditional methods.

[0007] Traditionally, in aviation, aerospace, and other industries involving the construction of very large structures, manufacturing facilities use overhead cranes, elevated work platforms, complex assembly lines, and require specialized equipment to lift, move, and work on such structures during construction, resulting in a highly specialized, capital-intensive infrastructure, safety concerns, and a time-consuming, costly, and difficult manufacturing process.

[0008] U.S. Patent No. 4,259,776, entitled "Method of Assembly of Airship Hull," filed August 9, 1978, issued April 7, 1981 to Airships International, Inc., and expired on or about August 9, 1998, contains a description of various methods used in the past to assemble or build large rigid airships, which description is incorporated herein by reference. As summarized in the background provided in application Ser. No. 16 / 156,913, now U.S. Patent No. 10,988,226 (the '226 patent), filed October 10, 2018, issued to Sergey Brin, Alan Weston et al., and assigned to LTA Research and Explorer LLC, conventional airships remain stationary during construction, which means that builders must climb or be suspended from a high altitude to build the airship.

[0009] To overcome this limitation, the '776 and '226 patents each disclose a method of rotating the airship structure so that the work area has the greatest degree of accessibility, convenience, and safety for personnel involved in assembly, while at the same time maintaining precise alignment of the hull components being assembled. The '776 patent discloses assembling the main transverse frames of the hull in a horizontal position, and upon completion, lifting and placing the two frames into a "vertical orientation on endless belts of air cushions supported on rotating cradles." One or more such rotating cradles are then used during installation to rotate the frames and temporary structural assemblies into a convenient position, and the air cushions are monitored for pressure and adjustments are made to provide adequate support.

[0010] The '226 patent discloses the use of a "roller coaster jig" structure that allows the airship (or a partially completed portion thereof) to rotate by adding removable wheels or rollers to the exterior of a circular main frame structure, such wheels being designed to "interface the main frame with roller coaster rails and allow the main frame to rotate along its axis" while the airship is constructed to allow the builder to "stay on the ground," thereby improving safety and allowing for greater assembly speeds. The systems, methods and apparatus disclosed in the '226 patent are complemented in U.S. Patent No. 11,254,408 to Jesus Zatarain et al. (the '408 patent), assigned to LTA Research. The '408 patent describes the use of a "universal jig" to build the large circular main frames of the airship's hull while each frame is oriented in a horizontal position, and then, once structurally properly completed, the partially assembled main frames are assembled and placed on the roller coaster jig disclosed in the LTA '226 patent.

[0011] The third invention, China Application No. CN 111232237A ('237 Application), entitled "Method for mounting parts on the outside of the framework of a large rigid airship and the airbag of a large rigid airship" filed by Beijing Kangtian High Technology Co., Ltd. on March 4, 2020, also contemplates rotating the airship so that the working area is located in the hull part closest to the factory floor. In the '237 patent application, the airship is lifted by a "process air column under the airship", and then the airship is rolled using human power or stepping motors connected to "rotating slings on the two sides of the airship" for the purpose of conveniently installing the airship's structure and equipment parts in a lower position, thereby increasing safety, reducing costs, and avoiding the need for expensive lifting platforms and complicated scaffolding.

[0012] To date, airship construction has not involved the extensive use of robots. LTA's '408 patent mentions robots only twice, and then simply as a possible alternative operator to assist in assembling the circular mainframe while it rests on its generic jig apparatus. More generally, however, as industrial robots become faster, better, and cheaper, more and more companies are beginning to integrate them into their workflows, along with their labor, as described in an April 2021 paper by CMTC (California Manufacturing Technology Consulting), "Ready or Not, Robotics in Manufacturing is on the Rise." Dating back to the early 1990s, various research groups, including NASA, JPL, and MIT and Caltech, have experimented with the use of robots to assemble large truss structures in space for the International Space Station, Extremely Large Telescopes, and other remotely constructed structures and space environments.

[0013] As summarized in a 2002 paper titled "Robotic Assembly of Truss Structures for Space Systems and Future Research Plans" by William Doggett, NASA's Automated Structural Assembly Laboratory (ASAL) has demonstrated reliable autonomous assembly and disassembly of an eight-meter planar structure consisting of 102 truss elements clad in twelve panels. Doggett's paper summarizes the relevant literature on fully autonomous and telerobotic systems for in-space assembly operations, inspection, and maintenance. Doggett's paper, which is incorporated herein by reference, summarizes the key hardware, software, and design philosophies that form the basis of a reliable assembly system for such planar structures.

[0014] On-orbit manufacturing and integration of spacecraft components has also been explored by Tethers Unlimited, a contractor for NASA's Innovative Advanced Concepts (NIAC) program. In this study, Tethers demonstrated the feasibility of extruding and assembling composite truss-based structures and enabling a robotic system to perform the assembly of these structures in a highly automated manner. In the so-called SpiderFab robotic proof-of-concept, NIAC tested custom robotic end effectors and truss joints, verified that an autonomous robot could grip, manipulate, and join trusses, and employed a robotic vision system that enabled closed-loop control of the assembly to support these functions. Tethers' 2016 final report on this study, entitled "SpiderFab: A Process for On-Orbit Construction of Kilometer-Scale Apertures," is also incorporated herein by reference.

[0015] The CMTC article lists six major types of robots: articulated robots, Cartesian robots, cylindrical robots, spherical robots, selective compliance assembly robotic arm (SCARA) robots, and delta robots. The paper also lists the attributes and types of tasks for which each of these types of industrial robots is best suited. Additionally, the CMTC paper lists applications for which robots are typically used in manufacturing. These applications include welding, painting, pick and place, packaging & labeling, assembly, disassembly, product inspection, product testing, palletizing, polishing, grinding, and buffing. Other papers summarize these and other tasks as falling into five general categories: material handling, welding, assembly, dispensing, and processing. Given the advances in robotic automation, the CMTC article also lists industries that utilize automation for greater efficiency, productivity, and precision. According to CMTC, these include electronics manufacturing, automotive manufacturing, medical, food manufacturing, and agriculture.

[0016] Robots, most often associated with the aforementioned industries and working with small components, play an important role in aerospace applications. According to RobotWorx, robots are widely used for the construction of aircraft engines and in performing tasks such as drilling and painting airframes due to their reliability, capability, and precision. According to their paper "Robots in the Aerospace Industry," the task robots are most often used for in aerospace is drilling holes in components. Painting and inspecting airframes for cracks, delaminating composite materials, and ensuring rivets are intact are also common tasks, and ultrasonic imaging is another common task for robots in the aerospace industry.

[0017] According to the RobotWorx paper, robots can also be used to lay carbon fiber strips in conjunction with automated fiber placement on composite fuselages, which helps eliminate errors due to the robot's greater precision for cutting and placing the fibers. As the paper shows, it is generally expected that the use of AI (artificial intelligence) and machine learning in aircraft manufacturing processes will help increase production speeds without compromising product quality. Aerospace giants like Boeing and Airbus are investing in the technology, and such investments by OEMs, along with previously referenced research on the use of autonomous robots to build large structures in space, are expected to contribute to the market growth of robots in the future.

[0018] The use (or proposed use) of robotics in relation to airship construction has been fairly minimal. In connection with the hybrid airship program, Lockheed Martin developed U.S. Patent No. 8,800,628 (the '628 patent) entitled "Self-Propelled Airship Hull Repair System" which encompasses its so-called "Self-Propelled Instrument for Damage Assessment and Repair", i.e., the SPIDER robot. The robot was programmed to autonomously inspect the airship's skin for holes and repair them if found. SPIDER is constructed in two halves, one half on the outside of the envelope and the other half on the inside. Magnetically coupled, the robot moves across the surface of the envelope, with the outer half shining a light onto the airship's surface, while the inner half uses a light sensor within the otherwise dark envelope to detect potential pinholes. Once SPIDER detects a hole, it can repair the hole using a repair mechanism and then transmit before and after photos of the area for repair verification. The robot is designed to operate on unevenly curved surfaces while driving itself up, down, left and right, using optical encoders to measure its movements in parallel with final assembly of the airship and during major maintenance checks.

[0019] Another Lockheed Martin patent application, culminating in U.S. Pat. No. 10,518,861 (the '861 patent), entitled "Continuous Fiber Reinforcement for Airship Construction," discloses the use of a robot similar to SPIDER disclosed in the '628 patent. In the '861 patent, the robot is proposed as a means to apply continuous fiber reinforcement to a gas-filled shape, thereby eliminating the need for individual structural joints in hull assembly by using continuous fiber reinforcement across the three-dimensional surface of the hull of an airship or lighter vehicle. According to the '861 patent disclosure, in certain embodiments, a thin film or fabric membrane constructed to a desired hull shape is first filled with gas and suspended above the floor of a manufacturing facility so that a fiber dispenser robot can be used to apply reinforcing fibers to its exterior surface. As disclosed, the robot may include a power source, drive subsystem, positioning subsystem, damage reporting subsystem, and / or control subsystem, and moves along the surface of the gas-filled shape "using wheels, rollers, tracks, balls, or any other type of mechanism that allows for movement across the membrane."

