Locking mechanism to prevent dropping

Abstract

To mitigate fall risks during various manufacturing processes.SOLUTION: A worker safety system includes a work stand 402, a safety barrier, and a flip door assembly 406. The flip door assembly selectively engages with a keyed portion of the safety barrier to prevent access to a defined area by a worker. The flip door assembly includes a flip door having a top surface that is substantially flush with a top surface of the work stand when the flip door is closed, and substantially not flush with the top surface of the work stand when the flip door is open. The flip door assembly further includes an interlock that prevents the flip door from being opened when the keyed portion of the safety barrier is not engaged with the interlock, and allows the flip door to be opened when the keyed portion of the safety barrier is engaged with the interlock.SELECTED DRAWING: None

Description

[Technical field]

[0001]

[0001] The present disclosure relates to the field of manufacturing, and more particularly, to reducing the risk of drops during various manufacturing processes. [Background technology]

[0002]

[0002] During the aircraft fuselage assembly process, temporary work stands are typically placed adjacent to the fuselage skin to allow workers to work on the fuselage. In some cases, it is desirable to perform work on areas of the fuselage that may be partially obscured by the work stand (e.g., when an end of the work stand terminates adjacent to the fuselage skin). To allow this work, a flip door is included in the floor of the work stand near the fuselage. The flip door opens up a portion of the floor in the work stand to allow workers below the platform to access the fuselage or pass equipment through the open portion in the work stand floor.

[0003]

[0003] However, problems may arise if a worker on the platform inadvertently falls through the open flip door and is injured. Therefore, it is desirable to reduce the risk of a worker falling when the flip door is open without the use of complex safety equipment, portable barriers, etc. Summary of the Invention

[0004]

[0004] A flip door assembly includes a flip door and an interlock that controls whether the flip door can be opened. The flip door assembly can be integrated with a work stand, whereby when the work stand is positioned proximate to a fuselage of an aircraft under production, the flip door can be opened to allow access to a portion of the fuselage obscured by the flip door if the flip door is closed. When a keyed portion of a safety barrier engages with the interlock, the flip door can be opened to allow access to the fuselage. When the safety barrier engages with the interlock, the safety barrier isolates a defined area from a worker and prevents the worker from inadvertently falling through an open flip door.

[0005]

[0005] One embodiment comprises a worker safety system including a work stand, a safety barrier, and a flip door assembly. The safety barrier has a keyed portion. The flip door assembly selectively engages the keyed portion of the safety barrier to prevent access to a defined area by a worker. The flip door assembly includes a flip door having a top surface that is substantially flush with a top surface of the work stand when the flip door is closed and that is substantially non-flush with a top surface of the work stand when the flip door is open. The flip door assembly further includes an interlock that prevents the flip door from opening when the keyed portion of the safety barrier is not engaged with the interlock and allows the flip door to be opened when the keyed portion of the safety barrier is engaged with the interlock.

[0006]

[0006] Another embodiment includes a method of operating a worker safety system in a manufacturing environment. The method includes providing a work stand including a flip door and an interlock that controls opening and closing of the flip door based on whether a keyed portion of the safety barrier is engaged or disengaged with the interlock. The method further includes preventing the flip door from opening in response to the keyed portion of the safety barrier not engaging with the interlock. The method further includes engaging the keyed portion of the safety barrier with the interlock and opening the flip door to prevent a worker from accessing the defined area.

[0007]

[0007] Another embodiment includes a worker safety system for a manufacturing environment. The worker safety system includes a work stand having a flip door and an interlock for the flip door, and a safety barrier. The safety barrier has a keyed portion that prevents access to a defined area when the keyed portion engages with the interlock. The interlock allows the flip door to be opened when the keyed portion engages with the interlock and prevents the flip door from being opened when the keyed portion does not engage with the interlock.

[0008]

[0008] The features, functions, and advantages discussed may be realized individually in various embodiments or may be combined in yet other embodiments, further details of which can be understood with reference to the following description and drawings.

[0009]

[0009] Some embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which the same reference numbers represent the same elements or the same types of elements, and in which: [Brief description of the drawings]

[0010] [Figure 1] 1-3 depict a prior art manufacturing environment. [Diagram 2] 1-3 depict a prior art manufacturing environment. [Diagram 3] 1-3 depict a prior art manufacturing environment. [Figure 4]

[0011] 4-9 depict a manufacturing environment in one exemplary embodiment. [Diagram 5] 4-9 depict a manufacturing environment in one exemplary embodiment. [Figure 6] 4-9 depict a manufacturing environment in one exemplary embodiment. [Figure 7] 4-9 depict a manufacturing environment in one exemplary embodiment. [Figure 8] 4-9 depict a manufacturing environment in one exemplary embodiment. [Figure 9] 4-9 depict a manufacturing environment in one exemplary embodiment. [Figure 10A]

[0012] FIG. 1 illustrates an isometric view of a safety barrier in an illustrative embodiment. [Figure 10B]

[0013] FIG. 2 illustrates an isometric view of a flip door assembly in an exemplary embodiment. [Figure 10C]

[0014] 10B is an isometric view of both the safety barrier of FIG. 10A and the flip door assembly of FIG. 10B in an exemplary embodiment. [Figure 11]

[0015] 11-14 are isometric views of a portion of the flip door assembly of FIG. 10A in an exemplary embodiment. [Figure 12] 11-14 are isometric views of a portion of the flip door assembly of FIG. 10A in an exemplary embodiment. [Figure 13] 11-14 are isometric views of a portion of the flip door assembly of FIG. 10A in an exemplary embodiment. [Figure 14] 11-14 are isometric views of a portion of the flip door assembly of FIG. 10A in an exemplary embodiment. [Figure 15]

