Aircraft assembly line

Abstract

To reduce amounts of space required for fabrication and assembly at a factory floor, increase throughput, and reduce downtime.SOLUTION: A method includes: receiving a half barrel section 117, 127 of a fuselage in an assembly line 110, 120 having a plurality of serially arranged work stations 114, 124; advancing the half barrel section 117, 127 in a process direction 199 through the assembly line 110, 120 such that the half barrel section 117, 127 extends across at least a portion of the work stations 114, 124; and performing work on the half barrel section 117, 127 with the portion of the work stations 114, 124 simultaneously.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001]

[0001] This disclosure relates to the field of aircraft, and more particularly to the manufacture of aircraft.

Background Art

[0002]

[0002] In the aerospace industry, processes related to the transport and assembly of airframe components are carried out within fixed cells. In each cell, the structure is scanned and / or indexed, and then tools, equipment, and / or workers enter a part of the structure where they must work in that cell. Every time a new structure is brought into the cell, this scanning and / or indexing process is performed. Further, when the structure moves to the next cell, it is scanned again and / or indexed, and the necessary tools, equipment, and / or workers are brought to a part of the structure where work needs to be done within that cell. Current assembly methods require tools, tooling, and technicians to enter a barrel section, which is part of the fuselage, through the barrel end or an access point. The tooling and tools need to be installed in place within the barrel section. When the work is completed, the tooling, tools, and technicians must exit through the barrel end or an access point.

[0003]

[0003] Therefore, it is desirable to have a method and apparatus that takes into account at least some of the above problems, as well as other possible problems.

Summary of the Invention

[0004]

[0004] Embodiments described herein provide continuous line assembly layouts and systems that enable work to be performed on the movement of machine components that are continuously pulsed or moving in the process direction to traverse a path of stations performing work on machine components. Work may include laying up preforms for curing into composite parts, curing composite parts in an autoclave, mounting frames, cutting holes for windows or doors, etc. These arrangements offer technical advantages over prior systems by reducing the space required for manufacturing and assembly on the factory floor, increasing throughput, and reducing downtime.

[0005]

[0005] Other exemplary embodiments (for example, methods and computer-readable media related to the embodiments described above) may also be described later. The features, functions, and advantages described above can be realized individually in various embodiments or in combination in yet another embodiment, and further details of these embodiments can be understood by referring to the following description and drawings.

[0006]

[0006] Some embodiments of the present disclosure are described hereby for illustrative purposes only with reference to the accompanying drawings. In all drawings, the same reference numerals represent the same element or element of the same type. [Brief explanation of the drawing]

[0007] [Figure 1]

[0007] An aircraft manufactured from a half-barrel section is illustrated. [Figure 2]

[0008] An illustration shows the assembly environment of a factory in an exemplary embodiment. [Figure 3]

[0009] An assembly line in a factory in an exemplary embodiment is illustrated. [Figure 4]

[0010] This is a flowchart illustrating a method for assembling an aircraft fuselage using the assembly environment shown in Figure 2, in an exemplary embodiment. [Figure 5]

[0011] Figure 2 illustrates in detail a portion of the assembly environment, including parallel and serial assembly lines for processing the upper and lower sections of the fuselage. [Figure 6]

[0012] This is a flowchart illustrating a method for utilizing the hybrid manufacturing system shown in Figure 5 in an exemplary embodiment. [Figure 7]

[0013] The lower section of the fuselage in the exemplary embodiment is shown inverted. [Figure 8]

[0014] A cross-sectional view of the torso in an exemplary embodiment is shown. [Figure 9]

[0015] This diagram illustrates the attachment of the splice plate as the upper half-barrel section moves along the assembly line. [Figure 10]

[0016] The illustration shows how a splice plate is used to join a half-barrel section of a fuselage in an exemplary embodiment. [Figure 11] The illustration shows how a splice plate is used to join a half-barrel section of a fuselage in an exemplary embodiment. [Figure 12]

[0017] This flowchart illustrates a method for attaching splice plates to join fuselage sections in an exemplary embodiment. [Figure 13]

[0018] This flowchart illustrates a method for simultaneously working on a single section of a fuselage through several stations on an assembly line in an exemplary embodiment. [Figure 14]

[0019] This is a flowchart illustrating the method for assembling the cycle time in an exemplary embodiment. [Figure 15]

[0020] A broad overview of the control components of the production system in an exemplary embodiment is provided. [Figure 16]

[0021] This is a flowchart illustrating a further method for assembling the cycle time in an exemplary embodiment. [Figure 17]

[0022] A flowchart illustrating a further tact time assembly method in an exemplary embodiment. [Figure 18]

[0023] A flowchart of an aircraft manufacturing and maintenance method in an exemplary embodiment [Figure 19]

[0024] A block diagram of an aircraft in an exemplary embodiment.

Embodiments for Carrying Out the Invention

[0008]

[0025] Specific exemplary embodiments of the present disclosure are provided by the drawings and the following description. Therefore, those skilled in the art can devise various devices not explicitly described or illustrated in this specification to embody the principles of the present disclosure, and it should be understood that they are included within the scope of the present disclosure. Furthermore, any examples described in this specification are for assisting in understanding the principles of the present disclosure and should not be construed as being limited to the specifically described examples and conditions. As a result, the present disclosure is not limited to the specific embodiments or examples described hereinafter, but is limited by the scope of the claims.

[0009]

[0026] The airframe components contemplated herein can be manufactured from metal or as composite parts. Composite parts such as carbon fiber reinforced polymer (CFRP) parts are first laid up in multiple layers collectively referred to as preforms. The individual fibers within each layer of the preform are aligned parallel to each other, but separate layers exhibit separate fiber orientations to enhance strength along the part in various dimensions of the resultant composite part. The preform includes a viscous resin that solidifies to make the composite part (e.g., for use in an aircraft). Carbon fibers impregnated with an uncured thermosetting resin or a thermoplastic resin are referred to as “prepregs”. Other types of carbon fibers include “dry fibers” that are not impregnated with a thermosetting resin but may include a tackifier or binder. Resin is injected into the dry fibers prior to curing. With respect to thermosetting resins, curing is a one-way process referred to as curing, while with respect to thermoplastic resins, the resin becomes viscous when reheated.

[0010]

[0027] Referring now to FIG. 1, a view of an aircraft 10 in which an exemplary embodiment can be implemented is shown. In this exemplary embodiment, the aircraft 10 has a right wing 15 and a left wing 16 attached to a fuselage 12. Each of the engines 14 is attached to the right wing 15 and the left wing 16. Embodiments of the aircraft 10 with additional engines 14 and different engine arrangements are known. The fuselage 12 includes a tail 18 and a nose portion 38. The horizontal stabilizers 20, 21, and the vertical stabilizer 23 are attached to the tail 18 of the fuselage 12. The aircraft 10 is an example of an aircraft in which most of the fuselage 12 is formed from several semi-barrel sections 24, the manufacture of which is partially illustrated in FIG. 2. When several semi-barrel sections 24 are attached together, they form most of the fuselage 12.

[0011]

[0028] As described, the fuselage 12 is manufactured from several half-barrel sections 24. Each half-barrel section 24 is configured to be either an upper half-barrel section (e.g., upper half-barrel sections 40-1, 40-2, 40-3, 40-4, or 40-5) or a lower half-barrel section (e.g., lower half-barrel sections 42-1, 42-2, 42-3, 42-4, or 42-5), which are eventually joined together to form a complete barrel section 44. The upper half-barrel sections may generally be referred to as upper half-barrel sections 40. The lower half-barrel sections may generally be referred to as lower half-barrel sections 42. Figure 1 illustrates a complete barrel section 44 including 44-1, 44-2, 44-3, 44-4, and 44-5. For completeness, a complete barrel section 44-1 is manufactured using the upper half-barrel section 40-1 and the lower half-barrel section 42-1; a complete barrel section 44-2 is manufactured using the upper half-barrel section 40-2 and the lower half-barrel section 42-2; a complete barrel section 44-3 is manufactured using the upper half-barrel section 40-3 and the lower half-barrel section 42-3; a complete barrel section 44-4 is manufactured using the upper half-barrel section 40-4 and the lower half-barrel section 42-4; and a complete barrel section 44-5 is manufactured using the upper half-barrel section 40-5 and the lower half-barrel section 42-5. Complete barrel sections 44-1 and 44-2 correspond to sight line AA, and the diagram illustrates that the complete barrel sections 44 are fastened in series within the fuselage 12. The lower half-barrel section 42-3 may also be referred to as the wing box when wings 15 and 16 are attached to this section.

[0012]

[0029] All of the above-mentioned half-barrel sections (for example, the upper half-barrel section 40 and the lower half-barrel section 42) will generally be referred to as half-barrel sections 24 unless otherwise specified. As shown in Figure 1, each half-barrel section 24 includes one or more frames 146 separated by a frame pitch 147, which helps to define the inner mold line 60 and the outer mold line 62 for the half-barrel section 24. In some embodiments, the half-barrel section 24 includes hardened composite or metal outer sections (such as window surrounds 145 and door surrounds 145-1 (view AA) and sections awaiting frame 146 mounting) to increase rigidity.

[0013]

[0030] Figure 2 illustrates an assembly environment 100, or system 100, in an exemplary embodiment. The assembly environment 100 includes an arrangement of machinery and tools that facilitates the efficient and repeatable manufacture of aircraft, such as aircraft 10. The assembly environment 100 has been improved to enable the manufacture and assembly of large airframe components, such as wing panels or fuselage sections, on a continuous, micropulse-moved and / or pulse-moved assembly line. This allows parts of the structure requiring work to be brought to the workers, tools, and equipment, rather than bringing workers, tools, and equipment into or into the structure. The assembly environment 100 provides substantial benefits by reducing the amount of non-value-added time spent during airframe assembly, while also reducing the amount of factory space occupied by increased work density. The embodiment has one half-barrel section 24 as a composite skin for one aircraft model, and another half-barrel section 24 as a metal skin portion that progresses continuously through the assembly environment 100.

[0014]

[0031] The process tracking server 102 tracks and / or manages the operation of the assembly environment 100 via memory 104 and controller 106. In the illustrated embodiment, the assembly environment 100 includes assembly lines 110 and 120. Assembly line 110 operates to perform assembly operations on the upper half-barrel section 116 and the lower half-barrel section 118. Assembly line 120 operates to perform assembly operations on the upper half-barrel section 126 and the lower half-barrel section 128. One difference between assembly lines 110 and 120 is that assembly line 110 is configured for the assembly of non-cylindrical half-barrel sections, while assembly line 120 is configured for the assembly of cylindrical half-barrel sections. Generally, the operation of assembly lines 110 and 120 is identical, and reference numbers referring to components found in both assembly lines 110 and 120 will be used for, for example, work stations 114 and 124. In this case, work station 114 is located within assembly line 110, and work station 124 is located within assembly line 120. A similar method is used when referring to the components assembled on assembly lines 110 and 120. For example, the upper half-barrel section 116 is assembled on assembly line 110, while the upper half-barrel section 126 is assembled within assembly line 120. Similarly, the lower half-barrel section 118 is assembled on assembly line 110, while the lower half-barrel section 128 is assembled on assembly line 120. Any differences between the two assembly lines 110 and 120 that are relevant will be described herein.

[0015]

[0032] As will be further discussed herein, the process tracking server 102 directs the operation of one or more work stations 114, 124 within the assembly environment 100. In this embodiment, the process tracking server 102 includes memory 104 for storing one or more numerical control (NC) programs for operating the assembly lines 110, 120. The controller 106 of the process tracking server 102 may further process feedback from the work stations 114, 124 and / or the assembly lines 110, 120 and provide commands to the work stations 114, 124 or reports to operators based on such feedback.

[0016]

[0033] In one embodiment, the indexing action is made possible by RFID readers or other indexing components 115, 125 associated with the corresponding work stations 114, 124, allowing the indexing action to issue commands directly to the work stations 114, 124. These commands are for the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 within range 114-1, 124-1 of the work stations 114, 124. In such an embodiment, commands can be exchanged between the controller 106 and specific work stations 114, 124. The controller 106 may be implemented, for example, as a custom circuit, as a hardware processor that executes programmed commands, or as some combination thereof. Memory 104 stores commands for operating the controller 106 and stores digital data.

[0017]

[0034] In this embodiment, the assembly environment 100 includes an assembly line 110 for manufacturing sections of the fuselage 12 that have a non-uniform cross-section over their length, and further includes an assembly line 120 for manufacturing sections of the fuselage 12 that have a large, uniform cross-section over their length. Assembly line 110 processes an upper half-barrel section 116 and a complementary lower half-barrel section 118, respectively. Assembly line 120 processes an upper half-barrel section 126 and a complementary lower half-barrel section 128, respectively. When upper or lower is irrelevant, the upper half-barrel section 116 and the lower half-barrel section 118 may be collectively referred to as half-barrel section 117, while the upper half-barrel section 126 and the lower half-barrel section 128 may be collectively referred to as half-barrel section 127. The arc section 119 refers to any type of barrel section, including half-barrel sections 117, 127, quarter-barrel sections, and one-third barrel sections, which may or may not have a uniform cross-section.

[0018]

[0035] The half-barrel sections 117, 127 correspond to the half-barrel sections 24 after processing through the assembly environment 100. The assembly lines 110, 120 discussed herein may be further operated to produce several sets of half-barrel sections 117, 127 or other arc-shaped sections 119.

[0019]

[0036] The assembly line 110 is comprised of a work station 114 capable of accommodating not only other arcuate sections 119 near the nose section 38 or tail section 18, but also upper half-barrel sections 116 and lower half-barrel sections 118 with more specialized shapes, such as tapered shapes. The assembly line 110 associated with the work station 114 exhibits a wider range of motion to accommodate the tapered nature of these half-barrel sections 117 and the non-uniform cross-sectional arcuate sections 119.

[0020]

[0037] The assembly line 110 further includes a track 112 along which the upper half-barrel section 116 and the lower half-barrel section 118 advance in the process direction 199. The track 112 includes a drive system 113 for advancing the half-barrel section 117 along the track 112. The track 112 moves the half-barrel section 117 in the process direction 199 to tools and equipment (not shown) located in series in the process direction 199 at work stations 114, 124.

[0021]

[0038] Track 112 may include a series of individual supports having rollers, rails, or sets of rails (not shown). The machine components of track 112 may be progressively pulsed across work stations 114, 124 in the process direction 199. Work stations 114, 124 are aligned in series, with half-barrel sections 117 or arc sections 119 continuing in series through work stations 114, 124. Only a few work stations 114, 124 are shown, but many are intended, for work stations 114, 124 may be configured to perform operations such as demolition, window mounting, door mounting, trimming excess production, frame mounting, window excess cutting, or material removal, NDI inspection, edge sealing, door excess cutting, window mounting, and door mounting. While some of the above-listed tasks are performed at work stations 114 and 124, others are dedicated to a single task.

[0022]

[0039] In one embodiment, work stations 114, 124 are spaced apart and operated so that work is performed simultaneously by several work stations on the upper half-barrel section 116 of the body 12. The same applies to the lower half-barrel section 118. In a further embodiment, work stations 114 are arranged at a certain work density based at least partially on the takt time of the half-barrel section 117 or arc section 119 being manufactured. The same applies to work stations 124 relating to the upper half-barrel section 126 and the lower half-barrel section 128. In short, work stations 124 are arranged at a certain work density based at least partially on the takt time of the half-barrel section 127 or arc section 119 being manufactured.