[0020] As noted above, in the above-referenced '408 patent, LTA mentions the use of robots only twice in conjunction with the disclosure of a universal jig. The universal jig is thus described as comprising a plurality of tracks configured in a radial pattern and carts configured to be positionally adjusted along such tracks to assist in building the main frame of the airship structure. As disclosed therein, each track has a front cart and a rear cart thereon, the purpose of each of which is to secure the inner and outer portions of the main frame during assembly. The specification discloses that these carts are "utilized to assist in holding various components (e.g., joints and connectors) of the main frame, allowing a human, robot, or other assembly operator to assemble the main frame." The only other reference to robot assembly in the more than 70-page specification is this explanation: "Once the first component of the mainframe is secured to the cart, [...] an assembler (e.g., a human, machine, or robotic assembler) may then attach a connector, [and] additional joints may then be attached to the connector... This process of connecting joints and connectors may be repeated until the entire circular mainframe is assembled."

[0021] In U.S. Patent No. 11,353,856 (the '856 patent), entitled "System and method for flexible manufacturing," applicant Arrival Robotics Limited ("Arrival") discloses a process for creating a robotic control for manufacturing products. Arrival reports applying the teachings of the '856 patent and related know-how to produce commercial electric vehicle vans and buses using a microfactory production model. According to the material, "the fundamental principle behind the microfactory is the use of technological cells," which allows for a more flexible assembly method in which each technological cell is optimized to perform a specific production process. At a comparable annual production volume, Arrival estimates that the capital investment for its microfactory would be 50% less than a conventional OEM production facility, and its operational cost savings associated with its microfactory would be approximately 50% when compared to a conventional OEM facility with a similar production capacity.

[0022] A useful overview of behavior-based robotics, system control, and distributed local control, as well as hybrid robotic architectures, is provided in U.S. Pat. No. 7,343,222 (the '222 patent), entitled "System, method and apparatus for organizing groups of self-configurable mobile robotic agents in a multi-robotic system." The use of such techniques to enable groups of robots, sometimes called robot swarms for reasons described in the '222 patent, to work together to speed up the process of producing large-scale systems has also been described in non-patent literature, such as the February 2020 paper "Robots assemble large structures from little pieces," written by MIT researchers and published in Motion Design Magazine.

[0023] There is a great need for improved manufacturing systems, methods, and apparatus that take full advantage of such robotic technology and control methods to simplify the manufacture of airships and other very large and / or very heavy structures, reduce manufacturing time, costs, and capital investment requirements, while at the same time increasing the speed of moving from product design to actual manufacturing, increasing the level of precision, and making it much easier to scale up production from the first commercial airships to enable the production of multiple units and the replication of such manufacturing facilities at multiple locations. [Prior art documents] [Patent documents]

[0024] [Patent Document 1] U.S. Patent No. 9,102,391 [Patent Document 2] U.S. Patent No. 11,066,145 [Patent Document 3] U.S. Patent No. 4,259,776 [Patent Document 4] U.S. Pat. No. 10,988,226 [Patent Document 5] U.S. Pat. No. 11,254,408 [Patent Document 6] U.S. Patent No. 8,800,628 [Patent Document 7] U.S. Pat. No. 10,518,861 [Patent Document 8] U.S. Pat. No. 11,353,856 [Patent Document 9] U.S. Patent No. 7,343,222 [Non-patent literature]

[0025] [Non-Patent Document 1] Ready or Not, Robotics in Manufacturing is on the Rise [Non-Patent Document 2] Robotic Assembly of Truss Structures for Space Systems and Future Research Plans [Non-Patent Document 3] Robots assemble large structures from little pieces Summary of the Invention [Means for solving the problem]

[0026] In at least one aspect, the present technology relates to the use of specially designed and programmed robots to provide a fast, cost-effective method for building airships and other large structures with much less initial capital investment in facilities and equipment than traditional approaches. The present disclosure has utility for assembling structures and attaching the skins of airships and will be described in connection with such utility, although other commercial utilities are contemplated without departing from the principles of the present disclosure.

[0027] In some embodiments, groups of robots work at heights of 50 feet or more, allowing workers to avoid unsafe conditions when performing assembly operations, and allowing automated quality supervision and human oversight from safe, remote locations through innovative sensory systems. This combination of experienced technicians overseeing the robotic capabilities of the system and method delivers superior results in a fraction of the time and at a fraction of the cost of traditional construction, while dramatically reducing the infrastructure required for manufacturing operations.

[0028] In another embodiment, a special class of heavy lift robots may be used in conjunction with other specialized robotic worker classes to allow the airship to be manufactured top-down, with an active assembly work surface within a suitable distance from the floor of the manufacturing facility. In such an embodiment, once the top of the airship is completed, the partially completed hull is pushed upwards to allow more of its structure to be assembled beneath the completed top, and then the process is repeated until the complete airship is assembled. In an exemplary embodiment of this approach, the exterior surface material for the airship is attached to the structure as each successive portion of the hull is assembled, rather than after the complete hull is completed. Also, in a further exemplary embodiment, other subsystems that are inside the airship and extend from the exterior surface are added as the work surface of the partially completed hull is added, rather than waiting to add such components until the entire hull is physically completed.

[0029] In another exemplary embodiment, each robot is controlled by pre-programmed routines and / or through the use of advanced artificial intelligence (AI) that can be trained to respond to different structural shapes, systems, part numbering, and markings including various forms of visual fiducial markers such as AprilTag. By way of example and not limitation, if the airship uses structures such as exoskeletons in Applicant's '391 and '628 patent applications, the robots can be pre-programmed to climb existing structures and automatically orient themselves in three-dimensional space such that each structural member is properly aligned when the structural assembly is completed.

[0030] In a further exemplary embodiment, a robot utilizes remote cameras, computer vision, and machine learning to adapt to the geometry of the airship's exoskeleton, select and assemble specific parts as such a robot assembles the exoskeleton, attaches the skin, and performs other specialized tasks necessary to build an airship or other structure. In addition to labor-saving and safety benefits, the use of such robotic technology cells frees airship manufacturers from the need to install expensive overhead cranes and from purchasing or installing additional equipment that would otherwise be required for mass-produced airships.

[0031] While traditional production assembly solutions (including the use of overhead cranes, assembly machines, elevated worker platforms, and the "roller coaster jigs" proposed in the '226 patent) involve the use of capital-intensive manufacturing facilities, specialized equipment, and personnel, the use of robotic assembly dramatically accelerates the construction of airships, with swarms of robots being able to be controlled by operators standing safely on the ground.

[0032] The system and method are also designed with scalability in mind. Because multiple robot classes can be built to work in parallel in a coordinated fashion and on separate tasks or geographic areas, the system can be easily scaled on multiple levels to meet desired project durations, regardless of airship size, number of airships, and number of assembly locations. The ability to quickly enter multiple markets, generate good paying business, and increase local tax revenues helps build widespread community support and adoption.

[0033] In one exemplary embodiment, the system builds the airship structure linearly, with each robot attaching itself to and gaining support from one or more rows of pre-assembled hubs and tubes. In any embodiment, one or more temporary guide rails attached to such pre-assembled components and / or connected to supports separate from the structure of the airship itself provide additional support and / or guidance for the robots. In another optional embodiment, the system and method use one or more tracks or floor-mounted rails to provide additional support and / or guidance for the robots.

[0034] The systems and methods preferably include a movement mechanism for moving along such support structure, guide rails, and / or tracks. In any embodiment, including but not limited to where the robot cannot be attached to a previously completed portion of the structure, guide rails, or tracks, movement can be accomplished through a self-moving or autonomous motion base using battery or hydrogen fuel cell power and / or by being pulled along the guide rails or tracks utilizing wheels, cable crawlers, vacuum suction cups, and rack and pinion systems. When elevated from the manufacturing floor, the systems and methods can optionally include a gantry to hold the robot from the wire cable to protect it from falling. Also, when operating from the factory floor, the systems and methods can optionally include linear bearings and recirculating profile rails to increase load capacity.

[0035] In one exemplary embodiment, the robot is programmed to recognize shapes, respond to visual reference markers, perceive obstacles through sensors, and perform repetitive actions based on such sensor data.

[0036] In some embodiments, the robots may be programmed to operate independently based on machine vision, or may be pre-programmed to work as a swarm, where a group of two or more robots work in coordination with each other to coordinate their movements, destinations, and / or actions to perform a given task. In one preferred embodiment, such autonomous robots are programmed to avoid collisions with other robots, humans, and objects based on local processor capabilities.

[0037] In one embodiment, portions and subassemblies of the exoskeleton may be built in separate processes and then combined with other subassemblies and partially completed portions of the hull. In one such embodiment, a portion of the exoskeleton may be assembled lying on its side until the entire circumference is completed, and then the portion is raised to an upright position so that it can be connected to other partially completed portions to create a stable base for attaching guide rails and cables. In another embodiment, a specially designed robot is used to hold the partially completed circular truss section in the proper vertical orientation until the full circumference is completed while additional modules are added.

[0038] In another embodiment, one or more inflatable shapes may be used around which the exoskeleton is constructed by the robot, minimizing the need for overhead cranes or intermediate crossings to hold the partially constructed exoskeleton until the entire perimeter is completed, thereby allowing the circular shape to distribute the weight of the airship along the entire perimeter. In another embodiment, such inflatable structures may be used to lift the partially completed exoskeleton, thereby reducing some of the weight that must be lifted by the robot holding such structures in place.

[0039] In yet another embodiment, to minimize the need for cranes, mechanical and / or hydraulic jacks, and other lifting equipment, the buoyancy of such one or more inflatable shapes may be adjusted to maintain neutral or a desired level of negative buoyancy of the airship or selected portions thereof, so that the weight of such airship or portions thereof always remains within a predetermined tolerance as construction progresses.

