Systems and methods for manufacturing aircraft

Abstract

To provide systems and methods for manufacturing an aircraft.SOLUTION: An aircraft manufacturing system comprises: a first manufacturing zone configured to repetitively manufacture first aircraft subassemblies; a second manufacturing zone configured to repetitively manufacture second aircraft subassemblies; and a third manufacturing zone configured to receive the first aircraft subassemblies from the first manufacturing zone, to receive the second aircraft subassemblies from the second manufacturing zone, and to repetitively assemble the first aircraft subassemblies and the second aircraft subassemblies into an aircraft. In another example, a method for repetitively manufacturing aircraft assemblies comprises the steps of: assembling first aircraft subassemblies and second aircraft subassemblies in parallel on separate assembly lines at a common geographic region; and transferring the first aircraft subassemblies and the second aircraft subassemblies to a final assembly facility located in the same common geographic region.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to systems and methods for manufacturing aircraft. [Background technology]

[0002] Aircraft, particularly commercial aircraft, are large and complex, making them difficult, if not impossible, to manufacture on traditional assembly lines. Instead, many of the aircraft's large structures (e.g., wings, fuselage sections, tail sections, etc.) are manufactured as subassemblies at different locations and then transported to a central final assembly location. In fact, many such structures may be manufactured by various third-party suppliers at locations geographically distant from one another (e.g., different cities, countries, and / or continents) and then shipped to the aircraft manufacturer's final assembly facility for processing and final assembly. Such a production approach is time-inefficient and resource-inefficient. Therefore, more efficient production techniques that produce aircraft faster (i.e., at higher production rates) and / or at lower costs are desirable. Summary of the Invention [Means for solving the problem]

[0003] Systems and methods for manufacturing aircraft are disclosed. For example, an aircraft manufacturing system for repeatedly manufacturing aircraft includes a first manufacturing zone configured to repeatedly manufacture a first aircraft subassembly, a second manufacturing zone configured to repeatedly manufacture a second aircraft subassembly, and a third manufacturing zone configured to receive the first aircraft subassembly from the first manufacturing zone, receive the second aircraft subassembly from the second manufacturing zone, and repeatedly assemble the first aircraft subassembly and the second aircraft subassembly into an aircraft. In some examples, the first manufacturing zone, the second manufacturing zone, and the third manufacturing zone are located within the same geographic region. In some examples, one or more of the manufacturing zones include a fractional pulse assembly line configured to fractionally pulse the aircraft subassembly for less than a length of the manufacturing zone.

[0004] In another example, a method for repeatedly manufacturing aircraft assemblies includes assembling a first aircraft subassembly and a second aircraft subassembly in parallel on separate assembly lines in a common geographic area and transferring the first aircraft subassembly and the second aircraft subassembly to a final assembly facility located within the same common geographic area. In some examples, the first aircraft subassembly is a wing of an aircraft and the second aircraft subassembly is a portion of a fuselage of the aircraft. In some examples, the method optionally includes sending different subassemblies and / or components of these subassemblies down the same assembly line. Additionally or alternatively, the method optionally includes pulsing one or both of the first aircraft subassembly and constituent parts of the first aircraft subassembly piecemeal down the first assembly line and / or pulsing one or both of the second aircraft subassembly and constituent parts of the second aircraft subassembly piecemeal down the second assembly line. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 is a schematic diagram of an aircraft manufacturing system according to the present disclosure. [Figure 2] 1 is a time lapse schematic diagram comparing a prior art assembly line with a fractional pulse assembly line according to the present disclosure; [Figure 3] FIG. 2 is a time-lapse schematic diagram of an example fractional pulse assembly line of the aircraft manufacturing system of FIG. [Figure 4] 1 is a flow chart that schematically illustrates a method for manufacturing aircraft in a geographic region in accordance with the present disclosure. [Figure 5] 1 is a flow chart that generally illustrates a method of operating a fractional pulse assembly line in accordance with the present disclosure. [Figure 6] 1 is a flow chart that schematically illustrates a method for forming a fractional pulse assembly line in accordance with the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0006] Systems and methods for manufacturing aircraft are disclosed. In general, the above figures show elements that may be included in a given example with solid lines and elements that are optional for a given example with dashed lines. Block arrows indicate example movement of elements in space. However, elements shown with solid lines are not essential to all examples of the present disclosure, and elements shown with solid lines may be excluded from particular examples without departing from the scope of the present disclosure.

[0007] Traditionally, aircraft, particularly commercial aircraft, are manufactured by separately building large aircraft structures (e.g., wings, tails, fuselage sections, etc.) as separate subassemblies, often in different geographic locations (e.g., different cities, countries, and / or continents). These large structures are then transferred to a central facility (also referred to herein as a final assembly facility), where they are processed and assembled to form the aircraft. The present disclosure, on the other hand, provides systems and methods for manufacturing at least some of these large structures in one geographic area (e.g., an area proximate to, adjacent to, and / or within the central facility) to reduce production inefficiencies and / or costs. In particular, manufacturing at least some of the large structures within the same geographic area as the central facility can reduce and / or eliminate shipping time and costs. Furthermore, in some examples, the large structures of the present disclosure are manufactured in parallel and / or produced at approximately the same rate in a common geographic area to avoid final assembly delays.

[0008] In conventional approaches, large structures may be manufactured by multiple third-party suppliers in various remote geographic regions, making it difficult to synchronize the arrival times of all large structures at a final assembly facility. Furthermore, large structures may be unpredictably delayed for a variety of reasons, including supplier manufacturing delays, shipping delays, severe weather, etc. Because large structures may be manufactured by multiple third-party suppliers in many different locations around the world, the likelihood that at least one of the large structures will be delayed is relatively high. Thus, final assembly of an aircraft may be postponed and may not begin until all required large structures have arrived. By manufacturing large structures in parallel and / or at approximately the same rate within the same geographic region, the present disclosure reduces and / or completely eliminates final assembly delays. That is, the disclosed systems and methods can synchronize the arrival of large structures at a final assembly facility, thereby enabling faster and more consistent final assembly of aircraft. Stated slightly differently, because the large structures can arrive just-in-time (almost simultaneously) at the final assembly facility, the final assembly facility may not have to wait until all of the large structures have arrived and can begin final assembly sooner and / or more frequently than with traditional aircraft manufacturing methods.

[0009] Additionally or alternatively, the actual manufacturing process of the present disclosure may be more efficient and / or faster than traditional manufacturing approaches that utilize third-party suppliers. In some examples of the present disclosure, aircraft components are pulsed down an assembly line in a piecemeal fashion, allowing multiple workstations to simultaneously access different portions of the component. This configuration allows various workstations to simultaneously perform work operations (e.g., different work operations) on different areas of a given component. In this manner, work operations (e.g., different work operations) may be performed in parallel with one another, rather than sequentially. Such parallel processing can increase production speeds and reduce the time required to perform work on a component. In particular, increasing the workstation density on an assembly line allows more work to be performed on a component at any one time, thereby making the manufacturing process more efficient. Increasing the workstation packing density can also reduce the overall footprint (area) of a manufacturing system. That is, by dividing work operations into smaller work operations, more modular units, workstations, work-performing devices (e.g., machines, robots, tools, etc.), and aircraft components can be packed more closely together, reducing the overall size of the manufacturing system.

[0010] Dividing components into multiple work areas also reduces the effective work area, reducing the amount of tool, robot, machine, and / or human movement required to complete a work operation, thus reducing production inefficiencies. Thus, workers, tools, machines, and / or robots may not need to travel as far to complete a work operation (the work operation can be completed using a smaller range of motion). Furthermore, because work areas can be made smaller, the tools and / or machines used by workers (also referred to herein as manufacturing personnel) in these work areas can be made smaller and / or lighter, thereby increasing worker safety.

[0011] In addition to not having to travel as far to complete a work step, tools, robots, machines, etc. may not need to complete as many work steps. For example, each tool, robot, and / or machine may only be responsible for completing one work step. Thus, by dividing components into multiple work areas and / or pulsing components piecemeal, the size, complexity, and cost of tools, robots, machines, and / or other work-performing devices may be reduced. Stated slightly differently, the present disclosure provides work-performing devices that are smaller, simpler, and less expensive than traditional aircraft manufacturing approaches.

[0012] Pulsing components in pieces can discourage worker lethargy and promote worker productivity because components move down the assembly line more frequently and / or regularly than on a traditional pulsed assembly line. Stated slightly differently, workers may experience less idle time and therefore be less likely to become bored and / or apathetic. Furthermore, pulsing a piece line more frequently may increase worker accountability because unfinished / incomplete work may be more visible to other workers and supervisors. In particular, incomplete work may stall the line (i.e., interrupt / pause normal line movement), which may be more noticeable / apparent on a more frequently pulsating piece pulse line, thereby ensuring that workers are held accountable for their work.

[0013] FIGS. 1-6 illustrate systems and methods for manufacturing aircraft according to the present disclosure. FIGS. 1-3 provide examples of an aircraft manufacturing system 10 and / or components or portions thereof according to the present disclosure. In particular, FIG. 1 schematically illustrates an example aircraft manufacturing system 10, and FIGS. 2 and 3 illustrate an example fractional pulse assembly line 126 that may be included in the aircraft manufacturing system 10. Where appropriate, reference numerals from the schematic diagram of FIG. 1 are used to indicate corresponding parts of the example of FIGS. 2 and 3, but the example of FIGS. 2 and 3 is non-exclusive and does not limit the fractional pulse assembly line 126 to the illustrated embodiment of FIGS. 2 and 3. That is, the aircraft manufacturing system 10 is not limited to the particular embodiment of FIGS. 2 and 3, and the fractional pulse assembly line 126 may incorporate any number of the various aspects, configurations, characteristics, properties, etc. of the fractional pulse assembly line shown in and discussed with reference to the embodiments of FIGS. 1 and / or 2 and 3, and variations of these embodiments, but need not include all such aspects, configurations, characteristics, properties, etc. For purposes of brevity, each of the aforementioned components, parts, portions, aspects, regions, etc., or variations thereof, may not be discussed again, illustrated, and / or labeled with respect to the examples of Figures 2 and 3, but it is within the scope of this disclosure that the aforementioned aspects, variations, etc. may be utilized in the examples of Figures 2 and 3.

[0014] 4-6 show flow charts that generally represent methods 500, 600, and 700. Specifically, FIG. 4 shows a method 500 of manufacturing an aircraft in accordance with the present disclosure, FIG. 5 shows a method 600 of operating a fractional pulse assembly line in accordance with the present disclosure, and FIG. 6 shows a method 700 of forming a fractional pulse assembly line in accordance with the present disclosure.

[0015] As shown schematically in FIG. 1 , aircraft manufacturing system 10 is configured to produce aircraft 300. Aircraft 300 typically includes at least a fuselage 302, wings 320, engine(s) 330, and a tail section 318. Fuselage 302 may include any number of separate sections. In some examples, fuselage 302 includes (e.g., may be divided into) a forward fuselage section 304 disposed forward of wings 320, a mid-fuselage section 310 (also referred to as a wing-fuselage section 310 and / or a mid-main cabin section 310) disposed aft of forward fuselage section 304 (e.g., where wings 320 connect to the fuselage), and an aft fuselage section 312 disposed aft of mid-fuselage section 310.

[0016] In some other such examples, forward fuselage section 304 includes a nose portion 306 (also referred to as cockpit portion 306) disposed at the front of the aircraft and a forward main cabin portion 308 disposed aft of the nose portion between nose portion 306 and mid-fuselage section 310. Additionally or alternatively, wing-fuselage section 310 includes a wing box and an over-wing fuselage portion. The over-wing fuselage portion may be disposed above the wing box, and together, the wing box and the over-wing fuselage portion may form a complete (e.g., substantially cylindrical) section of the fuselage. As an example, the over-wing fuselage portion may comprise a hemispherically cylindrical portion (i.e., a half-barrel) of the mid-fuselage section. Additionally or alternatively, aft fuselage section 312 includes an aft main cabin portion 314 and a tail portion 316 disposed aft of the aft main cabin portion. Thus, aft main cabin section 314 may be disposed between mid-fuselage section 310 and tail section 316. Wings 320 include port and starboard wings 322, 324 that are mirror images of each other and / or disposed on opposite sides of fuselage 302.

[0017] In some examples, engine 330 includes two engines, one coupled to each wing (as shown in the example of FIG. 1 ). In some examples, tail section 318 includes one or more aerodynamic structures / surfaces, such as a vertical stabilizer (also referred to herein as a tail fin) and / or a horizontal stabilizer. Tail section 318 may also be referred to herein as empennage 318 and / or tail assembly 318. The aforementioned components of aircraft 300 are collectively referred to herein as section assembly 340 and / or aircraft large structure 340. Thus, section assembly 340 includes various portions of fuselage 302 (e.g., tail section 316, aft main cabin section 314, mid-main cabin section 310, forward main cabin section 308, and nose section 306), wings, tail, and engines.

[0018] Aircraft manufacturing system 10 includes manufacturing zones 12 configured to produce components of aircraft 300 (e.g., section assemblies, subassemblies, larger structures, components, subcomponents, base parts, subassemblies, and / or other parts of aircraft 300), and / or the entire aircraft itself. In some examples, first manufacturing zone 20, second manufacturing zone 40, and fourth manufacturing zone 80, when included, are configured to produce aircraft subassemblies, which are then assembled in third manufacturing zone 60 to produce aircraft assembly 78. In particular, first manufacturing zone 20, second manufacturing zone 40, and fourth manufacturing zone 80, when included, are configured to produce first aircraft subassembly 38, second aircraft subassembly 58, and third aircraft subassembly 98, respectively, which are assembled together in third manufacturing zone 60 to produce aircraft assembly 78. Accordingly, in the description herein, "subassembly" is used to describe components that are assembled together to produce aircraft assembly 78. In some examples, one or more of the aircraft subassemblies (e.g., first aircraft subassembly 38, second aircraft subassembly 58, third aircraft subassembly 98, etc.) include and / or are the same as one or more of the larger aircraft structures, as discussed above. Thus, in some such examples, one or more of first manufacturing zone 20, second manufacturing zone 40, and fourth manufacturing zone 80 are configured to produce section assembly 340, and / or third manufacturing zone 60 is configured to produce aircraft 300. However, in other examples, none of the aircraft subassemblies include a large aircraft structure.

[0019] "Constituent part" is used generally herein to refer to any and all parts of aircraft 300. "Component" is used herein to refer to a primary component of a given aircraft structure, and "sub-component" is used herein to refer to a secondary component (i.e., a component of a component) of a given aircraft structure. As an example, first aircraft subassembly 38 and / or second aircraft subassembly 58 are components of aircraft assembly 78, and these subassemblies include their own individual components that are subcomponents of aircraft assembly 78. Thus, "component" and "sub-component" are relative terms used to refer to the relationship of a given component to one or more larger structures in which it is included. Meanwhile, "component" is used herein to collectively refer to any and all parts of a structure (e.g., any and all parts of aircraft assembly 78), regardless of the order of subcomponents and components that separate the component from the structure.