[0023]

[0040] Assembly line 110 processes the upper half-barrel section 116 and transports it to assembly stage 320, which is configured as a crown module mounting station for mounting, for example, a crown module 364. Assembly line 110 processes the lower half-barrel section 118 for transport to assembly stage 330, which is configured as a floor grid mounting station for joining, for example, a passenger floor grid 326 and / or cargo floor grid 324.

[0024]

[0041] Almost identically, the work station 124 is spaced and operated within the assembly line 120 to process the upper half-barrel section 126 and the lower half-barrel section 128, in short, the half-barrel section 127, along a track 122 having a drive system 113-1. The assembly line 120 processes the upper half-barrel section 126 and transports its upper half-barrel section 126 to an assembly stage 321 for joining to the crown module 364, as does the lower half-barrel section 128, which is transported to an assembly stage 331 for joining to the passenger floor grid 326 and / or cargo floor grid 324. The upper half-barrel section 126 is cylindrical and is represented as being longer than the upper half-barrel section 116, but for ease of understanding, since both crown modules will be referred to as the crown module 364 in this specification, the crown module of the upper half-barrel section 116 is understood to be different from the crown module of the upper half-barrel section 126. Similarly, regardless of which lower half-barrel section is being referred to, the passenger floor grid will be referred to as passenger floor grid 326, the cargo floor grid as cargo floor grid 324, and the combined floor grid will be referred to as floor grid 365 (Figure 5) in the following figures.

[0025]

[0042] Assembly line 120 includes a track 122 along which the upper half-barrel section 126 and the lower half-barrel section 128 advance in the process direction 199 in a manner similar to that described earlier for assembly line 110. Assembly line 120 further includes a work station 124 having a marking component 125. The work station 124, the marking component 125, and the track 122 may be implemented in a manner similar to that of the components of assembly line 110 as similarly cited. However, the work station 124 may differ in that it may be more tightly fitted to each of the upper half-barrel sections 126 and the lower half-barrel sections 128 on which they are being worked. There is less cross-sectional variation between the upper half-barrel section 126 and the lower half-barrel section 128 than between the upper half-barrel section 116 and the lower half-barrel section 118. As described above, the upper half-barrel section 126 and lower half-barrel section 128 of assembly line 120 are more uniform in shape and size than the upper half-barrel section 116 and lower half-barrel section 118 of assembly line 110.

[0026]

[0043] In a further embodiment, an additional assembly line manufactures wings 15, 16 for assembly together with the fuselage 12 to form a complete airframe. Assembly lines 110, 120 are operated in a pulsed manner, with the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 advancing in the process direction 199 by a distance equal to the length of pulses 123, 123-1 or micropulse 129. Both pulses 123 and 123-1 are used to show that the pulse lengths may differ for assembly lines 110 and 120. Micropulse 129 is smaller than pulses 123, 123-1 and, in an embodiment, is equal to the frame pitch 147 between the frames 146 of the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128, or a fraction or multiple thereof. The length of pulse 123, or the length of micropulse 129, may be the same or different for assembly lines 110 and 120. The frame pitch 147 of the embodiment is approximately 18 to approximately 36 inches. After the micropulse 129, the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 pause and then move again in the process direction 199 with micropulses 129.

[0027]

[0044] Another embodiment has upper half-barrel sections 116, 126 and lower half-barrel sections 118, 128 that advance continuously in the process direction 199 without pulse movement. Thus, the assembly lines 110, 120 considered herein allow the half-barrel sections 117, 127 to advance a desired cycle across several different work stations 114, 124 in a pulsed 123, 123-1 manner, a micro-pulse 129 manner, or a continuous manner.

[0028]

[0045] During these processes, tools such as layup mandrels may be placed on or removed from tracks 112, 122 as needed. In one embodiment, tracks 112, 122 include a drive system 113, 113-1, such as a chain drive, which moves the half-barrel sections 117, 127, but in a further embodiment, these sections are driven independently along tracks 112, 122.

[0029]

[0046] In one embodiment, referring to assembly line 110, the upper section 116 and the lower half-barrel section 118 pulse simultaneously and synchronously move the same distance in the process direction 199. Workstations 114 then perform work on the upper half-barrel section 116 or the lower half-barrel section 118 during pauses between pulses and / or during pauses in a common takt time. Thus, during the manufacturing process, several workstations 114 perform work on the upper half-barrel section 116 and / or the lower half-barrel section 118 during identical pauses between micropulses 129 and / or during micropulses 129.

[0030]

[0047] Similarly, referring to assembly line 120, the upper half-barrel section 126 and the lower half-barrel section 128 pulse simultaneously and synchronously move the same distance in the process direction 199. Workstation 124 then performs work on the half-barrel section 126 or the lower half-barrel section 128 during pauses between pulses and / or during pauses in a common takt time. Thus, during the manufacturing process, several workstations 124 perform work on the upper half-barrel section 126 and / or the lower half-barrel section 128 during identical pauses between micropulses 129 and / or during micropulses 129.

[0031]

[0048] In one embodiment of assembly line 110, one or more work stations 114 also perform these operations independently or synchronously on the same half-barrel section 117 or arc section 119 during a pulse. Similarly, with respect to assembly line 120, one or more work stations 124 also perform these operations independently or synchronously on the same half-barrel section 127 or arc section 119 during a pulse. Such work stations are attached to the half-barrel section and move with the half-barrel section, and may therefore be referred to as mobile work stations 139, 139-1. These operations may include non-destructive testing (NDI), trimming of excess production, or application of sealant, or other processes. In a further embodiment, the half-barrel sections 117, 127 move continuously along the tracks 112, 122, and as the half-barrel sections 117, 127 and the mobile work stations 139, 139-1 attached thereto continue moving, the work stations 114, 124 perform work on the half-barrel sections 117, 127.

[0032]

[0049] In some embodiments of the assembly line 110 or 120, the half-barrel sections 117, 127 are spaced apart by a predetermined gap 131, such as a micropulse distance equal to a fraction or multiple of the frame pitch 147, or any distance less than or equal to the length of the half-barrel sections 117, 127 or the arc section 119. Such gaps 131 help to account for production delays such as rework or misalignment of the half-barrel sections 117, 127, or maintenance of the arc section 119 or work stations 114, 124 and / or break times for technicians.

[0033]

[0050] Rework or misalignment operations are rarely required, but in certain environments, such as when a portion of a half-barrel section 117, 127 or an arc section 119 that requires rework or misalignment is located between work stations 114 and 124, or within a work station where work is not required, such as a window mounting station opposite the lower half-barrel section 118, these operations may be performed. This allows unforeseen delays to be absorbed into the production process. The rework or misalignment operations discussed above may be performed within the gap 131 between work stations 114 and 124. Furthermore, in one embodiment, while rework or misalignment operations are being performed, the half-barrel section 117, 127, or arc section 119 continues to advance through work stations 114 and 124. Thus, the assembly environment 100 does not stop moving forward in the process direction 199 to accommodate work on the half-barrel section 117, 127, or arc section 119 and to accommodate rework or misalignment operations. Such misalignment work may include both scheduled and unscheduled maintenance.

[0034]

[0051] During movement, or between micropulses 129 or pulses 123, 123-1, the half-barrel sections 117, 127 or arc section 119 encounter the indexing components 115, 125 at the work stations 114, 124. The indexing components 115, 125 either physically interact with the indexing features 133 on or within the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128, or non-destructively inspect the indexing features 133, allowing for alignment to the work stations 114, 124 before the work is performed.

[0035]

[0052] Indexing features 133, such as physical characteristics or radio frequency identifier (RFID) chips, are engaged by indexing components 115, 125 associated with work stations 114, 124. Each indexing component 115, 125 transmits the 3D characteristics of the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 within the range 114-1, 124-1 of work stations 114, 124 to work stations 114, 124. Indexing also enables work stations 114, 124 to determine what tasks should be performed in a particular half-barrel section 117. The work / task is based on the information transmitted by the indexing features 133 to the indexing components 115, 125.

[0036]

[0053] Returning to Figure 1, the inner mold line (IML) 60 and / or outer mold line (OML) 62 are examples of 3D characteristics. By indexing as described above, instructions for the work to be performed by the work stations 114, 124 in the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 are provided to the work stations 114, 124. This indexing process may be performed multiple times and simultaneously for each of several work stations 114, 124, with each pulse or micropulse 129. The work stations 114, 124 may then perform the work during the pauses between micropulses 129, or during the micropulses 129 themselves.

[0037]

[0054] The indexing components 115, 125 may include hard stops, pins, holes, and grooves complementary to the indexing feature 133 for physical fixation. Embodiments may have, for example, a number of indexing features aligned on the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 in the excess production portion. In further embodiments, the indexing components 115, 125 may include sensors, such as laser, ultrasonic, or visual inspection systems, that track and then align with the indexing feature 133.

[0038]

[0055] The additional indexing feature 133 also includes an RFID chip. An RFID reader is another embodiment of the indexing components 115, 125 and reads the RFID chip. These contactless technologies are utilized within assembly lines 110, 120 that move the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 in succession, and may further be used to control the movement of the half-barrel section 117 and / or the arc section 119.

[0039]

[0056] In a further embodiment, indexing components 115, 125, such as hard stops, pins, holes, or grooves, complementary to the indexing feature 133, are used in a continuous moving system utilizing mobile work stations 139, 139-1. In such an embodiment, engagement of the indexing feature 133 with the indexing components 115, 125 occurs while the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 advance within the range 114-1, 124-1 of the next work stations 114, 124. The work stations 114, 124 can track the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 as they advance in the process direction 199. Next, the mobile work stations 139, 139-1 are mounted on the upper half-barrel sections 116, 126 or the lower half-barrel sections 118, 128 at the work stations 114, 124, and are carried along with the half-barrel sections 117, 127 when moving in micropulse 129, pulse 123 or continuously.

[0040]

[0057] Mobile work stations 139, 139-1 perform work on the half-barrel sections 117, 127, then detach and return to mounting point 139-2 for future use. An example of a mobile work station 139, 139-1 is a curved track device or some similar device that follows a track detachably mounted on the upper half-barrel sections 116, 126 and / or the lower half-barrel sections 118, 128.

[0041]

[0058] Before entering the assembly environment 100, the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 are laid up on a layup mandrel (not shown) oriented with the crowns 135, 135-1 facing upward and the keels 137, 137-1 facing upward, respectively. The orientation of the lower half-barrel sections 118, 128 is maintained upward from the time of demolition from the layup mandrel through the installation of the floor grid 365 until the lower half-barrel sections 118, 128 are reversed to an orientation with the keels 137, 137-1 facing downward. This reversal is performed at the reversal station 560 (Figure 7) just before pulse-moving to the joining station 194. This configuration allows different work stations 114 and 124 to process the upper half-barrel sections 116 and 126 and the lower half-barrel sections 118 and 128 in series, in a manner that pulses through the same work station 114 and 124 during manufacturing.

[0042]

[0059] In one embodiment, the orientation of the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 on assembly lines 110, 120 is set by a layup mandrel on which the sections are laid up. The layup mandrel advances from layup through curing, and the preform is laid up on it. After curing, the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 are then removed from their respective layup mandrels without changing their orientation.

[0043]

[0060] In one embodiment, several aircraft models are processed in series on assembly lines 110, 120. The upper half-barrel sections 116, 126 and lower half-barrel sections 118, 128 of one model proceed in series along assembly lines 110, 120, followed by the upper half-barrel sections 116, 126 and lower half-barrel sections 118, 128 of another model. For example, the lower half-barrel sections 118, 128 proceed along assembly lines 110, 120, followed by the complementary upper half-barrel sections 116, 126. Similarly, these lower half-barrel sections 118, 128 and upper half-barrel sections 116, 126 may be followed by lower half-barrel sections 118, 128 and upper half-barrel sections 116, 126 of another aircraft model, and between aircraft models, this may be followed by lower half-barrel sections 118, 128 and upper half-barrel sections 116, 126 of yet another model, if such a production method meets the needs. In addition, in some embodiments, multiple assembly lines 110, 120 are also assumed to ensure that the upper half-barrel sections 116, 126 and lower half-barrel sections 118, 128 are produced at the desired speed.

[0044]

[0061] In some embodiments, the work stations 114, 124 considered herein have the capability to perform work on different portions of the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128, and can accommodate different diameters for each model. Each indexing operation between the indexing components 115, 125 and the indexing feature 133 tells the work stations 114, 124 which lower half-barrel sections 118, 128 and upper half-barrel sections 116, 126, and which aircraft models are within their range 114-1, 124-1, and what work should be performed, or whether there is no work to be performed. For example, a window production excess portion cutting station may not cut windows when the lower half-barrel sections 118, 128 are within range 114-1, 124-1, because window cutting is not required.

[0045]

[0062] The process tracking server 102 tracks and / or manages the operation of the assembly lines 110, 120 under consideration herein, for example, by directing the operation of one or more work stations 114, 124 in the assembly environment 100. In this embodiment, the process tracking server 102 includes a memory 104 for storing one or more numerical control (NC) programs for operating the assembly lines 110, 120. The controller 106 of the process tracking server 102 can further process feedback from the work stations 114, 124 and / or the assembly lines 110, 120 and provide commands to the work stations 114, 124 or reports to operators based on such feedback. In one embodiment, an RFID reader or other indexing component 125 enables the indexing act to directly issue commands to the work stations 114, 124 for a portion of the upper half-barrel sections 116, 126 and lower half-barrel sections 118, 128 within range 114-1, 124-1 of the work stations 114, 124. In such an embodiment, commands can be exchanged between the controller 106 and the specific work stations 114, 124. The controller 106 may be implemented, for example, as a custom circuit, as a hardware processor that executes programmed commands, or as some combination thereof. The memory 104 may store commands for operating the controller 106 and may include suitable receptacles for storing digital data.

[0046] As shown in Figure 2, each work station 114 in the assembly line 110 may be a material and / or component given / supplied by a corresponding feeder line 149 (e.g., based on the takt time of the body section and shown in Figure 3). These materials and / or components are attached to the upper half-barrel sections 116, 126 and lower half-barrel sections 118, 128, which are being worked on by work stations 114, 124. The feeder line 149 provides additives / components to work stations 114, 124. Each feeder line 149 is designed to generate material in takt time and also pulses through in takt time, providing additives / components to work stations 114, 124 just-in-time (JIT) for assembly on larger structures (e.g., body sections). In short, the feeder line 149 transports components to work stations 114, 124 in JIT order of use by work stations 114, 124. In some exemplary embodiments, the feeder line 149 carries components to one of the work stations 114, 124 as the half-barrel section pulses toward or through a work station. In some exemplary embodiments, the transport of components is performed in the order of use by the work station.

[0047]

[0063] In one embodiment, the feeder line 149 has a cycle time equal to a portion of the body cycle time.

[0048]

[0064] The cycle times of feeder line 149 and / or assembly lines 110, 120 do not need to be the same. For example, the upper half-barrel section 116 and the lower half-barrel section 118 may be moved simultaneously in micropulses through several work stations 114. The upper half-barrel section 116 and the lower half-barrel section 118 are indexed to work stations 114. Each dedicated feeder line 149 performs tasks such as NDI, window mounting, door mounting, trimming / removal of excess window production, trimming / removal of excess door production, window installation, and door installation. Feeder line 149 also includes output from work stations 114, including NDI inspection data and any excess trimmed from the upper half-barrel section 116 and the lower half-barrel section 118. Similar scenarios can occur for assembly line 120 and various components and assemblies.