[0040] In certain embodiments, one or more such inflatable shapes may be filled with air, in other embodiments, such shapes may be filled with a lighter-than-air gas such as helium or hydrogen, and in yet other embodiments, each of one or more such inflatable shapes may be comprised of inflatable layers, with an outer layer filled with a buoyancy gas and an inner layer (also called a "balloon") filled with air. In other embodiments, this order is reversed, with the outer layer filled with air and the inner layer filled with a buoyancy gas.

[0041] In certain embodiments, the automatic control system may be programmed to control the relative amounts of buoyancy gas and air contained in one or more inflatable shapes, the purpose of such control system programming being to maintain the desired buoyancy characteristics of the airship or airship component by continuously monitoring the net weight and adjusting the amounts of air and buoyancy gas as construction progresses so as to always maintain both the integrity of the one or more inflatable shapes and an overall neutral or desired net negative buoyancy level.

[0042] In one embodiment, the combined weight of the exoskeleton and skin will ultimately exceed 250,000 pounds, with the net weight of the airship not exceeding approximately 25,000 pounds.

[0043] In one embodiment, an outer layer of lightweight fabric, such as aramid fiber or Kevlar®, is produced in the desired configuration of one or more inflatable shapes and disposed around the outer surface of such one or more inflatable shapes to reduce the risk of abrasion when in contact with the exoskeleton and / or the risk of being damaged during construction; in one preferred embodiment, such one or more inflatable shapes and this fabric will remain permanently inside the exoskeleton for the life of the airship and will serve as the buoyancy gas compartments and corresponding air bladders, if any, after construction is complete.

[0044] In certain embodiments, a sleeve is designed with a lightweight fabric draped over one or more inflatable shapes, through which spokes can be threaded during assembly of the exoskeleton, thereby ensuring that said shapes adhere to the desired portions of the exoskeleton.

[0045] Also, in some exemplary embodiments, the placement of hubs, spokes, and other critical components may be drawn directly onto the surface of one or more inflatable shapes using human and / or machine readable text or symbols, and lightweight fabric, if any, may be placed around their exterior surfaces and / or on the surfaces of other components to aid in placing such components within the three dimensional spatial geometry.

[0046] In some embodiments, individual robots or robot fleets can utilize such drawings, visual reference markers, and optional unique numbers to ensure that the correct components are assembled in the correct location and in the correct three-dimensional orientation so that the placement of the completed exoskeleton and skin conforms to its intended design.

[0047] In some embodiments, additive construction techniques, 3D printing, stereolithography processes, etc. may be used to provide portions of the exoskeleton and / or skin. In such embodiments, one or more robots may be used to "print" these components. Optionally, in such cases, a second robot or robots later smoothes the surface or surfaces of the object.

[0048] In some embodiments, once the exoskeleton is complete, end caps may be coupled to the exoskeleton and a rotating device axle may be attached to it. Once attached, in one preferred embodiment, the amount of buoyancy gas may be adjusted to reduce the net weight of the airship body, after which, in one embodiment, the body may be rotated by said axle to aid in inspection, application of a smooth skin surface, and other desired manufacturing steps.

[0049] Also, in some embodiments, selected ones of the inflatable shapes can be used to lower the front of the airship and raise the rear of the airship to help connect the end caps or front compartments, and selected ones of the inflatable shapes can be used to lower the rear of the airship and raise the front to help connect the end caps or rear engines.

[0050] In one exemplary embodiment, multiple robots of the same or different types are interconnected to form a robot swarm, each with local on-board processing, communication, and sensing capabilities that enable them to interact with each other and react autonomously to their environment. [Brief description of the drawings]

[0051] [Figure 1] FIG. 1 includes subparts 1(a) through 1(c), where subpart 1(a) illustrates an exoskeleton structure for a lighter-than-air vehicle constructed by application of the principles of the present disclosure.

[0052] FIG. 1(b) shows a standard truss module that, when connected with adjacent truss modules, can be used to construct a circular structural frame as part of such an exoskeleton structure.

[0053] FIG. 1(c) provides a schematic diagram of a cross-section of such an exoskeleton at a midpoint between the anterior and posterior ends of such a structure.

[0054] [Diagram 2] FIG. 2 is a table listing base robot functions and base automated operations employed by one or more robots in carrying out the systems and methods according to the principles of the present disclosure.

[0055] [Diagram 3] FIG. 3, which includes subparts 3(a)-3(c), illustrates an embodiment of assembling such an exoskeleton using a bottom-up construction alternative, with subpart 3(a) showing a partially completed exoskeleton with horizontal cables temporarily attached to segments of the structure being assembled by one or more robots.

[0056] FIG. 3(b) provides an example of how a column with such horizontal cables attached may be fixed to the hub of the exoskeleton, and subpart 3(c) shows providing guide rails for one or more of said robots to connect and utilize the cables to the column.

[0057] [Figure 4] FIG. 4 includes subparts 4(a) through 4(c), and in subpart 4(a) illustrates the use of inflatable gas bags to maintain three dimensional space until the entire circumference of the exoskeleton is completed, and in any embodiment, to ensure that the net weight of the partially completed airship is continuously maintained within a predetermined acceptable weight range.

[0058] FIG. 4(b) shows a cross-sectional view of a partially completed exoskeleton structure, an inflatable gas bag, and the use of guide wires that can be strung over the three-dimensional space to enable placement of horizontal and vertical guide cables for the robot's locomotion.

[0059] FIG. 4(c) shows a single representative gas bag and illustrates the inclusion therein of an optional balloon for adjusting the buoyancy of the gas bag, as well as the optional use of fabric to reduce the risk of abrasion and / or damage to the gas bag.

[0060] FIG. 4(d) shows that in one optional embodiment, end caps are attached to each end of the exoskeleton, and each end cap is then connected to an axle of a rotating device.

[0061] [Diagram 5] Figure 5, including subparts 5(a)-5(c), shows alternative aspects of top-down construction. Figure 5(a) shows, in one embodiment, a schematic layout of floor rails or tracks used by a class of heavy lifter robots to hold a partially completed exoskeleton at an appropriate distance from the floor of an assembly facility and then to lift the partially completed structure as assembly of the airship frame progresses.

[0062] FIG. 5(b) shows diagrammatically the use of such a heavy lifter robot to hold the structural frame while construction is taking place, and FIG. 5(c) provides a series of the same views over time to show the progression of such a robot lifting the exoskeleton according to an alternative embodiment of top-down construction as assembly progresses.

[0063] [Figure 6] FIG. 6 includes subparts 6(a) and 6(b), and in subpart 6(a) shows a perspective view of a heavy lifter robot holding a partially completed section of the main cross frame while lifting the next modular segment of the frame into place with the assistance of an autonomous assembly robot.

[0064] FIG. 6(b) shows additional classes of supporting robots, including a schematic diagram of a swarm of autonomous assembly and fixturing robots connecting subassemblies produced by other robotic work cells, along with the assistance of dedicated autonomous robots for shuttling raw materials and subassemblies to the main assembly area. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0065] Although the embodiments are described herein by way of example, one skilled in the art will recognize that the embodiments are not limited to the described examples or drawings. The drawings and their detailed description are not intended to limit the implementation to the disclosed form, but on the contrary, are intended to encompass all modifications, equivalents, and alternatives within the spirit and scope defined by the appended claims. As used throughout this application, the word "may" is used in an permissive sense (i.e., meaning to have the possibility) rather than a mandatory sense (i.e., meaning to have to). Similarly, the words "include", "including", and "includes" mean including but not limited to. Additionally, as used herein, the verbs "connect," "couple," and "attach," and the corresponding descriptive terms "connected," "coupled," or "attached," may each refer to the act of connecting two or more components together, or the attribute by which such components are connected together, whether the connection is permanent (e.g., welding, gluing, joining, or brazing) or temporary (e.g., bolted, held by pins, held in place by friction or tension, or through a joint or mating), direct or indirect (i.e., through an intermediate), mechanical, chemical, optical, or electrical.

[0066] The present technology describes improvements over conventional techniques for assembling airships and other large structures, particularly in aviation and aerospace. In exemplary embodiments, these improvements are achieved by using specially programmed autonomous, semi-autonomous, and / or human-directed robots to assemble structural frames, attach, lay up, or print skins, manufacture airships, and perform other tasks in building other structures that are otherwise difficult, inefficient, or unsuitable for humans to perform, and / or that would otherwise require significant investments and long lead times to build highly capital-intensive manufacturing facilities.

[0067] These and other aspects of the subject technology are disclosed through the use of the following illustrative figures.

[0068] FIG. 1, consisting of FIGs. 1(a) through 1(c), illustrates an exoskeleton 101 for one embodiment of an airship. As illustrated, FIG. 1 generally corresponds to the exoskeleton for one preferred embodiment of an airship disclosed in applicant's prior '145 patent and described in more detail with respect to FIG. 5 thereof. Exoskeleton 101 is presented herein as a non-limiting illustration of the frame of any airship and other large structure whose size and / or weight tend to make construction using conventional systems and methods difficult, inefficient, or unsuitable for humans to perform and / or would otherwise require significant investments to be made in highly capital-intensive manufacturing facilities and equipment.

[0069] 1(a) shows the entire length of the airship structure 101, including the front end 102 and the rear end 103, and indicates the approximate midline 104 of said airship, as well as the presence of one or more circular structural frames 105 that may optionally be used to provide additional rigidity to such structure. As a non-limiting example, the schematic diagram shown in FIG. 1(a) shows a total of 18 circular frames, including a circular frame 105(a) in the front quarter of the airship, a circular frame 105(b) in the rear quarter of the airship, and a circular frame 105(c) at the midpoint between the front 102 and rear 103 of the airship structure.