[0020] The manufacturing zones 12 are distinguishable by their output (e.g., section assemblies, aircraft subassemblies, components, parts, etc.) manufactured, assembled, and / or otherwise produced by the manufacturing zone and / or the processes performed within the manufacturing zone. That is, the manufacturing zones are each configured to produce different outputs. For example, the first manufacturing zone 20 is configured to manufacture, assemble, produce, and / or otherwise output a first aircraft subassembly 38, the second manufacturing zone 40 is configured to manufacture, assemble, produce, and / or otherwise output a second aircraft subassembly 58 that is different from the first aircraft subassembly 38, and the third manufacturing zone 60 is configured to manufacture, assemble, produce, and / or otherwise output an aircraft assembly 78. The third manufacturing zone 60 is also configured to receive the first aircraft subassembly from the first manufacturing zone 20 and the second aircraft subassembly from the second manufacturing zone 40, and to assemble the first aircraft subassembly and the second aircraft subassembly to manufacture, assemble, produce, and / or otherwise output an aircraft assembly 78.

[0021] In some examples, the aircraft assembly 78 is an aircraft 300, and therefore the third manufacturing zone 60 is configured to produce the aircraft 300. Additionally or alternatively, the first aircraft subassembly 38 and / or the second aircraft subassembly 58 is an aircraft large structure 340 (e.g., a wing, one or more fuselage sections, a tail section, etc.), and therefore the first manufacturing zone 20 and / or the second manufacturing zone 40 are configured to produce the section assembly 340. In some such examples, the first aircraft subassembly 38 includes a wing 320 and the second aircraft subassembly 58 includes at least a portion of the fuselage 302 (e.g., at least the forward main cabin section 308 and the aft main cabin section 314), and thus the first manufacturing zone 20 is configured to produce the wing 320 and the second manufacturing zone 40 is configured to produce at least a portion of the fuselage 302, including one or more of the forward main cabin section 308, the aft main cabin section 314, the nose section 306, and / or the tail section 316. In some such examples, the second manufacturing zone 40 is configured to produce the forward main cabin section 308 and the aft main cabin section 314.

[0022] If the first manufacturing zone 20 is configured to produce a wing 320, the first manufacturing zone may be configured to output the wing in its final and / or substantially final form. That is, the wing may require only minor cosmetic modifications (e.g., paint, detailing, coating, curing, or other surface treatments) before it is ready for flight and / or delivery to a customer. Thus, the wing may include all of the wing's component parts when it leaves the first manufacturing zone 20. If the second manufacturing zone 40 is configured to produce at least a portion of a fuselage 302, the fuselage 302 portions leaving the second manufacturing zone 40 may also be flight-ready and / or ready for final assembly to produce an aircraft 78, but may not be ready for use by a customer. As an example, the fuselage 302 portions leaving the second manufacturing zone 40 may not include interior features such as flooring, seating, lighting, and / or other customer-specific customization.

[0023] In some examples, manufacturing zone 12 includes additional manufacturing zones. As one such example, manufacturing zone 12 includes a fourth manufacturing zone 80 that is configured to produce a third aircraft subassembly 98 that is different from first aircraft subassembly 38 and second aircraft subassembly 58 and / or that is not configured to be produced by either first manufacturing zone 20 or second manufacturing zone 40. Thus, if included, fourth manufacturing zone 80 is configured to produce a subassembly that is different from first aircraft subassembly 38 and second aircraft subassembly 58, but is nevertheless configured to be supplied to third manufacturing zone 60 and assembled to form aircraft assembly 78. As one example, fourth manufacturing zone 80 is configured to produce one or more of wing-fuselage section 310 (including wing box and upper half / upper portion of wing-fuselage section), tail section 318, nose portion 306 of fuselage 302, tail portion 316 of fuselage 302, landing gear, and / or engines. However, in some instances, the engines and / or landing gear are not manufactured by the manufacturing zone 40 but are delivered to a third manufacturing zone 60 from one or more third party suppliers.

[0024] In some examples, the tail section 316 and / or nose section 306 of the fuselage 302 are output to the second manufacturing zone 40 before delivery to the third manufacturing zone 60. Additionally or alternatively, the wing-fuselage section 310 is output directly to the third manufacturing zone 60.

[0025] The manufacturing zones 12 may also be referred to herein as production zones, assembly zones, manufacturing areas, manufacturing locations, manufacturing facilities, manufacturing hangars, manufacturing wings, and / or manufacturing plants. As noted above, manufacturing zones differ in the type(s) of aircraft components, aircraft subassemblies, assemblies, and / or other aircraft parts that they are configured to manufacture and / or the types of processes that they are configured to perform.

[0026] In some examples, two or more of the manufacturing zones are physically separated (i.e., spaced apart) from one another, but not so far apart that the manufacturing zones are within different geographic regions (e.g., different cities, different counties, different states, different provinces, different administrative regions, different countries, and / or different continents). As one example, the first manufacturing zone 20 and the second manufacturing zone 40 are physically separated from one another. Additionally or alternatively, the third manufacturing zone 60 is physically separated from the first manufacturing zone 20 and / or the second manufacturing zone 40. If included, the fourth manufacturing zone 80, in some examples, is physically separated from the other manufacturing zones. However, in other examples, the fourth manufacturing zone 80 is not physically separated from at least one of the manufacturing zones (e.g., the third manufacturing zone 60) and thus may be considered to overlap with or be within another manufacturing zone 12.

[0027] If two or more of the manufacturing zones are physically separated from one another, they may be physically separated from one another by at least 1 meter (m), at least 5 m, at least 10 m, at least 20 m, at least 30 m, at least 40 m, at least 50 m, at least 75 m, at least 100 m, at most 3 kilometers (km), at most 2 km, at most 1 km, at most 0.75 km, at most 0.5 km, at most 0.3 km, at most 0.2 km, at most 0.1 km, at most 75 m, at most 50 m, and / or at most 25 m. As just one such example, first manufacturing zone 20 and second manufacturing zone 40 are physically separated from one another by at least 5 m, at most 5 km.

[0028] Additionally or alternatively, two or more of the manufacturing zones 12 are not spaced apart from one another. As one such example, two or more of the manufacturing zones 12 are adjacent to one another. As another example, two or more of the manufacturing zones 12 overlap one another. When two or more of the manufacturing zones 12 are not spaced apart from one another, the manufacturing zones may nevertheless be distinguished from one another by the output of the manufacturing zones and / or the work processes performed within the manufacturing zones.

[0029] In some examples, the manufacturing zone 12 includes one or more buildings 14 that define the physical boundaries of the manufacturing zone 12. If included, the one or more buildings 14 include walls that define the limits (e.g., square footage) of the manufacturing zone 12. Additionally or alternatively, the one or more buildings 14 include ceilings, floors, etc.

[0030] In some examples, the one or more buildings 14 include only one building, and all of the manufacturing zones 12 are contained within one building. In some such examples, the building includes wings, and two or more of the manufacturing zones are physically separated from one another within separate wings of the building, but are nevertheless connected to one another as part of one building. As one such example, the first manufacturing zone 20 and the second manufacturing zone 40 comprise different wings of a building (and are therefore physically separated from one another), but are connected to one another by the third manufacturing zone 60. As one such example, the first manufacturing zone 20 and the second manufacturing zone 40 are joined to different portions of the third manufacturing zone 60 so as to form two physically distinct but connected wings.

[0031] However, in other examples, the one or more buildings 14 include multiple buildings, with two or more of the manufacturing zones contained within different buildings. That is, two or more of the manufacturing zones are contained within their own separate buildings that are physically separated from one another and not physically connected by walls or other building structures. As an example, the first manufacturing zone 20 is contained within a first building, and the second manufacturing zone 40 is contained within a second building. In some such examples, the first manufacturing zone 20 and / or the second manufacturing zone 40 are physically separated from the third manufacturing zone 60, and thus the output of the first manufacturing zone 20 and / or the second manufacturing zone 40 is transported between the first manufacturing zone 20 and / or the second manufacturing zone 40 and the third manufacturing zone 60 across the distance / gap that separates the first manufacturing zone 20 and / or the second manufacturing zone 40 from the third manufacturing zone 60.

[0032] Thus, in some examples, such as when two or more of the manufacturing zones 12 are physically separated from one another in different buildings, the aircraft manufacturing system 10 includes one or more transfer devices 100 configured to transfer components, subcomponents, assemblies, aircraft subassemblies, and / or other aircraft parts to, from, and / or between one or more of the manufacturing zones. In some examples, the transfer devices 100 include one or more of a hoist mechanism 102, a conveyor system 104, and / or a shuttle 106. The hoist mechanism 102 is configured to lift and transport aircraft components. By way of example, the hoist mechanism 102 may include a crane and / or a pulley system. In some examples, the hoist mechanism 102 is configured to rotate, pivot, translate, and / or otherwise move about a fixed point. The conveyor system 104 includes any suitable conveyor, such as a roller conveyor, a belt conveyor, a chain conveyor, or the like. The shuttle 106 may include a powered land, water, and / or air vehicle configured to travel to, from, between, and / or around one or more of the manufacturing zones to transport components. By way of example, the shuttle 106 may include one or more of a barge, a cargo ship, a truck, a bus, a van, a tractor, a train, a drone, and / or a helicopter.

[0033] In one example, the first transfer device 110 is configured to transfer components between the first manufacturing zone 20 and the third manufacturing zone 60. As an example, the first transfer device 110 includes a crane configured to transfer the first aircraft subassembly 38 from the first manufacturing zone 20 to the third manufacturing zone 60. In some such examples, the crane is a gantry crane or other type of overhead rolling mechanism. Additionally or alternatively, the transfer device 100 may include a second transfer device 112 configured to transfer components between the second manufacturing zone 40 and the third manufacturing zone 60. If a fourth manufacturing zone 80 is included, the transfer device 100 may additionally or alternatively include a third transfer device 114 configured to transfer components between the fourth manufacturing zone 80 and the third manufacturing zone 60 and / or a fourth transfer device 116 configured to transfer components between the fourth manufacturing zone 80 and the second manufacturing zone 40. As an example, the fourth transfer device 116 includes a conveyor system and / or a gantry crane or other mobile hoist mechanism configured to transfer parts of the aircraft 300 from the fourth manufacturing zone 80 to the second manufacturing zone 40.

[0034] In some examples, the third transfer device 114 is configured to transfer the mid-fuselage section 310 (including the wing box and / or the upper half / upper portion of the mid-fuselage section) from the fourth manufacturing zone 80 to the third manufacturing zone 60.

[0035] In some examples, the fourth transfer device 116 is configured to transfer at least a portion of the fuselage 302 from the fourth manufacturing zone 80 to the second manufacturing zone 40. In some such examples, the fourth transfer device 116 is configured to transfer the nose section 306 and / or the tail section 316 of the fuselage 302 from the fourth manufacturing zone 80 to the second manufacturing zone 40.

[0036] The manufacturing zone 12 additionally or alternatively includes one or more doorways 16 configured to allow components 200 to enter and / or exit the manufacturing zone 12. The one or more doorways 16 may also be referred to or described as gates, portals, entrances, exits, gangways, transfer points, entrances, and / or exits. In some examples, the one or more buildings 14 include one or more doorways. The components 200 include base parts 202 and subassemblies 204. In some examples, the one or more doorways 16 are configured to receive the base parts 202. The base parts 202 are components that are manufactured or otherwise procured from outside the aircraft manufacturing system 10 (and thus may include one or more of raw materials, prefabricated parts, fasteners, tools, etc.) and brought into the manufacturing zone by a transfer device. Thus, work operations within a manufacturing zone begin by adding to, subtracting from, and / or otherwise modifying a base part, i.e., the base part is the primary component (e.g., input) to the manufacturing zone. Subassemblies 204 are assemblies of two or more base parts 202 that are assembled on one or more of the feeder lines and introduced to one or more of the assembly lines via one or more of the feeder lines. In some such examples, third manufacturing zone 60 includes one or more doorways 16 configured to receive one or more of first aircraft subassemblies 38, second aircraft subassemblies 58, and / or third aircraft subassemblies 98.

[0037] Subassembly components 204 may include precursors 206 to one or more of the aircraft subassemblies, also referred to herein as aircraft subassembly precursors 206. An aircraft subassembly precursor comprises a structure on assembly line 120 that advances along assembly line 120 and ultimately becomes the output of the manufacturing zone upon completion of work steps within the manufacturing zone. For example, a precursor may be a structure to which components from feeder line 140 are added. Thus, an aircraft subassembly precursor may be a structure on the backbone of assembly line 120 (the common assembly line that ultimately produces the final output of the manufacturing zone in which it is contained) that advances toward the end of assembly line 120 and becomes the final output of the manufacturing zone. For example, a precursor in a first manufacturing zone may be a wing precursor. The wing precursor advances along the assembly line in the first manufacturing zone and may take on different shapes, structures, and / or properties as the wing precursor advances along the assembly line and is added, removed, modified, processed, and / or otherwise acted upon. Thus, precursor 206 is shown in FIG. 1 with a dashed line to reflect that the shape, size, structure, composition, properties, and / or other characteristics of the precursor may change as it progresses down assembly line 120. Once all of the work steps in the first manufacturing zone are performed on the precursor, the precursor may ultimately be transformed into the final output (i.e., the precursor may ultimately become a completed left wing or right wing). Thus, the precursor is only an incomplete and / or partial version of the final output of the manufacturing zone.

[0038] In some such examples, a manufacturing zone includes a sufficient number of entry / exit points such that each of the one or more entry / exit points is configured to accept a unique component and / or a unique set of components. That is, different components may be delivered to different entry / exit points. Accordingly, including more entry / exit points along a manufacturing zone allows components to be delivered closer to their point of consumption, assembly, and / or use within the manufacturing zone. Furthermore, delivering components from multiple origins (e.g., entry / exit points) to their final destination streamlines the delivery process, reduces congestion, and alleviates bottlenecks in the delivery process. In this manner, components may be delivered to their final destination in a more efficient manner than traditional delivery approaches that deliver components from a single source / origin (e.g., entry / exit point) to various locations within a manufacturing zone.