[0049]

[0065] In a further example, feeder line 149 provides frame 146 JIT to workstation 114 where frame 146 is attached to upper half-barrel section 116 and lower half-barrel section 118. Similarly, feeder line 149 provides window surrounds JIT to workstation 114 where window surrounds are attached, and door surrounds JIT to workstation 114 where door surrounds are attached. For each feeder line 149, production time is designed based on the takt of the associated workstation 114. Each feeder line 149 pulses components in series during manufacturing, and completed components arrive at each workstation 114 with a common takt time. This takt time design runs through each of the feeder lines 149, from the smallest parts to the largest final assemblies.

[0050]

[0066] If the cycle time cannot be achieved, it is possible to adjust the work statement for a particular work station 114 to increase or decrease the amount of work performed at that particular work station 114. In a further embodiment, it is possible to add or remove work stations 114 from the process based on the work statement and the desired cycle time for the entire assembly line 110. The cycle time can be thought of as a number of minutes per month divided by the required number of desired units per month (aircraft, stringers, frames, etc.). The sum of the cycle times of micropulses is equal to the cycle time of a pulse. In short, after the number of micropulses equals the number of complete pulses, the entire unit has advanced its length through the assembly line 110. For example, the assembly line 110 consists of integer multiples of standard module work stations 114. This allows for a pre-designed system with a low percentage of blank or unused workstations 114, and enables the addition of functional workstations 114 (when required for specific processes to these unused workstations 114), thereby accommodating higher product volumes in areas sensitive to product volume.

[0051]

[0067] Referring particularly to assembly line 120 and a similar assembly line 110 as shown in Figure 2, each work station 124 in assembly line 120 may be material and / or components provided / supplied by the corresponding feeder line 149 (e.g., based on the takt time of the half-barrel section 127, as shown in Figure 3 below). These material and / or components are attached to the upper half-barrel section 126 and lower half-barrel section 128, which are being worked on by work station 124. The feeder line 149 provides additives / components to work station 124. Each feeder line 149 is designed to generate material in takt time and also provides additives / components to work station just-in-time (JIT) for assembly on a larger structure (e.g., a body section) which is pulsed in takt time. The takt time of feeder line 149 may be the same as or different from the takt time of assembly line 120. In short, the feeder line 149 transports components to the work station 124 in a just-in-time (JIT) manner in the order of use by the work station 124. In one embodiment, the feeder line 149 has a cycle time equal to or equivalent to the body cycle time.

[0052]

[0068] The cycle times of the feeder line 149 and / or assembly line 120 do not need to be the same. For example, the upper half-barrel section 126 and the lower half-barrel section 128 may be moved simultaneously through several work stations 124 in micropulse mode. The upper half-barrel section 126 and the lower half-barrel section 128 are indexed to work stations 124. Each dedicated feeder line 149 performs NDI, window mounting, door mounting, trimming / removal of excess window production, trimming / removal of excess door production, window installation, and door installation, etc. The feeder line 149 also includes production output from work stations 124, including NDI inspection data and any excess trimmed from the upper half-barrel section 126 and the lower half-barrel section 128. The feeder line 149 is synchronized with the pulse time or the speed of the main assembly line, supplying what is needed when it is needed.

[0053]

[0069] In a further example, feeder line 149 provides frame 146 JIT to workstation 124 where frame 146 is attached to upper half-barrel section 126 and lower half-barrel section 128. Similarly, feeder line 149 provides window surrounds JIT to workstation 124 where window surrounds are attached, and door surrounds JIT to workstation 124 where door surrounds are attached. For each feeder line 149, production time is designed based on the takt of the associated workstation 124. Each feeder line 149 pulses components in series during manufacturing, and completed components arrive at each workstation 124 with a common takt time. This takt time design runs through each of the feeder lines 149, from the smallest parts to the largest final assemblies.

[0054]

[0070] If the cycle time cannot be achieved by the assembly line 120 or the feeder line 149, it is possible to adjust the work statement for a particular work station 124 to increase or decrease the amount of work performed at that particular work station 124. In a further embodiment, based on the work statement and the desired cycle time for the entire assembly line 120, it is possible to add or remove a work station 124 from the assembly line 120. The cycle time can be thought of as the number of minutes per month divided by the required number of desired units per month (aircraft, stringers, frames 146, etc.). The sum of the cycle times of micropulses is equal to the cycle time of a complete pulse. In short, after the number of micropulses 129 is equal, they advance that length through the assembly line 120.

[0055]

[0071] Figure 2 further illustrates the airframe assembly areas 180 and 190, which receive the production output of assembly lines 110 and 120, respectively. The upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 are joined within the various full barrel sections 44 described with reference to Figure 1. It is important to note that the upper half-barrel sections 116 and the lower half-barrel sections 118 can have various shapes and lengths, as shown in Figure 2.

[0056]

[0072] The joining of the upper half-barrel section 116 and the lower half-barrel section 118 takes place within the joining area of ​​work station 182, and the joining of the upper half-barrel section 126 and the lower half-barrel section 128 takes place within the joining area of ​​work station 192. Joining station 184 is part of work station 182, and joining station 194 is part of work station 192. The resulting complete barrel section 44 proceeds along tracks 186 and 196 to the respective work cells 188 and 198 where the complete barrel sections are joined together. As shown in Figure 2, the complete barrel section includes sections having uniform and non-uniform cross-sections. In further embodiments, the operations of the assembly lines 110, 120 considered herein are merged into a single assembly line.

[0057]

[0073] Arrow 101 indicates the movement of the upper half-barrel section 116 and the lower half-barrel section 118, which have different shapes, as they leave the assembly line 110 and enter the aircraft assembly area 180. For example, arrow 101 indicates that the lower half-barrel section 118 and the upper half-barrel section 116 move to assembly stage 320 and assembly stage 330, respectively, then move to joining station 184 for joining, and then move to another assembly line, etc. Arrow 101 also indicates the movement of the upper half-barrel section 126 and the lower half-barrel section 128, which are formed similarly, as they leave the assembly line 120 and enter the aircraft assembly area 190. For example, arrow 101 indicates that the lower half-barrel section 128 and the upper half-barrel section 126 move to assembly stage 321 and assembly stage 331, respectively, then move to joining station 194 for joining, and then move to another assembly line, etc.

[0058]

[0074] In this embodiment, the upper half-barrel section 116 joins with the crown module 364, and the lower half-barrel section 118 joins with the cargo floor grids 324 and / or passenger floor grids 326, respectively, within assembly stages 320 and 330. Assembly stages 321 and 331 are part of the assembly process for the upper half-barrel section 126 and the lower half-barrel section 128, and assembly stages 320 and 330 are part of the assembly process for the upper half-barrel section 116 and the lower half-barrel section 118, with the crown module 364, cargo floor grids 324, and passenger floor grids 326 being similarly mounted. Similarly, joining station 184 is part of the assembly process for the upper half-barrel section 116 and the lower half-barrel section 118, and similarly corresponds to joining station 194, which is part of the assembly process for the upper half-barrel section 126 and the lower half-barrel section 128.

[0059]

[0075] Figure 3 shows an assembly line 150, or system, for factory components 170-1, 170-2 in an exemplary embodiment. The assembly line 150 is used for any components 170-1, 170-2 for post-curing or pre-curing manufacturing and / or assembly processes, and may be used as a feeder line 149 (Figure 2) to provide components 170-1, 170-2 used by the downstream assembly line 150. Component 170-1 may be distinct from component 170-2, or components 170-1 and 170-2 may be completely identical. For example, in relation to subsequent figures, components 170-1, 170-2 may be an intercostal 513, a floor beam 511, a crown module 364, or a floor grid 365 at various stages of completion.

[0060]

[0076] Components 170-1 and 170-2 proceed through work stations 152-1 through 152-n, arranged in series, with some of these work stations performing work on component 170-1, while additional work stations perform work on component 170-2 during the pauses between micropulses 129-3 or 129-3. Work stations 152-1 through 152-n or their subgroups may be referred to as work station 152. As components move down assembly line 150, it is understood that, depending on the progress of the components through assembly line 150, only a single work station may perform work on a single component.

[0061]

[0077] In this embodiment, the assembly line 150 includes work stations 152-1 to 152-n that perform operations such as layup, inspection, curing, trimming, collection and placement, joining, and fastening as components 170-1 and 170-2 advance along track 154. Work stations 152-1 to 152-n perform operations on components 170-1 and 170-2 as described in the previous paragraph during the same pause between pulses 123, 123-1 (Figure 2) or micropulse 129-3 (Figure 2) of components 170-1 and 170-2 in process direction 199.

[0062]

[0078] In the illustrated embodiment, one of the work stations 152-n is positioned in the gap 121 between components 170-1 and 170-2 that are moving or pulsed 123 in the process direction 199. While positioned in the gap 121, the work station 152-n is serviced and / or inspected, and / or the technician operating the work station 152-n may take a break while the work station 152-n is not performing work on one of the components 170.

[0063]

[0079] In one example of the illustrated embodiment, exit line 169-1 carries inspection data 167-1 from work station 152-1, while exit line 169-2 carries material 167-2 removed from one of the work stations 152-n. One example of inspection data 167-1 is inspection data for component 170 from work station 152-1, which is configured as an NDI station. Similarly, when component 170 is mechanically trimmed, the removed material 167-2 is taken out from two work stations 152-n on exit line 169-2. A particular work station 152-n is configured as a trimming station.

[0064]

[0080] Feeder lines 160-1 to 160-n provide auxiliary components 162-1 to 162-n to one of the work stations 152-2, 152-3, and 152-n. In some exemplary embodiments, feeder lines 160-1 to 160-n or their subgroups may be referred to as feeder line 160. In some exemplary embodiments, auxiliary components 162-1 to 162-n or their subgroups may be referred to as auxiliary component 162. In one example, auxiliary component 162-1 is connected to component 170 located in work station 152-2. Auxiliary components 162-1 and 162-n arrive at various work stations 152-2 and 152-n, and these work stations 152-2 and 152-n utilize the auxiliary components 162-1 and 162-n by consuming, placing, or utilizing them to facilitate the production of components 170-1 and 170-2.

[0065]

[0081] Route 164 passes through an inlet 165-2 and an outlet 165-3 for each work station 152, an example of which is shown at work station 152-2 for component 170. In this embodiment, each feeder line 160-1, 160-n provides auxiliary components 162-1, 162-n to work stations 152-1, 152-2, 152-3, 152-n, and may provide auxiliary components 162-1, 162-n via an inlet / outlet port 165-1 independent of route 164.

[0066]

[0082] The material to be removed 167-2 may also be removed via an independent inlet / outlet port 165-1. In one embodiment, the operation of feeder lines 160-1, 160-n and assembly line 150 is coordinated to facilitate just-in-time (JIT) transport of components from work station 152-1 to subsequent assembly line 150-1, given according to the takt time of components 170-1, 170-2 that 152-n works on. In one embodiment, assembly line 150 is utilized to manufacture floor grids 324, 326, and feeder lines 160-1, 160-n provide floor grid components such as intercostals, floor beams, tracks, electrical equipment, lead pipes, and floor panels. The panels are provided just-in-time (JIT) for joining into the floor grid 365.

[0067]

[0083] In one embodiment, one or more of the work stations 152-1, 152-2, 152-3, and 152-n comprise an NDI station, a downstream work station of the NDI station that addresses any cross-out conditions identified by the NDI inspection. Many of these work stations 152-1, 152-2, 152-3, and 152-n include feeder lines 160-1, 160-n dedicated to material input for additions at these work stations 152-1, 152-n. Assembly line 150 represents one or all of assembly line 110, assembly line 120, assembly area 180, and assembly area 190. As further described herein, assembly line 150 may also represent assembly stages 320, 321, 330, and 331.

[0068]

[0084] Figure 4 is a flowchart illustrating a method 200 for assembling an aircraft fuselage using the assembly environment of Figure 2 in an exemplary embodiment. The steps of method 200 will be described with reference to the assembly environment section 100 of Figure 2, but those skilled in the art will recognize that method 200 may be carried out in other systems. The steps in the flowcharts described herein are not exhaustive and may include other steps not shown. The steps described herein may be performed in a different order.

[0069]

[0085] Referring to the flowchart, the lower half-barrel section 118 and upper half-barrel section 116 of the first pair of fuselage 12 advance along the first assembly line 110 in the process direction 199 202. This can be done in a synchronous micropulse manner. The lower half-barrel section 118 and upper half-barrel section 116 are advanced in series by micropulses 129, then pause or advance as part of a continuous movement process. The lower half-barrel section 118 and upper half-barrel section 116 may be manufactured in an alternative manner, and the lower half-barrel section 118 and upper half-barrel section 116 may be paired for joining into the same complete barrel section 44 and must be mounted adjacent to each other in series on the assembly line 110. Furthermore, the lower half-barrel section 118 and upper half-barrel section 116 may be positioned front to back or back to front, and adjacent paired sections correspond to adjacent longitudinal portions for cylindrical joining within the fuselage 12.

[0070]

[0086] A pair of lower half-barrel sections 118 and upper half-barrel sections 116 are indexed in the first assembly line 110.203 As previously discussed, indexing can be performed by carrying the 3D characteristics of a portion of the lower half-barrel section 118 and upper half-barrel section 116 within the range 114-1 of each work station 114 and physically connecting them to indexing features located in the excess production area, scanning a barcode located in the excess production area, reading an RFID chip located in the excess production area, or by other means. Indexing also carries models of the lower half-barrel section 118 and upper half-barrel section 116 to each work station 114.

[0071]

[0087] Station 114 performs work on the lower half-barrel section 118 and upper half-barrel section 116 of the first set in the first assembly line 110. This may include marking the lower half-barrel section 118 and upper half-barrel section 116 to work station 114 and performing operations such as layup, curing, demolition, frame mounting, window production excess cutting, door production excess cutting. In embodiments where the lower half-barrel section 118 and upper half-barrel section 116 are advanced by micropulses 129, work may be performed during pauses between micropulses 129 and / or during micropulses 129. In embodiments where the lower half-barrel section 118 and upper half-barrel section 116 are moved continuously, work may be performed while the lower half-barrel section 118 and upper half-barrel section 116 are moving in the process direction 199. The lower half-barrel section 118 and the upper half-barrel section 116 are assembled together into a complete barrel section (e.g., 44-5) at the end of each assembly line 110.

[0072]

[0088] In addition to these steps described above, various additional steps taken to form other cylindrical complete barrel sections (e.g., 44-1 to 44-4) are described. A pair of upper half-barrel sections 126 and lower half-barrel sections 128 of the body are advanced along a second assembly line 120 in the process direction 199. Track 122 has a drive system for advancing the lower half-barrel section 128 and upper half-barrel section 126 along track 122. This may be performed in a synchronous pulsed manner. The lower half-barrel section 128 and upper half-barrel section 126 are advanced in series by micropulses 129, then paused or advanced as part of a continuous movement process. The lower half-barrel section 128 and upper half-barrel section 126 are manufactured in an alternative manner, and the lower half-barrel section 128 and upper half-barrel section 126 that form the same complete barrel section (e.g., 44-2) are adjacent on assembly line 120.