[0016] 1 is a flowchart of a method of operating a flip door assembly in an exemplary embodiment. [Figure 16]

[0017] 16-17 are flow charts illustrating further details of the method of FIG. 15 in an exemplary embodiment. [Figure 17] 16-17 are flow charts illustrating further details of the method of FIG. 15 in an exemplary embodiment. [Figure 18]

[0018] FIG. 1 is a block diagram of a manufacturing environment in an illustrative embodiment. [Figure 19]

[0019] 1 is a flowchart illustrating an aircraft manufacturing and service method in an illustrative embodiment. [Figure 20]

[0020] 1 is a diagrammatic illustration of an aircraft in an illustrative embodiment; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011]

[0021] The drawings and the following description show specific exemplary embodiments. Those skilled in the art will recognize that various configurations embodying the principles described herein and falling within the contemplated scope of the claims that follow this description can be devised, even if not explicitly described or illustrated herein. Furthermore, any examples described herein should be construed as being intended to aid in the understanding of the principles of the disclosure, and not as being limiting. As a result, this disclosure is not limited to the specific embodiments or examples described below, but rather by the claims and their equivalents.

[0012]

[0022] 1-3 depict a prior art manufacturing environment 100. In some embodiments, the environment 100 may include an aircraft manufacturing environment. However, the environment 100 may include other types of environments in various embodiments. The environment 100 includes an elevated platform 102 for assembling a fuselage 104 and / or performing manufacturing processes on the fuselage 104. In FIGS. 1-3 , the fuselage 104 is supported by fixtures 106 on a factory floor 108 during assembly, and the elevated platform 102 is positioned proximate an exterior surface 110 of the fuselage 104 to allow workers to assemble the fuselage 104 and / or perform manufacturing processes on the fuselage 104. The elevated platform 102 is elevated and supported above the factory floor 108 using one or more vertical supports 112. To provide access to a portion 114 of the fuselage 104, the elevated platform 102 includes a door 116 rotatably coupled to the elevated platform 102 using one or more hinges 118. As shown in FIG. 1 , when the door 116 is in the closed position, an upper surface 120 of the door 116 substantially coincides with a walking surface 122 of the elevated platform 102, thereby allowing a worker to walk on both the walking surface 122 and the upper surface 120 of the door 116 to access the fuselage 104.

[0013]

[0023] When the door 116 rotates in the direction of arrow 202 to the open position (see FIG. 2 ), the top surface 120 of the door 116 forms an angle of approximately 90 degrees with the walking surface 122 of the raised platform 102, exposing an open portion 204 between the outer surface 110 of the fuselage 104 and an end 206 of the raised platform 102 adjacent the fuselage 104.

[0014]

[0024] The door 116 in the open position may allow a worker 302 to work below the elevated platform 102 and access the portion 114 of the fuselage 104 during fabrication and / or manufacturing processes performed on the fuselage 104 (see FIG. 3 ). For example, the mobile platform 304 may be moved to a position below the door 116 so that the worker 302 can utilize the mobile platform 304 to access the door 116 and lift the door 116 to the open position shown in FIG. 3 . This may pose a risk of falling to the worker 306 working on the elevated platform 102, especially when the height 308 of the door 116 between the walking surface 122 of the elevated platform 102 and the end 310 of the door 116 is low. In particular, the height 308 of the door 116 may be below minimum safety standards at locations within the environment 100 or the structural integrity of the door 116 may be insufficient to act as a barrier.

[0015]

[0025] In the embodiments described herein, a flip door assembly is described that uses an interlock that prevents the flip door from being opened unless the safety barrier is engaged with the interlock. When the safety barrier is in place and engaged with the interlock, the flip door can be opened. With the safety barrier so engaged, it prevents access to the defined area by the worker. Once the flip door is open, the safety barrier cannot be removed from the interlock, thereby preventing inadvertent removal of the safety barrier while the flip door is open. Once the flip door is closed, the safety barrier can be removed from the interlock to allow access to the defined area by the worker. This reduces a potential fall hazard to a worker working on a work stand that utilizes the flip door.

[0016]

[0026] 4-9 depict, in one example embodiment, manufacturing environment 400. In some embodiments, environment 400 may include an aircraft manufacturing environment. However, environment 400 may include other types of environments in various embodiments.

[0017]

[0027] Environment 400 in this embodiment includes a worker safety system 401 that is adjacent to fuselage 104 and is used by workers to assemble fuselage 104 and / or perform manufacturing processes on fuselage 104. Worker safety system 401 in this embodiment includes a work stand 402, a flip door assembly 406, and a safety barrier 418.

[0018]

[0028] The work stand 402 is positioned proximate the exterior surface 110 of the fuselage 104 to allow workers to perform assembly and / or manufacturing processes on a portion 114 of the fuselage 104 proximate an end 403 of the work stand 402. The work stand 402 is elevated and supported above the factory floor 108 using one or more vertical supports 404. To provide access to the portion 114 of the fuselage 104, the work stand 402 includes a flip door assembly 406. The flip door assembly 406 includes a flip door 408 and an interlock 410. In some embodiments, the interlock 410 is fully mechanical in design and does not rely on electro-mechanical elements, thereby simplifying its design and use. In this embodiment, the flip door assembly 406 is proximate the end 403 of the work stand 402, although in other embodiments the flip door assembly 406 may be positioned at various locations along the work stand 402.