[0039] Additionally or alternatively, one or more doorways 16 are configured to receive and / or transport components 200 between manufacturing zones 12. As one example, the fourth manufacturing zone 80 and the second manufacturing zone 40 include one or more doorways 16 configured to allow components 200 to be transferred from the fourth manufacturing zone 80 to the second manufacturing zone 40. As described above, in some such examples, a transfer apparatus 100 is also included between the fourth manufacturing zone 80 and the second manufacturing zone 40 and configured to transfer components between the fourth manufacturing zone 80 and the second manufacturing zone 40. As one example, the transfer apparatus 100 is configured to transfer at least a portion of the fuselage 302 from the fourth manufacturing zone 80 to the second manufacturing zone 40. In one such example, the transfer apparatus 100 is configured to transfer the nose section 306 and / or the tail section 316 of the fuselage 302 from the fourth manufacturing zone 80 to the second manufacturing zone 40. Additionally or alternatively, one or more doorways 16 are configured to discharge the output of the manufacturing zones 12 from the manufacturing zones. By way of example, the first manufacturing zone 20 includes one or more doorways 16 configured to discharge a first aircraft subassembly 38, the second manufacturing zone 40 includes one or more doorways 16 configured to discharge a second aircraft subassembly 58, the third manufacturing zone 60 includes one or more doorways 16 configured to discharge an aircraft assembly 78, and / or the fourth manufacturing zone 80 includes one or more doorways 16 configured to discharge a third aircraft subassembly 98. By way of example, one or more of the doorways are configured to discharge a nose portion 306 and / or a tail portion 316 of the fuselage 302 into the second manufacturing zone 40, and / or one or more different doorways are configured to discharge a wing-fuselage section 310 into the third manufacturing zone 60.

[0040] In some examples, the base parts 202 are delivered to the manufacturing zones 12 via pathways 18. If included, the pathways 18 are configured to enable delivery of the base parts 202 to the manufacturing zones 12 from outside the aircraft manufacturing system 10, or at least from outside the manufacturing zones 12 of the system. As an example, the pathways 18 are configured to enable movement of the transfer devices 100, the transfer devices being configured to carry the base parts 202 of the aircraft assemblies 78. In some examples, the pathways 18 extend around at least a portion of the manufacturing zones 12. In particular, the pathways 18 are configured to enable movement of the transfer devices 100 around at least a portion of the manufacturing zones. In such examples, the pathways 18 extend around at least a portion of the periphery of one or more of the first manufacturing zone 20, the second manufacturing zone 40, the third manufacturing zone 60, and / or the fourth manufacturing zone 80. In some such examples, path 18 extends to one or more doorways 16, allowing transport device 100 to travel directly to one or more doorways 16 and thus deliver component parts 200 directly to the one or more doorways. As an example, if transport device 100 comprises a land vehicle (e.g., a truck, van, bus, shuttle, train, etc.), path 18 comprises a road or other suitable surface configured to allow movement of these land vehicles. In some examples, path 18 is configured to be a one-way path that restricts movement of transport device 100 to one direction.

[0041] In some examples, one or more of the manufacturing zones 12 includes an assembly line 120. If included, the assembly line 120 includes a series of workstations configured to perform operations on components 200 of the aircraft assembly 78. The assembly line 120 is configured to guide the components 200 through the series of workstations along a one-way path that forms at least a portion of one or more of the manufacturing zones 12. In this manner, operations are performed on the components at various points (e.g., workstations) on the assembly line 120.

[0042] In some examples, assembly line 120 includes a drive mechanism 122 (e.g., an electric motor) configured to propel components down assembly line 120. In some such examples, drive mechanism 122 is configured to propel mechanical linkages 124 (e.g., one or more of a belt, chain, pulley, cable, and / or platform) configured to maintain contact (e.g., by frictional and / or magnetic forces) with one or more of the components as drive mechanism 122 moves, thus propelling the components through at least a portion of manufacturing zone 12. In some other such examples, assembly line 120 includes a conveyor system driven by drive mechanism 122, such as one or more of a belt conveyor system, a roller conveyor, a belt conveyor, a chain conveyor, a cable conveyor, etc. However, in other examples, drive mechanism 122 includes a motorized vehicle, such as an aircraft tug.

[0043] The assembly line 120, in some examples, includes one or more of a first assembly line 130, a second assembly line 132, and a third assembly line 134. If included, the first assembly line 130 is included within the first manufacturing zone 20 and is configured to propel components 200 of first aircraft subassemblies 38 and / or first aircraft subassemblies 38 through at least a portion of the first manufacturing zone 20. If included, the second assembly line 132 is included within the second manufacturing zone 40 and is configured to propel components 200 of second aircraft subassemblies 58 and / or second aircraft subassemblies 58 through at least a portion of the second manufacturing zone 40. If included, the third assembly line 134 is included within the third manufacturing zone 60 and is configured to propel components 200 of aircraft assemblies 78 and / or aircraft assemblies 78 through at least a portion of the third manufacturing zone 60. While FIG. 1 shows three assembly lines 120 (one each in a first manufacturing zone, a second manufacturing zone, and a third manufacturing zone), it should be understood that in other examples, each manufacturing zone may include more or fewer than three assembly lines 120. Furthermore, each assembly line 120 may include one or more subassembly lines. For example, one or more of the assembly lines may include one or more main assembly lines and one or more tributary assembly lines (e.g., feeder line 140) that branch off from the larger main assembly line. Assembly lines 120 may, in some examples, branch off into smaller and smaller subassembly lines. Thus, each assembly line may include a network of tributary assembly lines that ultimately feed into a common assembly line. In this manner, assembly lines 120 may branch off into one or more subassembly lines and / or may join together to form one or more common assembly lines.

[0044] In some examples, if included, the fourth manufacturing zone 80 does not include an assembly line 120. However, in other examples, the fourth manufacturing zone 80 includes one or more assembly lines 120. Regardless, the fourth manufacturing zone 80 includes fixture bays 84 (also referred to herein as parking spaces 84 and / or hangers 84) that are configured to perform multiple work operations on components 200 at once (i.e., serially). The fixture bays 84 are configured to hold components 200 for longer periods of time than the workstations of the assembly line 120. In some examples, different fixture bays 84 are configured to manufacture different parts. As an example, one of the fixture bays 84 is configured to manufacture at least a portion of a wing-fuselage section 310, another one of the fixture bays 84 is configured to manufacture a tail portion 316 of the fuselage 302, and another one of the fixture bays 84 is configured to manufacture a nose portion 306 of the fuselage 302. In some examples, the fixture bays 84 are configured to produce a third aircraft subassembly 98.

[0045] Manufacturing zone 12 further includes feeder line 140 in some examples. If included, feeder line 140 is configured to introduce base parts 202 and / or subassembly parts 204 to assembly line 120. As an example, feeder line 140 is configured to transfer base parts 202 and / or subassembly parts 204 from doorway 16 to assembly line 120. In particular, feeder line 140 can interface with one or more of the assembly lines to deliver base parts 202 and / or subassembly parts 204 to the assembly lines. In some examples, assembly line 120 includes feeder line 140. In such examples, feeder line 140 can be a subassembly line (also referred to herein as a tributary assembly line) of assembly line 120. In other examples, feeder line 140 can be separate and distinct from assembly line 120. Similar to assembly line 120, feeder line 140 can include one or more secondary feeder lines branching off from one or more primary feeder lines. That is, a feeder line may include a network of tributary feeder lines that ultimately flow into a main feeder line.

[0046] Additionally or alternatively, the feeder lines are configured to orient the base parts and / or subassemblies in a final orientation. The final orientation is the orientation in which the base parts and / or subassemblies will be coupled to a structure (e.g., aircraft subassembly precursor 206) on the assembly line. In some examples, doorways 16 are configured to receive the parts in their final orientation. Additionally or alternatively, the feeder lines themselves are configured to orient the parts in their final orientation after the parts are loaded onto the feeder lines. Thus, the orientation of the base parts and / or subassemblies may not need to be rotated, pivoted, or otherwise changed by a robot, machine, and / or worker when the base parts and / or subassemblies are assembled or coupled to a larger aircraft structure (e.g., aircraft subassembly precursor 206) on the assembly line. Thus, providing base parts and / or subassemblies to the feeder lines and / or assembly lines in their final orientation can reduce production inefficiencies within the manufacturing zone.

[0047] In some examples, the feeder line includes a fractional pulse assembly line configured to fractionally pulse the base component 202 and / or the subassembly component 204 to the assembly line 120. As an example, the feeder line includes a fractional pulse assembly line 126.

[0048] Additionally or alternatively, the feeder line may include two or more fractional pulse assembly lines and / or may include a main feeder line and one or more secondary feeder lines configured to deliver components to the main feeder line. In this manner, the feeder line may branch into smaller and smaller upstream feeder lines. Thus, each of the manufacturing zones 12 may include one or more of the assembly lines, and each of the assembly lines may branch into smaller and smaller feeder lines. In this manner, the manufacturing zones 12 may include a network of tributary assembly lines that all ultimately flow into the third manufacturing zone 60.

[0049] In some examples, base parts 202 are delivered by transport device 100 to manufacturing zone 12 via pathway 18, enter manufacturing zone 12 via doorway 16, and then transported to assembly line 120 via feeder line 140. In some examples, feeder line 140 includes the same or similar equipment (e.g., a conveyor system) as assembly line 120. In some examples, subassembly parts 204 are manufactured on feeder line 140 and / or are the product / output of feeder line 140. In such examples, transport device 100 can deliver base parts 202 to feeder line 140, and subassembly parts can be manufactured on the feeder line from these base parts.

[0050] By including a pathway, one or more entrances and exits, and / or feeder lines, components may be delivered closer to the component's assembly point on the assembly line. Additionally, by supplying components to the assembly line from multiple feeder lines, as opposed to a shared dock, queue wait times and / or other component delivery inefficiencies are reduced, thereby increasing production rates.

[0051] In some examples, the different doorways are configured to receive components in the order in which they are assembled on the assembly line. As an example, a first door can receive a first component, and an adjacent second door can receive a second component configured to be assembled immediately after the first component. For example, a fuselage frame can be installed before the windows and / or window frames of a fuselage skin, and therefore the fuselage frame can be delivered to a different doorway than the windows and / or window frames. Furthermore, the fuselage frame can be supplied via one of the feeder lines to a location on the assembly line upstream of the windows and / or window frames.

[0052] In some examples, assembly line 120 includes a fraction pulse assembly line 126. If included, fraction pulse assembly line 126 is configured to pulse (i.e., periodically move) components in the direction of movement by only a fraction of the length of component 200 (i.e., a length less than the length of component 200). Thus, unlike conventional pulsating assembly lines in which component 200 is pulsed (e.g., pulsed a length greater than the length of the component) to an entirely different, non-overlapping location where a new workstation is located, fraction pulse assembly line 126 micro-pulses components from their previous location to an overlapping location that still includes at least one or more of the workstations. Furthermore, unlike conventional pulsating assembly lines in which operations are performed on a given component by one workstation at a time (i.e., different workstations perform operations on the component sequentially), multiple workstations in fraction pulse assembly line 126 are configured to perform operations on the component in parallel (i.e., simultaneously). Because the fractional pulse assembly line 126 pulses the component 200 a distance less than the length of the component, a given work station performs sequential operations on different sections of a given component as the component is fractionally pulsed past the work station with multiple pulses. That is, unlike conventional pulsed assembly lines where a component enters a work station with one pulse and exits with an immediately adjacent second pulse, the fractional pulse assembly line 126 of the present disclosure utilizes three or more pulses for components to enter and exit a work station.

[0053] In some examples, two or more of the first manufacturing zone 20, the second manufacturing zone 40, and the fourth manufacturing zone 80, if included, produce the first aircraft subassembly 38, the second aircraft subassembly 58, and the third aircraft subassembly 98, respectively, at at least substantially the same rate (e.g., the production times of the aircraft subassemblies are within 5% of each other) such that the aircraft subassemblies are provided to the third manufacturing zone 60 at approximately the same time (i.e., just in time). In some such examples, the base part 202 is provided to the first manufacturing zone 20, the second manufacturing zone 40, and the fourth manufacturing zone 80, if included, at approximately the same time. In some other such examples, when the first manufacturing zone 20 and the second manufacturing zone 40 include assembly lines of substantially the same length (e.g., within 5% of each other's length), the average speeds of the assembly lines are substantially the same (e.g., within 5% of each other).

[0054] 2 and 3, FIGS. 2 and 3 illustrate an example fragment pulse assembly line 400 of the fragment pulse assembly line 126. The fragment pulse assembly line 126 may be included in the assembly line 120, the feeder line 140, and / or other assembly lines of the aircraft manufacturing system 10. The fragment pulse assembly line 126 includes workstations configured to perform operations on components pulsed by the fragment pulse assembly line. Additionally, the workstations may include powered mechanisms (e.g., conveyor systems) configured to move (e.g., fractionally pulse) the components along the assembly line. The distance between the centerlines of adjacent workstations on the fragment pulse assembly line may be referred to herein as the workstation pitch. The number of workstations per unit length on the assembly line may be referred to as the workstation density or the workstation packing density.

[0055] 2 provides graphs comparing the fractional pulse assembly line 126 of the present disclosure with a conventional pulsed assembly line. In particular, graph 450 illustrates an example conventional pulsed assembly line 440, while graphs 452 and 454 illustrate an example fractional pulse assembly line 400 according to the present disclosure. Unlike the conventional pulsed assembly line 440, in which the components 200 are pulsed between workstations 410 a distance greater than the length of the components, the components 200 of the present disclosure are pulsed between workstations 410 a distance less than the length of the components. In particular, in the conventional pulsed assembly line 440, the components 200 are pulsed from a first workstation 412 to a second workstation 414, whereas in the fractional pulse assembly line 126 of the present disclosure, the components 200 are pulsed a distance less than the length of the components from the first workstation 412 to the second workstation 414. Thus, the workstations are smaller and / or closer together in the present disclosure than in a conventional pulsating assembly line 440 for equivalently sized components. Stated slightly differently, the assembly line of the present disclosure has a higher workstation packing density than a conventional assembly line. In this manner, more workstations can access a part at any time, and therefore more operations can be performed on the part at any time. Furthermore, the workstations can be packed more densely together, thereby reducing the overall footprint (area) of the manufacturing system. Graph 452 shows an example in which one of the components 200 is pulsed one-third of its length during each pulse, and graph 454 shows an example in which one of the components 200 is pulsed one-ninth of its length during each pulse.

[0056] As shown, as the pulse length (e.g., the distance the component 200 travels during the pulse) decreases, the workstations become smaller and / or closer together (i.e., the workstation pitch decreases). Additionally or alternatively, the pulse frequency increases as the pulse length decreases. That is, shortening the pulse length decreases the time between pulses because more pulses are required to propel the component 200 the same distance. As shown in the example of FIG. 2 , the component 200 in graph 454 is pulsed more frequently than the component 200 in graph 452 because the component in graph 452 is pulsed farther than the component in graph 454. Shortening the pulse length and making the workstations smaller allows more workstations to simultaneously perform operations on the component 200 (i.e., increasing the workstation packing density). Increasing the amount of parallel processing of the component 200 in this manner improves production efficiency and reduces production time. The minimum size of a workstation is limited by various factors, including one or more of the uniformity of the component 200 along its length, the amount of similarity of work operations to be performed on the component along its length, the sequence of the work operations, the delay between the work operations, and / or the size of the machines, robots, tools, and / or workers required to perform the work operations at the workstation.