[0070] Each such circular frame 105 uses a truss consisting of multiple truss modules 106 that together make up its entire perimeter. FIG. 1(b) shows an illustrative embodiment of one such truss module 106 constructed with an open skeletal assembly of longitudinal members 107, struts 108, and joints 109 to achieve a support structure with high load-bearing capacity relative to its weight. Each truss module 106 includes coupling joints 110(a), 110(b), 110(c) that connect with corresponding coupling joints 111(a), 111(b), 111(c) of the next adjacent truss module. The structural frame 105 is shown as being based on a geometric triangle to take advantage of its inherent stiffness in supporting coplanar loads. Notwithstanding this description, the shape, as well as the number of such structural frames 105, the number of modules 106 comprising each such circular frame, and the respective dimensions, weights, materials of construction, and methods used to connect the individual components comprising such modules are non-limiting and are used for illustrative purposes only, and may vary without departing from the principles of the present disclosure.

[0071] Also, for purposes of illustration and not limitation, the diameter of the airship structure 101 at the midline 104 is assumed to be 200 feet, and the length of the airship is assumed to be 1,000 feet. Such dimensions would require an assembly facility with a width and ceiling height of a minimum of 225 feet (approximately equivalent to the height of a 20-story building) and a minimum length of 1,100 feet (approximately equivalent to the length of three football fields placed end-to-end). Using conventional construction techniques, this approximately 250,000 square foot, 20-story high structure would require one or more large overhead cranes with a free span of at least 200 feet that can lift the entire exoskeleton, or a major portion thereof. For illustrative purposes, an airship of this size is estimated to weigh over 100 tons, including its structure and skin, and over 200 tons when the cockpit, engines, tail, and internal mechanical, electrical, propulsion, thermal management, and storage systems are included.

[0072] FIG. 1(c) provides a cross-sectional view of section AA of FIG. 1(a). As shown, FIGS. 1(a) and 1(c) include structural members 112, which may optionally reflect different strength levels of the framework according to the selected design of the project sponsor. For illustrative purposes only, the structural elements shown in FIG. 1 generally correspond to the triangular pattern disclosed for the exoskeleton in one preferred embodiment of the airship in applicant's prior '145 patent. As described in more detail in this patent, there are 48 triangles on each side of the midline 104 that makes up the circumference of the structure. The number of triangles may remain the same, but the length of each structural member gradually shortens and the angle of arrangement changes as the diameter of the exoskeleton 101 narrows. As described in more detail in the '145 patent, the number of triangles may decrease as the structure moves in the direction of the front 102 or rear 103, but the exoskeleton 101 assumes that the number of triangles remains the same even as the diameter of the exoskeleton becomes narrower. It will be apparent to one skilled in the art that the length, location, and orientation of such assemblies require precise placement in three-dimensional space, as well as appropriate testing and control to ensure that the right parts are used in the right locations.

[0073] One or more autonomous, semi-autonomous, and / or human-directed robots operating independently and in robotic swarms are used to address these challenges and overcome other limitations of the prior art, as described below. In this regard, the '856 patent describes a system and method that utilizes computer-integrated manufacturing (CIM), a manufacturing approach that uses a computer to control the entire production process. As disclosed therein, the disclosure of which is fully incorporated herein by reference, CIM enables flexible product manufacturing using a software-defined product design flow in which core robotic functions and automated operations are selected, sequenced, verified, tested, and planned, and instant feedback is provided to the designer so that the designer knows whether the design is suitable for production and / or if the robot needs additional capabilities added to the sequence to manufacture such design. This approach of using a computer to control the entire production process is used in the system and method of the '856 patent to control individual processes, enable processing robots to exchange information with each other and with design personnel, and initiate actions that can change the way a product is produced. This reduces manufacturing time and reduces errors. The systems and methods of the '856 patent also describe utilizing software and computerized systems to assist in configuring manufacturing for various process steps, thereby reducing the time required to prepare a factory for product production, improving process efficiency, lowering production costs, and improving factory efficiency.

[0074] Referring to FIG. 2, table 201 provides a non-limiting list of base robot functions 202 and base automated operations 203 that, in one preferred embodiment, are used by one or more robots in carrying out the disclosed systems and methods. The base robot functions 202 are functional elements that can be part of many different tasks, and the base automated operations 203 are the core tasks that the robot is designed and programmed to perform through employing these basic capabilities. Those skilled in the art of robotics will understand that such core tasks may be performed using different tooling or end effectors to perform the assigned tasks. For example, the simplest robot may consist of an arm with a tool attached to perform a particular task, and different end effectors may be attached that allow the same robot to perform another task. Similarly, those skilled in the art will understand that robot operations may vary depending on the manufacturing requirements of a particular structure, and further, additional base robot functions 202 and base automated operations 203 may be added in combination with alternative tooling and software programming to carry out the spirit and scope of the present disclosure.

[0075] To function, the robot must have power, and as shown, the base robot functionality 202 required to fabricate the various components, assemble the frame, attach the skin to the airship structure 101, and perform other manufacturing tasks includes a power source 204. In a preferred embodiment, the robots used obtain their energy from electricity. Stationary robots are used for the extrusion and fabrication of the parts used in the assembly of the airship structure 101 and can be plugged in, but a significant number of the robots used are required to move around. Such robots require battery power, and in a preferred embodiment utilize hydrogen fuel cell based power to benefit from the longer operating duration and greater torque strength that results therefrom.

[0076] A second key capability is the robot's control system 205, which consists of a central processing unit, or CPU, that can be programmed to perform automated tasks or to interpret and respond to signals from the sensors 206 and adjust its operation accordingly. In one exemplary environment, the control system 205 includes both remote and centralized processing that allows the robot to function autonomously, when necessary, remotely controlling one or more robot operations in concert with other robots or in response to commands provided by a human operator. In one preferred embodiment, the sensors 206 are smart sensors that collect certain types of data from the physical environment (external or internal), use computing resources built into the sensor to perform a predefined programmed function on the data it is collecting, and then pass that data over a network connection. These include, but are not limited to, precision position sensors, level sensors, pressure sensors, weight sensors, temperature sensors, proximity sensors, heat and flow sensors, fluid velocity sensors, and current sensors. The sensors 206 monitor different processes, collect data, take measurements and in a preferred embodiment transmit this data using an Industrial Internet of Things (IIoT) and cloud computing platform to monitor and record data from throughout the manufacturing process and thus direct and control it.

[0077] Another basic robotic capability is locomotion 207, encompassing a full range of mobility and motion, depending on the requirements of the task to be performed. For example, many of the robots used in the disclosed systems and methods may be equipped with wheels, sleds, or mechanisms for basic automated motions such as rolling 216 on flat surfaces, irregular surfaces, or along guides or cables, or may use arms that mimic human motions for climbing 217. Other motions required for the manufacture of airships include gripping 218, reaching 219, and braking 220, as described in more detail with respect to Figures 3 and 4, as well as gripping 218, lifting 226, holding in place 227, connecting 227, and inspecting 233 with respect to Figure 6, in each case using actuators well known to those skilled in the art of robotics. To effectively perform these movements, another fundamental robotic function in one preferred embodiment is location awareness 208, which can incorporate data from sensors 206 that detect the robot's current physical location relative to specified three-dimensional spatial coordinates, a particular work area or application, or in relation to one or more other robots, and can then manipulate this data to control actions, information, and movements of the robot.

[0078] Location awareness 208 can also be based on machine vision 209, which is yet another basic robotic function in one preferred embodiment. Machine vision 209 employs one or more video cameras and / or digital sensors in one or more industrial cameras with dedicated optics to perform various functions, in addition to optionally assisting location awareness 208. In performing the system and method, this includes, for example, identifying 221 a particular part, reading a unique identification code printed or otherwise displayed on such part, and, for example, picking 222 the correct part to perform a desired task. Another use of machine vision 209 can be to read AprilTags, other visual fiducial markers, and laser pointers to ensure proper placement and orientation of components.

[0079] Another basic robotic function is the articulated arm 210, which assists in performing numerous tasks including, but not limited to, climbing 217, reaching 219, picking 222, handling 223, placing 224, inserting 225, lifting 226, connecting 229, and attaching 230, as described in more detail below with respect to Figures 3, 4, and 6. Yet another basic robotic function is communication 211. It is generally understood that distributed intelligence in robotics and autonomous systems applications depends heavily on seamless wireless connectivity. In particular, the IIoT / cloud-based robotic paradigm requires such communication technology to offload high-complexity computational tasks to edge / cloud platforms. Thus, such communication 211 capabilities, in a preferred embodiment, connect with a central controller system, other robots, and with individuals when supervision or remote control by a human operator is required or desired.

[0080] In one optional embodiment, the base robot functionality 202 also includes 3D printing 212, an additive process in which layers of material are built up to create 3D parts or printed surface areas, which may optionally be used in conjunction with the articulated arm 210. One non-limiting example where this may be employed is to print the skin or certain parts of the external structure 101, thereby achieving functional capabilities that would otherwise be difficult or impossible without employing additive manufacturing techniques. Such 3D printing 212 may use several different materials, including but not limited to plastics, composites, or metals, to create objects that vary in shape, size, stiffness, density, and color. 3D printing 212 may also be used to manufacture parts such as grippers, sensor mounts, end-of-arm tooling, and various replacement parts for other robots used in the systems and methods.