[0019]

[0029] In this embodiment, the flip door assembly 406 includes one or more rotating members 412 that allow the flip door 408 to rotate in the direction of arrow 414 when certain conditions are met. In particular, the interlock 410 of the flip door assembly 406 prevents the flip door 408 from pivoting in the direction of arrow 414 on the rotating members 412 to an open position unless the keyed portion 416 of the safety barrier 418 is engaged with the interlock 410 of the flip door assembly 406.

[0020]

[0030] 4, when the flip door 408 is in the closed position, the top surface 420 of the flip door 408 may substantially coincide with the top surface 422 of the work stand 402, thereby allowing a worker to walk on both the top surface 422 of the work stand 402 and the top surface 420 of the flip door 408 to access the fuselage 104. FIG. 4 also shows the bottom surface 424 of the work stand 402 opposite the top surface 422 of the work stand 402.

[0021]

[0031] To open the flip door 408, the safety barrier 418 is moved in the direction of arrow 502 (see FIG. 5 ) to allow the keyed portion 416 (not shown in FIG. 5 ) of the safety barrier 418 to engage the interlock 410 of the flip door assembly 406. As shown in FIG. 5 , when the safety barrier 418 is in place, a worker on the work stand 402 is prevented from accessing a defined area 504 that exists around the flip door 408. In this embodiment, the defined area 504 is located between the safety barrier 418 and the fuselage 104. When the safety barrier 418 is in place and the keyed portion 416 is engaged with the interlock 410, the flip door 408 is no longer locked in the closed position shown in FIG. 5 , but rather is released by the interlock 410 to rotate in the direction of arrow 414 to an open position as shown in FIG. 6 . When the flip door 408 is open, an open portion 612 is formed between the flip door 408 and the exterior surface 110 of the fuselage 104 .

[0022]

[0032] 6, when the flip door 408 is in the open position, in this embodiment, it is apparent that the height 602 between the top surface 422 of the work stand 402 and the end 604 of the safety barrier 418 is greater than the height 606 between the top surface 422 of the work stand 402 and the end 610 of the flip door 408. This provides a greater measure of safety for the worker on the work stand 402 than the height 606 of the flip door 408 alone, thereby reducing the risk of a worker on the work stand 402 falling when the flip door 408 is open.

[0023]

[0033] As shown in Figures 5-6, with the safety barrier 418 in place, the flip door 408 can freely rotate between a closed position, as shown in Figure 5, and an open position, as shown in Figure 6. Although the flip door 408 is shown in an open position with the end 610 of the flip door 408 above the upper surface 422 of the work stand 402, other embodiments may allow the flip door 408 to open in the opposite direction, such that the end 610 of the flip door 408 is below the lower surface 424 of the work stand 402. Thus, the open position of the flip door 408 is not limited to the particular orientation depicted in Figure 6.

[0024]

[0034] 7, the keyed portion 416 of the safety barrier 418 is locked by the interlock 410 and cannot be removed from its current position (e.g., the safety barrier 418 is prevented from moving in the direction of arrow 702). In particular, the interlock 410 engages and locks the keyed portion 416 of the safety barrier 418 in place, thereby preventing the safety barrier 418 from being removed from the work stand 402. This ensures that a worker is prevented from inadvertently falling through the flip door 408 while the flip door 408 is open and the safety barrier 418 remains in place.

[0025]

[0035] To remove the keyed portion 416 of the safety barrier 418 from the interlock 410, the flip door 408 is first closed (e.g., the flip door 408 is moved in the direction of arrow 802) as shown in FIG. 8, and the interlock 410 releases the keyed portion 416 of the safety barrier 418, thereby allowing the safety barrier 418 to be removed from its position adjacent to the flip door 408 as shown in FIG. 9 (e.g., the safety barrier 418 can be moved in the direction of arrow 702 as shown in FIG. 9). With the safety barrier 418 removed and the flip door 408 closed, the previously inaccessible defined area 504 that was blocked by the safety barrier 418 is now accessible by a worker working on the work stand 402. For example, when the safety barrier 418 is removed, the worker can move freely across both the top surface 422 of the work stand 402 and the top surface 420 of the flip door 408. In general, the safety barrier 418 may have any shape desired to prevent a worker on the work stand 402 from falling through the open portion 612 created when the flip door 408 is opened (see FIG. 6 ). Thus, the safety barrier 418 may have a complex shape depending on where the flip door 408 is positioned on the work stand 402. If the flip door 408 is closer to the end 403 of the work stand 402, the safety barrier 418 may be a simple planar gate that isolates the worker on the work stand 402 from the defined area 504. If the flip door 408 is more centrally positioned on the work stand 402, the safety barrier 418 may include multiple sides that create a volumetrically defined area around the flip door 408 that is inaccessible by the worker on the work stand 402 as long as the safety barrier 418 is in place.

[0026]

[0036] 10A is an isometric view of a safety barrier 418 in one exemplary embodiment. In this example, the safety barrier 418 has a bottom portion 1002 having legs 1003, each leg 1003 including a keyed portion 416, and a top portion 1004 that extends away from the interlock 410 when the keyed portions 416 are inserted into the interlock 410 of the flip door assembly 406. The particular configuration of the safety barrier 418 in FIG. 10A is shown for illustrative purposes only. In this view, leg 1003-1 includes a keyed portion 416-1 adjacent to the bottom portion 1002 of the safety barrier 418, and leg 1003-2 includes a keyed portion 416-2 adjacent to the bottom portion 1002.