[0057] In some examples, the first workstation 412 and the second workstation 414 perform different work operations on the component 200. Additionally or alternatively, different tools, robots, and / or operators perform operations on the component 200 at the first workstation 412 and the second workstation 414. The work operations include one or more of adding to the component 200 (e.g., joining two or more base parts 202 to one another, joining a subassembly part 204 to a base part 202, joining a base part 202 and / or a subassembly part 204 to one of the aircraft subassembly precursors 206, joining two or more subassemblies 204 to one another, etc.), subtracting from the component (e.g., drilling holes in the component), and / or otherwise modifying the component (e.g., reshaping, remolding, bending, curing, sterilizing, treating, heating, cooling, pressurizing, etc.). Thus, performing a work operation includes performing an operation on one or more of the component 200.

[0058] As shown in FIG. 3 , each workstation 410 (also referred to herein as assembly line workstations 410) includes a work-performing device 420 configured to perform a work process (i.e., perform an operation on a component 200). By way of example, the work-performing device 420 includes one or more of a robot 422, a machine 424, a human worker 426, and / or a tool 428. The robot 422 is an autonomous device configured to perform an operation without human input and / or intervention. The machine 424 is a relatively large device configured to perform an operation based on human input. By way of example, the machine 424 may be a machine tool such as a press, mill, lathe, etc. The tool 428 is smaller than the machine 424 and configured to perform an operation based on human input. By way of example, the tool 428 may be a handheld device.

[0059] In some examples, two or more of the workstations perform different work operations on component 200. In some such examples, the workstations each perform a unique type of work operation on the component such that all of the workstations perform different work operations on the component. Additionally or alternatively, in some examples, the workstations each perform only one type of work operation on the component (e.g., only drill holes, only cut windows, only install frames, only install stringers, only install sealant, etc.). Thus, in such examples, each workstation performs only one type of work operation unique to that particular workstation.

[0060] Additionally or alternatively, in some examples, two or more of the workstations include different types of work performance devices 420 configured to perform different types of work operations. In some such examples, the workstations each include a unique type of work performance device 420 and / or a unique combination of work performance devices 420 such that all of the workstations are configured to perform different types of work operations. In some such examples, each workstation includes only one work performance device 420 and / or one type of work performance device.

[0061] As an example, a portion of a segment pulse assembly line includes at least seven workstations located at various sequential positions along the assembly line, each performing its own unique work process. In some such examples, the at least seven workstations are divided into a first set of workstations that install fuselage frames and a second set of workstations located downstream from the first set of workstations that install window frames. Thus, in such examples, the fuselage frame is installed first, followed by the window frames. The fuselage frame may be installed first to enhance the structural integrity of the fuselage skin before installing the windows. In some such examples, installing the fuselage frame and window frames includes drilling holes for fasteners, laying up the window frames and / or fuselage frame using temporary fasteners, and then installing the fasteners.

[0062] For example, the most upstream workstation in a first set of workstations (the fuselage frame installation workstation) drills holes in the skin for the fuselage frame fasteners, the next workstation (the adjacent downstream workstation) lays up the fuselage frame on the skin using temporary fasteners, and then the third workstation installs the permanent fasteners. Two of the most upstream workstations in a second set of workstations (the window frame installation workstations) drill holes in the fuselage skin for the window frame fasteners and cut window openings in the skin. A downstream workstation in the second set of workstations lays up the window frames using temporary fasteners and then installs the permanent fasteners in the window frames.

[0063] In this manner, each workstation 410 and / or each work performing device 420 can repeatedly perform the same work steps on various sections of the component. That is, by dividing the component into sections and configuring workstations to perform work on only one section at a time, each workstation and / or work performing device can be simplified to perform the same work repeatedly and / or only one type of work. Not only can workstations and / or work performing devices be configured to perform the same type of work, but the workstations and / or work performing devices can also be configured to perform the same type of work on the same locations on each section of the component. As an example, a given workstation configured to drill holes in a fuselage skin can also be configured to drill these holes in the same locations on each section of the fuselage skin (i.e., the sections can all include the same number of holes, the same positioning of the holes, and / or the same hole configuration / pattern). Thus, the work-performing device may not need to move at all and / or can move in the same manner as sections are pulsed piecemeal past a workstation as different sections of the fuselage skin are drilled after each pulse. In this manner, the work-performing device itself and / or its programming can be simplified compared to traditional assembly line approaches.

[0064] In this manner, by performing only one type of work operation, the size, complexity, and / or cost of the work performance device may be reduced compared to conventional work performance devices configured to perform multiple types of work operations. Additionally, by pulsing components in a piecemeal fashion and dividing the work operations into smaller work areas, the amount of movement required to perform the work operations is reduced, thereby further reducing the size, complexity, and cost of the work performance device.

[0065] In the example of FIG. 3 , six workstations 410 are shown. However, in other examples, more or fewer than six workstations 410 are included in the example fraction pulse assembly line 400. Although the workstations 410 are shown along only one side of the component, workstations may be located along both sides of the component. Furthermore, the example fraction pulse assembly line shown in FIG. 3 is, in some examples, only a portion of the fraction pulse assembly line 126. In some such examples, the fraction pulse assembly line 126 includes two or more of the example fraction pulse assembly lines 400.

[0066] In some examples, the piecemeal pulse assembly line 400 includes an assembly area 430 configured to assemble subcomponents 404 to form a component 406. Additionally or alternatively, the components 406 enter a queue 434 that is not configured to have operations performed on them. The components 406 are pulsed piecemeal through the workstations, with operations performed on them by respective operation performance devices 420. In some examples, subassemblies 204 and / or base components 202 are added to the component 406 at one or more of the workstations 410. After exiting the workstation 410, the components 406, in some examples, enter another assembly area 430 and are assembled together to become subcomponents of a new component.

[0067] In some examples, components 200 having different physical properties are pulsed down the same fragment pulse assembly line and / or workstations 410 perform operations on components 200 having different physical properties, such as one or more of shape, geometry, size, weight, surface morphology, etc. As one example, components 406 include first component 407 and second component 408 that include different physical properties. In one such example, as shown in FIG. 3 , first component 407 is longer than second component 408. Thus, in such examples, components of different lengths are pulsed down the same fragment pulse assembly line.

[0068] Additionally or alternatively, FIG. 3 illustrates how, in some examples, the workstations 410 are not all the same length. In some such examples, the length of a workstation 410 is a multiple of the length of another workstation. For example, in FIG. 3, the longer workstation is twice the length of the other workstations. However, in other examples, the length of a workstation 410 is not an exact integer multiple (e.g., 2x, 3x, 4x, etc.) of the length of the other workstations. In some examples, the component 200 is pulsed an amount equal to the shortest of the workstations 410 (i.e., the minimum workstation length).

[0069] The pulse length 460 is the distance the component 402 travels during a pulse. As discussed above, the pulse length in the fraction pulse assembly line 126 of the present disclosure is less than the length of the component. Thus, in the example of FIG. 3 , the pulse length is equal to one-third the length of the first component 407 and one-half the length of the second component 408. The work period 464 is the period between pulses during which the component 402 is stationary and / or an operation is configured to be performed on the component 402. In other words, the work period 464 is the period between the end of a pulse and the beginning of the next pulse. The pulse period 466 is the time it takes to complete a pulse, i.e., the time it takes to move the component 402 the entire pulse length to its new position on the fraction pulse assembly line 126. The pulse period 462 is equal to a full fraction pulse cycle, i.e., the work period + pulse period.

[0070] In some examples, the component length is an integer multiple of the pulse length. By way of example, the length of component 200 is 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, and / or 20 times the length of the pulse length. Thus, in such examples, the pulse length is equal to 1 / X the length of component 200, where X is an integer value. As noted above, in some such examples, the pulse length is equal to the length of the shortest workstation(s) among workstations 410 (i.e., the minimum workstation length), and thus the shortest workstation(s) among workstations 410 is also equal to 1 / X the length of component 200, where X is an integer value.

[0071] In some examples, a given work operation (e.g., drilling holes) may be performed at uniform intervals along the length of a component. For example, Y vertically aligned holes (e.g., five holes) may be drilled every X meters (e.g., every 1 m) in an aircraft skin. Thus, in some such examples, the five holes may be drilled 1 meter apart in the aircraft skin. In some other such examples, the uniform interval for a given work operation may be equal to the pulse length. Thus, in the above example, the pulse length may be 1 meter, and therefore the work-performing device does not need to move to drill holes in the next section of the component. In some examples, workstations on a fractional pulse assembly line are selected based on the uniform interval for the work operations they perform. In some examples, workstations having the same uniform interval and / or an integer multiple of this interval may be selected, and therefore the pulse length does not need to be changed and / or the work-performing device does not need to move equally laterally between pulses to perform work operations on different sections.

[0072] As an example, a component may be configured to include windows every X meters, frames every X meters, and rows of vertical holes every X / Y meters. A first workstation may be configured to cut window openings, a second workstation may be configured to install frames, and a third workstation may be configured to drill holes. In some such examples where X = 1 meter, Y = 2 meters, and pulse length = 0.5 meters, the third workstation performs its work step after each pulse (drilling a vertical row of holes). However, the first and second workstations only perform their work steps after every second pulse (every other pulse), because these work steps only need to be performed at 1-meter intervals (equal to two pulse lengths). In another such example where X=1 meter and Y=2 meters, but pulse length=1 meter, the third workstation must drill two rows of vertical holes after each pulse, and the first and second workstations perform their work steps (cutting the window opening and installing the frame) once after each pulse.

[0073] However, in other instances, X is not an integer value and the length of component 200 is not equal to an integer multiple of the pulse length.

[0074] 4-6 provide schematic flow diagrams illustrating illustrative, non-exclusive examples of methods according to the present disclosure. In FIGS. 4-6, some steps are shown within dashed boxes to indicate that such steps may be optional or may correspond to optional versions of methods according to the present disclosure. However, not all methods according to the present disclosure need include steps shown within solid boxes. The methods and steps shown in FIGS. 4-6 are not limiting, and as will be understood from the discussion herein, other methods and steps are within the scope of the present disclosure, including methods having more or fewer steps than those shown. Different methods and / or additional steps from different figures may be combined.

[0075] 4-6 illustrate example methods according to the present disclosure. In particular, FIG. 4 illustrates a method 500 of manufacturing an aircraft assembly (e.g., aircraft assembly 78), such as an aircraft (e.g., aircraft 300), according to the present disclosure; FIG. 5 illustrates a method 600 of fractionally pulsing a component (e.g., component 200) down a fractional pulse assembly line (e.g., fractional pulse assembly line 126); and FIG. 6 illustrates a method 700 of designing and / or building an aircraft manufacturing system (e.g., aircraft manufacturing system 10) according to the present disclosure. Within the scope of the present disclosure are methods that include steps from more than one of method 500, method 600, and / or method 700, as understood from the discussion herein.

[0076] Method 500 includes, at 502, manufacturing (or assembling) aircraft subassemblies (e.g., first aircraft subassembly 38, second aircraft subassembly 58, and / or third aircraft subassembly 98) in parallel within the same geographic region and / or on separate assembly lines (e.g., assembly line 120). For example, the manufacturing at 502 may include sending the first aircraft subassembly 38 and one or more of the components 200 of that assembly down the first assembly line 130 and sending the second aircraft subassembly 58 and one or more of the components 200 of that assembly down the second assembly line 132, which may be fractional pulse assembly lines as discussed herein. As described above, manufacturing within the same geographic region includes manufacturing aircraft subassemblies within manufacturing zones (e.g., manufacturing zone 12) that are separated by at most 3 km, at most 2 km, at most 1 km, at most 0.75 km, at most 0.5 km, at most 0.3 km, at most 0.2 km, at most 0.1 km, at most 75 m, at most 50 m, and / or at most 25 m. Thus, in such examples, manufacturing at 502 includes manufacturing aircraft subassemblies within different manufacturing zones. As one such example, manufacturing includes manufacturing a first aircraft subassembly within a first manufacturing zone (e.g., first manufacturing zone 20) and manufacturing a second aircraft subassembly within a second manufacturing zone (e.g., second manufacturing zone 40). In some examples, manufacturing aircraft subassemblies on separate assembly lines includes at least partially manufacturing a first aircraft subassembly on a first assembly line (e.g., first assembly line 130) and at least partially manufacturing a second aircraft subassembly on a second assembly line (e.g., second assembly line 132). In some such examples, the first assembly line is included in a first manufacturing zone and the second assembly line is included in a second manufacturing zone.

[0077] Manufacturing the aircraft subassemblies at 502 includes manufacturing the aircraft subassemblies at the same rate so that the aircraft subassemblies are produced and transferred to the third manufacturing zone at approximately the same time. When manufacturing the first aircraft subassembly and the second aircraft subassembly on the first assembly line and the second assembly line, method 500 optionally includes advancing the first aircraft subassembly on the first assembly line and the second aircraft subassembly on the second assembly line at the same average rate to achieve the same production rate and provide the aircraft subassemblies to the third manufacturing zone at approximately the same time.

[0078] As already mentioned above, manufacturing components within the same geographic region reduces assembly delays and increases production rates. In particular, manufacturing components within the same geographic region allows aircraft subassemblies to be delivered more simultaneously (i.e., just-in-time) and / or more reliably to final assembly facilities (e.g., third manufacturing zones), thereby allowing assembly to begin more quickly and / or more frequently. In this way, final assembly of aircraft assemblies is not subject to unexpected delays (e.g., third-party manufacturer delays, shipping delays, etc.). Overall production of aircraft assemblies may be more streamlined and consistent, reducing downtime.

[0079] The manufacturing step at 502 optionally includes at least partially manufacturing (or assembling) the aircraft subassembly on a fractional pulse assembly line (e.g., fractional pulse assembly line 126) at 504. In some such examples, the assembly line includes a fractional pulse assembly line. Method 600 shown in FIG. 5 provides an example of fractionally pulsing a component part (e.g., component 200) of an aircraft assembly. Thus, in some examples, at least a portion of method 600 is performed at 504 of method 500. Additionally or alternatively, the manufacturing step at 502 optionally includes providing a base part (e.g., base part 202) to a manufacturing zone at 506. As mentioned above, providing, in some examples, includes delivering the base part to the manufacturing zone by a transport device (e.g., transport device 100), such as a land vehicle (e.g., truck, van, bus, train). Providing the base parts to the manufacturing zone at 506 may include providing the base parts to an assembly line (e.g., assembly line 120) and / or a feeder line (e.g., feeder line 140). As described above, the feeder line includes a drive mechanism (e.g., drive mechanism 122) that propels the parts down the feeder line and toward the assembly line. Optionally, at 512, method 500 includes manufacturing the aircraft subassemblies in separate buildings (e.g., building 14). As an example, the first manufacturing zone and the second manufacturing zone are contained in different buildings that are physically separated from one another, and manufacturing the aircraft subassemblies in these two manufacturing zones includes manufacturing the aircraft subassemblies in the different buildings.