[0081] Changing such end effectors, tooling, robot peripherals, and robot accessories is important to the smooth operation of the system and method. Accordingly, another basic robotic function in any preferred embodiment is end-of-arm tooling 213, i.e., automatic tool exchange, which provides an automated process of changing tools and handing off various utilities without human intervention. Such end-of-arm tooling 213, in combination with other base robotic functions 202, enables one or more robots to perform tasks including, in a preferred embodiment, gripping 218, cutting 228, connecting 229, attaching 230, smoothing 231, and cementing 232, the usefulness of which will be readily apparent to one of ordinary skill in the art in performing the tasks described with respect to Figures 3, 4, and 6 below.

[0082] Assembly techniques 214 refer to a library of standardized assembly routines or scripts that use various base automation operations 203 executed by one or more robots, either alone or in groups. In one preferred embodiment, such assembly techniques 214 are software-based instructions, and in another optional embodiment, these instructions are burned directly onto a dedicated ROM-based chip used by one or more robots. Such assembly techniques 214 preferably include all aspects of the manufacturing process, including, in one optional embodiment, instructions for the build-out of the underlying production process equipment itself within the building shell. In one preferred embodiment, such assembly techniques 214 include instructions for the individual process steps required to produce custom-fabricated or extruded components and parts, select and assemble these components to produce the airship frame 101, and apply the skin to it. In another optional embodiment, such scripts are used for adding electrical and mechanical systems, attaching 230 and connecting 229 third-party equipment and vessels, and other related tasks.

[0083] Machine Learning / AI 215 is another basic robotic capability in a preferred embodiment. Those skilled in the art will understand that this includes computer systems that can learn and adapt without following explicit instructions. This is accomplished by using algorithms and statistical models to analyze patterns in data and draw inferences therefrom. Incorporating these capabilities allows the robots used, in one preferred embodiment, to become more adept at executing systems and methods without being explicitly programmed to do so. This is accomplished by using historical data as input to predict new output values. In any preferred embodiment, such processing crosses from machine learning to AI (artificial intelligence), as used herein to indicate that a robot can perform a task "smartly", such as by working in a cooperative manner with other robots to complete the task in an optimal manner, or by allowing humans to communicate with such robots using normal everyday language to perform the task.

[0084] The final two base automated operations 203, Inspect 233 and Photography 234, use a combination of multiple base robotic functions 202, including control system 205, locomotion 207, machine vision 209, articulated arms 210, and communications 211 to, in one preferred embodiment, provide documentation and assurance that the frame assembly and skin surfaces meet stringent aviation certification and performance requirements, even when most of the surfaces inspected or photographed are well outside the range of direct human inspection.

[0085] As discussed above, additional base robotic capabilities 202 and / or base automated operations 203 may be necessary or desirable to meet the manufacturing requirements of certain oversized or very heavy structures. Buttons 235(a) and 235(b) respectively indicate that in a preferred embodiment, there is the ability to add such additional capabilities and operation functions where useful to overcome design, manufacturing, assembly, or inspection challenges, resolve production inefficiencies, reduce costs or production times, perform tasks that are unsuitable or unsafe for humans to perform, or improve quality, repeatability, and scalability.

[0086] 3 and 4, a series of diagrams and corresponding disclosure are provided relating to the use of these robotic capabilities to assemble an airship in a bottom-up embodiment. This is followed by a series of diagrams and associated disclosure in Figures 5 and 6 relating to an alternative approach by which assembly of such an airship may proceed according to a top-down alternative embodiment. Those skilled in the art will readily appreciate that hybrid approaches incorporating aspects of both bottom-up and top-down assembly alternatives may also be useful and will often represent preferred embodiments for implementing the present disclosure.

[0087] FIG. 3(a) shows a partially assembled lower part of the exoskeleton 101 seated on a sled 301, which in one embodiment may be coupled to a structure at four locations where the structure 101 is reinforced to mount an internal loading bay area when the airship is completed. The sled 301 is preferably made from reinforced carbon fiber members that are hollow so as to be lightweight, very strong, and non-corrosive, and sits on a landing base 302, which is specially designed to couple to the sled 301 for convenient servicing of the airship when docked, and in one optional embodiment includes adding or removing hydrogen from said airship, and in another optional embodiment fills the hollow part of the sled 301 with water as temporary ballast when unloading cargo, and then empties the water when the airship is about to leave. The landing base 302 is permanently built on a reinforced foundation 303. In one optional preferred embodiment, once the airship is completed it may be flown, with sled 301 attached, to its remote intended base of operation, with a separate landing base 302 constructed for it.

[0088] FIG. 3(a) also shows the cable 304 suspended horizontally between the struts 305(a) and 305(b). FIG. 3(b) then shows how the strut 305 can be securely coupled to the hub 307 of the exoskeleton 101. The hub 307, the spokes 308 attached to the hub, and other components of the hub are discussed in detail in the specification of the applicant's prior patent '145, particularly in the detailed description associated with FIG. 4 thereof. As shown in FIG. 3(b), the opening 306 provides a socket opening for the strut 305 to be securely fixed. The collar 309 functions to restrict the strut 305 from being pushed all the way through the opening 306, and in one preferred embodiment, the complementary shapes of the strut 305 and the opening 306 allow for a secure coupling that does not allow the strut 305 to rotate once embedded in the opening 306. Once in place, the strut 305 can be used as a base for the robot and / or the cable 304 can be passed through the eyelet 310 to assist in movement.

[0089] In this regard, FIG. 3(c) provides a cross-sectional view of section AA of FIG. 3(b). As shown, cable 304 is threaded through eyelet 310, with clamp 311 attached to prevent cable 304 from slipping out. Once such cable 304 is secured at the other end, robot base 312 and wheels 313 are attached thereto, thus enabling the climbing robot to move across large open areas during construction of exoskeleton 101 and assist in attaching skin to said exoskeleton. Once a particular manufacturing process is completed, struts 305 may be removed from openings 306 and used elsewhere until construction is complete. Clamp 312 illustrates the use of one or more additional clamps to optionally limit the movement of the range of motion of said robot along horizontal cable 304 or to connect horizontal cable 304 to vertical cable 403, as described in more detail below.

[0090] It will be apparent to one of ordinary skill in the art how a multi-arm robot, including but not limited to a SPIDER bot, using base robot functionality 202 to perform base automated operations 203 in conjunction with the components described in FIG. 3 can enable individual robots, or groups of robots working in coordination, to work at heights of 50 feet or more, thereby enabling workers to avoid hazardous conditions when performing assembly and other manufacturing operations involving airships or other large and / or heavy structures.

[0091] In one embodiment, a portion of the exoskeleton may be built lying on its side until the entire circumference is completed, after which the portion is raised to an upright position so that it can be connected to other partially completed portions to create a stable base for attaching guide rails and cables in the manner described. In another embodiment, the airship structure 101 can be assembled linearly using one or more robots attached 230 to the struts 305 in the manner described above to obtain support from one or more rows of already completed assembled hubs 307 and spokes 308. In any alternative embodiment, the robot generally inserts one or more struts 305 into the space 306 of the hub 307 on either side of the open area, as illustrated by struts 305(a) and 305(b), places the cables 304 between them, and then uses wheels 313 to move along the cables 304 and build the open area in between.

[0092] In yet another embodiment, the cables 304 may be connected at one or both ends to one or more secure points separate from the structure 101 of the airship itself, for example attached to the floor of a building or factory where such assembly is taking place. In this case, material handling robots may travel along these cables, such fetch robots identifying 221 the appropriate parts required at the intended location of assembly on said exoskeleton 101, and then picking 222, gripping 218, and transporting (e.g., handling 223) these parts to other robots at or near the intended assembly location. Upon receiving such parts from these fetch robots, assembly robots can connect these parts with other parts according to the assembly technique 214 corresponding to the design of the frame. As a non-limiting example, such an assembly technique 214 for a hub and spoke structure described in Applicant's prior '145 patent requires inserting 225 two prongs on one end of each insert 314 into one of six three-pronged sockets 315 to form a hinge connection on the desired side of the hub 307 for the addition of the next spoke 308. That robot, or another robot working in communication 211 with it, can then couple the spokes 308 with the corresponding inserts 314 and, using position awareness 208, properly align and seat these structural members when the structural assembly is complete. One of these robots (or a third robot working in communication 211 with them) may then secure the connection by inserting 225 a pin 316.

[0093] FIG. 4 shows other aspects of an alternative embodiment, bottom-up, made of four sub-parts. FIG. 4(a) illustrates the use of one or more inflatable shapes, such as gas bags or cells, inside the partially completed exoskeleton 101 of FIG. 3(a). As shown, in one non-limiting example, twelve (total) such gas cells are provided, six on each side of a midline that runs longitudinally from the front 102 to the rear 103 of said exoskeleton 101. In one preferred embodiment, the volumes of all such gas cells are equal, which will result in shapes having different lengths and profiles as the diameter of the airship's hull shape changes. Thus, as shown, gas cell 401(a) located to the left of this midline, and gas cell 401(b) located to the right of it, have matching shapes that taper with the final shape of the [future] hull and are fairly long, while gas cells 402(a) and 402(b) on either side of said midline just behind cells 401(a) and 401(b) contain the same volume of gas but are much shorter in length. Other shapes and configurations of these gas cells may be employed while still following the principles of the present disclosure.