[0027]

[0037] 10B is an isometric view of a flip door assembly 406 in one exemplary embodiment. In this embodiment, the flip door 408 of the flip door assembly 406 has a particular size and shape, although the flip door 408 may have other dimensions in other embodiments. In this embodiment, the flip door assembly 406 includes two receptacles 1006 that include openings 1008 sized to receive the keyed portion 416-1 and the keyed portion 416-2 (see FIG. 10A ) of the safety barrier 418. In particular, the receptacle 1006-1 includes an opening 1008-1 and the receptacle 1006-2 includes an opening 1008-2.

[0028]

[0038] 10B also shows that flip door 408 is rotatably attached to member 1010 using rotating member 412-1 and rotating member 412-2. In this embodiment, rotating member 412-1 and rotating member 412-2 are shown as hinges. Rotating member 412-1 is adjacent to socket 1006-1 and rotating member 412-2 is adjacent to socket 1006-2.

[0029]

[0039] In some embodiments, member 1010 may be part of work stand 402 proximate end 403 , while in other embodiments member 1010 is attached to work stand 402 at end 403 .

[0030]

[0040] In this embodiment of the flip door assembly 406, two receptacles 1006 and openings 1008 are shown, although other embodiments may include additional receptacles and openings as a matter of design choice based on the design of the safety barrier 418. In some embodiments, each receptacle 1006 may include its own interlock 410, while in other embodiments, a subset of the total number of receptacles 1006 may include interlocks 410. In the embodiment shown in FIG. 10B, receptacle 1006-1 includes an interlock 410 (not shown), while receptacle 1006-2 does not include an interlock 410. However, which of the receptacles 1006 include their own interlocks 410 is a matter of design choice.

[0031]

[0041] In this embodiment, the opening 1008 is sized to allow the keyed portion 416-1 and keyed portion 416-2 of the safety barrier 418 to engage with the receptacle 1006. In particular, the keyed portion 416-1 of the safety barrier 418 engages with the receptacle 1006-1 and the keyed portion 416-2 of the safety barrier 418-2 engages with the receptacle 1006-2. FIG. 10C is an isometric view of the safety barrier 418 of FIG. 10A engaged with the receptacle 1006 of the flip door assembly 406 depicted in FIG. 10B in one exemplary embodiment. As shown in FIG. 10C, when the safety barrier 418 engages with the flip door assembly 406, the legs 1003 protrude away from the member 1010 such that the safety barrier 418 blocks access to the flip door 408 from a worker entering from the left of FIG. 10C.

[0032]

[0042] 11-14 are isometric views of a portion of the flip door assembly 406 along section line 11-11 of FIG. 10C in an exemplary embodiment. In particular, FIGS. 11-14 do not include member 1010, which has been removed to allow for easier observation of the interlock 410.

[0033]

[0043] In the embodiment shown in Figures 11-14, the interlock 410 includes a first member 1102 adjacent the receptacle 1006-1, a second member 1104 adjacent the first member 1102, a third member 1106 secured to the flip door 408, and a fourth member 1108 connecting the second member 1104 and the third member 1106 together. The first member 1102 in this figure includes a cutout 1110 in an outer edge 1120 of the first member 1102 adjacent the receptacle 1006-1. The cutout 1110 engages with a keyed portion 416-1 of the leg 1003-1 of the safety barrier 418. In Figure 11, the keyed portion 416-1 is not engaged with the receptacle 1006-1. When the keyed portion 416-1 is not engaged with the receptacle 1006-1 (e.g., the keyed portion 416-1 is not inserted into the opening 1008-1 of the receptacle 1006-1), the flip door 408 is prevented from being opened in the direction of arrow 1116 by selective interference between the first member 1102 and the second member 1104. In particular, when attempting to open the flip door 408, the fourth member 1108 may translate rotation of the third member 1106 into rotation of the second member 1104, but the second member 1104 is prevented from rotating when the outer edge 1120 of the first member 1102 is disposed within the notch 1114 in the outer edge 1122 of the second member 1104. In FIG. 11, the first member 1102 selectively interferes with the rotation of the second member 1104. The first member 1102 may be spring biased to the position shown in FIG. 11, which may be referred to as being in a first position in some embodiments. When the flip door 408 is closed, as shown in FIG. 11, the second member 1104 may also be considered to be in a first position. Thus, the configuration depicted in FIG. 11 represents the first position for both the first member 1102 and the second member 1104. In this configuration, the first member 1102 prevents the second member 1104 from rotating in the direction of arrow 1118, which prevents the flip door 408 from being opened in the direction of arrow 1116.

[0034]

[0044] In Fig. 12, the keyed portion 416-1 has been inserted into the opening 1008 of the receptacle 1006-1 in the direction of arrow 1202. The insertion causes the first member 1102 to be rotated in the direction of arrow 1204 as the notch 1110 of the first member 1102 engages the keyed portion 416-1 of the leg 1003-1 of the safety barrier 418. When the first member 1102 is rotated to the position shown in Fig. 12, the first member 1102 may be referred to as being in a second position. Thus, Fig. 11 depicts the first member 1102 when in the first position, while Fig. 12 depicts the first member 1102 in the second position. The difference between the first and second positions for the first member 1102 is whether the keyed portion 416-1 of the safety barrier 418 engages with the notch 1110 of the first member 1102. For example, when the leg 1003-1 of the safety member 418 is moved in the direction of arrow 1206, the keyed portion 416-1 engages with the notch 1110 of the first member 1102 while rotating the first member 1102 in the direction of arrow 1208, thereby moving the outer edge 1120 of the first member 1102 into the notch 1114 of the second member 1104.