[0073]

[0089] Furthermore, the lower half-barrel section 128 and the upper half-barrel section 126 are positioned front to back or back to front, and adjacent pairs of lower half-barrel sections 128 and upper half-barrel sections 126 correspond to adjacent longitudinal portions for joining within a complete, non-cylindrical barrel section (e.g., 44-5). This allows the complete barrel sections 44-1 to 44-5 to be joined circumferentially to form most of the fuselage 12. For example, this may include assembling the lower half-barrel section 128 and the upper half-barrel section 126 together to form a complete barrel section (e.g., 44-2) by joining the upper section 126 longitudinally to the lower half-barrel section 128, for example, around a door or window splice.

[0074]

[0090] Work station 124 performs operations on a pair of lower half-barrel sections 128 and upper half-barrel sections 126 in the second assembly line 120. This may include marking the lower half-barrel section 128 and upper half-barrel section 126 to work station 124 and performing operations such as layup, curing, demolition, frame mounting, and window cutting. In embodiments where the lower half-barrel section 128 and upper half-barrel section 126 are advanced by micropulses 129, operations may be performed during pauses between micropulses 129 and / or during micropulses 129. In embodiments where the lower half-barrel section 118 and upper half-barrel section 116 are moved continuously, operations may be performed while the lower half-barrel section 118 and upper half-barrel section 116 are moving in the process direction 199.

[0075]

[0091] The lower half-barrel section 128 and the upper half-barrel section 126 are either fitted into a complete barrel section (e.g., 44-2) or joined together. For example, this may involve assembling the lower half-barrel section 128 and the upper half-barrel section 126 together to form a complete barrel section (e.g., 44-2) by longitudinally joining the lower half-barrel section 128 to the upper half-barrel section 126, as well as not only accommodating any door and / or window splices. The complete barrel sections of the fuselage (e.g., 44-1 to 44-5) can then be assembled front to back (or back to front) by circumferential joining. In short, the complete barrel sections (e.g., 44-1 to 44-5) are fitted together (e.g., via circumferential / hoop joining) to form most of the fuselage 12.

[0076]

[0092] Method 200 offers technical advantages compared to prior systems and technologies because it allows the machine to be manufactured in an efficient manner in terms of both time and space. Method 200 provides greater access to the lower half-barrel section 128 and upper half-barrel section 126, as well as the lower half-barrel section 118 and upper half-barrel section 126, than prior complete barrel assembly methods. This method allows the lower half-barrel section 128 and upper half-barrel section 126, as well as the lower half-barrel section 118 and upper half-barrel section 116, to be brought to the work station, tooling equipment, and technicians through virtually free access to the IML 60 (Figure 1).

[0077]

[0093] In the preceding assembly method, tools, tooling equipment, and technicians are required to enter the barrel section through the end or entrance of the barrel. The tooling equipment and tools must be positioned in the correct location within the complete barrel section. Once the work is complete, the tooling equipment, tools, and technicians must be transported out through the end or entrance of the barrel. Micropulse movement 129 of the lower half-barrel section 128 and the upper half-barrel section 126, and micropulse movement 129 of the lower half-barrel section 118 to the upper half-barrel section 116 through work stations 124 and 114 respectively, brings the structure to the technicians, tools, and tooling equipment, saving all non-value-added work (transportation, installation, disassembly, and transport time of tools, tooling equipment, and technicians).

[0078]

[0094] Furthermore, manufacturing delays become easier to identify visually based on the position of one section relative to other sections on the line. Newly manufactured complete barrel sections of the fuselage 12 (e.g., 44-1 to 44-5) are immediately assembled together in the airframe in progress, and continuous line assembly technology allows complete barrel sections 44 to be rapidly constructed from the upper half-barrel section 116 and the lower half-barrel section 118, as well as the upper half-barrel section 126 and the lower half-barrel section 128 (or other fuselage sections). Moreover, the continuous line assembly technology described herein allows substantially the same process to be rapidly performed in parallel on the same assembly line 110 for both the upper half-barrel section 116 and the lower half-barrel section 118. Similarly, the continuous line assembly technology allows substantially the same process to be rapidly performed in parallel on the same assembly line 120 for both the upper half-barrel section 126 and the lower half-barrel section 128.

[0079]

[0095] Figure 5 shows a detailed portion of the assembly environment 100 of Figure 2, which will be referred to herein as the manufacturing system 300. The manufacturing system 300 utilizes parallel and serial assembly lines for processing the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 in the exemplary embodiment. For brevity and clarity, reference numbers introduced with respect to assembly line 120 and assembly area 190 will be used, although the embodiments described are also relevant to assembly line 110 and assembly area 180.

[0080]

[0096] In particular, Figure 5 shows an area of ​​assembly line 120 that includes a work station 124 that performs work on both the lower half-barrel section 128 and the upper half-barrel section 126. Work after assembly line 120 is divided into assembly stages 321 and 331 for the upper half-barrel section 126 and the lower half-barrel section 128, respectively. Assembly stages 321 and 331 are stationary, complete pulse positions for performing tasks such as mounting the floor grid 365 or the crown module 364, respectively. Assembly stages 321 and 331 correspond, for example, to a floor grid mounting station and a crown module mounting station. These assembly stages 321 and 331 include work stations 322 and 332, which perform specialized operations specifically for the upper half-barrel section 126 and the lower half-barrel section 128.

[0081]

[0097] While on the assembly line 120, the lower half-barrel section 128 and the upper half-barrel section 126 advance along a track 122, which may consist of a series of discretized columns and / or rollers. The lower half-barrel section 128 and the upper half-barrel section 126 may be driven along the track 122 via an automated guided vehicle (AGV), or the rollers (not shown) of the track 122 may be driven by themselves via a motor (not shown).

[0082]

[0098] Furthermore, a workspace 124 dedicated to trimming and / or removing excess window, door, and / or bearing edge production includes a workspace inlet port 165-2 and an outlet port 165-3 (see Figure 3). An example of an outlet port 165-3 includes a chute 398 from which the trimmed material is removed from the assembly line 120. Each chute 398 represents the start of a production-high feeder line for removing material / scrap / fragments from the assembly line 120. The chutes 398 can be tracked from the workspace 124 using an optical scanner and / or an RFID scanner, with the excess production being tagged with a barcode or RFID tag. The material / scrap / fragments may be generated by trimming at one or more workspaces 124 dedicated to window excess removal, one or more workspaces 124 dedicated to door excess removal, and one or more workspaces dedicated to bearing edge excess removal.

[0083]

[0099] Referring to the previous diagram, several work station inlet ports 165-2 allow feeder line 396 supply frame 146 and window perimeters 145 and door perimeters 145-1, along with tool equipment, tools, and technicians, to pass through to work station 124. Several exit ports 165-3 track the removal of material / scrap / fragments from work station 124 through chute 398. Thus, the paths traveled by the lower half-barrel section 128 and the upper half-barrel section 126 are different from the paths of the material being removed, feeder line 359 supply frame 146, tools, tool equipment, or technicians. More specifically, the inlet port 165-2 tracks the route to the work station 124, along with barcode or RFID tagged tool equipment, tools, and technicians, from the feeder line 359 supply frame 146, window surrounds 145, and door surrounds 145-1, using an optical scanner and / or RFID scanner connected to the inlet port 165-2 of a particular work station 124.

[0084]

[0100] On assembly line 120, the lower half-barrel section 128 is processed in process direction 199 before its corresponding upper half-barrel section 126. Further directional transitions of the upper half-barrel section 126 and the lower half-barrel section 128 will be indicated and further described as arrows. The lower half-barrel section 128 exits assembly line 120 (a complete barrel section 44 is formed using micropulses 129 before the upper half-barrel section 126 to which they will be joined). In a continuous assembly line, the lower half-barrel section 128 and the upper half-barrel section 126 move continuously at the desired speed without pausing. This process sequence in this embodiment is intended to allow the lower half-barrel section 128 to undergo more labor-intensive and time-consuming work than the upper half-barrel section 126, which has a single crown module 364 installed, by installing separate cargo floor grids 324 and passenger floor grids 326 (which constitute floor grid 365).

[0085]

[0101] Feeder lines 366-1 to 366-4, as illustrated, supply components 363-1 to 363-4 to feeder lines 361 and 362 that manufacture the crown module 364 and the floor grid 365. Components 363-1 and 363-2 may include ceiling panels or cargo containers for the crown module 364, while components 363-3 and 363-4 may include beams and intercostals for the floor grid 365. All illustrated feeder lines are JIT and may have additional feeder lines (not illustrated) that provide fasteners, sealants, or other auxiliary components. Each of the feeder lines 366-1 to 366-4 operates according to its own takt time, which may be different from or the same as the takt time of the lower half-barrel section 128 and the upper half-barrel section 126, through the assembly line 120 to the work station 124.

[0086]

[0102] In contrast to the upper half-barrel section 126, to accommodate this time difference for specific operations performed in the lower half-barrel section 128, the lower half-barrel section 128 exits the assembly line 120 before the upper half-barrel section 126. This gives the lower half-barrel section 128 additional time (i.e., approximately twice the length) in assembly stage 331, where the corresponding upper half-barrel section 126 continues to move through the assembly line 120. In assembly stage 331, the lower half-barrel section 128 may be held in place to receive work during a complete pulse. For example, the lower half-barrel section 128 is processed in twice the time of the upper half-barrel section 126, from its exit from the assembly line 120 to its arrival at the joining station 194.

[0087]

[0103] The joining station 194 is a complete pulse work cell. Again, the lower half-barrel section 128 has a floor grid 365 on which it is then inverted from a keel-up orientation to a keel-down orientation and placed in a position to be joined with the upper half-barrel section 126 at the joining station 194. In particular, this arrangement allows the lower half-barrel section 128 to leave the inversion station 560 and the upper half-barrel section 126 to leave the assembly stage 321 almost simultaneously for joining preparation at the joining station 194. In one embodiment, as the half-barrel sections move along their respective paths 392 and 390, the lower half-barrel section 128 moves in front of the upper half-barrel section 126 to provide time for movement along path 394 and rotation of the lower half-barrel section 128 before joining.

[0088]

[0104] Tracing back through the manufacturing system 300, both the upper half-barrel section 126 and the lower half-barrel section 128 leave the assembly line 120 and proceed onto path 388. The upper half-barrel section 126 proceeds to assembly stage 321 on path 386, while the lower half-barrel section 128 proceeds to assembly stage 331 on path 384. This ensures that there is no substantial delay in the waiting time for assembling the complete barrel section 44.

[0089]

[0105] As described above, Figure 3 shows several feeder lines 361, 362, and 396. Feeder line 396 supplies materials such as frame 146, window surrounds 145, and door surrounds 145-1; feeder line 316 supplies crown module 364; and feeder line 362 supplies floor grid 365. Feeder line 361 contains assembled crown module 364 for installation into the upper half-barrel section 126, and feeder line 362 carries floor grid 365, including assembled, installation-ready, completed or nearly completed passenger floor grid 326 and cargo floor grid 324, into the lower half-barrel section 128. Door surrounds 145-1, window surrounds 145, frame 146, and other auxiliary components are supplied into the work station 124 via feeder line 359.

[0090]

[0106] Additional feeder lines supply fasteners and sealants. For example, a fastener feeder line 380 supplies assembly line 120 to several locations and within assembly stages 321 and 331. A sealant feeder line 382 supplies assembly line 120 to several locations and within assembly stages 321 and 331. Both the fastener feeder line 380 and the sealant feeder line 382 are configured and operated to provide just-in-time (JIT) transport and insertion into work station 124 and assembly stages 321 and 331.

[0091]

[0107] In a further embodiment, gaps 121 are placed within the assembly line 120 that utilizes the micropulse 129 when components are moved less than their length and paused for a short progression time. Some of the gaps 121 provide gaps in the work performed by the work station 124 when the gaps 121 are within range 124-1. In addition, the lower half-barrel section 128 or upper half-barrel section 126 within range 124-1 of the work station 124 may not require any work to be performed on them, depending on whether the lower half-barrel section 128 or upper half-barrel section 126 within range 124-1 requires any specific work to be performed by the work station 124.

[0092]

[0108] For example, a window trimming station or a window overproduction station performs little to no work in the lower half-barrel section 128, which has no windows (in contrast, the upper half-barrel section 126 has many windows to install). However, the lower half-barrel section 128 is home to a cargo door installation station, which includes trimming of enclosures and overproduction such as door trimming, while the upper half-barrel section 126 does not have cargo door installation. Furthermore, the physical gap 121 between the upper half-barrel section 126 and the lower half-barrel section 128 as they move in series along the assembly line 120 also reduces the assembly work at each of the individual work stations 124 as the gap 121 reaches each of them. The gap 121 considered herein allows for planned maintenance of work stations 124 and / or break times for technicians. The technician performing the maintenance may not be the same technician working on the upper half-barrel section 126 and the lower half-barrel section 128 while they are within range 124-1 of the work station 124.

[0093]

[0109] Figure 6 is a flowchart illustrating a method 400 for utilizing the hybrid manufacturing system 300 of Figure 5 in an exemplary embodiment. The method 400 includes advancing a keeled-up lower half-barrel section 128 in the process direction 199 through the assembly line 120 402 such that the lower half-barrel section 128 and the upper half-barrel section 126 advance in series. The lower half-barrel section 128 is in a keeled-up position as it advances through the work station 124 and therefore has a similar cross-sectional shape and orientation to the subsequent upper half-barrel section 126. This allows the upper half-barrel section 126 and the lower half-barrel section 128 to utilize more common assembly and tooling equipment across the work station 124. When the work station 124 is not performing work for both the upper half-barrel section 126 and the lower section 128 (for example, when window frame installation or window production excess cutting is not applied to the lower half-barrel section 128), the work station 124 can quietly perform maintenance or other stand-down functions when it is not working on a particular half-barrel section. Furthermore, when the work station 124 is not in use, the worker assigned to the work station 124 can rest and / or maintenance can be performed at the work station 124.

[0094]

[0110] Forwarding 402 may include driving the lower half-barrel section 128 via a motorized track, via motorized wheels on a post / pogo positioned in the work area, or via an independent means attached to the lower half-barrel section 128 (e.g., a cart or an Autonomous Guided Vehicle: AGV). Furthermore, this step may be performed by moving the lower half-barrel section 128 forward by pulses 123 or micropulses 129 such as a frame pitch 147 or a multiple or fraction thereof. Then, during pauses or pauses between micropulses 129, or between both pauses and pulses or micropulses 129, indexing and work are performed by the work station 124. In one embodiment, the lower half-barrel section 128 moves continuously, and indexing and work are performed by the work station 124 during continuous movement.

[0095]

[0111] Next, the upper half-barrel section 126 moves forward in the process direction 199 through the assembly line 120, in series behind the lower half-barrel section 128 and simultaneously with the lower half-barrel section 128.404 In some exemplary embodiments, the upper half-barrel section 126 moves forward in the process direction 199 through the assembly line 120, in series behind the lower half-barrel section 128 and simultaneously with the lower half-barrel section 128, so that the lower half-barrel section 128 and the upper half-barrel section 126 move forward in series through the work station 124.404 This can be performed in a similar manner to and synchronously with the forwarding step 402 described above. For example, driving a track 122 on the assembly line 120 can move both the lower half-barrel section 128 and the upper half-barrel section 126 together. Therefore, in one embodiment, the assembly line 120, and potentially the assembly stages 321 and 331, include a track 122 that causes the lower half-barrel section 128 and / or the upper half-barrel section 126 to be periodically pulsed or micropulsed 129 in the process direction 199. This section may consist of the upper half-barrel section 126 and the lower half-barrel section 128 arranged alternately. Thus, in a particular order, when joined longitudinally, these pairs of sections later form a complete barrel section 44, forming the fuselage 12 of the aircraft 10. Alternatively, the lower half-barrel section 128 and the upper half-barrel section 126 of the first aircraft 10 or first model of an aircraft may be immediately followed by a section of another aircraft or another model of an aircraft.