[0094] In one optional embodiment, such gas cells may contain ambient air and serve as a temporary shape around which the exoskeleton structure 101 may be built. In such optional embodiment, the primary function of such gas cells is to occupy the three-dimensional space of the shape of the future airship hull, provide resistance to aid in the stability of the partially complete exoskeleton 101, and help prevent the structure from "falling on itself" before all-around stability allows said exoskeleton 101 to maintain its own shape. Upon expansion, these gas cells will allow vertical cables 403 to be pulled out onto the outer surface of such inflatable shape and connected to struts 305 inserted into hubs 307 located on either side of it. As shown, the vertical cables are attached to the struts 305(a) and 305(b) in the manner previously disclosed, and clamps 314 shown in FIG. 3(c) allow horizontal cables 304 to be attached to such vertical cables 403, thereby increasing the area that an assembly robot can reach.

[0095] FIG. 4(b) shows a cross-sectional view of the front end of the partially completed exoskeleton structure 101 with inflatable gas cells 401(a) and 401(b) positioned inside and gas cells 402(a) and 402(b) positioned immediately behind them. The figure also shows strut 305(a) used to secure vertical cable 403 to the right side of the partially completed exoskeleton 101, which is strung across the top of inflatable gas cells 402(a) and 402(b) and then connects to strut 305(c) on the left side of said exoskeleton frame 101. This minimizes the need for overhead cranes or construction of intermediate crossings to hold the partially constructed exoskeleton until the entire circumference of the exoskeleton 101 is completed, thereby allowing the structure to distribute the weight of the airship along its entire circumference.

[0096] Referring to FIG. 4(c), a diagram of gas cell 401(b) is provided as representative of all gas cells. As shown in the figure, in one alternative embodiment, the inflatable shape may be filled with a buoyancy gas such as helium or hydrogen, and may optionally include a second, inner gas cell 404 filled with air. Those skilled in the art of lighter-than-air design will recognize that the inner gas cell 404 is similar to a so-called "balloon." A balloon is generally understood to be an air bag disposed inside an outer envelope containing buoyancy gas such that as the balloon expands, the volume available for buoyancy decreases, thereby increasing its density and decreasing the overall buoyancy, which in turn causes the airship to descend, while as the balloon deflates, the buoyancy increases. While air bladders are typically used for buoyancy control in non-rigid or semi-rigid airships, and may or may not, in fact, have any utility to the operation of the airship being constructed depending on the design intent of its sponsor, the use of the inner gas cell 404 within each inflatable shape may be useful in the manufacture of such airships.

[0097] In yet another alternative embodiment, gas cell 401(b) and the remaining gas cells may be filled with air, and inner gas cell 404 may be filled with the desired buoyancy gas (e.g., helium or hydrogen). This alternative embodiment has the advantage of being closer to the configuration of gas bags used in rigid airships, with the buoyancy gas cells being flexible envelopes protected within the hull of the airship. In such a case, each buoyancy gas cell has an access point for filling (e.g., adding buoyancy gas) and venting as needed, and there is an envelope of air around the gas cell that serves as a safety feature. To the extent that hydrogen is used as the lift gas, hydrogen molecules move slowly through the walls of the gas cells, so this leakage needs to be dissipated before reaching flammable concentrations. Because hydrogen lifts quickly, the airship is configured to have a slow but steady flow of air along the tops of the gas cells, along with monitors to measure hydrogen concentration, and the ability to increase ventilation as needed.

[0098] In another embodiment, an outer layer of lightweight fabric 405, such as aramid fiber or Kevlar®, is produced in the desired form of the inflated shapes and placed around their outer surface to reduce the risk of abrasion if they inadvertently come into contact with the exoskeleton, as well as to reduce the risk of such shapes being damaged during construction. In one preferred embodiment, the "sleeve" may be designed with a lightweight fabric through which the spokes 308 can be threaded during assembly of the exoskeleton. Doing this ensures that said shapes will adhere to the desired parts of the exoskeleton structure 101. In some optional embodiments, the inflatable shapes and this fabric may be removed upon completion of construction, while in other preferred embodiments, one or more inflatable shapes and this fabric will remain permanently inside the exoskeleton for the life of the airship and will be used in its operation after completion of construction. In a preferred embodiment, helium may be used as a lift gas during construction, and hydrogen may be used once the airship is completed and put into operation.

[0099] Also, in some embodiments, the placement of hubs, spokes, and other critical components may be drawn directly onto the surface of one or more inflatable shapes or lightweight fabrics 405 using human and / or machine readable text or tags to assist the robot in identifying 221 and placing 224 such components in three-dimensional space. In any other embodiment, the robot or robot "swarm" may utilize such drawings and any unique numbers and tags to ensure that the correct components are assembled in the correct locations such that the placement of the completed exoskeleton and skin follows its intended design.

[0100] Using one of the gas cell alternatives discussed above, in one embodiment the buoyancy of such inflatable shapes may be adjusted to maintain neutral or a desired level of negative buoyancy of the airship or selected portions thereof. This will ensure that the weight of such airship or portions thereof always remains within a predetermined tolerance as construction progresses, minimizing the need for cranes, mechanical and / or hydraulic jacks, and other lifting equipment. In one preferred embodiment, an automated control system may be programmed to control the relative amounts of buoyancy gas and air contained in one or more inflatable shapes, the purpose of such control system programming being to continuously monitor the net weight of the partially completed airship and maintain the desired buoyancy characteristics by adjusting the amount of air and buoyancy gas as construction progresses to always maintain both the integrity of said one or more inflatable shapes and an overall neutral or desired net negative buoyancy level.

[0101] In one embodiment, the effective net weight of the airship (e.g., the total weight of the completed ship portions minus the effect of the buoyancy capacity of the buoyancy gas filled inflatable shapes) is maintained within the range of 10,000 to 20,000 pounds. This range (e.g., 5 to 10 tons) may be modified according to the desires of the manufacturer, illustrating the principles of this aspect of the disclosure that, although the actual total weight of the airship may ultimately exceed 250,000 pounds, by implementing the disclosed principles, the effective weight can be kept much more manageable.

[0102] In one embodiment, prefabricated curvilinear pieces, including portions of the skin, are attached 230 to the exoskeleton via robots performing their assembly techniques 214. In another embodiment, the skin is applied, laid up, or cemented 232, smoothed 231, and inspected 233 to ensure it does not have wrinkles, bubbles, dents, or other unacceptable defects. In any embodiment, additive construction techniques 212 can be used to provide portions of the exoskeleton and / or skin. In such an embodiment, one or more robots are mounted on struts 305, horizontal cables 304, and / or vertical cables 403 to lay up or 3D print 212 these components using one or more computer-controlled articulated arms 210. Optionally, in such cases, a second robot or robots later smooth 231 the surface to minimize surface friction and drag during flight.

[0103] FIG. 4(d) shows another alternative embodiment. In some embodiments, once the exoskeleton 101 is completed, a temporary end cap 406(a) is coupled to the front 102 of said exoskeleton 101 and a temporary end cap 406(b) is coupled to the rear 103 of said exoskeleton. The axle 407 of a rotation device 408 may be temporarily coupled thereto. Loading the completed airship onto this device can assist the process by adjusting the height of the rotation device on its mounting 409, while simultaneously reducing the effective net weight of the airship using the automated control system described above to increase the relative amount of lift gas and reduce the volume of air contained in the inflatable shape or shapes. Once coupled to such a rotation machine 408, in one preferred embodiment, the amount of lift gas may then be adjusted to further reduce the effective net weight of the airship closer to neutral buoyancy, after which, in one embodiment, the entire airship body may be rotated by said rotation device 408 to aid in inspection, laying up smooth skin surfaces, and other desired production steps.

[0104] Also, in any other embodiment, selected ones of the inflatable shapes can be used to lower the front 102 of the airship and raise the rear 103 of the airship to help mate the end cap 406(a) or the front compartment attached to the exoskeleton. In another embodiment, selected ones of the inflatable shapes can be used to lower the rear 103 of the airship and raise the front 102 to help mate the end cap 406(b) or attach to the rear engine or work on the rear engine.

[0105] Referring now to FIG. 5, several diagrams are provided regarding an alternative approach by which airship assembly proceeds according to a top-down alternative embodiment. FIG. 5(a) shows a diagram of a manufacturing facility floor 501 on which dashed lines 502 represent an imaginary shape of the outer edge of the finished surface of airship 101 (referred to herein as its drip line). Vertical lines shown extending just beyond the edge of said drip line 502 indicate epoxy or stud mounted subplate tracks 503 attached to the facility floor, the placement of each such track corresponding to the location of the circular support frame 105 of airship 101. As shown, when viewed in the direction of arrow 504(a) pointing forward of the airship, track 503(a) corresponds to the location of support frame 105(a) in the forward quarter of airship 101. When viewed in the direction of arrow 504(b) toward the rear of the airship, track 503(b) corresponds to the location of support frame 105(b) in the rear quarter of airship 101. Trajectory 503(c) corresponds to the position of support frame 105(c) at the midline 104 of airship 101. Each such trajectory 503 provides a linear path for two or more so-called hand-over-hand (HOH) support robots 505, as described in more detail below with respect to Figures 5(b) and 6.

[0106] FIG. 5(b) illustrates the primary function of such an HOH support robot, which is to lift 226 and hold in place 227 the partially completed airship 101, thereby allowing assembly and construction activities on the structural, exterior, and interior components to ideally take place at or near the factory floor 502. The view shown in FIG. 5(b) is section AA along the linear trajectory 503(c) from FIG. 5(a) near the start of construction. HOH support robots 505(a) and 505(b) respectively hold 227 the left and right ends of the top of the partially completed structural frame 105(c), which contains the six truss modules 106(a)-106(f). 6, HOH support robot 505(a) grips 218 truss modules 106(a) and 106(b), while HOH support robot 505(b) grips 218 truss modules 106(e) and 106(f), which are connected to the apexes of structural frame 105(c), which is made up of truss modules 106(c) and 106(d).