[0035]

[0045] When the first member 1102 is in the second position shown in FIG. 12, the second member 1104 can freely rotate in the direction of the arrows 1118 and 1119 as shown in FIG. 12. At this time, the outer edge 1122 of the second member 1104 rotates into the notch 1112 of the first member 1102 depending on whether the flip door 408 is moved in the direction of the arrow 1116 to be opened or moved in the direction of the arrow 1210 to be closed. Thus, the first member 1102 no longer selectively interferes with the second member 1104. As shown in FIG. 13, when the flip door 408 is opened, the third member 1106 uses the fourth member 1108 to pivot the second member 1104 in the direction of the arrow 1118. In FIG. 13, the second member 1104 can be considered to be in the second position. Thus, Figure 12 depicts the second member 1104 in a first position, while Figure 13 depicts the second member 1104 in a second position. As the flip door 408 moves from the open position depicted in Figure 13 to the closed position depicted in Figure 12, the second member 1104 rotates in the direction of arrow 1119.

[0036]

[0046] When the first member 1102 and the second member 1104 are both in the second position shown in FIG. 14, the keyed portion 416-1 of the leg 1003-1 of the safety barrier 418 cannot be removed from the opening 1008-1 of the receptacle 1006-1 because the first member 1102 and the second member 1104 interfere with each other when the notch 1110 of the first member 1102 engages the keyed portion 416-1 and the leg 1003-1 of the safety barrier 418 is moved in the direction of the arrow 1206. In particular, the notch 1112 of the first member 1102 engages the outer edge 1122 of the second member 1104 and cannot rotate in the direction of the arrow 1208. This prevents the keyed portion 416-1 of the safety barrier 418 from being removed from the interlock 410 when the flip door 408 is open. As depicted in Figure 12, closing the flip door 408 allows the keyed portion 416-1 of the safety barrier 418 to be removed from the receptacle 1006-1 (e.g., the keyed portion 416-1 of the leg 1003-1 of the safety barrier 418 is removed from the opening 1008-1 of the receptacle 1006-1 when the leg 1003-1 of the safety barrier 418 is moved in the direction of arrow 1206).

[0037]

[0047] 11-14 depict a particular size, orientation, and relationship between the first member 1102, the second member 1104, the third member 1106, and the fourth member 1108 of the interlock 410, but the interlock 410 is not limited to this particular size, orientation, and component relationship. One skilled in the art will recognize that the functionality described herein for the interlock 410 may be implemented in a variety of different ways.

[0038]

[0048] FIG 15 is a flow chart of a method 1500 of operating a flip door assembly in an exemplary embodiment, and FIGS. 16-17 depict further details of the method 1500 in an exemplary embodiment. Although the method 1500 is described with respect to the flip door assembly 406 of FIGS. 4-14, the method 1500 may be performed by other systems not shown. The method 1500 may include other steps not shown. Additionally, the steps of the method 1500 may be performed in an alternative order.

[0039]

[0049] Step 1502 (see FIG. 15) includes providing a work stand 402 including a flip door 408 and an interlock 410. The interlock 410 controls the opening and closing of the flip door 408 based on whether the keyed portion 416 of the safety barrier 418 is engaged or disengaged with the interlock 410 (see FIG. 4). Step 1504 includes preventing the flip door 408 from being opened in response to the keyed portion 416 of the safety barrier 418 not engaging with the interlock 410 (see FIG. 4, the flip door 408 is prevented from being opened in the direction of the arrow 414). With reference to FIG. 11, for example, when the keyed portion 416-1 is disengaged with the interlock 410, the first member 1102 and the second member 1104 are both in a first position. When both are in the first position, the notch 1114 in the second member 1104 and the outer edge 1120 of the first member 1102 prevent the second member 1104 from rotating in the direction of arrow 1118, thereby preventing the flip door 408 from being opened.

[0040]

[0050] Step 1506 includes engaging the keyed portion 416 of the safety barrier 418 with the interlock 410 (see FIG. 5) to prevent access by the worker to the defined area 504. With reference to FIG. 12, for example, when the keyed portion 416-1 engages the notch 1110 of the first member 1102, the first member 1102 rotates in the direction of arrow 1204 to remove interference previously created between the notch 1114 of the second member 1104 and the outer edge 1120 of the first member 1102.

[0041]

[0051] Step 1508 includes opening the flip door 408, as shown in Figure 6. When the keyed portion 416 of the safety barrier 418 is engaged with the interlock 410, the flip door 408 is free to open in the direction of arrow 414. With reference to Figure 13, for example, opening the flip door 408 pivots the third member 1106, which uses the fourth member 1108 to rotate the second member 1104 in the direction of arrow 1118. The outer edge 1122 of the second member 1104 is free to rotate into the notch 1112 of the first member 1102.

[0042]

[0052] Step 1602 includes preventing the keyed portion 416 of the safety barrier 418 from disengaging from the interlock 410 in response to the flip door 408 being open. With reference to FIG. 7, FIG. 7 illustrates that the safety barrier 418 cannot be moved in the direction of arrow 702 while the flip door 408 is open. With reference to FIG. 14, for example, if an attempt is made to remove the safety barrier 418 from the flip door assembly 406 when the flip door 408 is open, the keyed portion 416-1 of the leg 1003-1 will attempt to rotate the first member 1102 in the direction of arrow 1208, but is prevented by interference between the first member 1102 and the second member 1104. In particular, the notch 1112 of the first member 1102 engages the outer edge 1122 of the second member 1104, preventing the first member 1102 from rotating in the direction of arrow 1208. This ensures that the leg 1003-1 of the safety barrier 418 cannot be removed from the interlock 410 when the flip door 408 is open.