[0096]

[0112] Next, as the section moves in series through the assembly line 120, work is performed on the upper half-barrel section 126 and the lower half-barrel section 128 406. Work stations 124 perform work on the upper half-barrel section 126 and the lower half-barrel section 128 as they move through work stations 124 on the assembly line 120 406. Work stations 124 on the assembly line 120 may perform work such as composite layup, frame installation, trimming of excess production, window frame installation, door frame installation, window cutting, and door cutting. The upper half-barrel section 126 and the lower half-barrel section 128 are joined together to form a complete barrel section 44, which may be intended for joining in the subsequent steps described below.

[0097]

[0113] In one embodiment, during this process, the lower half-barrel section 128 and the upper half-barrel section 126 move periodically forward through the assembly line 120 in the process direction 199 by full pulses or micropulses 129 (e.g., synchronously) by the track 122 or other components. Then, during pauses between full pulses or micropulses 129 and / or during full pulses or micropulses 129, work is performed on the upper half-barrel section 126 and the lower half-barrel section 128 406. In a further embodiment, the lower half-barrel section 128 and the upper half-barrel section 126 move continuously through the assembly line 120 in the process direction 199. Then, while the lower half-barrel section 128 and the upper half-barrel section 126 move continuously, work is performed on the upper half-barrel section 126 and the lower half-barrel section 128 406.

[0098]

[0114] The lower half-barrel section 128 is removed from assembly line 120 408 and placed in the first assembly stage. This may include reorienting the lower half-barrel section 128 via a switching station 378 (shown in Figure 5) that advances the lower half-barrel section 128 along path 384 to assembly stage 331 in a complete pulse. The advance of the lower half-barrel section 128 along path 384 is lateral translation, but other methods are also possible.

[0099]

[0115] The floor grid is installed within the lower half-barrel section 410. In some exemplary embodiments, the floor grid 365 is installed within the lower half-barrel section 128, following the lower half-barrel section 128 410, while the upper half-barrel section 126 continues through the assembly line 120 with a full pulse or micropulse 129. The installation of the floor grid 365 may be performed by a work station 332 while the lower half-barrel section 128 remains inverted (i.e., oriented keel-up). It is further conceivable to install a floor grid 365 with two floor levels, including a cargo floor grid 324 and a passenger floor grid 326, into the lower half-barrel section 128 410. In one embodiment, the floor grid 365 is pre-assembled so that the cargo floor grid 324 and the passenger floor grid 326 are installed within the lower half-barrel section 128 in a single process 410. In a further embodiment, the cargo floor grid 324 and the passenger floor grid 326 are installed separately within the lower half-barrel section 128 410.

[0100]

[0116] While the corresponding upper half-barrel section 126 is still moving along the assembly line 120 to the work station 124, the installation 410 of the floor grid 365 begins. In preparation, the floor grid 365, more specifically the cargo floor grid 324 and the passenger floor grid 326 are assembled or at least partially assembled before the lower half-barrel section 128 arrives at the assembly stage 331 in Figure 5. As described above, the cargo floor grid 324 and the passenger floor grid 326 are assembled on feeder lines 366-3, 366-4 and move forward in full pulses or micropulses 129 before being placed in the feeder lines 362 for final placement in one or more work stations 332. Embodiments have several work stations 332 as components of the assembly stage 331, which are fixed cells.

[0101]

[0117] While the upper half-barrel section continues to move along the assembly line, the lower half-barrel section is replaced on the assembly line with a new keel-up lower half-barrel section that is in series behind the upper half-barrel section 412. Referring to the depiction in Figure 5, the lower half-barrel section 128 is removed from the assembly line 120 408 and advances to assembly stage 331, so at the start of the assembly line 120 it is replaced with a new keel-up lower half-barrel section 128 412.

[0102]

[0118] The upper half-barrel section 126 is removed from assembly line 120 414 and positioned in a second assembly stage away from assembly line 120, where the crown module is installed inside the upper half-barrel section 126. Similarly, the upper half-barrel section 126 passes through assembly line 120 and work station 124 as described above, is then removed from assembly line 120 414, and then moves forward to assembly stage 321. At assembly stage 321, specific operations are performed on the upper half-barrel section 126, such as the installation of the crown module.

[0103]

[0119] While floor grid installation into the lower half-barrel section continues, the upper half-barrel section is replaced on assembly line 126 with a new upper half-barrel section located in series behind the new lower half-barrel section 416. When the upper half-barrel section 126 is removed from assembly line 120 and moves on to assembly stage 321, it is replaced at the beginning of assembly line 120 with a new keel-up half-barrel section 126 416. The number of upper half-barrel sections 126 and lower half-barrel sections 128 in assembly line 120 at a single point in time can be changed. Indeed, the length of assembly line 120 compared to the lengths of the upper half-barrel sections 126 and lower half-barrel sections 128 is a factor in such a number.

[0104]

[0120] Continuing with method 400, the crown module 364 is mounted on the upper half-barrel section 126 418. As described herein, the crown module 364 may be fully assembled or partially assembled and transported to the assembly stage 321 simultaneously or immediately before the upper half-barrel section 126 arrives at the assembly stage 331. As shown by Figure 5, the crown module 364 is assembled in feeder lines 366-1, 366-2, which advance in full pulses or micropulses 129, before being placed in the feeder line 361 for placement in one or more work stations 322. Embodiments have several work stations 322 as components of the assembly stage 321, which are fixed cells.

[0105]

[0121] Continuing with method 400, the lower half-barrel section 128 is positioned at the inversion station 560 420, and the lower half-barrel section 128 is inverted to a keel-down orientation. In some exemplary embodiments, the lower half-barrel section 128 is positioned for rotation / inversion to a keel-down position, which is performed at the inversion station 560 via path 394 420. The lower half-barrel section 128 is inverted into a keel-down position while inside the inversion station 560.

[0106]

[0122] The lower half-barrel section 128-1 in assembly stage 330 is replaced with a new lower half-barrel section 128 422, and another new lower half-barrel section is placed on the assembly line and positioned in series behind the new upper half-barrel section 126, while the installation of the floor grid 365 into the new lower half-barrel section 128-1 begins. The lower half-barrel section 128-1 in assembly stage 330 is replaced with a new lower half-barrel section 128 from assembly line 120 422, and positioned in series behind the upper half-barrel section 126, while the installation of the floor grid 365 into the new lower half-barrel section 128-1 begins. The lower half-barrel section 128-4 in assembly line 120 is positioned behind the upper half-barrel section 126.

[0107]

[0123] To complete the description of method 400, the lower half-barrel section 128 is moved from the inversion station 560 to the joining station 194 via path 392. The joining station 194 is a complete pulse working cell. In substantially the same amount of time, the upper half-barrel section 126 is moved from the assembly stage 321 to the joining station 194 via path 390. The new upper half-barrel section 126 and the new lower half-barrel section 128 are placed in the assembly stages 321 and 331. The lower half-barrel section 128 is joined to the upper half-barrel section 126. The lower half-barrel section 128, which has just been removed from the inversion station 560, is joined to the upper half-barrel section 126, which has just been removed from the assembly stage 321, within the joining station 194, 424, forming a complete barrel section 44.

[0108]

[0124] Method 400 offers technical advantages over the prior art because it enables the rapid production of complete barrel sections 44 of the fuselage from arc-shaped sections of the fuselage (particularly sections such as the lower half-barrel section 128 and the upper half-barrel section 126), while the fuselage sections still share one or more work stations 124 that operate in a micropulse 129, full pulse, or continuous line environment.

[0109]

[0125] Furthermore, this assembly technique facilitates easier access to the interior of the lower half-barrel section 128 and the upper half-barrel section 126 during manufacturing. This is because dividing the barrel section in half longitudinally allows the structure requiring work, along with the tooling equipment, tools, and technicians, to be transported to the work station 124-1, with virtually free access. Along with the marking, this technique significantly reduces non-value-added setup time compared to other methods that involve moving tools, tooling equipment, and technicians to the work area and setting up the work station 124 within the complete barrel section 44.

[0110]

[0126] As can be understood, setting up work stations within a complete barrel section 44, and then moving the work stations within the complete barrel section 44 to all work sites and disassembling them again for removal, represents no value-added time during the construction process. The arrangement described herein allows as much assembly work as possible to be performed while the fuselage section is in a half-state, reducing the amount of assembly work that will be used after joining within the complete barrel. Easier access can facilitate the insertion of tools and equipment into the stations, inspection, worker exit, and part exit. This increases the efficiency of the work stations represented by work stations 124, 322, and 332. Furthermore, by ordering the lower half-barrel section 128 and the upper half-barrel section 126, it is ensured that the specific work performed does not delay the production of the complete barrel section 44.

[0111]

[0127] As shown in Figure 7, the reversing station 560 rotates the lower half-barrel section 128 around its longitudinal centerline 567 and mounts it in a keel-down orientation 563-1. More specifically, Figure 7 shows the lower half-barrel section 128 inverted in an exemplary embodiment. In Figure 7, the reversing station 560 includes a frame 562 to which the rotating element 564 is mounted. The lower half-barrel section 128 rotates around its longitudinal centerline 567 before joining to the upper half-barrel section 126 (shown in Figure 8). A strut 566 protrudes from the rotating element 564 and is mounted to the lower half-barrel section 128, on which one or more floor grids 365 are installed. Next, the rotating element 564 rotates, inverting the keel 563-2 of the lower half-barrel section 128 from keel-up orientation 563-3 to keel-down orientation 563-1, and positioning the lower half-barrel section 128 in a position to be joined to the upper half-barrel section 126 within the joining station 194.

[0112]

[0128] As described elsewhere in this specification, the joining station 194 integrates the lower half-barrel section 128 with the upper half-barrel section 126. As a result of this joining process, the upper half-barrel section 126 and the lower half-barrel section 128 are spliced ​​together longitudinally, and this also includes the splicing of the outer panels and frames 146 and any enclosures. A splice plate (not shown) may be fully installed within the joining station 194. Figure 8 shows a cross section of the complete barrel section 44 of the joining station 194, including the cargo floor 594 and the cabin floor 596. Figure 8 further shows the addition of a crown module 599 and a doubling 597 to the complete barrel section 44 of the fuselage. In one embodiment, the crown module 599 includes storage boxes and interior lighting, but for clarity, these details are not shown in Figure 8. The insulation 591 and interior panels 593 when installed are also shown.

[0113]

[0129] Figure 9-11 shows in more detail the process involved in joining the upper half-barrel section 126 and the lower half-barrel section 128. As mentioned above, the following description pertains to assembly line 120, but it should be understood that the process is similar for joining the upper half-barrel section 116 to the lower half-barrel section 118.

[0114]

[0130] In Figure 9, a portion of the assembly line 120 includes a portion of a track 122 that transports the upper half-barrel section 126 of the fuselage, which has a lower boundary (e.g., boundary 902) in the process direction 199. The assembly line 120 may also be used to transport the lower half-barrel section 128 described herein, but these are not shown for the sake of brevity of explanation.

[0115]

[0131] The splicing work station 910 (a particular embodiment of work station 124) includes an end effector 912 and / or tooling equipment for aligning the segments 922 of the splice plate 920 and installing fasteners 930 through the splice plate 920 and the upper half-barrel section 126. In particular, the splicing work station 910 installs the splice plate 920 on each side of an arc (e.g., IML 60) defined by the upper half-barrel section 126. This segment has a height and length L that protrudes by a distance H from the lower boundary 902 of the upper half-barrel section 126. During installation, the splice plate 920 is held in contact with the IML 60 of the upper half-barrel section 126. After installation, the height of the track 122 can be changed by a distance H. Thus, the highest point 932 of the upper half-barrel section 126 remains constant across the assembly line 120. In further embodiments, the splice plate 920 is located only on the OML62 side, or on both the IML60 and OML62. Either of these configurations is possible via the operation of the end effector 912 of the splicing station 910.

[0116]

[0132] In a further embodiment, the bending track device 940 following the track 942 is detachably mounted on the upper half-barrel section 126, and the splice plate 920 is installed while the crown module 364 is being mounted on the assembly stage 321. In another embodiment, the bending track device 940 following the track 942 is detachably mounted on the lower half-barrel section 128 and the splice plate 920 while the cargo floor grid 324 and passenger floor grid 326 are being mounted within the assembly stage 331. In yet another embodiment, the bending track device 940 following the track 942 that spans the splice zone is detachably mounted, and the splice plate 920 is installed while the upper half-barrel section 126 is being joined to the lower half-barrel section 128 at the joining station 194.

[0117]

[0133] In any of these embodiments, the flex track device 940 moves relative to the upper half-barrel section 126 and / or the lower half-barrel section 128, regardless of whether they are stationary, pulsed, micropulsed, or continuously moving. In any of the embodiments, the flex track device moves relative to the upper half-barrel section 126 and / or the lower half-barrel section 128, drilling and fastening. The track 942 is stationary while the flex track device 940 acts as a drill and fastening installation device moving longitudinally along the track 942. The track 942 is placed across the splice zone, and then the drill and fastening installation device (e.g., the flex track device 940) moves across the track 942, drilling and fastening to join the splice plate 920. The splice plate 920 may be installed on the OML62 or IML60, or as part of a longitudinally aligned stringer spanning a splice zone (not shown).

[0118]

[0134] Figure 10 is an end view of the upper half-barrel section 126 prepared and positioned to be joined to the lower half-barrel section 128 using a splice plate 920. Figure 10 corresponds to Figure 11, which shows the upper half-barrel section 126 and the lower half-barrel section 128 joined together using a butt splice 944. According to Figure 10, the splice plate 920 includes a contour 924 that contacts the IML 60 of the upper half-barrel section 126 and the IML 60 of the lower half-barrel section 128. The splice plate 920 is held in place in the upper half-barrel section 126 via a fastener 930. One embodiment has a splice plate 920 that is ultimately fastened to the upper half-barrel section 126, while another embodiment has a splice plate 920 tuck that is fastened in place. Another embodiment has a splice plate 920 that is ultimately fastened to the lower half-barrel section 128. Yet another embodiment has a splice plate 920 that is fully mounted within a splice station 194. The lower half-barrel section 128 is held within a lower support 950. The splice plate 920 also facilitates alignment with the upper half-barrel section 126 as part of the splice, ensuring that the upper half-barrel section 126 is in the desired contour at least at the splice point 960 while the splice plate 920 is spliced ​​in place. The lower support 950 mechanically supports the lower half-barrel section 128.