[0107] FIG. 5(c) shows six optional views of section AA of FIG. 5(a), beginning with section 506(a) corresponding to the view shown in FIG. 5(b). The next five views show the progression of the construction of support frame 105(c) from the first top module connected 229 in section 506(a) to the completed airship in section 506(f). These six exemplary views show the positions of HOH support robots 505(a) and 505(b) along linear trajectory 503(c) given the current level of completion of airship 101, and the addition of two corresponding HOH support robots to each circular structural frame as the construction progresses from midline 104 in the direction of arrow 504(b) in FIG. 5(a).

[0108] As shown in cross-sections 506(a) and 506(f), respectively, HOH support robots 505(a) and 505(b) start and end closest to each other near the center of linear trajectory 503(c). In cross-sections 506(b), 506(c), and 506(d), HOH support robots 505(a) and 505(b) move further apart as airship 101 is built, reaching their maximum separation at the "equator" of such assembly (e.g., the midpoint between the top and bottom of the airship), as shown in cross-section 506(d). As shown in detail in FIG. 6, HOH support robot 505 has a pivot that allows the support arm to always match the curvature of circular frame 105. The + / - 90 degree rotation of this pivot allows HOH support robot 505 to conform to both concave and convex curvatures relative to the build centerline. Thus, once the structure's equator passes the build level, the support robots are rotated horizontally and rolled from inside to outside to complete the build. This is shown in cross-sections 506(a)-506(d), which show HOH support robots 505(a) and 505(b) positioned on the inside of circular frame 105 during these initial stages of build, and once the equator is passed, cross-sections 506(e) and 506(f) show such HOH support robots 505(a) and 505(b) moving to the outside of the build.

[0109] The airship 101 structure begins with the circular support frame 105(c) being assembled from the linear track 503(c), as shown in cross-section 506(a) and FIG. 5(b), but as the airship structure progresses toward the equator, assembly also moves toward the front 102 and rear 103 of the structure. As the active area in which the construction of the structure is taking place moves laterally (e.g., in the direction of arrows 504(a) and 504(b), respectively), additional HOH support robots 505 are added to each successive linear track, with such robots functioning in the same manner as described with respect to the robot on linear track 503(c). Thus, as shown in cross-sections 506(d) and 506(e), two HOH support robots 505 are employed on each of the linear tracks 503 once the airship 101 structure reaches the equator. Optionally, as shown in cross-sectional view 506(f), after each such circular support frame 105 is completed, some or all of such HOH support robots 505 may be left in place to provide additional support, if needed.

[0110] Referring now to FIG. 6, a schematic diagram of such an HOH support robot 505 is provided in FIG. 6(a). As shown, in a preferred embodiment, a linear bearing rail 601 is mounted on a linear track 503. In one embodiment, the HOH support robot 505 may not employ track mounting, but in a preferred embodiment, these mobile robots are track mounted since there may be cases where there may be upward stresses (e.g., during positive buoyancy stress testing) or high moment loads that are transferred to the floor. While the optional use of gas cells as disclosed with respect to FIG. 3 and FIG. 4 may provide some of this support for the heavier stages of construction, in a preferred embodiment, the HOH support robot 505 employs the conservative assumption that there will be no such offloading, thereby requiring the HOH support robot to carry the entire weight of the airship 101 until it is fully assembled.

[0111] Assuming the completed airship 101 weighs 400,000 pounds total and has 16 structural frames 105, eight HOH support robots 505 would be used on each side. In this case, each HOH support robot 505 would need to support approximately 25,000 pounds plus a safety factor to account for possible unloading due to heavier weight and buoyancy in some areas. While various mounting methods are possible, the use of linear bearings 602(a) and 602(b) provides high load capacity, rigidity, and shock and impact resistance, while providing support for the load of the robot carriage 603 while it moves along the linear track 503 and providing a low friction sliding surface for the bearing rails 601. In any embodiment, carriage 603 may be configured to extend upward (e.g., in the Y-axis direction) to support a portion of the airship 101 at one or both ends once construction of the airship 101 has progressed beyond the equator and construction of the corresponding circular support frame 105 for that portion of the airship 101 has been completed.

[0112] Those skilled in the art will recognize that several methods can be used to drive the linear (e.g., X-axis) motion of the robot, including, but not limited to, belt, rack and pinion, and chain drives. As shown, in a preferred embodiment, the HOH support robot 505 uses a rack 604 and traverse drive (pinion) 605. To reduce cabling, the power source 204 for the HOH support robot 505, in a preferred embodiment, uses an on-board battery. Because these robots only move short distances at a time and are idle for the majority of the assembly period, in a preferred embodiment, a trickle charge can be provided via the linear bearings to replenish the on-board batteries.

[0113] As described with respect to FIG. 5(b), the HOH support robot 505 is a heavy lift device having a pivot axis 606 to allow the robot's arm assembly 607 to rotate + / - 90 degrees to be oriented according to the build centerline 608 of its respective circular structural frame 105, thereby accommodating both concave and convex curvatures as the airship build progresses. In a preferred embodiment, such pivoting arm assembly 607 provides gripping 218, lifting 226, and position holding 227 functions. Assuming the use of a triangular truss to construct the circular structural frame 105, in a preferred embodiment, such arm assembly 607 includes a total of nine node grippers 609 mounted in sets of three node grippers each on a recirculating track 610 with drive means.

[0114] Node grippers 609(a), 609(b), and 609(c) are connected to a recirculating track 610(a), node grippers 609(d), 609(e), and 609(f) are connected to a recirculating track 610(b) (node ​​gripper 609(d) is hidden behind the rest of the figure), and node grippers 609(g), 609(h), and 609(i) are connected to a recirculating track 610(c). Arrows 611(a) and 611(b) indicate the direction that recirculating track 610(a) travels as the HOH support robot 505 lifts the truss modules 106 it is gripping (as described below) and then lifts the structural frames 105 that these modules comprise, and arrows 611(c) and 611(d) indicate the return of the recirculating tracks 610(b) and 610(c) and their corresponding node grippers 609, respectively.

[0115] Three truss modules 106 are shown in various stages of assembly to their corresponding structural frame 105. As shown, truss module 612(a) is being moved into position by assembly and fixturing robot (FixBot) 613, the characteristics of which are described below. As shown, FixBot 613 positions coupling joints 110(a), 110(b), 110(c) of truss module 612(a) at grip node 609(i) on recirculating track 610(c), grip node 609(f) on recirculating track 610(b), and grip node 609(c) on recirculating track 610(a), respectively. Once properly positioned, in a preferred embodiment, FixBot 613 (or a second FixBot with the appropriate end of its end-of-arm tooling 213 for attaching these coupling joints in the desired manner) connects the three corresponding coupling joints 111(a), 111(b), and 111(c) of truss module 612(a) to coupling joints 110(a), 110(b), and 110(c) of truss module 612(b). Gripper nodes 609(h), 609(e), and 609(b) then grip the connected joints between truss modules 612(a) and 612(b), thereby holding 227 these modules firmly in place while work proceeds on the layer corresponding to truss module 612(c), including connecting the remainder of the structural elements to the skin as described with respect to FIG. 6(b), and connecting other components of the airship 101 for that layer of assembly.

[0116] Once all components of a layer are completed, gripping nodes 609(a), 609(d), 609(g) open, thereby releasing their final hold on truss module 612(c), and recirculating tracks 610(a), 610(b), 610(c) lift truss modules 612(a), 612(b), thereby indexing upwardly the corresponding structural frame 105 consisting of truss modules 610(a), 610(b), 610(c), the corresponding three truss modules 106 on the opposite side of the airship 101, and all of the connecting truss modules 106 therebetween. A similar operation is simultaneously performed by the pair of HOH support robots 505 holding the other circular frame 105, thereby raising the entire structure 101. Once this is completed, the aforementioned series of steps are repeated until the construction of the entire structural frame, the attachment of its skin, and the connection of the associated components are complete.

[0117] It will be apparent to one skilled in the art that the operation of any HOH support robots 505 that come into contact with the airship 101 structure must be coordinated to ensure that such structure 101 is raised in the desired manner. The HOH support robots 505 have identical stop and start times, but different rates. To ensure proper operation, all HOH support robots 505 are precisely coordinated by the system's control system 205, pre-programmed assembly techniques 214, and communications 211 to function in a predicted manner such that a failure of any of the recirculation tracks 610, gripper nodes 609, traverse drives 605, or slewing drives 606 will immediately halt operation of all HOH support robots 505 until such failure is diagnosed and corrected.

[0118] As mentioned above, FixBot 613 is a light payload robot programmed to hold subassemblies such as truss modules 106 in place. Autonomous guided vehicles such as FixBot 613 are used throughout manufacturing facilities for other material handling and placement tasks. To enable FixBot 613 to move autonomously without an on-board operator or driver, they are built on an Autonomous Mobile Robot (AMR) base 614, such as those manufactured by Bosch Rexroth. And to perform a wide range of tasks, each such FixBot 613 has a six-axis articulated arm 615, such as those manufactured by FANUC, Yaskawa Motoman, ABB, and KUKA, equipped with end-of-arm tooling 213 to perform the task, and a camera 616 to read fiducials for destinations and gripping parts to precisely position and inspect such subassemblies.