[0043]

[0053] Step 1702 includes closing the flip door 408 as depicted in FIG. 8. The flip door 408 is able to move in the direction of arrow 802 to the closed position shown in FIG. 8 because the keyed portion 416 of the safety barrier 418 remains engaged with the interlock 410. Referring to FIG. 12, for example, closing the flip door 408 in the direction of arrow 1210 causes the third member 1106 to pivot, which is translated by the fourth member 1108 into a rotation of the second member 1104 in the direction of arrow 1119. When the second member 1104 rotates in the direction of arrow 1119, the interference between the notch 1112 of the first member 1102 and the outer edge 1122 of the second member 1104 is removed. Step 1704 includes removing the keyed portion 416 of the safety barrier 418 from the interlock 410 to allow the worker access to the defined area 504. FIG. 9 depicts the safety barrier 418 moved in the direction of arrow 702 to disengage the keyed portion 416 from the interlock 410 when the flip door 408 is closed. With reference to FIG. 12, for example, the leg 1003-1 of the safety barrier 418 is moved in the direction of arrow 1206, which rotates the first member 1102 in the direction of arrow 1208. The outer edge 1120 of the first member 1102 thereby pivots into the notch 1114 of the second member 1104 to the orientation depicted in FIG. 11. That orientation prevents the flip door 408 from being opened.

[0044]

[0054] 18 is a block diagram of a manufacturing environment 400 in an example embodiment. In this embodiment, the environment 400 includes a worker safety system 401 and a fuselage 104 of an aircraft 1802. The worker safety system 401 includes a work stand 402 including a flip door 408 and an interlock 410 for the flip door 408. The worker safety system 401 further includes a safety barrier 418 having a keyed portion 416 that prevents access to a defined area 504 of the worker safety system 401 when the keyed portion 416 engages the interlock 410. The interlock 410 allows the flip door 408 to move to an open position 1804 when the keyed portion 416 engages the interlock 410 and prevents the flip door 408 from moving to the open position 1804 when the keyed portion 416 does not engage the interlock 410.

[0045]

[0055] In some embodiments, the flip door 408 is proximate the end 403 of the work stand 402. When the flip door 408 is in the open position 1804 and the keyed portion 416 is engaged with the interlock 410, the interlock 410 prevents the keyed portion 416 of the safety barrier 418 from disengaging from the interlock 410.

[0046]

[0056] In some embodiments, the end 403 of the work stand 402 is proximate to the fuselage 104. In particular, the end 403 may be proximate to the portion 114 of the fuselage 104.

[0047]

[0057] In some embodiments, the interlock 410 includes a receptacle 1006 that selectively engages a keyed portion 416 of a safety barrier 418 and a first member 1102. The first member 1102 is proximate to the receptacle 1006 and oriented to a first position 1808 when the keyed portion 416 of the safety barrier 418 is not engaged with the receptacle 1006 and is oriented to a second position 1810 when the keyed portion 416 is engaged with the receptacle 1006. In this embodiment, the interlock 410 includes a second member 1104 proximate to the first member 1102. The second member 1104 is oriented to a first position 1812 when the flip door 408 is in the closed position 1806 and is oriented to a second position 1814 when the flip door 408 is in the open position 1804.

[0048]

[0058] In this embodiment, selective interference between the first member 1102 and the second member 1104 allows the second member 1104 to transition between the first position 1812 and the second position 1814 when the first member 1102 is oriented in the second position 1810 and prevents the second member 1104 from moving between the first position 1812 and the second position 1814 when the first member 1102 is oriented in the first position 1808.

[0049]

[0059] In one embodiment, the interlock 410 further includes a third member 1106 attached to the flip door 408 and a fourth member 1108 coupling the third member 1106 to the second member 1104. The fourth member 1108 transitions the second member 1104 from a first position 1812 to a second position 1814 when the flip door 408 moves from the closed position 1806 to the open position 1804 and transitions the second member 1104 from the second position 1814 to the first position 1812 when the flip door 408 moves from the open position 1804 to the closed position 1806.

[0050]

[0060] In one embodiment, selective interference between the first member 1102 and the second member 1104 prevents the keyed portion 416 of the safety barrier 418 from being removed from the receptacle 1006 when the second member 1104 is oriented in the second position 1814.

[0051]

[0061] In one embodiment, the first member 1102 includes a notch 1110 adjacent the receptacle 1006. The notch 1110 engages with a keyed portion 416 of the safety barrier 418 to move the first member 1102 between the first position 1808 and the second position 1810.

[0052]

[0062] In some embodiments, when the flip door 408 is in the open position 1804, it is possible to access a portion 114 of the fuselage 104 of the aircraft 1802 that was obscured by the flip door 408 when the flip door 408 was in the closed position 1806.

[0053]

[0063] In one embodiment, the interlock 410 and the flip door 408 may be collectively referred to as the flip door assembly 406 .

[0054]

[0064] An embodiment of the disclosure may be described in the context of an aircraft manufacturing and service method 1900 as shown in FIG. 19 and an aircraft 2000 as shown in FIG. 20. During the pre-production stage, the example method 1900 may include specification and design 1902 of the aircraft 2000 and procurement of materials 1904. During the production stage, manufacturing 1906 of components and subassemblies of the aircraft 2000 and system integration 1908 takes place. The aircraft 2000 may then go through certification and delivery 1910 and be placed into service 1912. While operated by a customer, the aircraft 2000 is scheduled for routine maintenance and service 1914, which may include modification, reconfiguration, refurbishment, etc.