[0080] In some examples, method 500 includes manufacturing different types of components in their final component orientations and / or delivering these different types of components to a third manufacturing zone in their final orientations. As an example, a first assembly line is configured to deliver a left wing to a third manufacturing zone in its final left wing orientation and a right wing to a final assembly facility (e.g., the third manufacturing zone) in its final right wing orientation. The left wing is configured to be coupled to a fuselage in its final left wing orientation, and the right wing is configured to be coupled to a fuselage in its final right wing orientation. In this manner, the wings may not need to be rotated or pivoted within the third manufacturing zone and / or when transferring the wings to the third manufacturing zone. The wings may be output by the first manufacturing zone in their final wing orientations such that no further manipulation is required before final assembly.

[0081] Method 500 includes combining aircraft subassemblies within the same geographic region at 520. As one example, combining at 520 includes assembling the aircraft subassemblies in a third manufacturing zone (e.g., third manufacturing zone 60) within the same geographic region as the first manufacturing zone and the second manufacturing zone to form an aircraft assembly. Optionally, combining at 520 includes transferring the aircraft subassemblies to the third manufacturing zone at 522. As one example, transferring includes moving the aircraft subassemblies from one or more of the first manufacturing zone, the second manufacturing zone, and / or the fourth manufacturing zone (e.g., fourth manufacturing zone 80) to the third manufacturing zone by one or more transfer devices. As just one such example, as already mentioned above, transferring includes hoisting and transporting the first aircraft subassembly from the first manufacturing zone to the third manufacturing zone using a crane.

[0082] In some examples, method 500 optionally includes, at 524, pulsing the aircraft subassembly and / or aircraft assembly through a third manufacturing zone and down a third assembly line (e.g., third assembly line 134). In some such examples, pulsing includes pulsing the aircraft subassembly and / or aircraft assembly piecemeal in a manner similar to that described at 504.

[0083] 5 illustrates a method 600 for fractionally pulsing one or more components of an aircraft assembly; thus, method 600 may also be described as a method for repeatedly manufacturing an aircraft. Method 600 and / or portions thereof may be used to fractionally pulse components of an aircraft assembly at various points within a manufacturing system (e.g., aircraft manufacturing system 10). Thus, while method 600 may be utilized to fractionally pulse components along a main assembly line (e.g., assembly line 120), method 600 may additionally or alternatively be utilized to fractionally pulse components along a tributary assembly line, such as a subassembly line, toward the main assembly line, along a feeder line (e.g., feeder line 140) toward the main assembly line, and / or along a secondary feeder line toward the feeder line. Thus, the fractional pulse assembly line may be configured to pulse aircraft assemblies (e.g., aircraft assembly 78), aircraft subassemblies (e.g., first aircraft subassembly 38, second aircraft subassembly 58, etc.) and / or subcomponents, undercarriage, and components thereof. Additionally, method 600 may be utilized to fractionally pulse aircraft assemblies and / or aircraft subassemblies within a final assembly zone (e.g., third fabrication zone 60).

[0084] At 602, method 600 optionally includes placing one or more components (e.g., subcomponent 404, base component 202, and / or subassembly 204) on the same and / or different fractional pulse assembly lines. At 604, method 600 includes fractionally pulsing one or more components down the same and / or different fractional pulse assembly lines. In some examples, the fractionally pulsing includes propelling one or more components with a drive mechanism (e.g., drive mechanism 122). The fractionally pulsing includes periodically pulsing one or more components down the assembly line(s) a length less than the length of the one or more components (pulsing one or more components and then waiting a period of time before pulsing the one or more components again). The pulsing step itself includes propelling, translating, and / or otherwise moving one or more components down the assembly line(s) a length less than the length of the one or more components during a single pulse. The waiting period includes waiting a time interval. In some examples, the time interval includes an amount of time required to complete a work operation on one or more components.

[0085] Optionally, at 605, the fractional pulsing step includes fractionally pulsing (i.e., sending) different types of components sequentially down the same assembly line or feeder line and / or sequentially producing different types of components on the same assembly line or feeder line. As discussed in more detail below, it may be determined that different types of components share sufficient similarity and / or the component work processes share sufficient similarity, that different types of components may be sequentially pulsed down the same assembly line or feeder line and / or produced on the same assembly line or feeder line. In some examples, different aircraft subassembly precursors may be pulsed down the same assembly line. By way of example, left and right wing components, such as left and right wings and / or left and right wing precursors, may be pulsed down the same assembly line or feeder line and / or produced sequentially on the same assembly line or feeder line. As another example, different sections of the fuselage, and / or components of that section, may be pulsed down the same assembly line or feeder line and / or produced sequentially on the same assembly line or feeder line.

[0086] Different types of components differ structurally, functionally, and / or physically (e.g., in shape, geometry, size, etc.) from one another. As an example, left and right wings are different types of components because the geometries of these wings are different (i.e., they are mirror images of one another). As another example, different sections of the fuselage (e.g., forward main cabin section 308 vs. aft main cabin section 314) are different types of components because these sections may be different shapes, sizes (e.g., lengths), and may include different numbers of windows and / or windows in different positions, etc. Thus, in some examples, a given assembly line produces two different types of components.

[0087] By producing and / or pulsing different types of components on the same line (assembly line or feeder line), the same work-performing device can be utilized to produce the different types of components. This reduces the number of workers, robots, machines, and / or tools required to produce an aircraft assembly, thus reducing costs in the aircraft manufacturing system. Furthermore, even though different tools may be required to produce the different types of components, the same workers can still be utilized to produce the different types of components, thereby reducing costs. At 606, method 600 includes simultaneously performing different work operations on different sections of one or more components. Performing different work operations includes one or more of utilizing different work-performing devices (e.g., work-performing device 420) to perform the operations, performing different types of operations (e.g., drilling vs. painting vs. laminating vs. removing vs. attaching a component, etc.), and / or performing operations on different areas of the same section of a given component. In particular, performing different work operations on different sections of one or more components includes performing the different work operations at different workstations (e.g., workstation 410). In such an example, two or more of the workstations are configured to simultaneously perform different types of operations on a given component. Furthermore, two or more of the workstations are configured in sufficient proximity to one another such that a given component simultaneously occupies two or more of the workstations. Thus, the fractionally pulsing step of method 600 includes simultaneously occupying at least two workstations with at least one of the one or more components and / or simultaneously performing operations on at least one of the one or more components at at least two or more workstations.

[0088] Pulsing one or more components in fragmented sections and simultaneously performing different work operations on one or more components can increase parallelism and reduce production inefficiencies. In particular, more operations can be performed on one or more components at any given time. Furthermore, dividing one or more components into fragmented sections reduces the amount of movement of the work-performing device required to complete a work operation. This reduction in movement also increases production efficiency.

[0089] Performing an operation on the one or more components optionally includes removing material from the one or more components at 608, adding material to the one or more components at 610, and / or treating, cleaning, curing, and / or exposing the one or more components to an external stimulus (e.g., a change in pressure, a change in temperature, electromagnetic radiation, etc.) at 612. In some examples, adding material to the one or more components at 610 includes bonding a base part (e.g., base part 202) and / or a subassembly (e.g., subassembly 204) to the one or more components. In particular, the base part and / or subassembly may be bonded to an aircraft subassembly precursor (e.g., aircraft subassembly precursor 206). In some examples, the base part and / or subassembly is introduced to the fragment pulse assembly line via one or more feeder lines, as described above in the description of method 500 of FIG. 5. Optionally, at 611, the step of adding material includes adding parts (eg, base parts) from one or more of the feeder lines to one or more of the component parts.

[0090] Optionally, at 614, method 600 includes removing one or more components from the fragment pulse assembly line(s), and / or merging different assembly lines (e.g., two or more fragment pulse assembly lines) with one another at 615. Merging different assembly lines may include joining the different assembly lines to form a common assembly line. Additionally or alternatively, merging may include joining tributary assembly lines and / or sub-assembly lines to a main assembly line.

[0091] Optionally, at 616, method 600 includes combining one or more components to form a component assembly. Combining one or more components at 616, in some examples, includes bonding one or more components together. As an example, the combining may include combining a base part and / or a subassembly with an aircraft subassembly precursor on a main assembly line. The bonding is accomplished by using fasteners, adhesives, and / or other bonding mechanisms. In some examples, method 600 includes one or more of returning the component assembly onto the assembly line(s), pulsing the component assembly piecemeal down the assembly line(s), and / or pulsing the component assembly piecemeal down a common assembly line.

[0092] Thus, method 600 may include assembling, bonding, and / or otherwise combining components together. In some examples, this may be done by taking components from an assembly line, combining the components, and then returning the components to the same assembly line or placing the components on a different assembly line. In other examples, this assembling, bonding, and / or combining may be performed on the assembly line without having to remove the components from the assembly line. In other examples, components from a first assembly line (e.g., feeder line 140) may be transferred to a second assembly line (e.g., assembly line 120) and assembled, bonded, and / or otherwise combined with components from the second assembly line on the second assembly line. As an example, a smaller secondary feeder assembly line may merge with a larger primary assembly line when components are attached to a larger base structure, such as an aircraft subassembly precursor (e.g., when a wing flap is attached to the remainder of the wing). In some examples, the first assembly may merge and / or interface with a second assembly line such that components may be transferred to the second assembly line by a conveyor mechanism of the first assembly line.

[0093] In this manner, aircraft subassemblies may be at least partially manufactured from base parts by piecemeal pulsing the aircraft subassemblies and / or one or more of the aircraft subassemblies' components down one or more assembly lines and / or feeder lines.

[0094] FIG. 6 illustrates a method 700 of designing and / or building an aircraft manufacturing system of the present disclosure that includes a fractional pulse assembly line. At 702, the method 700 includes determining and / or back-calculating a component production rate (i.e., takt time) based on one or both of the takt time and the number of components of an aircraft assembly (e.g., aircraft assembly 78). The aircraft assembly takt time is the customer-requested production rate (e.g., the number of aircraft assemblies per unit time), which is effectively the production rate or frequency at which the aircraft assemblies are produced. For example, if one of the aircraft assemblies (e.g., aircraft 300) is produced every four hours to meet customer demand, the takt time of the aircraft assembly is four hours. Based on the takt time of the aircraft assembly, the takt time for each of the aircraft assembly's component types is back-calculated based on the number of components of each type. Notably, the back-calculating step, in some examples, is performed iteratively, working backward from component to subcomponent until the takt times for all of the components have been calculated. The more subcomponents a component contains, the shorter the takt time of the subcomponents. That is, if a component comprises two or more subcomponents, the subcomponents will have a shorter takt time than the component's takt time in order to maintain the component's takt time. Continuing with the aircraft assembly example above, because the aircraft assembly includes two wings (a left wing and a right wing), the takt time for the wings must be shorter than the takt time for the aircraft assembly in order to maintain the takt time for the aircraft assembly since there are more wings than the aircraft assembly (e.g., wings must be delivered for final assembly every two hours so that two complete wings are delivered every four hours).

[0095] At 703, method 700 includes determining how many assembly lines (e.g., fractional pulse assembly lines) to include in the aircraft manufacturing system. The determining step at 703 may be based on the feasibility of manufacturing components on an assembly line, the number of components to be produced, the amount of similarity between the components to be produced, and / or the amount of similarity between the work operations performed on the components to be produced. The number of assembly lines may be influenced by the number of components that are actually feasible to manufacture using the assembly line. As an example, manufacturing a third aircraft subassembly on an assembly line may not be feasible due to unique physical characteristics (geometry, shape, size, surface configuration, etc.) of the third aircraft subassembly and / or due to unique work operations to be performed on the third aircraft subassembly and / or components of the third aircraft subassembly. Thus, the third aircraft subassembly may be manufactured in a fixed bay (e.g., fixed bay 84) or not on an assembly line.

[0096] Additionally or alternatively, the number of assembly lines to include in an aircraft manufacturing system may be influenced by the number of components to be produced. As an example, because it may be feasible to manufacture both the first aircraft subassembly and the second aircraft subassembly on an assembly line, at least two assembly lines may be included: one assembly line for manufacturing the first aircraft subassembly (e.g., first assembly line 130) and another assembly line for manufacturing the second aircraft subassembly (e.g., second assembly line 132).

[0097] Additionally or alternatively, the number of assembly lines to include in an aircraft manufacturing system may be influenced by the amount of similarity between components to be produced and / or the amount of similarity between the operations to be performed on the components to be produced. This is because components whose physical characteristics and / or the operations to be performed on the components are sufficiently similar may, in some examples, be manufactured on the same assembly line. For example, as described below in step 707, both the left and right wings may be manufactured on the same assembly line (e.g., first assembly line 130). As another example, different sections of a fuselage may be similar enough that these sections may be manufactured on the same assembly line (e.g., second assembly line 132). Thus, in some examples, an aircraft manufacturing system includes two assembly lines, each configured to produce two or more different types of components for an aircraft. In this manner, fewer assembly lines may be included in an aircraft manufacturing system if more components can be manufactured on the same assembly line.

[0098] At 704, method 700 includes determining a line length for a fractional pulse assembly line of the aircraft manufacturing system based on one or more of the following line parameters: As an example, at 706, method 700 optionally includes determining the line length based on whether the components are produced serially or in parallel. In particular, line length is shorter when components are produced in parallel on separate lines. As an example, the fractional pulse assembly lines of the first manufacturing zone and the second manufacturing zone are parallel to each other and therefore have a shorter collective line length than the fractional pulse assembly lines would have if they were continuous to each other.

[0099] In some examples, method 700 optionally includes determining 707 whether to produce different components on the same assembly line (serial) or on different assembly lines (parallel) at 706. In some examples, this determination is based on at least the amount of similarity between the components (e.g., similarity in size, shape, geometry, and / or other physical characteristics) and / or the amount of similarity in the work operations to be performed on the components (e.g., drilling, painting, curing, fastening, assembling the components, etc.).