[0119]

[0135] In further embodiments, an upper support (not shown) is used in conjunction with a lower support 950 (hereinafter referred to as the “lower support”). The lower support 950 also facilitates the longitudinal rotation of the lower half-barrel section 128 before joining it with the upper half-barrel section 126. Thus, the lower support 950 is used for both rotation and joining. The upper support (not shown) and the lower support 950 are indexed to each other via complementary cups and cones or similar systems attached to the supports. In short, one support utilizes cups, while the other support utilizes complementary cones at multiple positions. The supports are dimensioned to provide sufficient clearance from the splice zone 970 so that the fabrication of the butt splice 944 is permitted. The clearance is located on the OML62 and IML60. Therefore, the clearance allows for the installation of splice plates 920, frame splices, window / door splices, and other splices as described herein.

[0120]

[0136] In Figure 11, the upper half-barrel section 126 is mounted in a butt splice configuration such that the upper boundary 904 of the lower section 128 contacts the lower boundary 902 of the upper half-barrel section 126. A fastener 906 is installed to complete the joining of the upper half-barrel section 126 and the lower half-barrel section 128, resulting in a complete barrel section 44. The embodiment has a joining station 194 to attach the splice plate 920 by driving a fastener through the splice plate 920 while the splice plate 920 contacts the IML 60 of the upper half-barrel section 126 and the IML 60 of the lower half-barrel section 128. The splice plate 920 could be attached to either the upper half-barrel section 126 or the lower half-barrel section 128 before or while inside the joining station 194. The embodiment includes a splice plate 920 that is mounted as part of the upper half-barrel section 126 of the assembly line 120, or alternatively, mounted on the lower half-barrel section 128 within the assembly line 120. The splice plate 920 is shown in Figure 10-11 with an exaggerated curved structure to match the exaggerated small radius of the complete barrel section 44.

[0121]

[0137] In a further embodiment, the method of joining the upper half-barrel section 126 to the lower half-barrel section 128 is similar to the method described above, except that both the upper half-barrel section 126 and the lower half-barrel section 128 advance to a joining station 194. The upper half-barrel section 126 and the lower half-barrel section 128 are aligned for joining at the joining station 194, and one or more splice plates 920 are mounted on the upper half-barrel section 126 and / or the lower half-barrel section 128 to form a butt splice 944 either by a coupling and / or by several rows of fasteners and a fay surface sealing.

[0122]

[0138] Each frame 146 is also butt-spliced ​​at the splice station 194 with a splice plate specific to each frame 146. As a result, the upper half-barrel section 126 and the lower half-barrel section 128 are spliced ​​together longitudinally, and this also includes splicing the outer panel 911 and the frames 146, as well as any doors and / or windows. The splice station 194 may also be configured to perform any electrical or plumbing installation in the splice area, as well as the installation of insulation and wall panels in the splice zone.

[0123]

[0139] Figure 12 is a flowchart illustrating a method 1000 for attaching a splice plate 920 to join body sections in an exemplary embodiment. The splice plate 920 may be made of composite material or aluminum. In the case of aluminum, galvanic problems are avoided when the splice plate 920 is fastened and sealed at the joint surface or otherwise sealed and secured to the lower half-barrel section 128 and the upper half-barrel section 126 and other composite materials. The composite splice plate 920 is joined and / or fastened in place.

[0124]

[0140] Method 1000 includes receiving a half-barrel section at an assembly line 120, an assembly stage, or a joining station 1002. Continuing to use assembly line 120 as an exemplary example, Method 1000 includes receiving an upper half-barrel section 126 at assembly line 120, an assembly stage, or a joining station 1002. As understood, Method 1000 applies to the upper half-barrel section 116, as well as the lower half-barrel sections 118, 128, assembly line 110, assembly stages 320, 321, 330, 331 (as needed), and / or joining station 194.

[0125]

[0141] The splice plate 920 is mounted in a section 1004. The section may take the form of an upper half-barrel section 126 or a lower half-barrel section 128. In some exemplary embodiments, the splice plate 920 is mounted on the upper half-barrel section 126 1004. More specifically, and in one embodiment, the splice plate 920 is mounted on a dedicated work station 124 1004. In another embodiment, the splice plate 920 is mounted on the assembly line 120 using a bending track device 940 (Figure 9) followed by a track 942 that is detachably mounted on the upper half-barrel section 126. Once the splice plate 920 is mounted, the bending track device 940 and track 942 are separated and then circulated to back up the assembly line 120.

[0126]

[0142] The upper half-barrel section 126 leaves the assembly line 120 with the splice plate 920 attached to one or both of its longitudinal edges and advances to the assembly stage 321 for crown module 364 installation. The other side of the splice plate 920 is fastened to the corresponding lower half-barrel section 128 at the joining station 194. In another embodiment, the splice plate 920 is fully attached to both the upper half-barrel section 126 and the corresponding lower half-barrel section 128 within the joining station 194 1004. The splice plate 920 is attached by utilizing several rows of fasteners 906 with joint surface sealing and / or coupling 1004.

[0127]

[0143] Attaching the splice plate 920 1004 may include attaching the splice plate 920 during pauses between micropulses 129, during the micropulses 129, or during both pauses between micropulses 129 and between micropulses 129 of the upper half-barrel section 126 in the process direction 199 in the assembly line 120. In a further embodiment, the splice plate 920 is attached during the continuous motion of the upper half-barrel section 126 in the process direction 1004. Thus, the splice plate 920 is attached in the assembly line 120 as the upper half-barrel section 126 moves 1004. In a further embodiment, the splice plate 920 is attached after the upper half-barrel section 126 has left the assembly line 120 and entered the assembly stage 321 1004. In a further embodiment, attaching the splice plate 920 1004, This is performed simultaneously during the installation of the crown module 364 to one or both of the upper half-barrel section 126 and the lower half-barrel section 128, or during the installation of the cargo floor grid 324 and the passenger floor grid 326.

[0128]

[0144] The splice plate 920 is dimensionally determined for IML60 mounting 1004. The butt splice 944 itself may include the splice plate 920 positioned on the IML60. In short, the splice plate 920 is mounted on the IML60, or partially mounted on the upper half-barrel section 126 and partially mounted on the lower half-barrel section 128. The splice plate 920 may be the same length as the previously considered half-barrel sections 117, 127, or some fraction thereof. Several longitudinally positioned splice plates 920 may be positioned along the entire length of the half-barrel sections 117, 127. Furthermore, the splice plate 920 may be longitudinally mounted on either the upper half-barrel section 126 or the lower half-barrel section 128 before entering the joining station 194 as part of the assembly stage 320, or in the mounting stage 330 1004. Furthermore, the splice plate 920 can be longitudinally attached to both the upper half-barrel section 126 and the lower half-barrel section 128, straddling the splice zone 914, as part of the work performed at the splice station 194. In yet another embodiment, when the splice plate 920 is connected to the upper half-barrel section 126 and the lower half-barrel section 128, it acts as a longitudinally extending stringer straddling the splice zone.

[0129]

[0145] The above splice is a butt splice 944. In yet another embodiment, a splice plate 920 is wrapped around the upper half-barrel section 126 to join it to the lower half-barrel section 128, with an overlap between the lower half-barrel section 128 and the upper half-barrel section 126.

[0130]

[0146] The next step of method 1000 includes aligning the upper half-barrel section 126 with the lower half-barrel section 128 1006, forming a splice zone between them as described later. In one embodiment, this includes aligning the upper half-barrel section 126 with the lower half-barrel section 128, while the upper half-barrel section 126 remains in contact with the lower half-barrel section 128, supported by a lower support 950 or other device. Thus, the lower half-barrel section 128 may be placed within the lower support 950 before aligning with the upper half-barrel section 126. In an embodiment in which the lower half-barrel section 128 is processed via an assembly line 120, aligning the upper half-barrel section 126 with the lower half-barrel section 128 may include rotating the lower half-barrel section 128 via the aforementioned inversion station 560 from an orientation that has been vertically inverted from a keel-up orientation 563-3 to a keel-down orientation 563-1.

[0131]

[0147] The sections are joined by attaching a splice plate 1008. The upper half-barrel section 126 and the lower half-barrel section 128 are joined by attaching a splice plate 920 within the splice zone 1008. In one embodiment, the upper half-barrel section 126 is joined to the lower half-barrel section 128 by attaching the rear half of the splice plate 920 to the half-barrel section 1008, where the front half of the splice plate 920 has not yet been attached. Depending on the materials used in manufacturing the aircraft 10, the splice plate 920 may be attached to the lower half-barrel section 128 and the upper half-barrel section 126 via co-bonding and / or fastening, or both.

[0132]

[0148] In addition, to complete the butt splice 944, the frame 146 is spliced ​​together within the splice zone. As shown in Figure 1, each half-barrel section 117, 127 includes a frame 146 and a frame splice. The embodiment includes a stub frame that joins the frame 146 and the splice plate 920 to the outer plate of the half-barrel sections 117, 127. The frame 146 terminates prior to the frame splice to facilitate the direct placement of the splice plate 920 onto the outer plate within the splice zone. These frame splices are placed on the IML 60 of the upper half-barrel section 126 and the lower half-barrel section 128, and then the stub frame is placed so that the frame 146 of the upper half-barrel section 126 connects to the frame 146 of the lower half-barrel section 128.

[0133]

[0149] A further advantage is that the length of the frame 146, which is installed before entering the splicing station 194, facilitates the movement of the half-barrel sections 117, 127 along the track 112 before splicing and joining at the splicing station 194. The installation of the splice plate 920 is also facilitated. The splice plate 920 is installed within the splice zone to connect the outer shell of the upper half-barrel section 126 to the outer shell of the lower half-barrel section 128. Furthermore, the splice plate 920 is designed as a segment 922 to occupy the entire length of, or part thereof, the upper half-barrel section 126 and the lower half-barrel section 128.

[0134]

[0150] In the IML60, the splice plate 920 acts as a longitudinally extending stringer connecting the outer plate of the upper half-barrel section 126 to the outer plate of the lower half-barrel section 128. In such embodiments, the outer plate from each upper half-barrel section 126 abuts against the corresponding outer plate from the lower half-barrel section 128. In further embodiments, the outer plates of the upper half-barrel section 126 and the outer plates of the lower half-barrel section 128 overlap as part of a lap splice.

[0135]

[0151] In this embodiment, other components such as electrical, insulating, and piping are found in both the upper half-barrel section 126 and the lower half-barrel section 128, and / or even partially within the splice zone. The upper electrical components are joined to the lower electrical components by electrical component splices that straddle or are located within the splice zone 914. The upper piping components are joined to the lower piping components by piping components that straddle or are located at least partially within the splice zone 914. The piping components may, for design selection, be hydraulic (water or hydraulic fluid) and / or pneumatic.

[0136]

[0152] Similarly, the upper door surround components are joined to the lower door surround components by door surround splices that span or are located within the splice zone. The upper window surrounds are joined to the lower window surrounds by window surround splices that span or are located within the splice zone.

[0137]

[0153] Figure 13 is a flowchart illustrating a method 1300 for working simultaneously on a single section of a fuselage via several work stations 114, 124 described herein on assembly lines 110, 120. Method 1300 includes receiving a section of the fuselage 1302. In some exemplary embodiments, method 1300 includes receiving a half-barrel section 117, 127 (e.g., upper half-barrel sections 116, 126 or lower half-barrel sections 118, 128) 1302. This operation includes demolding the composite part from a layup mandrel (not shown) and placing the composite part on a track 122 of assembly line 120, as discussed earlier.

[0138]

[0154] The section moves forward simultaneously in the process direction 199 across several work stations 114, 124 along the assembly line 1304. In some exemplary embodiments, the half-barrel sections 117, 127 move simultaneously in the process direction 199 across several work stations 114, 124 along the assembly line 1304. This can be done by driving a motor to drive the half-barrel sections 117, 127 onto a track 122 (for example, by driving rollers on the track 122). In one embodiment, the half-barrel sections 117, 127 move in a pulsed manner, while in another embodiment, the half-barrel sections 117, 127 move continuously. As shown in Figure 5, many of the work stations 124 are located along the length of the half-barrel sections 117, 127 as they move forward. For a half-barrel section 117, 127 of considerable length (e.g., 25-40 feet), each work station 114, 124 is separated from other work stations 114, 124 by a distance of frame pitch (e.g., 16-40 inches), and many work stations 114, 124 can be arranged for operation. These work stations 114, 124 may include tasks such as frame mounting, window mounting, trimming, sealing, non-destructive testing (NDI) of the half-barrel section 117, 127, and cleaning. Thus, in one embodiment, advancing the half-barrel section 117, 127 involves moving the half-barrel section 117, 127 through several work stations 114, 124 that are spaced apart from each other in the process direction 199.

[0139]

[0155] Work is performed simultaneously on a section via several stations 1306. In some embodiments of method 1300, work is performed simultaneously on half-barrel sections 117, 127 via several work stations 114, 124 1306. In short, each work station 114, 124 can perform work simultaneously with and independently of other work stations 114, 124 1306. This is because the spaced arrangement of the work stations 114, 124 ensures that collisions between the work stations 114, 124 cannot occur. The steps of advancing 1304 and performing 1306 can be repeated iteratively on a single half-barrel section 117, 127 as the half-barrel sections 117, 127 advance through work stations 114, 124 arranged in series on the assembly lines 110, 120. If additional work is required, work stations 114, 124, which are part of assembly lines 110, 120 from the start of the serial process, perform the additional work 1306. There is no "on-the-fly" addition of work stations 114, 124 to the process. If work stations 114, 124 are not required, then the execution of work 1306 at the half-barrel sections 117, 127 is not instructed. Furthermore, the receiving step 1302, the advancing step 1304, and the execution step 1306 may be repeated iteratively for every few half-barrel sections 117, 127 on assembly lines 110, 120. Completed half-barrel sections 117, 127 may then be joined to other half-barrel sections 117, 127 to form a complete barrel section 44.

[0140]

[0156] A determination 1308 is made to determine whether the half-barrel sections 117 and 127 have received all the desired work on the assembly lines 110 and 120. In short, the determination 1308 concerns whether the half-barrel sections 117 and 127 have successfully passed through the assembly lines 110 and 120 in order to receive all the work they were intended to receive. Prior to the commencement of processing of the half-barrel sections 117 and 127 through the assembly lines 110 and 120, a determination 1308 is made to determine whether the half-barrel sections 117 and 127 need to pass through certain work stations 114 and 124 a certain number of times. When the assembly lines 110 and 120 are formed, a process is made to determine the number of work stations 114 and 124 of a certain type and the cycle time. If, for some reason, not all the work can be performed within the assembly lines 110 and 120, then the work proceeds further downstream and is performed "out of position". Once the work is complete, the half-barrel sections 117, 127 continue along the assembly line 110, 120 and are joined with the complementary half-barrel sections 117, 127 to form a complete barrel section 44 1310.

[0141]

[0157] Method 1300 offers substantial advantages over the prior art, because it allows many work stations 114, 124 to perform work simultaneously on the half-barrel sections 117, 127 of a single fuselage 12, without requiring a separate fixed cell for each type of work to be performed. This increases efficiency and throughput, and reduces the space occupied on the factory floor.

[0142]

[0158] Therefore, as discussed earlier, in one embodiment, the assembly lines 110, 120 include respective tracks 112, 122 that receive half-barrel sections 117, 127 of the fuselage 12, and advance these half-barrel sections 117, 127 simultaneously in the process direction 199 across several work stations 114, 124. The work stations 114, 124 are positioned along the tracks 112, 122 in the process direction 199 for a distance less than the length of the half-barrel sections 117, 127, so that at least two of the work stations 114, 124 can simultaneously perform work on the half-barrel sections 117, 127 while the half-barrel sections 117, 127 pass through the work stations 114, 124. For example, the work stations 114, 124 may be separated from adjacent work stations 114, 124 by a distance equal to the frame pitch 147 in the process direction 199.