[0119] Referring now to FIG. 6(b), FixBots 613(a) and 613(b) are shown equipped with different end-of-arm tooling that equips them to assemble and connect structural elements between circular structural frames 105. As a non-limiting example of operating as a robot swarm, FixBot 613(a) is shown holding spokes 308 in place, while FixBot 613(b) connects the spoke to other spokes at hubs 309. The figure also shows other subassemblies 617 connected to truss modules 612(c) with connectors 618, and the attachment of skin panels 619 onto such exoskeletons. FIG. 6(b) also shows another specialized class of robots, called FetchBots 620, which in a preferred embodiment may be used to shuttle pre-cut lengths of raw materials, such as spokes 308, and pre-assembled components, such as subassemblies 617, to the main assembly floor from other areas of the facility where these components are produced, stocked, and otherwise prepared by the robotic work cells. As shown, such a FetchBot includes an AMR base 614 and a dedicated track 621 for holding such raw materials and subassemblies.

[0120] In a preferred embodiment, all of the assembly steps, i.e., attaching the skin (230), laying up, or 3D printing (212), and the processes involved in ensuring that the finished surfaces are properly formed and smooth, as well as other steps involved in manufacturing the airship, will be performed similarly. As this work is performed, the base robotic functionality 202 can also be used to provide automated quality oversight by enabling human monitoring of such robotic activity through inspection 233 and / or through the use of machine vision 209 and communication 211 with remote screens used by said managers from the factory floor, control room, or by observing from a remote location. The combination of an experienced technician supervising in real time and / or asynchronously observing filming 234 of such robotic activity performed in accordance with the disclosed systems and methods results in superior performance results in a fraction of the time and at a fraction of the cost of traditional construction approaches.

[0121] Moreover, based on the foregoing disclosure, it will be apparent to one of ordinary skill in the art how the requirements for the factory infrastructure in which such assembly occurs may be simultaneously reduced. While large physical structures are still required to shield such operations from the elements and perform them in a protected environment, the disclosed systems, methods, and apparatus allow project sponsors to avoid the need for very expensive elevated building platforms, one or more massive overhead cranes, and additional foundations, highly reinforced structures, and associated building infrastructure to support such elements, as would be required using traditional manufacturing techniques.

[0122] Using the foregoing disclosure, and without having to perform undue study, robot suppliers such as KUKA, ABB (ASEA Brown Boveri), Omron Adept Technologies, Mitsubishi Electric, Bosch, Yaskawa, Kawasaki, Nachi Fujikoshi, Comau Robotics, Yamaha, IGM, Rethink Robotics, Arrival, and others, can provide robots and control systems 205 capable of performing all base automation operations 203. Such suppliers would also be enabled to configure, from CAD drawings provided by the airship designer, assembly techniques 314 that such robots can use to perform the tasks required to assemble the exoskeleton 101 and complete other manufacturing steps in accordance with the principles of the present disclosure. By following such computer-controlled pre-programmed assembly techniques 214 and / or utilizing machine learning / AI 215, it would be apparent to one skilled in the art how such robots can be trained to respond to the different structural shapes, systems, part numbering schemes, tags, and markings for each such manufacturing project.

[0123] In another preferred embodiment, these robots can utilize machine vision 209 and machine learning 215 to adapt to the geometry of the airship exoskeleton 101 and perform other specialized tasks required to build the airship. In addition to the labor-saving and safety benefits, as well as the ability to reduce capital costs and specialized equipment needs for manufacturing facilities, the disclosed systems and methods are also designed with manufacturing speed and scalability in mind. For example, the time required for construction can be accelerated by assigning additional robots to work in concert on specific tasks, or by employing additional "teams" of robots programmed to work in parallel on different parts of the airship, thereby allowing production levels to be easily scaled up to meet desired project duration goals, virtually regardless of the size of the airship and number of airships. Furthermore, by replicating the assembly techniques 214, additional manufacturing facilities can be easily developed in other geographic areas, thereby expanding the number of assembly locations, quickly entering multiple markets, creating a well-paying business, and adding local tax revenue, all of which help build widespread community support and adoption.

[0124] In summary, based on the foregoing disclosure, it will be apparent to one of ordinary skill in the art how, by using bottom-up assembly methods, top-down assembly methods, and / or a useful combination of the two methods, multiple teams of robot-based work cells producing raw materials and subassemblies, FetchBots 620, and FixBots 613, can work in coordination with HOH support robots 505 and robots equipped to ascend, to simultaneously build airships faster, less expensive, of higher quality, and in a significantly more replicable and scalable manner than the prior art, while overcoming the stated limitations of such prior art methods.

[0125] From the above disclosure, it will be understood that although certain embodiments have been described herein for illustrative purposes, various modifications may be made without departing from the spirit and scope of the appended claims and the elements described therein. Furthermore, while certain aspects are presented as alternative, optional, or preferred embodiments, not all such embodiments are required and may therefore be incorporated as dictated by circumstances to achieve the desired results. Furthermore, although certain aspects are presented below in certain claim formats, the inventors contemplate the various aspects in any available claim format. As would be apparent to one skilled in the art having the benefit of this disclosure, various modifications and changes may be made. It is intended to encompass all such modifications and changes, and therefore the above description should be considered in an illustrative and not a limiting sense.

Claims

1. 1. A method for top-down robotic manufacturing of an airship, comprising: placing a partial airship hull on at least one truss held by at least one support robot; using one or more specialized robotic worker classes to complete a build task cycle on a selected work surface of said partial airship hull assembly, thereby completing a build task cycle on an upper section of said airship; robotically elevating the active assembly work surface of the partial airship hull assembly using at least one support lift robot; selecting a further lower active assembly work surface and completing a build task cycle with the robot on the further selected lower assembly work surface; and repeatedly raising subsequent lower active assembly work surfaces and robotically completing a build task cycle on subsequent selected lower active assembly work surfaces until the airship is fully constructed; A method comprising:

2. the at least one support robot is capable of adjusting a contact point between the at least one truss and the airship according to a position and curvature of a frame of the airship; Optionally, said at least one support robot communicates with one or more other support robots to properly orient itself according to said construction tasks in said assembly of said airship. The method of claim 1.

3. The method of claim 1 , wherein the construction task cycles on the airship are performed by one or more robots working independently or in a robot swarm.

4. the robot swarm includes a plurality of robots, either homogeneous or heterogeneous, or a mixture thereof, forming a robot swarm, each robot within the robot swarm having processing, communication, and sensing capabilities that enable the robots to interact with each other and accomplish the construction task cycle, and being controlled by pre-programmed routines, artificial intelligence, or a combination thereof; 4. The method of claim 3, wherein the robot swarm utilizes remote cameras, computer vision, and machine learning to perform specific unique functions as it completes construction task cycles for the frame, exoskeleton, cover, or other portion of the airship.

5. 10. The method of claim 1, wherein the robot swarm comprises at least one heavy-lift robot that coordinates with other specialized robots to complete the construction task cycle of the airship.

6. The method of claim 1 , wherein the airship hull exterior surface material is applied by a specialized homogeneous robot within the robot fleet.

7. The method of claim 4 , wherein each robot attaches itself to and derives support from one or more already assembled components.

8. 1. A method for robotically manufacturing an airship, comprising: attaching the partially completed airship exoskeleton to the sled; inserting at least one strut into at least one hub of the exoskeleton of the airship; attaching at least one cable to the at least one pole; attaching at least one robot to the at least one cable; and utilizing the at least one robot to complete construction of the lighter-than-air vehicle; A method comprising:

9. 10. The method of claim 8, wherein the at least one robot communicates with one or more robots of similar or different capabilities forming a robot swarm, the robots in the robot swarm being configured with sensory systems that enable remote automated quality monitoring and human oversight.

10. 10. The method of claim 9, wherein the robots in the robot swarm are controlled by manual control, wireless control, semi-autonomous, or fully autonomous, where the fully autonomous control uses pre-programmed routines, artificial intelligence, or a combination thereof to control the functions and tasks of the robot swarm.

11. 10. The method of claim 8, further comprising inserting at least one gas cell into the exoskeleton of the airship, said gas cell containing air or a lighter-than-air gas, said air or lighter-than-air gas maintaining the shape of the exoskeleton during construction or reducing the weight of the airship that needs to be supported.

12. 10. The method of claim 8, wherein at least a portion of the airship is constructed while lying on its side and then lifted to an upright position by at least one heavy lift robot to allow completion of construction of the airship.

13. The method of claim 8 , wherein the at least one robot has a locomotion mechanism configured for self-locomotion or guided locomotion.

14. 10. The method of claim 8, wherein the exoskeleton or other portions of the airship are robotically constructed in separate processes and then assembled in another manufacturing process.

15. 12. The method of claim 11, connecting at least one end cap and at least one end cap to the exoskeleton; securing at least one front end rotating device and at least one rear end rotating device to the exoskeleton; adjusting the level of lift gas in the at least one gas call to reduce the weight of the airship that needs to be supported; and rotating the exoskeleton using the at least one front end rotation device and the at least one rear end rotation device; A method comprising:

16. 1. A method for robotically manufacturing an airship, comprising: placing a portion of the airship on at least one truss held by at least one support robot; robotically completing a portion of the construction tasks on the airship; releasing at least one gripping node of the at least one support robot and elevating the at least one truss by rotating at least one recirculating orbit; robotically completing a construction task cycle on said airship; and repeating the construction task cycle until the airship is fully constructed; A method comprising:

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