[0100] As one example, a left wing (e.g., left wing 322) and a right wing (e.g., right wing 324) may, in some instances, be produced on the same assembly line because at least the same and / or similar work processes are performed on both wings and / or because the physical properties of the wings (e.g., size, shape, etc.) are similar enough to be produced on the same assembly line. In some such instances, both wings are produced on a first assembly line in a first manufacturing zone. As another example, a forward main cabin section of a fuselage (e.g., forward main cabin section 308 of fuselage 302) and an aft main cabin section of the fuselage (e.g., aft main cabin section 314) of an aircraft assembly may, in some instances, be produced on the same assembly line because at least the same and / or similar work processes are performed on both fuselage sections and / or because the physical properties of the fuselage sections (e.g., size, shape, color, etc.) are similar enough to be produced on the same assembly line. In particular, the fuselage sections may, in some instances, have the same and / or similar semi-cylindrical shapes. In some such examples, both fuselage sections are produced on a second assembly line in a second manufacturing zone. As another example, a fuselage tail portion (e.g., tail portion 316) may, in some examples, include two frusto-conical sections. In some such examples, due to the similarity in the shape of the frusto-conical sections, the two fuselage sections may additionally or alternatively be manufactured sequentially on the same assembly line. Additionally or alternatively, the determining step at 707 is based on takt time. In particular, in some examples, processing components sequentially on the same line may take longer than processing the components in parallel on different lines. In some such examples, the components may need to be processed in parallel on separate lines to meet the takt time.

[0101] The determining step at 707 may additionally or alternatively be based on spacing the work steps along the length of the component. As introduced above, a given work step may be performed repeatedly on different parts of the component at a given workstation by pulsing the component in sections piecemeal past the workstation. In particular, the work step may be performed at regular intervals along the length of the component as different sections of the component are pulsed piecemeal past the workstation (e.g., windows may be installed every X meters along a fuselage skin). In some such examples, the regular interval is equal to the pulse length. In such examples, the work step may be performed in series with other workstations on the assembly line when the regular interval of the work step is equal to the pulse length of the assembly line (and the regular intervals of other work steps on the assembly line), an integer multiple of this pulse length, and / or Xth of this pulse length.

[0102] In this way, different work steps may be similarly divisible along the length of components on the same assembly line, such that the regular intervals at which work steps are performed along the length of the components are equal to each other, integer multiples of each other, and / or X-fold smaller than each other. If work steps cannot be divided into regular intervals that are equal to, integer multiples of, and / or X-fold smaller than the regular intervals and / or pulse lengths of other work steps on the assembly line, then the work steps may need to be performed on different assembly lines and / or different sections of the assembly line having different pulse lengths and / or frequencies.

[0103] Thus, the step of determining whether operation steps can be performed together in series (on the same portion of the same assembly line) at 707 can be based on the similarity of the divisibility of the operation steps along the length of the component to be worked on. Specifically, the step of determining whether operation steps can be performed together in series on the same portion of the same assembly line (i.e., whether the workstations can be located adjacent to each other on the assembly line) can be based on whether the operation steps can be performed at regular intervals along the length of the component that are equal to each other, integer multiples of each other, and / or X times smaller than each other.

[0104] The determining step at 704 may additionally or alternatively be based on the physical characteristics of the subcomponents as they are pulsed down the fragment pulse assembly line. By way of example, method 700 optionally includes determining line length based on one or more of: subcomponent part length at 708; the number of subcomponents within the component at 709; the size of the gaps between successive adjacent subcomponents on the line at 710; and / or the number of gaps between successive subcomponents on the line at 712. In particular, the line length is longer when the subcomponents are longer, there are more successive subcomponents on the line, there are more gaps between successive subcomponents on the line, and / or the size of those gaps is larger.

[0105] Additionally or alternatively, the line length is determined based on the workstations at 704. By way of example, method 700 optionally includes determining the line length based on one or more of the size of the workstations at 714, the number of workstations at 716, and / or the number and / or size of gaps between the workstations at 718. The line length is longer when there are more workstations, when the workstations are larger (e.g., wider), and / or when there are more and / or larger gaps between the workstations because more and / or larger workstations and / or gaps increase the distance a component must travel to pass through all of the workstations on a fractional pulse assembly line.

[0106] In some examples, the size of the workstations, the number of workstations, and / or the number and / or size of gaps between workstations are determined based on the divisibility of the component and / or workspace constraints. As an example, when a component is divisible into more sections, the number of workstations that can be pushed along the length of the component to simultaneously perform operations on the component increases. However, the number of workstations that can simultaneously perform operations on a component is limited by the physical size of the operation performance device. That is, the operation performance device may limit the amount by which a workstation can be reduced to accommodate more workstations, and in some examples, a workstation may be equal to or greater than the size of the operation performance device.

[0107] The divisibility of the component into smaller sections is determined based on one or more of the amount of similarity of the component's physical characteristics along its length, the location of the work operation to be performed on the component along its length (i.e., the points on the component where the work operation should be performed), and / or the repeatability of the work operation along its length (i.e., the amount of similarity of a given work operation to be performed on the component along its length). For example, the component may be broken down into shorter and shorter sections until a given operation (e.g., drilling a hole) becomes so dissimilar in different sections of the component that it becomes impractical for the operation to be performed on all sections consecutively (e.g., the work operation is no longer repeatable on each section). Thus, the determining step at 704 optionally includes determining a minimum common section length along which the component can be broken down while still maintaining sufficient similarity between the sections of the component such that the same work operation can be performed on all sections consecutively.

[0108] As previously discussed, reducing the size of a workstation can increase worker safety at least because it can reduce the size of the work-performing devices handled by the worker and / or reduce the amount the worker must travel to perform a work operation. Additionally, increasing the number of workstations simultaneously performing work on component parts can increase parallel processing of parts and / or increase production efficiency because less travel may be required to perform a work operation.

[0109] At 720, method 700 includes determining an average line speed. Determining the average line speed is based on the takt time. In particular, the average line speed, in some examples, is the average line speed required to meet the takt time. In some such examples, determining the average line speed takes into account scheduled worker breaks, servicing of work-performing devices at workstations, gaps in the assembly line (e.g., in assembly areas where various subcomponents are assembled into components (e.g., assembly area 430)), and / or parallel versus sequential processing of parts. In particular, sequential processing of parts at these gaps / gaps in the assembly line can create bottlenecks that require an increase in the average line speed of the assembly line.

[0110] By accounting for worker breaks, maintenance, and / or other scheduled gaps in the line where no work steps are being performed, the line can continue to move even though work is not being performed on one or more of the components on the line. By having the line substantially continuously pulse components on the line piecemeal and / or continue to pulse components on the line more regularly, incomplete work steps can be more easily identified because holdups in a continuously pulsing line are more visible (i.e., components downstream of the holdup can continue to move, while components upstream of the holdup can stop, thus providing a visual indication of where the holdup has occurred). In this way, workstation failures can be more easily and immediately identified and corrected than in traditional manufacturing approaches where components are not pulsed regularly, or are pulsed regularly but at much longer time intervals. In some instances, small time buffers can be created between work steps to accommodate slight delays in the work steps. However, for longer delays, line movement can be stopped upstream of the holdup, allowing management to easily identify and correct the holdup.

[0111] At 722, method 700 includes determining a pulse length based on one or both of a minimum workstation length and / or a minimum section length of the component. As discussed above at 704, the minimum workstation length may be limited by the physical size of the task-performing devices and / or the required spacing between task-performing devices. The minimum section length of the component may be determined based on the divisibility of the task along the component's length (i.e., the number of regular intervals along the component's length at which a given task can be performed in the same or substantially the same manner). The divisibility of the task may be determined based on the uniformity of the component along its length (different sections of the component) and / or the uniformity of the task to be performed along its length. As introduced above, the component may be grouped into sections of equal length, and the same and / or similar task may be repeatedly performed on each of the component's sections by pulsing the component past a workstation at a fixed pulse length and / or pulse frequency. This pulse length may therefore be equal to the length of each of the sections of the component, an integer multiple of this length, and / or X times this length. In this way, the working steps may be repeated in the same and / or similar manner at regular intervals along the length of the component.

[0112] Additionally or alternatively, the pulse length is equal to the minimum workstation length and / or an integer multiple of the minimum workstation length, and thus in such instances the component is pulsed by at least the minimum workstation length and / or by at least the shortest section of the component.

[0113] In some examples, the pulse length is determined based on the divisibility of the work process along the length of the component.

[0114] At 724, method 700 includes determining a pulse frequency based on one or more of the average line speed, the line length, and / or the pulse length. In particular, the pulse frequency may be the frequency necessary to achieve the average line speed given the line length and the pulse length. In particular, the line length may be divided by the average line speed to give the total line time. The line length may be divided by the pulse length to determine the number of pulses on the line. The number of pulses divided by the total line time gives the pulse frequency (i.e., the number of pulses per unit time). In that case, the pulse period (e.g., pulse period 462) is the time period between each pulse and may include both the work period during which work is being performed on the component and the time it takes to pulse the component (e.g., pulse duration 466).

[0115] At 726, the method 700 optionally includes building an assembly line based on one or more of the above specifications (eg, line length, pulse length, pulse frequency, etc.).

[0116] Illustrative, non-exclusive examples of inventive subject matter according to the present disclosure are described in the following enumerated sections.

[0117] A. An aircraft manufacturing system for repeatedly producing aircraft assemblies, each aircraft assembly comprising at least a first aircraft subassembly and a second aircraft subassembly, the aircraft manufacturing system comprising: a first manufacturing zone configured to repeatedly manufacture a first aircraft subassembly; a second manufacturing zone configured to repeatedly manufacture a second aircraft subassembly; a third manufacturing zone configured to receive a first aircraft subassembly from the first manufacturing zone, receive a second aircraft subassembly from the second manufacturing zone, and repeatedly assemble the first aircraft subassembly and the second aircraft subassembly into an aircraft assembly; and An aircraft manufacturing system comprising:

[0118] A1. The aircraft assembly is an aircraft, the first aircraft subassembly is a wing; the second aircraft assembly is a fuselage section; An aircraft manufacturing system as described in paragraph A.

[0119] A1.1 An aircraft manufacturing system as described in paragraph A1, wherein the fuselage section comprises a main passenger compartment portion of the fuselage.

[0120] A2. The aircraft manufacturing system of any one of paragraphs A to A1.1, wherein the first manufacturing zone and the second manufacturing zone are generally parallel to one another such that an overall flow direction of a first aircraft subassembly in the first manufacturing zone is generally parallel to an overall flow direction of a second aircraft subassembly in the second manufacturing zone.

[0121] A3. The aircraft manufacturing system of any one of paragraphs A-A2, wherein the first manufacturing zone comprises a first assembly line and the second manufacturing zone comprises a second assembly line.

[0122] A3.1. An aircraft manufacturing system as described in paragraph A3, wherein the first assembly line and the second assembly line each include a conveyor system, the conveyor system of the first assembly line configured to advance a first aircraft subassembly along the first assembly line within the first manufacturing zone, and the conveyor system of the second assembly line configured to advance a second aircraft subassembly along the second assembly line within the second manufacturing zone.

[0123] A3.2. An aircraft manufacturing system as described in paragraph A3 or A3.1, wherein the first assembly line and the second assembly line comprise workstations where work is performed on components of an aircraft assembly, and the work processes performed at adjacent workstations are different.

[0124] A3.2.1. An aircraft manufacturing system as described in paragraph A3.2, in which adjacent workstations comprise different robots, different machines, and / or different manufacturing personnel.

[0125] A3.2.2. An aircraft manufacturing system as described in paragraph A3.2 or A3.2.1, wherein the workstations are shorter in length than the first aircraft subassembly and the second aircraft subassembly such that two or more of the workstations perform work on the same subassembly simultaneously.

[0126] A3.2.3. An aircraft manufacturing system as described in paragraph A3.2.2 in which the workstations are of unequal length.

[0127] A3.2.4. An aircraft manufacturing system as described in any one of paragraphs A3.2 to A3.2.3, wherein each workstation on the first assembly line performs a unique type of work operation and / or each workstation on the second assembly line performs a unique type of work operation.

[0128] A3.2.5. An aircraft manufacturing system as described in any one of paragraphs A3.2 to A3.2.3, wherein each workstation on the first assembly line performs exactly one work operation and / or each workstation on the second assembly line performs exactly one work operation.

[0129] A3.3. An aircraft manufacturing system as described in any one of paragraphs A3.1 to A3.2.3, wherein the conveyor system in the first manufacturing zone is configured to pulse the first aircraft subassembly forward along the first assembly line in a piecemeal manner, and the conveyor system in the second manufacturing zone is configured to pulse the second aircraft subassembly forward along the second assembly line in a piecemeal manner.

[0130] A3.3.1. An aircraft manufacturing system as described in paragraph A3.3 when subject to any one of paragraphs A3.2 to A3.2.3, wherein the conveyor system in the first manufacturing zone is configured to advance the first aircraft subassembly at most a minimum length of a workstation during each pulse, and the conveyor system in the second manufacturing zone is configured to advance the second aircraft subassembly at most a minimum length of a workstation during each pulse.

[0131] A3.4. An aircraft manufacturing system as described in any one of paragraphs A3 to A3.3.1, wherein the first aircraft subassembly includes both a left wing and a right wing.

[0132] A3.4.1. An aircraft manufacturing system as described in paragraph A3.4, wherein the first assembly line is configured to deliver left wings to the third manufacturing zone in a final left wing orientation and deliver right wings to the third manufacturing zone in a final right wing orientation.

[0133] A3.4.1.1. An aircraft manufacturing system as described in paragraph A3.4, wherein the left wing is configured to be joined to the fuselage in a final left wing orientation and the right wing is configured to be joined to the fuselage in a final right wing orientation.

[0134] A4. The aircraft manufacturing system of any one of paragraphs A3.1 to A3.2.1, wherein the first manufacturing zone and the second manufacturing zone include doorways configured to allow components to be delivered to the workstations.

[0135] A4.1. The aircraft manufacturing system of paragraph A4, wherein the first manufacturing zone and the second manufacturing zone include a feeder line configured to orient one or more of the components in a desired orientation and advance the components away from the doorway and / or toward the first assembly line or the second assembly line.

[0136] A5. The aircraft manufacturing system of any one of paragraphs A-A4, wherein the first manufacturing zone and the second manufacturing zone are separated from each other by at most 3 kilometers (km).

[0137] A5.1. An aircraft manufacturing system as described in paragraph A5, wherein the first manufacturing zone and the second manufacturing zone are separated from each other by at least 10 meters (m).

[0138] A6. The aircraft manufacturing system of any one of paragraphs A-A5, wherein the third manufacturing zone is physically connected to the first manufacturing zone and the second manufacturing zone.

[0139] A7. The aircraft manufacturing system of any one of paragraphs A-A6, wherein the third manufacturing zone is physically separated from at least one of the first manufacturing zone and the second manufacturing zone.

[0140] A7.1. An aircraft production system as described in paragraph A7, wherein the third production zone is physically separated from the second production zone.

[0141] A7.1.1. An aircraft production system as described in paragraph A7.1, wherein the third production zone is separated from the second production zone by at least 5 m and at most 3 km.

[0142] A7.2. An aircraft production system as described in paragraph A7, wherein the third production zone is physically separated from the first production zone.