[0055]

[0065] Each of the steps of method 1900 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and subcontractors of major systems, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0056]

[0066] 20 , an aircraft 2000 produced by exemplary method 1900 may include an airframe 2002 having a number of systems 2004 and an interior 2006. Examples of high level systems 2004 include one or more of a propulsion system 2008, an electrical system 2010, a hydraulic system 2012, and an environmental system 2014. Any number of other systems may also be included. Although an aerospace example is provided, the principles described herein may be applied to other industries, such as the automotive industry.

[0057]

[0067] Apparatus and methods embodied herein may be employed during any one or more stages of manufacturing and service method 1900. For example, components or subassemblies corresponding to step 1906 may be fabricated or manufactured in a manner similar to components or subassemblies manufactured while aircraft 2000 is in service. Also, one or more apparatus embodiments, method embodiments, or combinations thereof may be utilized during component and subassembly manufacturing 1906 and system integration 1908 stages, for example, by substantially streamlining the assembly of aircraft 2000 or reducing the cost of aircraft 2000. Similarly, one or more of apparatus embodiments, method embodiments, or combinations thereof may be utilized during aircraft 2000 service, for example, but not limited to, maintenance and service 1914.

[0058]

[0068] Any of the various elements shown in the figures or described herein may be implemented as hardware, software, firmware, or any combination thereof. For example, certain elements may be implemented as dedicated hardware. Dedicated hardware elements may be referred to as "processors," "controllers," or some similar terminology. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Furthermore, explicit use of the terms "processor" or "controller" should not be construed as referring solely to hardware capable of executing software, but may implicitly include, without limitation, digital signal processor (DSP) hardware, network processors, application specific integrated circuits (ASICs) or other circuits, field programmable gate arrays (FPGAs), read only memory (ROM) for storing software, random access memory (RAM), non-volatile storage, logic units, or any other physical hardware component or module.

[0059] Furthermore, an element may be implemented as instructions executable by a processor or computer to perform the functions of the element. Some examples of instructions are software, program code, and firmware. The instructions, when executed by a processor, are operable to instruct the processor to perform the functions of the element. The instructions may be stored in a storage device readable by the processor. Some examples of storage devices are digital or solid state memory, magnetic storage media such as magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media.

[0060] Article 1. 1. A worker safety system comprising: a work stand; a safety barrier having a lockable portion; and a flip door assembly configured to selectively engage the lockable portion of the safety barrier to prevent access to a defined area by a worker, the flip door assembly comprising a flip door having a top surface that is substantially flush with a top surface of the work stand when the flip door is closed and that is not substantially flush with a top surface of the work stand when the flip door is open; and an interlock configured to prevent the flip door from being opened when the lockable portion of the safety barrier is not engaged with the interlock and to allow the flip door to be opened when the lockable portion of the safety barrier is engaged with the interlock.

[0061] Article 2. 2. A worker safety system as described in clause 1, wherein the defined area is adjacent to an end of the work stand.

[0062] Article 3. 2. The worker safety system of claim 1, wherein the interlock is configured to prevent the keyed portion of the safety barrier from disengaging from the interlock when the flip door is open.

[0063] Article 4. 2. The worker safety system of claim 1, wherein the interlock comprises a receptacle configured to selectively engage a keyed portion of the safety barrier, a first member adjacent to the receptacle and configured to be in a first position responsive to the keyed portion of the safety barrier not engaging the receptacle and to be in a second position responsive to the keyed portion of the safety barrier engaging the receptacle, and a second member adjacent to the first member and configured to be in a first position responsive to the flip door being closed and to be in a second position responsive to the flip door being open, wherein selective interference between the first member and the second member allows the second member to transition between the first position and the second position responsive to the first member being in the second position and prevents the second member from moving between the first position and the second position responsive to the first member being in the first position.

[0064] Article 5. The worker safety system of claim 4, wherein the interlock includes a third member attached to the flip door and a fourth member coupling the third member to the second member configured to transition from a first position to a second position in response to the flip door transitioning from closed to open and to transition from the second position to the first position in response to the flip door transitioning from open to closed.

[0065] Article 6. 5. The worker safety system of claim 4, wherein selective interference between the first member and the second member prevents the keyed portion of the safety barrier from being removed from the receptacle in response to the second member being in the second position.

[0066] Article 7. 7. The worker safety system of claim 6, wherein the first member includes a notch adjacent to a receptacle that engages with a keyed portion of the safety barrier to move the first member between the first and second positions.

[0067] Article 8. 1. A method of operating a worker safety system in a manufacturing environment, comprising: providing a work stand including a flip door and an interlock that controls opening and closing of the flip door based on whether a keyed portion of the safety barrier is engaged or disengaged with the interlock; preventing the flip door from being opened in response to the keyed portion of the safety barrier not engaging with the interlock; engaging the keyed portion of the safety barrier with the interlock to prevent a worker from accessing a defined area; and opening the flip door.

[0068] Article 9. 9. The method of claim 8, further comprising: in response to the flip door being open, preventing the keyed portion of the safety barrier from disengaging from the interlock.

[0069] Article 10. 9. The method of claim 8, further comprising closing the flip door and removing the keyed portion of the safety barrier from the interlock to allow the worker access to the defined area.

[0070] Clause 11. The method according to clause 8, wherein the defined area is adjacent to an end of the work stand.

[0071] Article 12. 12. The method of claim 11, wherein the manufacturing environment includes an aircraft manufacturing environment, and opening the flip door provides access to a portion of the aircraft fuselage that was obscured by the flip door when the flip door was closed.

[0072] Article 13. 1. A worker safety system for a manufacturing environment comprising: a work stand including a flip door and an interlock for the flip door; and a safety barrier having a keyed portion that prevents access to a defined area when the keyed portion is engaged with the interlock, the interlock allowing the flip door to be opened when the keyed portion is engaged with the interlock and preventing the flip door from being opened when the keyed portion is not engaged with the interlock.