[0143]

[0159] In a further embodiment, a plurality of work stations 114, 124 remove material from half-barrel sections 117, 127 or add material (not shown) to half-barrel sections 117, 127. As described elsewhere in this specification, half-barrel sections 117, 127 refer to both the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128, respectively.

[0144]

[0160] Figure 3 generally describes the methods and systems of this specification, while Figure 14 is a flowchart illustrating a takt time assembly method 1400 in an exemplary embodiment. Method 1400 includes transporting a series of auxiliary components 162-1, 162-n through a series of work stations 152-1 to 152-n in a common takt time 1402. In some exemplary embodiments, the work stations may also be called manufacturing stations. In one embodiment, the auxiliary components 162-1, 162-n are transported according to a common takt time. Thus, transport is provided JIT from feeder lines 160-1 to 160-n, and each feeder line 160-1 to 160-n may or may not have a common takt time. The feeder lines 160-1 to 160-n may have their own takt times, which may or may not be equal to a portion of the body takt time.

[0145]

[0161] The term takt time requires further explanation. For example, referring to Figure 3, there is a Takt time of Product (TTP) for each assembly line 150 and for each feeder line 160-1 through 160-n. This explanation also applies to other figures described herein, e.g., assembly lines 110, 120, and feeder line 149. Since feeder lines 160-1 through 160-n must always be synchronized with assembly line 150, their takt times are often identical, but they may differ. For example, if there is only one assembly line 150 and eight half-barrel sections 117 descending from assembly line 150, the TTP for assembly line 150 is 4 hours, combined with the product demand requiring eight half-barrel sections 117 every 32 hours available. TTP is equal to pulse time only when the pulse length is the complete length of the product being produced. For lines transported by micropulses, if the pulse length is part of the length of the complete product, the gap 121 between products must be taken into account, and the pulse time (PT) is much smaller. All feeder lines 160-1 through 160-n must support the main line TTP, PT, or speed. As an additional example, if the pulse length is equal to the frame pitch 147 (approximately 2 feet), then the frame feeder line would need to transport several frames 146 (e.g., two) per frame station. Some half-barrel sections 117 have no doors, so the feeder line must supply two frames 146 per pulse time. Some half-barrel sections 117 include doors, and in these areas, at least some micropulses do not require frames 146. However, feeder lines 160-1 through 160-n still must be synchronized with the assembly line 150 pulse time. If the number of products per pulse is greater than 1 and there is only one feeder line, feeder lines 160-1 through 160-n may have a larger TTP. If the number of products is greater than 1, and the number of feeder lines 160-1 through 160-n for that product is the same as the number of products in the feeder line, then the PT of the feeder line will be the same as the PT of the assembly line 150.When it is not necessary to supply feeder products to assembly line 150, the PT is then variable relative to the feeder line.

[0146]

[0162] In feeder lines 160-1 to 160-n, additional work stations 152-1 to 152-n perform work on auxiliary components 162-1, 162-n during pauses between pulses of auxiliary components 162-1, 162-n in the process direction 199. Some auxiliary components 162-1, 162-n may be produced in a manner that does not involve continuous pulse movement or micropulse movement. Method 1400 includes transporting first type auxiliary components to work stations just in time, together with second type auxiliary components produced in parallel with the first type auxiliary components 1404. Auxiliary components 162-1, 162-n are transported to work stations just in time (JIT) in the order of use. Method 1400 also includes joining second type auxiliary components to first type auxiliary components 1406 to form components. In one embodiment, the auxiliary component is a section of the fuselage 12 (for example, upper half-barrel sections 116, 126 or lower half-barrel section 128). In a further embodiment, component 170-1 is a complete barrel section 44 formed from the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128.

[0147]

[0163] In further embodiments, the method further includes performing work on auxiliary components simultaneously via a plurality of work stations 152. Depending on the embodiment, proceeding includes repeatedly pulse-moving auxiliary components 162-1, 162-n by less than their length, and then pausing while work is performed on auxiliary components 162-1, 162-n. Alternatively, proceeding includes repeatedly pulse-moving auxiliary components 162-1, 162-n by at least their length, and then pausing while work is performed on auxiliary components 162-1, 162-n. Alternatively, proceeding includes continuously moving auxiliary components 162-1, 162-n while work is performed on them. In the pulsed-moved embodiment, the first type of auxiliary component and the second type of auxiliary component are joined within component 170 at the work station after being pulsed-moved.

[0148]

[0164] Now, looking at Figure 15, control components of a production system performing continuous production (e.g., assembly environment 100) are broadly illustrated. Controller 1600 coordinates and controls the operation of work stations 1620 (corresponding to the movement of any and all of the work stations 114, 124, 152-1 to 152-n described herein, as well as one or more of the aircraft components described herein) along a moving line 1660 having a powertrain 1662. Controller 1600 may include a processor 1610 connected to a memory 1612 that stores a program 1614. In one example, a mobile platform 1670 is driven along the moving line 1660, which is continuously driven by the powertrain 1662 controlled by controller 1600. In this example, the mobile platform 1670 includes a utility connection 1672 which may include an electrical, pneumatic and / or hydraulic quick disconnect connecting the mobile platform 1670 to an external source utility 1640. In other examples, as previously mentioned, the mobile platform 1670 includes an Automated Guided Vehicle (AGV) with an in-vehicle utility and a GPS / automatic guidance system 1674. The mobile platform 1670 also includes some or all of the aforementioned indexing system, barcode and RFID systems. In further examples, the movement of the mobile platform 1670 is controlled using a laser tracker 1650. The laser tracker 1650 uses an indexing unit, barcode reader or RFID reader. A positioning and / or monitoring sensor 1630 connected to the controller 1600 is used to determine the position of the mobile platform 1670 and the powertrain 1662.

[0149]

[0165] Figure 16 is a flowchart illustrating a further method 1700 of takt-time assembly for manufacturing the airframe of an aircraft 10 in an exemplary embodiment. Method 1700 includes receiving sections of the fuselage 1702. In some exemplary embodiments, Method 1700 includes receiving half-barrel sections 117, 127 at assembly lines 110, 120 1702 and placing the bearing edges 117, 127 of the half-barrel sections onto tracks 112, 122. Method 1700 continues by bringing the sections of the fuselage into the process direction 199 to stations arranged in series in the process direction 199 1704. In some exemplary embodiments, Method 1700 continues by bringing the half-barrel sections 117, 127 into the process direction 199 to work stations 114, 124 (with any tools and / or equipment placed therein) arranged in series in the process direction 199 1704. This step brings the half-barrel sections 117, 127 to the tools, tool equipment and technicians of the work stations 114, 124 or several work stations 114, 124 simultaneously. In one embodiment, bringing the half-barrel sections 117, 127 to the work stations 114, 124 includes advancing them by micropulse 129. Method 1700 includes performing work on the sections simultaneously through the stations 1706. In some exemplary embodiments, Method 1700 includes indexing the half-barrel sections 117, 127 within range 114-1, 124-1 of the work stations 114, 124 1706. At a desired takt time, work is performed on the half-barrel sections 117, 127 simultaneously within range 114-1, 124-1 of the work stations 114, 124 1708. The work being performed 1708 may include any of the various tasks described above. For example, in one embodiment, the operation performed 1708 includes removing material from half-barrel sections 117, 127. In another embodiment, the operation performed includes adding material to half-barrel sections 117, 127.

[0150]

[0166] In a further embodiment, the method further includes establishing the takt times for half-barrel sections 117, 127 within a range 114-1, 124-1 of work stations 114, 124 arranged in series. The takt times help determine / select the number of work stations 114, 124 to be arranged in series in the process direction 199 for the half-barrel sections 117, 127, based on the work speed of each work station 114, 124, the size of the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128, and the takt times. In a further embodiment, the method includes selecting the number of work stations 114, 124 to perform parallel tasks in the half-barrel sections 117, 127 based on the takt times required for a desired throughput. If the two work stations 114 and 124 are unable to install the required number of frames 146 in the upper half-barrel section 116, for example, within the takt time, a third work station 114 or 124 is added to the work stations 114 and 124 during the planning of the assembly line 110 or 120 for mounting the frames 146.

[0151]

[0167] Figure 17 is a flowchart illustrating a further method 1800 for manufacturing the airframe of aircraft 10 in a desired cycle time, in an exemplary embodiment.

[0152]

[0168] Method 1800 includes receiving a component 170, such as a half-barrel section 117, 127, a part of a crown module 364 or floor grid 365, a frame 146, a window surround 145, a door surround 145-1, a floor beam intercostal, or several other components represented as component 170. Method 1800 continues by bringing the component 170 (Figure 3) in the process direction 199 to a work station 152 (Figure 3) (including any tools, tooling and equipment placed therein) arranged in series in the process direction 199. In one embodiment, bringing the component 170 1804 includes advancing the component 170 by micropulse movement 129-3 less than its length. In further embodiments, bringing the component 170 1804 includes advancing the component 170 along tracks 112, 122. In some exemplary embodiments, the component is a section. Method 1800 includes performing work on component 170 simultaneously via station 152 1806. The work may include any of the various tasks described above. For example, in one embodiment, performing work 1806 includes removing material from component 170, such as the bearing edges of half-barrel sections 117, 127. Work station 152 may perform additive manufacturing by adding material, or subtractive manufacturing by removing material from component 170 or auxiliary component 162. Alternatively, the process may proceed to applying auxiliary component 162 to component 170 simultaneously via work station 152 1808.

[0153]

[0169] In further embodiments, the method further includes establishing the takt time for the component 170 and determining the number of work stations 152 to be arranged in series with respect to the component 170 in the process direction 199, based on the work speed of each station, the size of the component 170 on which the work is being performed, and the takt time within each work station 152. In further embodiments, the method includes selecting the number of work stations 152 to perform the same task on the component 170, based on the takt time. For example, a third work station 152 would be added if two work stations 152 cannot install the required number of storage boxes for the crown module 364 within the takt time. Similar processes are used for other components 170, many of which are described and / or referenced herein.

[0154]

[0170] With more detailed reference to the drawings, embodiments of the present disclosure can be described in terms of the manufacture and maintenance of an aircraft in Method 1900 shown in Figure 18, and in terms of an aircraft 1902 shown in Figure 19. In the pre-manufacturing stage, Method 1900 may include the specification and design 1904 of the aircraft 1902 and the procurement of materials 1906. In the manufacturing stage, the manufacture 1908 of the components and subassemblies of the aircraft 1902 and system integration 1910 are carried out. The aircraft 1902 can then be put into operation 1914 after certification and delivery 1912. During its operation by the customer, the aircraft 1902 is scheduled for periodic maintenance and upkeep 1916 (which may also include modifications, reconfigurations, and refurbishments). The apparatus and methods embodied herein may be used in any preferred one or more stages of the manufacture and maintenance described in Method 1900 (e.g., specification and design 1904, procurement of materials 1906, manufacture of components and subassemblies 1908, system integration 1910, authorization and delivery 1912, operation 1914, maintenance and servicing 1916) and / or in any preferred component of the aircraft 1902 (e.g., airframe 1918, systems 1920, interior 1922, propulsion system 1924, electrical system 1926, hydraulic system 1928, environmental system 1930).

[0155]

[0171] Each process of Method 1900 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). In this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military organization, service organization, etc.

[0156]

[0172] As shown in Figure 19, an aircraft 1902 manufactured by method 1900 may include a fuselage 1918 having several systems 1920 and interior 1922. Examples of systems 1920 include one or more of the propulsion system 1924, electrical system 1926, hydraulic system 1928, and environmental system 1930. Any number of other systems may also be included. Although an example from the aerospace industry is shown, the principles of the present invention can also be applied to other industries such as the automotive industry.

[0157]

[0173] As already stated above, the apparatus and methods embodied herein may be used in any one or more stages of the manufacturing and maintenance described in Method 1900. For example, components or subassemblies corresponding to the manufacturing of components and subassemblies 1908 may be manufactured or produced in a similar manner to components or subassemblies manufactured during the operational life of the aircraft 1902. Also, one or more embodiments of the apparatus, embodiments of the method, or combinations thereof may be used in the manufacturing of subassemblies 1908 and system integration 1910, for example, by significantly improving the efficiency of the assembly of the aircraft 1902 or by significantly reducing the cost of the aircraft 1902. Similarly, one or more embodiments of the apparatus, embodiments of the method, or combinations thereof may be used during the operational life of the aircraft 1902 (for example, in maintenance and servicing 1916). Accordingly, the present invention may be used at any stage considered herein, or in any combination thereof, such as specifications and design 1904, procurement of materials 1906, manufacture of components and subassemblies 1908, system integration 1910, authorization and delivery 1912, maintenance 1914, servicing and repair 1916 and / or any suitable component of the aircraft 1902 (e.g., airframe 1918, systems 1920, interior 1922, propulsion system 1924, electrical system 1926, hydraulic system 1928, and / or environmental system 1930).

[0158]

[0174] In one embodiment, a component comprises part of the airframe 1918 and is manufactured in the manufacture of components and subassemblies 1908. This component is then incorporated into the aircraft in system integration 1910 and may be used in operation 1914 until it becomes unusable due to wear. Subsequently, in maintenance and servicing 1916, this component may be discarded and replaced with a newly manufactured component. To manufacture the new component, ingenious components and methods may be used throughout the manufacture of components and subassemblies 1908.

[0159]

[0175] Furthermore, this disclosure includes examples of the following clauses:

[0160]

[0176] Clause 1. A method for assembling an aircraft, comprising receiving half-barrel sections 117, 127 of a fuselage 12 on assembly lines 110, 120 having a plurality of work stations 114, 124 arranged in series; advancing the half-barrel sections 117, 127 in a process direction 199 through the assembly lines 110, 120 such that the half-barrel sections 117, 127 extend across at least a portion of the work stations 114, 124; and simultaneously performing work on the half-barrel sections 117, 127 using a portion of the work stations 114, 124.

[0161]

[0177] Clause 2. The method according to Clause 1, comprising moving half-barrel sections 117, 127 forward through assembly lines 110, 120, pulse-moving the half-barrel sections 117, 127 123.

[0162]

[0178] Clause 3. The method in Clause 2, wherein a portion of the work stations 114, 124 perform work 117, 127 on the half-barrel section during the pause between pulses 123.

[0163]

[0179] Clause 4. The method according to Clause 1, comprising moving the half-barrel sections 117, 127 through at least one range 114-1, 124-1 of the working stations 114, 124, in a micropulse motion 129.

[0164]

[0180] Clause 5. The method in Clause 4, wherein a portion of the work stations 114, 124 perform work 117, 127 on the half-barrel section during a pause between micropulses 129.

[0165]

[0181] Clause 6. The method according to Clause 1, wherein advancing the half-barrel sections 117, 127 includes moving the half-barrel sections 117, 127 continuously through the assembly lines 110, 120.

[0166]

[0182] The method according to Clause 7, comprising moving half-barrel sections 117, 127 through assembly lines 110, 120 in pulses according to a common takt time, wherein the common takt time is based on a desired number of half-barrel sections 117, 127 per month.

[0167]

[0183] The method according to Clause 8, further comprising, during the pause between pulses 123, indexing half-barrel sections 117, 127 to at least one of series-arranged work stations 114, 124.