[0143] A7.2.1. An aircraft production system as described in paragraph A7.2, in which the third production zone is separated from the first production zone by at least 5 m and at most 3 km.

[0144] A7.3. An aircraft manufacturing system as described in any one of paragraphs A7 to A7.2.1, further comprising a delivery route extending along at least a portion of the perimeter of one or more of the first manufacturing zone, the second manufacturing zone, and the third manufacturing zone, the delivery route being configured to enable an electric vehicle to travel around at least a portion of one or more of the first manufacturing zone, the second manufacturing zone, and the third manufacturing zone.

[0145] A7.3.1. An aircraft manufacturing system as described in paragraph A7.3 when subject to paragraph A4 or A4.1, wherein the delivery route is configured to allow an electric vehicle to transport the component to the entrance or exit of the first manufacturing zone and / or the second manufacturing zone.

[0146] A8. The aircraft manufacturing system of any one of paragraphs A through A7.2, further comprising a hoist mechanism for lifting and transporting the first aircraft subassembly from the first manufacturing zone to the third manufacturing zone.

[0147] A8.1. An aircraft manufacturing system as described in paragraph A8, wherein the hoisting mechanism comprises a crane.

[0148] A8.2. An aircraft manufacturing system described in paragraph A8.2 when subject to paragraph A7.3 or A7.3.1, where one or more of the delivery paths extend below the hoist mechanism.

[0149] A8.3. An aircraft manufacturing system as described in any one of paragraphs A8 to A8.2 when subject to paragraph A3.4.1 or A3.4.1.1, wherein the hoist mechanism is configured to receive the left wing from the first manufacturing zone in a final left orientation and deliver the left wing to the third manufacturing zone in a final left orientation, and is configured to receive the right wing from the first manufacturing zone in a final right orientation and deliver the right wing to the third manufacturing zone in a final right orientation.

[0150] A9. The aircraft manufacturing system of any one of paragraphs A through A8.3, further comprising a fourth manufacturing zone configured to repeatedly manufacture a third aircraft subassembly.

[0151] A9.1. An aircraft manufacturing system as described in paragraph A9, wherein the third aircraft subassembly comprises one or more of a fuselage cockpit section, a fuselage tail section, and a fuselage mid-section, the fuselage mid-section including one or both of a fuselage wing box and an overwing section.

[0152] A9.2. The aircraft manufacturing system of paragraph A9 or A9.1, wherein the third manufacturing zone is further configured to receive a third aircraft subassembly from the fourth manufacturing zone and repeatedly assemble the third aircraft subassembly with the first aircraft subassembly and the second aircraft subassembly into an aircraft assembly.

[0153] A9.3. An aircraft manufacturing system as described in any one of paragraphs A9 to A9.2, wherein a fourth manufacturing zone is located between the first manufacturing zone and the second manufacturing zone.

[0154] A9.4. The aircraft manufacturing system of any one of paragraphs A9 to A9.3, wherein the fourth manufacturing zone comprises a hangar bay configured to accommodate each of the third aircraft subassemblies during assembly and manufacturing of the third aircraft subassemblies.

[0155] A9.5. An aircraft manufacturing system as described in any one of paragraphs A9 to A9.4, wherein the fourth manufacturing zone includes a doorway configured to allow components to be delivered to the hangar bay.

[0156] A9.6. An aircraft manufacturing system as described in paragraph A9.5, wherein the fourth manufacturing zone includes a feeder line that directs the component in a desired orientation.

[0157] A9.7. An aircraft manufacturing system as described in any one of paragraphs A9 to A9.6, wherein the fourth manufacturing zone is generally parallel to the first manufacturing zone and the second manufacturing zone such that the overall flow direction of the third aircraft subassembly is generally parallel to the overall flow direction of the first aircraft subassembly and the overall flow direction of the second aircraft subassembly.

[0158] A9.8. An aircraft manufacturing system as described in any one of paragraphs A9 to A9.7, wherein the fourth manufacturing zone is physically connected to the third manufacturing zone.

[0159] A9.9. An aircraft manufacturing system as described in any one of paragraphs A9 to A9.7, wherein the fourth manufacturing zone is physically separated from the third manufacturing zone.

[0160] A9.9.1. An aircraft production system as described in paragraph A9.9, wherein the third production zone is separated from the fourth production zone by at least 5 m.

[0161] A9.10. An aircraft manufacturing system as described in any one of paragraphs A9 to A9.9.1 when subject to paragraph A7.3 or A7.3.1, wherein the delivery path extends around at least a portion of the perimeter of the fourth manufacturing zone, and the delivery path is configured to enable an electric vehicle to travel around at least a portion of the perimeter of the fourth manufacturing zone.

[0162] A.9.10.1. An aircraft manufacturing system as described in paragraph A9.10, wherein the delivery route is configured to allow an electric vehicle to deliver the component to the entrance / exit of the fourth manufacturing zone.

[0163] A9.11. An aircraft manufacturing system as described in any one of paragraphs A9 to A9.10.1, further comprising one or more transfer devices configured to transfer components to, from, and / or between one or more of the manufacturing zones.

[0164] A9.11.1. An aircraft manufacturing system described in paragraph A9.11 when subject to any one of paragraphs A8 to A8.2, in which one or more transfer devices include a hoist mechanism.

[0165] A9.11.2. An aircraft manufacturing system as described in paragraph A9.11 or A9.11.1, wherein the one or more transfer devices comprise one or more of a hoist mechanism, a conveyor system, and a shuttle.

[0166] A9.11.3. An aircraft production system as described in paragraph A9.11.2, in which the shuttle comprises an electric vehicle.

[0167] A9.11.4. An aircraft manufacturing system as described in any one of paragraphs A9.11 to A9.11.2, wherein the one or more transfer devices include a first transfer device configured to transfer a first aircraft subassembly between the first manufacturing zone and a third manufacturing zone, and a second transfer device configured to transfer a second aircraft subassembly between the second manufacturing zone and the third manufacturing zone.

[0168] A9.11.5. An aircraft manufacturing system as described in paragraph A9.11.4 when subject to any one of paragraphs A8 to A8.2, wherein the first transfer device comprises a hoist mechanism.

[0169] A9.11.6 An aircraft manufacturing system as described in any one of paragraphs A9.11 to A9.11.5 when dependent on any one of paragraphs A9 to A9.10, comprising a third transfer device configured to transfer one or more of the third aircraft subassemblies between the fourth manufacturing zone and the third manufacturing zone, wherein the one or more transfer devices are configured to transfer one or more of the third aircraft subassemblies between the fourth manufacturing zone and the third manufacturing zone.

[0170] A9.11.7. An aircraft manufacturing system as described in any one of paragraphs A9.11 to A9.11.6 when dependent on any one of paragraphs A9 to A9.10, wherein the one or more transfer devices include a fourth transfer device configured to transfer one or more of the third aircraft subassemblies between the fourth manufacturing zone and the second manufacturing zone.

[0171] B. A method for repeatedly manufacturing an aircraft assembly, comprising: assembling the first aircraft subassembly and the second aircraft subassembly in parallel on separate assembly lines in a common geographic region; transporting the first aircraft subassembly and the second aircraft subassembly to a final assembly facility located within the same common geographic region; A method comprising:

[0172] B1. The method of paragraph B, wherein the first aircraft subassembly is a wing of the aircraft and the second aircraft subassembly is a portion of the fuselage of the aircraft.

[0173] B2. The method of paragraph B1, wherein the step of concurrently assembling the first aircraft subassembly and the second aircraft subassembly includes assembling the first aircraft subassembly and the second aircraft subassembly concurrently in time and / or space.

[0174] B3. The method of paragraph B1 or B2, wherein the step of assembling the first aircraft subassembly and the second aircraft subassembly in parallel on separate assembly lines includes: sending the first aircraft subassembly and / or a component of the first aircraft subassembly down the first assembly line; and sending the second aircraft subassembly and / or a component of the second aircraft subassembly down the second assembly line.

[0175] B3.1. The method of paragraph B3, wherein the step of assembling the first aircraft subassembly and the second aircraft subassembly in parallel on separate assembly lines in a common geographic area includes one or both of the steps of sequentially feeding different components of the first aircraft subassembly down the first assembly line and sequentially feeding different components of the second aircraft subassembly down the second assembly line.

[0176] B3.1.1. The method of paragraph B3.1, wherein the step of sequentially feeding different components of the first aircraft subassembly down the first assembly line includes sequentially feeding both the right and left wing and / or both wing components down the first assembly line.

[0177] B3.2 The method of any one of paragraphs B3 to B3.1.1, wherein the step of feeding the first aircraft subassembly and / or component of the first aircraft subassembly down the first assembly line comprises pulsing the first aircraft subassembly and / or component of the first aircraft subassembly piecemeal down the first assembly line, and the step of feeding the second aircraft subassembly and / or component of the second aircraft subassembly down the second assembly line comprises pulsing the second aircraft subassembly and / or component of the second aircraft subassembly piecemeal down the second assembly line.

[0178] B3.3. The method of any one of paragraphs B3 to B3.2, wherein the steps of feeding the first aircraft subassembly and / or component of the first aircraft subassembly down the first assembly line and feeding the second aircraft subassembly and / or component of the second aircraft subassembly down the second assembly line include advancing the first aircraft subassembly and / or component of the first aircraft subassembly and the second aircraft subassembly and / or component of the second aircraft subassembly in parallel general flow directions.

[0179] B3.4. The method of any one of paragraphs B3 to B3.3, wherein the steps of feeding the first aircraft subassembly and / or component of the first aircraft subassembly down the first assembly line and feeding the second aircraft subassembly and / or component of the second aircraft subassembly down the second assembly line include feeding the first aircraft subassembly and / or component of the first aircraft subassembly and the second aircraft subassembly and / or component of the second aircraft subassembly down the first assembly line and the second assembly line, respectively, at a common average speed.

[0180] B3.4.1. The method of paragraph B3.4 when dependent on paragraph B3.2, wherein sending the first aircraft subassembly and / or components of the first aircraft subassembly and the second aircraft subassembly and / or components of the second aircraft subassembly down the first assembly line and the second assembly line, respectively, at a common average velocity includes fractionally pulsating the first aircraft subassembly and / or components of the first aircraft subassembly and the second aircraft subassembly and / or components of the second aircraft subassembly at a common average velocity.

[0181] B4. The method of any one of paragraphs B through B3.3, wherein transferring the first aircraft subassembly to the final assembly facility includes hoisting and transporting the first aircraft subassembly to the final assembly facility.

[0182] B5. The method of any one of paragraphs B to B3, wherein transferring the first aircraft subassembly to a final assembly facility includes transferring the first aircraft subassembly at most 1 km.

[0183] B6. The method of any one of paragraphs B to B5, further comprising feeding components along one or more feeder lines to various locations along the first assembly line and / or the second assembly line, respectively.

[0184] B6.1. The method of paragraph B6, wherein the step of supplying the component includes the steps of orienting the component and advancing the component toward one or both of the first assembly line and the second assembly line.

[0185] B6.2. The method of B6 or B6.1, wherein assembling the first aircraft subassembly and the second aircraft subassembly includes adding components to precursor structures of one or more of the first aircraft subassembly and the second aircraft subassembly.

[0186] C. A method for repeatedly manufacturing an aircraft, comprising: periodically advancing the aircraft component down the assembly line a length less than the length of the aircraft component. A method comprising:

[0187] C1. The step of cyclically advancing is The aircraft component is advanced a pulse length that is less than the length of the aircraft component, and then Stopping the movement of aircraft components for a period of time, and then advancing the aircraft component a pulse length; The method of claim C, comprising:

[0188] C2. The method of claim C or C1, further comprising performing work on the aircraft component at a workstation during periods when the aircraft component is not moving.

[0189] C2.1. The method of paragraph C2, wherein performing an operation on the aircraft component includes adding a component to the aircraft component, removing material from the aircraft component, and / or modifying the aircraft component.

[0190] C2.2. The method of paragraph C2 or C2.1, wherein performing work on an aircraft component at the workstations includes performing different types of work operations at two or more of the workstations.

[0191] C.2.2.1. The method of Clause C2.2, wherein the step of performing different types of work operations at two or more of the workstations includes performing different types of work operations at each of the workstations.

[0192] C.2.3. The method of clause C2.2 or C2.2.1, wherein performing different types of work operations at two or more of the workstations includes simultaneously performing different types of work operations at two or more of the workstations.

[0193] C2.4. The method of any one of paragraphs C through C.2.3, wherein the step of performing work on the aircraft component at the workstations includes performing exactly one type of work process at each of the workstations.

[0194] C3. The method of any one of paragraphs C through C2.4, further comprising feeding components to an assembly line via one or more feeder lines.

[0195] C4. The method of any one of paragraphs C-C3, wherein the step of cyclically advancing includes cyclically advancing the aircraft component the same amount during each cyclic advance.

[0196] C5. The method of any one of paragraphs C to C4, further comprising: advancing the aircraft components along the assembly line at a common average velocity; and varying one or both of the pulse frequency and pulse length of the periodic advancement in different sections of the assembly line.

[0197] C5.1. Varying pulse frequency and pulse length in different sections of an assembly line pulsing an aircraft component in a first section of an assembly line at a first frequency and advancing the aircraft component a first distance during each pulse; pulsing the aircraft component in a second section of the assembly line at a second frequency higher than the first frequency and advancing the aircraft component a second distance during each pulse that is less than the first distance; The method of claim C5, comprising:

[0198] C5.2. The method of paragraph C5 or C5.1, wherein the pulse frequency and pulse length are varied based on the amount of divisibility of the work process to be performed on the aircraft component and / or the size of one or more workstations on the assembly line.

[0199] C5.2.1. The method of paragraph C5.2, in which the pulse frequency is increased and the pulse length is decreased due to an increase in the divisibility of the work processes to be performed on the aircraft component and / or a decrease in the size of one or more workstations.

[0200] D. A method for designing an aircraft manufacturing system, comprising: determining a fraction pulse length for fractionally pulsing one or more components of the aircraft on the fraction pulse assembly line based on one or both of a minimum workstation length of one or more assembly line workstations and / or a minimum section length of one or more work steps along the length of the one or more components; A method comprising:

[0201] D1. The method of paragraph D, wherein the minimum workstation length of one or more assembly line workstations is determined based on the physical size of one or more work performance devices included in the one or more assembly line workstations.

[0202] D1.2. The method of paragraph D1, wherein the fragment pulse length is equal to the smallest workstation length of one or more workstations, an integer multiple of this length, and / or one Xth of this length, where X is an integer.

[0203] D2. The method of any one of paragraphs D to D1.2, wherein the minimum section length of one or more work steps is determined based on the divisibility of the one or more work steps along the length of one or more components.