[0073] Article 14. 14. A worker safety system as described in clause 13, wherein the flip door is adjacent to an end of the work stand.

[0074] Article 15. 14. The worker safety system of claim 13, wherein the interlock prevents the keyed portion of the safety barrier from disengaging from the interlock when the flip door is open.

[0075] Article 16. 14. The worker safety system of claim 13, wherein the interlock comprises a receptacle that selectively engages the keyed portion of the safety barrier, a first member adjacent to the receptacle and oriented to a first position when the keyed portion of the safety barrier is not engaged with the receptacle and oriented to a second position when the keyed portion of the safety barrier is engaged with the receptacle, and a second member adjacent to the first member and oriented to the first position when the flip door is closed and to the second position when the flip door is open, wherein selective interference between the first member and the second member allows the second member to transition between the first position and the second position when the first member is oriented to the second position and prevents the second member from moving between the first position and the second position when the first member is oriented to the first position.

[0076] Article 17. 17. The worker safety system of claim 16, wherein the interlock includes a third member attached to the flip door and a fourth member coupling the third member to the second member that transitions from a first position to a second position when the flip door is open and from the second position to the first position when the flip door is closed.

[0077] Article 18. 17. The worker safety system of claim 16, wherein selective interference between the first member and the second member prevents the keyed portion of the safety barrier from being removed from the receptacle when the second member is oriented in the second position.

[0078] Article 19. 19. The worker safety system of claim 18, wherein the first member includes a notch adjacent the receptacle that engages with a keyed portion of the safety barrier to move the first member between the first and second positions.

[0079] Article 20. 14. The operational safety system of claim 13, wherein the manufacturing environment includes an aircraft manufacturing environment, and opening the flip door provides access to a portion of the aircraft fuselage that was obscured by the flip door when the flip door was closed.

[0080]

[0069] Although specific embodiments have been described herein, the scope of the disclosure is not limited to these specific embodiments. Rather, the scope of the disclosure is defined by the following claims and any equivalents thereof.

Claims

1. A work stand, a safety barrier having a keyed portion, and a flip door assembly of the work stand configured to selectively engage the keyed portion of the safety barrier to prevent an operator from accessing a defined area, the flip door assembly comprising a flip door rotatably coupled to the work stand via at least one rotating member, the flip door configured to pivot via the at least one rotating member between a closed position where an upper surface of the flip door is substantially in the same plane as an upper surface of the work stand and an open position where the upper surface of the flip door forms an angle with the upper surface of the work stand, and an interlock configured to prevent the flip door from pivoting to the open position when the keyed portion of the safety barrier is not engaged with the interlock and to enable the flip door to pivot to the open position when the keyed portion of the safety barrier is engaged with the interlock, an operator safety system.

2. The operator safety system according to claim 1, wherein the defined area is proximate an end of the work stand.

3. The operator safety system according to claim 1, wherein the interlock is configured to prevent the keyed portion of the safety barrier from being disengaged from the interlock when the flip door is in the open position.

4. The interlock comprises a receptacle configured to selectively engage the keyed portion of the safety barrier, a first member proximate the receptacle and configured to be in a first position in response to the keyed portion of the safety barrier not being engaged with the receptacle and to be in a second position in response to the keyed portion of the safety barrier being engaged with the receptacle, and a second member proximate the first member and configured to be in the first position in response to the flip door being closed and to be in the second position in response to the flip door being open. The selective interference between the first member and the second member enables the second member to shift between the first position and the second position in response to the first member being in the second position, and prevents the second member from moving between the first position and the second position in response to the first member being in the first position, the operator safety system according to claim 1.

5. The interlock is a third member attached to the flip door, and a fourth member that couples the third member to the second member configured to shift from the first position to the second position in response to the flip door shifting from closed to open and to shift from the second position to the first position in response to the flip door shifting from open to closed, the operator safety system according to claim 4.

6. The selective interference between the first member and the second member prevents the keyed portion of the safety barrier from being removed from the receptacle in response to the second member being in the second position, the operator safety system according to claim 4.

7. The first member includes a notch proximate to the receptacle that engages the keyed portion of the safety barrier to move the first member between the first position and the second position, the operator safety system according to claim 6.

8. A method of operating an operator safety system in a manufacturing environment, comprising providing a work stand including a flip door assembly configured to selectively engage a keyed portion of a safety barrier to prevent an operator from accessing a defined area, the flip door assembly including a flip door rotatably attached to the work stand via at least one rotating member, the flip door configured to pivot via the at least one rotating member between a closed position where an upper surface of the flip door is substantially coplanar with an upper surface of the work stand and an open position where the upper surface of the flip door forms an angle with the upper surface of the work stand, and An interlock that prevents the flip door from pivoting to the open position when the keyed portion of the safety barrier is not engaged with the interlock, and enables the flip door to pivot to the open position when the keyed portion of the safety barrier is engaged with the interlock, and provides a work stand equipped with the interlock. Preventing the flip door from opening to the open position in response to the keyed portion of the safety barrier not being engaged with the interlock. Engaging the keyed portion of the safety barrier with the interlock, and A method including opening the flip door to the open position by the keyed portion of the safety barrier being engaged with the interlock.

9. The method according to claim 8, further including preventing the keyed portion of the safety barrier from being disengaged from the interlock when the flip door is in the open position.

10. Moving the flip door to the closed position, and The method according to claim 8, further including removing the keyed portion of the safety barrier from the interlock.

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