[0204] D2.1. The method of paragraph D2, wherein the divisibility of one or more work operations along the length of one or more components is determined based on one or more of: where the one or more work operations are to be performed on one or more components; an amount of similarity of given work operations to be performed on the components along the length of the components; and an amount of similarity of one or more physical characteristics of the components along the length of the components.

[0205] D2.2. The method of paragraph D2 or D2.1, wherein the fragment pulse length is equal to the minimum section length, an integer multiple of this length, and / or X times this length, where X is an integer.

[0206] D3. The method of any one of paragraphs D to D2.2, further comprising determining the number of assembly lines to include in the aircraft manufacturing system based on one or more of the number of aircraft subassemblies to be produced, the amount of similarity of work operations to be performed on the aircraft subassemblies and / or components of the aircraft subassemblies, and the amount of similarity of physical characteristics of the aircraft subassemblies and / or components of the aircraft subassemblies.

[0207] D3.1 The method described in paragraph D3, where the aircraft subassembly includes left wing, right wing, and / or fuselage sections.

[0208] D3.2. The method described in paragraph D3 or D3.1, wherein the step of determining the number of assembly lines to include in the aircraft manufacturing system includes determining whether different types of aircraft subassemblies and / or components of such aircraft subassemblies should be produced together on the same assembly line or separately on different assembly lines.

[0209] D3.2.1. The method described in paragraph D3.2, where the number of assembly lines is reduced when more aircraft subassemblies and / or components are produced on the same assembly line.

[0210] D3.3. The method of any one of paragraphs D3 to D3.2.1, wherein the step of determining the number of assembly lines to be included in the aircraft manufacturing system includes determining whether different types of aircraft subassemblies and / or components of such aircraft subassemblies should be produced in parallel and / or sequentially with each other.

[0211] D3.3.1. The method described in paragraph D3.3 where the number of assembly lines increases when more aircraft subassemblies and / or components are produced in parallel.

[0212] D4. The method of any one of paragraphs D-D3, further comprising determining a pulse frequency based on one or both of an average speed of the fractional pulse assembly line and a fractional pulse length.

[0213] D4.1. The method of paragraph D4, wherein the average speed of the fragment pulse assembly line is determined based on one or more of the distance traveled by components on the fragment pulse assembly line, the production rate of the components, and the number of assembly lines producing the components in parallel.

[0214] D4.1.1. The method described in paragraph D4.1 in which the component production rate is determined based on the aircraft takt time and the number of components contained within the aircraft.

[0215] D4.1.2. The method of D4.1 or D4.1.1, wherein the average speed of the fragment pulse assembly line decreases as the number of assembly lines producing components in parallel increases.

[0216] D4.1.3. The method of any one of paragraphs D4.1 through D4.1.2, wherein the distance traveled by components on the fractional pulse assembly line is determined based on the length of the components, the length of one or more gaps separating components on the fractional pulse assembly line, and / or the length of the fractional pulse assembly line.

[0217] D4.2. The method of any one of paragraphs D4 through D4.1.3, wherein the fractional pulse frequency is equal to the average speed of the fractional pulse assembly line divided by the fractional pulse length.

[0218] Construct an aircraft manufacturing system designed in accordance with the methods described in any one of paragraphs D5.D through D4.2.

[0219] E1. A method of operating a fractional pulse assembly line and / or repeatedly manufacturing an aircraft, comprising: pulsing the components piecemeal down the assembly line. wherein the fractional pulsing step includes periodically advancing the component down the assembly line a length that is less than the length of the component.

[0220] E2. The method of paragraph E1, wherein the fractional pulsing step includes simultaneously performing different types of operations on the component at different workstations on the assembly line.

[0221] E3. The method of paragraph E1 or E2, further comprising pulsing two or more different types of components piecemeal in succession to one another down the assembly line.

[0222] E4. The method of any one of paragraphs E1-E3, further comprising pulsing two or more components piecemeal down two or more different assembly lines in parallel with each other.

[0223] E5. The method of paragraph E4, wherein two or more different assembly lines are located within different manufacturing zones.

[0224] E6. The method of paragraph E4 or E5, further comprising one or more of the following steps: merging two or more different assembly lines to form a common assembly line; assembling two or more components to form a component assembly; and / or pulsing the component assembly piecemeal down the common assembly line.

[0225] E7. The method of any one of paragraphs E4 to E6, further comprising merging two or more different assembly lines to form a common assembly line, wherein pulsing two or more components piecemeal down the two or more different assembly lines in parallel with one another comprises pulsing the components in parallel at the same average line speed such that the components are provided to the common assembly line at approximately the same time (i.e., just in time).

[0226] E8. The method of any one of paragraphs E1 to E6, further comprising the subject matter of any one of paragraphs B1 to D5.

[0227] Although the disclosure herein refers to aircraft assemblies and aircraft, the inventive subject matter herein may be applied to any manufactured assembly constructed from multiple components. Accordingly, the term “aircraft” herein may be replaced with one or more of the broader terms “apparatus,” “large apparatus,” “assembly,” “large assembly,” “object,” “large object,” “manufactured assembly,” or “large manufactured assembly” without departing from the scope of the present disclosure. Illustrative, non-exclusive examples of other manufactured assemblies to which the disclosed inventive subject matter may be applied include, but are not limited to, marine craft, ships, submarines, land vehicles, space vehicles, rail vehicles, machinery, wind turbines, and buildings.

[0228] As used herein, the terms “adapted” and “configured” mean that an element, component, or other subject matter is designed and / or intended to perform a given function. Thus, the use of the terms “adapted” and “configured” should not be interpreted to mean that a given element, component, or other subject matter is simply “capable of” performing a given function, but rather that the element, component, or other subject matter is specifically selected, made, implemented, utilized, programmed, and / or designed to perform that function. It is also within the scope of this disclosure that elements, components, and / or other described subject matter that are described as adapted to perform a particular function may additionally or alternatively be said to be configured to perform that function, and vice versa. Similarly, subject matter that is described as configured to perform a particular function may additionally or alternatively be said to be operative to perform that function.

[0229] As used herein, the term "and / or" placed between a first entity and a second entity means one of: (1) the first entity, (2) the second entity, or (3) the first entity and the second entity. Multiple entities listed with "and / or" should be construed similarly, i.e., "one or more" of the entities are conjoined. Optionally, other entities, whether related to the specifically identified entities or not, may be present other than the entities specifically identified by the "and / or" clause. Thus, as a non-limiting example, a reference to "A and / or B," when used with open-ended language such as "comprising," can refer, in one example, to A only (optionally including entities other than B), in another example, to B only (optionally including entities other than A), and in another example, to both A and B (optionally including other entities). These entities can refer to elements, actions, structures, sections, operations, values, etc.

[0230] The various disclosed elements of the apparatus and steps of the methods disclosed herein are not required for all apparatus and methods according to the present disclosure, and the present disclosure includes all novel and non-obvious combinations and subcombinations of the various elements and steps disclosed herein. Moreover, one or more of the various elements and steps disclosed herein may define independent inventive subject matter separate from the entirety of the disclosed apparatus or method. Thus, such inventive subject matter need not relate to the particular apparatus and methods expressly disclosed herein, and such inventive subject matter may find utility in apparatus and / or methods not expressly disclosed herein. [Explanation of symbols]

[0231] 10. Aircraft Manufacturing System 12 Manufacturing Zone 14 Building 16 Entrance / Exit 18 Routes 20 First Manufacturing Zone 38 First Aircraft Subassembly 40 Second Manufacturing Zone 58 Second Aircraft Subassembly 60 Third Manufacturing Zone 78 Aircraft assembly 80 4th Manufacturing Zone 84 fixed bays, parking spaces, hangars 98 Third Aircraft Subassembly 100 Transfer device 102 Hoist mechanism 104 Conveyor System 106 Shuttle 110 First Transfer Device 112 Second Transfer Device 114 Third Transfer Device 116 Fourth Transport Device 120 assembly lines 122 Drive mechanism 124 Mechanical Linkages 126 Fragment Pulse Assembly Line 130 First Assembly Line 132 Second Assembly Line 134 Third Assembly Line 140 Feeder Line 200 components 202 Base Parts 204 Subassembly parts 206 Aircraft Subassembly Precursors 300 aircraft 302 Torso 304 forward fuselage section 306 Nose and cockpit parts 308 Front main passenger compartment 310 Intermediate fuselage section, wing-fuselage section, intermediate main cabin section 312 aft fuselage section 314 Rear main cabin section 316 Tail part 318 Empennage, empennage, empennage assembly 320 wings 322 Left Wing 324 Right Wing 330 Engine 340 Section Assembly, Aircraft Large Structure 400 Partial Pulse Assembly Line Example 402 Components 404 Subcomponents 406 Components 407 First Component 408 Second Component 410 Assembly Line Workstation 412 Workstation 1 414 Second Workstation 420 Work execution device 422 Robot 424 Machinery 426 human workers 428 Tools 430 Assembly Area 434 Queue 440 Conventional Pulsation Assembly Line 450 graphs 452 graphs 454 graphs 460 pulse length 462 pulse period 464 Work cycle 466 Pulse Period 500 ways 600 ways 700 methods

Claims

1. An aircraft manufacturing system (10) for repeatedly manufacturing aircraft assemblies, the aircraft manufacturing system (10) comprising: a first manufacturing zone (20) for repeatedly manufacturing first aircraft subassemblies (38), the first aircraft subassemblies (38) being aircraft wings, the aircraft wings including a left wing and a right wing; a second manufacturing zone (40) for repeatedly manufacturing a second aircraft subassembly (58), said second aircraft subassembly (58) being a portion of an aircraft fuselage; a third manufacturing zone (60) that receives the first aircraft subassembly (38) from the first manufacturing zone (20) and the second aircraft subassembly (58) from the second manufacturing zone (40), and repeatedly assembles the first aircraft subassembly (38) and the second aircraft subassembly (58) into the aircraft assembly; a first transfer device (110) configured to transfer the left wing in a final left wing orientation and the right wing in a final right wing orientation from the first manufacturing zone (20) to the third manufacturing zone (60), wherein the left wing is configured to be coupled to the aircraft fuselage in the final left wing orientation and the right wing is configured to be coupled to the aircraft fuselage in the final right wing orientation; An aircraft manufacturing system (10) comprising:

2. 2. The aircraft manufacturing system (10) of claim 1, wherein the first manufacturing zone (20) comprises a first assembly line (130) and the second manufacturing zone (40) comprises a second assembly line (132).

3. 3. The aircraft manufacturing system (10) of claim 2, wherein the first assembly line (130) and the second assembly line (132) comprise workstations (410) where operations are performed on components (200) for the aircraft assembly, and adjacent workstations (410) perform different work processes.

4. 4. The aircraft manufacturing system of claim 3, wherein the workstations are shorter in length than the first aircraft subassembly and the second aircraft subassembly such that two or more of the workstations perform work on the same subassembly simultaneously.

5. 3. The aircraft manufacturing system of claim 2, wherein the first assembly line and the second assembly line each include a conveyor system, the conveyor system of the first assembly line configured to pulse the first aircraft subassembly piecemeal along the first assembly line within the first manufacturing zone, and the conveyor system of the second assembly line configured to pulse the second aircraft subassembly piecemeal along the second assembly line within the second manufacturing zone.

6. 3. The aircraft manufacturing system of claim 2, wherein the first manufacturing zone and the second manufacturing zone include a feeder line configured to orient one or more of the components in a desired orientation and advance the components toward the first assembly line or the second assembly line.

7. 2. The aircraft manufacturing system (10) of claim 1, further comprising a fourth manufacturing zone (80) that repeatedly manufactures a third aircraft subassembly (98), wherein the third manufacturing zone (60) is further configured to receive the third aircraft subassembly (98) from the fourth manufacturing zone (80) and repeatedly assemble the third aircraft subassembly (98) with the first aircraft subassembly (38) and the second aircraft subassembly (58) into the aircraft assembly.

8. An aircraft manufacturing system (10) as described in claim 1, further comprising a second transfer device (112) configured to transfer the second aircraft subassembly (58) between the second manufacturing zone (40) and the third manufacturing zone (60).

9. A method (500) for repeatably manufacturing aircraft assemblies, comprising: Assembling (502) a first aircraft subassembly (38) and a second aircraft subassembly (58) in parallel on separate assembly lines in a common geographic region; transferring (522) the first aircraft subassembly (38) and the second aircraft subassembly (58) to a final assembly facility located within the common geographic region; Including, the first aircraft subassembly (38) is a wing of an aircraft and the second aircraft subassembly (58) is a portion of a fuselage of an aircraft; transferring the first aircraft subassembly (38) and the second aircraft subassembly (58) to the final assembly facility includes transferring the first aircraft subassembly (38) and the second aircraft subassembly (58) by at most 1 km; assembling the first aircraft subassembly (38) includes manufacturing a left wing in a final left wing orientation and manufacturing a right wing in a final right wing orientation; the step of transferring the first aircraft subassembly to the final assembly facility includes delivering the left wing in the final left wing orientation to the final assembly facility and delivering the right wing in the final right wing orientation to the final assembly facility.

10. 10. The method of claim 9, wherein assembling the first aircraft subassembly and the second aircraft subassembly in parallel on separate assembly lines comprises: sending one or both of the first aircraft subassembly and a component of the first aircraft subassembly down a first assembly line; and sending one or both of the second aircraft subassembly and a component of the second aircraft subassembly down a second assembly line.

11. 11. The method of claim 10, wherein assembling the first aircraft subassembly and the second aircraft subassembly on separate assembly lines in parallel in a common geographic region includes one or both of: sequentially feeding different components of the first aircraft subassembly down the first assembly line; and sequentially feeding different components of the second aircraft subassembly down the second assembly line.

12. 11. The method of claim 10, wherein sending the one or both of the first aircraft subassembly and the component of the first aircraft subassembly down the first assembly line comprises pulsing the one or both of the first aircraft subassembly and the component of the first aircraft subassembly piecemeal down the first assembly line, and sending the one or both of the second aircraft subassembly and the component of the second aircraft subassembly piecemeal down the second assembly line comprises pulsing the one or both of the second aircraft subassembly and the component of the second aircraft subassembly piecemeal down the second assembly line.

13. 11. The method of claim 10, wherein the steps of feeding the one or both of the first aircraft subassembly and the component of the first aircraft subassembly down the first assembly line and feeding the one or both of the second aircraft subassembly and the component of the second aircraft subassembly down the second assembly line comprise feeding the one or both of the first aircraft subassembly and the component of the first aircraft subassembly and the one or both of the second aircraft subassembly and the component of the second aircraft subassembly down the first assembly line and the second assembly line, respectively, at a common average velocity.

14. 11. The method (500) of claim 10, further comprising feeding components (200) along one or more feeder lines (140) to various locations along one or both of the first assembly line (130) and the second assembly line (132).

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