[0168]

[0184] The method according to Clause 9. Transporting a component to one of the work stations 114, 124 when the half-barrel sections 117, 127 pulse-move 123 toward or through the work stations 114, 124, and joining the component 170 to the half-barrel sections 117, 127 at the work stations 114, 124.

[0169]

[0185] Clause 10. The method described in Clause 9, wherein the transport of component 170 is performed by work stations 114, 124 in the order of use.

[0170]

[0186] Clause 11. The method according to Clause 9, wherein joining the component 170 includes joining the component 170 to half-barrel sections 117, 127 during a pause between pulses 123.

[0171]

[0187] Clause 12. The method according to Clause 1, wherein advancing the half-barrel sections 117, 127 involves moving the half-barrel sections 117, 127 through several work stations 114, 124, the work stations 114, 124 being separated from each other by a distance less than the length of the half-barrel sections 117, 127.

[0172]

[0188] The method according to Clause 13, wherein advancing the half-barrel sections 117, 127 includes micropulse movement 129 of the half-barrel sections 117, 127 through several work stations 114, 124, the length of the micropulse movement 129 being equal to a multiple of the frame pitch 147 for the half-barrel sections 117, 127, and the work stations 114, 124 being separated by the frame pitch 147 for the half-barrel sections 117, 127.

[0173]

[0189] Clause 14. The method according to Clause 1, wherein performing work on half-barrel sections 117, 127 involves operating multiple work stations 114, 124 independently of each other.

[0174]

[0190] Clause 15. The method according to Clause 1, wherein performing work on half-barrel sections 117, 127 involves operating a portion of multiple work stations 114, 124 to remove material from half-barrel sections 117, 127.

[0175]

[0191] Clause 16. The method according to Clause 15, wherein operating a portion of a plurality of work stations 114, 124 includes removing and trimming excess production from doors, removing and trimming excess production from windows, and trimming excess production from bearing edges 117, 127 of half-barrel sections.

[0176]

[0192] Clause 17. The method according to Clause 1, wherein performing work on half-barrel sections 117, 127 involves operating a portion of multiple work stations 114, 124 to add component 170 to half-barrel sections 117, 127.

[0177]

[0193] Clause 18. The method of Clause 15, wherein operating a portion of a plurality of work stations 114, 124 includes installing frames 146, window frames 145, door frames 145-1, and sealants.

[0178]

[0194] Clause 19. The method according to Clause 1, which includes performing work on the half-barrel sections 117, 127, non-destructively inspecting the half-barrel sections 117, 127, non-destructively inspecting the trimmed edges of the half-barrel sections 117, 127, and operating a portion of a portion of a portion of the half-barrel sections 117, 124.

[0179]

[0195] Clause 20. Part of an aircraft 10 assembled in accordance with the method described in Clause 1.

[0180]

[0196] Clause 21. System 100 for processing half-barrel sections 117, 127 of a fuselage, comprising a plurality of work stations 114, 124 arranged in series, separated by a distance less than the length of the half-barrel sections 117, 127, and tracks 112, 122 configured to receive the half-barrel sections 117, 127 and to advance the half-barrel sections 117, 127 in a process direction 199 through the plurality of work stations 114, 124, so that at least two of the work stations 114, 124 can perform work on the half-barrel sections 117, 127 at the same time.

[0181]

[0197] The system 100 described in Clause 21, configured such that tracks 112, 122 pulse-move half-barrel sections 117, 127 through a plurality of work stations 114, 124.

[0182]

[0198] Clause 23. The system 100 as described in Clause 22, wherein work stations 114, 124 are operated to perform work on half-barrel sections 117, 127 during pauses between pulses 123.

[0183]

[0199] System 100 as described in Clause 21, configured such that tracks 112, 122 move half-barrel sections 117, 127 through at least one range 114-1, 124-1 of work stations 114, 124.

[0184]

[0200] Clause 25. The system 100 as described in Clause 24, wherein work stations 114, 124 are operated to perform work on half-barrel sections 117, 127 during pauses between micropulses 129.

[0185]

[0201] Clause 26. The system 100 described in Clause 21, wherein tracks 112, 122 are configured to move half-barrel sections 117, 127 in succession through a number of work stations 114, 124.

[0186]

[0202] Clause 27. The system 100 as described in Clause 21, wherein the distance between work stations 114 and 124 is equal to the frame pitch 147 associated with the half-barrel sections 117 and 127.

[0187]

[0203] System 100 as described in Clause 21, wherein tracks 112, 122 are configured to pulse-move half-barrel sections 117, 127 through multiple work stations 114, 124 according to a common takt time, the common takt time being based on a desired number of half-barrel sections 117, 127 per month.

[0188]

[0204] Clause 29. System 100 as described in Clause 21, wherein at least one of the work stations 114, 124 includes indexing components 115, 125, the indexing components 115, 125 operating in conjunction with indexing features 133 on half-barrel sections 117, 127 and tracks 112, 122, and positioning the half-barrel sections 117, 127 within the work stations 114, 124.

[0189]

[0205] Clause 30. System 100 as described in Clause 21, wherein multiple work stations 114, 124 are separately configured to perform work from a group consisting of frame 146 installation, window frame 145 installation, window excess trimming, door frame 145-1 installation, door excess trimming, trimming, cleaning, sealing of bearing edges of half barrel sections 117, 127, non-destructive testing (NDI) of half barrel sections 117, 127, and non-destructive testing (NDI) of trimmed edges.

[0190]

[0206] Clause 31. To manufacture a part of the aircraft 10 using the system 100 described in Clause 43.

[0191]

[0207] Clause 32. A method for assembling a fuselage 12, comprising advancing an upper half-barrel section 126 of the fuselage 12 with a uniform cross-section and a corresponding inverted lower half-barrel section 128 with a uniform cross-section along a first assembly line 120 in a process direction 199 in a first takt time, and advancing an upper half-barrel section 116 of the fuselage 12 with a non-uniform cross-section and a corresponding inverted lower half-barrel section 118 with a non-uniform cross-section along a second assembly line 110 in a process direction 199 in a second takt time, and two lower half-barrel sections 118 A method comprising: rotating 128 to a keel-down orientation 563-1; attaching the upper half-barrel sections 116, 126 to the corresponding lower half-barrel sections 118, 128 to form two complete barrel sections 44, wherein one complete barrel section 44 has a uniform cross-section and the other complete barrel section 44 has a non-uniform cross-section; and attaching the two complete barrel sections 44 together to form part of the fuselage 12.

[0192]

[0208] Clause 33. The method according to Clause 32, further comprising, during a cycle time, periodically pulse-moving a uniform cross-section upper half-barrel section 126 and a corresponding, inverted, uniform cross-section lower half-barrel section 128 simultaneously and in the same direction through a plurality of work stations 124 of the assembly line 120 in the process direction 199, and performing work on the uniform cross-section half-barrel sections 126, 128 at some of the work stations 124 during pauses between pulses 123.

[0193]

[0209] Clause 34. The method according to Clause 32, further comprising, during a second takt time, periodically pulse-moving an upper half-barrel section 116 with a non-uniform cross-section and a corresponding inverted lower half-barrel section 118 with a non-uniform cross-section simultaneously and in the same direction through a plurality of work stations 114 of a second assembly line 110, in the process direction 199, and performing work on the non-uniform cross-section half-barrel sections 116, 118 at some of the work stations 114 during pauses between pulses 123.

[0194]

[0210] The method according to Clause 35, further comprising moving the lower half-barrel section 128 of uniform cross-section from the assembly line 120 to the assembly stage 331, installing the floor grid 365 within the lower half-barrel section 128 of uniform cross-section, and moving the lower half-barrel section 128 of uniform cross-section to the joining station 194 after rotating the lower half-barrel section 128 of uniform cross-section to a keel-down orientation 563-1.

[0195]

[0211] Clause 36. The method according to Clause 32, further comprising moving the upper half-barrel section 126 of uniform cross-section from the assembly line 120 to the assembly stage 321, installing the crown module 364 into the upper half-barrel section 126 of uniform cross-section, and moving the upper half-barrel section 126 of uniform cross-section to the joining station 194.

[0196]

[0212] The method according to Clause 37, comprising rotating two lower half-barrel sections 118, 128 to position each lower half-barrel section 118, 128 in a corresponding inversion station 560, the inversion station 560 being located between the assembly stages 330, 331 and the joining stations 184, 194.

[0197]

[0213] Clause 38. The method according to Clause 32, wherein the upper half-barrel sections 116, 126 are attached to the corresponding lower half-barrel sections 118, 128, and the splice plate 920 is attached between the upper half-barrel sections 116, 126 and the corresponding lower half-barrel sections 118, 128.

[0198]

[0214] Clause 39. The method according to Clause 38, wherein the attachment of the splice plate 920 includes attaching the splice plate 920 to one of the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128, aligning the upper half-barrel sections 116, 126 with the corresponding lower half-barrel sections 118, 128, and attaching the splice plate 920 to the other of the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128.

[0199]

[0215] Clause 40. The method according to Clause 39, comprising aligning the upper half-barrel sections 116, 126 with the lower half-barrel sections 118, 128, and bringing the lower boundary 902 of the upper half-barrel sections 116, 126 into contact with the upper boundary 904 of the lower half-barrel sections 118, 128.

[0200]

[0216] Clause 41. Part of an aircraft 10 assembled in accordance with the method described in Clause 32.

[0201]

[0217] Clause 42. A system for assembling a portion of a fuselage 12, comprising: a first set of assembly stages 320, 321 for placing a crown module 364 within upper half-barrel sections 116, 126 with uniform and non-uniform cross-sections; a second set of assembly stages 330, 331 for placing a floor grid 365 within inverted lower half-barrel sections 118, 128 with uniform and non-uniform cross-sections; a first joining station 184 for attaching the upper half-barrel section 116 and the lower half-barrel section 118 with non-uniform cross-sections to form a complete barrel section 44 with a non-uniform cross-section; and a second joining station 194 for attaching the upper half-barrel section 126 and the lower half-barrel section 128 with uniform cross-sections to form a complete barrel section 44 with a uniform cross-section.

[0202]

[0218] Clause 43. The system according to Clause 42, further comprising a first inversion station 560 for inverting a lower half-barrel section 118 with a non-uniform cross-section from a keel-up orientation 563-3 to a keel-down orientation 563-1, and a second inversion station 560 for inverting a lower half-barrel section 128 with a uniform cross-section from a keel-up orientation 563-3 to a keel-down orientation 563-1.

[0203]

[0219] Clause 44. The system according to Clause 43, further comprising at least one work cell 188, 198 for joining complete barrel sections 44 together.

[0204]

[0220] Clause 45. The system according to Clause 42, wherein each of the first multiple assembly stages 320, 321 comprises at least one feeder line 366 that is operable to provide the completed crown module 364 and one of the crown module components to the respective assembly stages 320, 321.

[0205]

[0221] Clause 46. The system according to Clause 42, wherein each of the second set of assembly stages 330, 331 comprises at least one feeder line 366 that is operable to provide the respective assembly stages 330, 331 with a completed floor grid 365 and one of the floor grid components.

[0206]

[0222] Clause 47. The system according to Clause 42, wherein each of the first multiple assembly stages 320, 321 comprises at least one feeder line 380, 382 that is operable to provide one of fasteners and sealants to the respective assembly stage 320, 321.

[0207]

[0223] Clause 48. The system according to Clause 42, wherein each of the second set of assembly stages 330, 331 comprises at least one feeder line 380, 382 that is operable to provide one of fasteners and sealants to each assembly stage 330, 331.

[0208]

[0224] Clause 49. The system as described in Clause 42, further comprising at least one track 186, 196 for moving complete barrel sections 44 to work cells 188, 198 for joining complete barrel sections 44 together.

[0209]

[0225] Clause 50. The system according to Clause 42, wherein at least one of the assembly stages 320, 330 and the first joining station 184 is operable to attach the splice plate 920 to one or both of the upper half-barrel section 116 and the lower half-barrel section 118 with an uneven cross-section, and at least one of the assembly stages 321, 331 and the second joining station 194 is operable to attach the splice plate 920 to one or both of the upper half-barrel section 126 and the lower half-barrel section 128 with a uniform cross-section.

[0210]

[0226] Clause 51. The system according to Clause 50, further comprising at least one work cell 188 for joining complete barrel sections 44 together, wherein at least one work cell 188 is operable for aligning the upper half-barrel section 116 with the lower half-barrel section 118 with a non-uniform cross-section by bringing the lower boundary 902 of the upper half-barrel section 116 with a non-uniform cross-section to the upper boundary 904 of the lower half-barrel section 118 with a non-uniform cross-section, and for attaching a splice plate 920 to one or both of the upper half-barrel section 116 and the lower half-barrel section 118 with a non-uniform cross-section.

[0211]

[0227] Clause 52. The system according to Clause 50, further comprising at least one work cell 198 for joining complete barrel sections 44 together, wherein at least one work cell 198 is operable for aligning the upper half-barrel section 126 with the lower half-barrel section 128 with a uniform cross-section by bringing the lower boundary 902 of the upper half-barrel section 126 with a uniform cross-section to contact the upper boundary 904 of the lower half-barrel section 128 with a uniform cross-section, and for attaching a splice plate 920 to one or both of the upper half-barrel section 126 and the lower half-barrel section 128 with a uniform cross-section.

[0212]

[0228] Clause 53. To manufacture a part of aircraft 10 using the system described in Clause 42.

[0213]

[0229] Clause 54. A method for assembling an aircraft, comprising moving half-barrel sections 117, 127 of a fuselage 12 along an assembly line 150 having a plurality of work stations 152 arranged in series, wherein each of the particular work stations 152 includes one or more of the workers, tools, and equipment used for the assembly tasks assigned to the half-barrel sections 117, 127 at each particular work station 152, and performing the assembly tasks of the half-barrel sections 117, 127 at each particular work station 152.

[0214]

[0230] Clause 55. The method of Clause 54, wherein moving the half-barrel sections 117, 127 includes advancing the half-barrel sections 117, 127 in the process direction 199 through the assembly line 150 such that the half-barrel sections 117, 127 extend across at least a portion of the work station 152.

[0215]

[0231] Clause 56. The method of Clause 55, comprising at least one of the following: advancing half-barrel sections 117, 127 in the process direction 199 through an assembly line 150; pulse-moving half-barrel sections 117, 127 by a less than their length through a plurality of work stations 152 arranged in series; micro-pulsing half-barrel sections 117, 127 through a range associated with one of the plurality of work stations 152 arranged in series 129; and continuously moving half-barrel sections 117, 127 through a plurality of work stations 152 arranged in series.

[0216]

[0232] Clause 57. The method of Clause 56, wherein performing an assembly task includes performing work on half-barrel sections 117, 127 during a pause between a pulse and a micropulse 129.

[0217]

[0233] Clause 58. The method according to Clause 55, wherein performing an assembly task includes applying an auxiliary component 162 to half-barrel sections 117, 127 using at least one of the series-arranged work stations 152, and simultaneously removing excess production from half-barrel sections 117, 127 using at least one of the series-arranged work stations 152.

[0218]

[0234] The method of Clause 54, further comprising establishing a takt time for the half-barrel sections 117, 127 of the fuselage 12, and determining the number of series-arranged work stations 152 required to perform the assembly task in takt time, based on the working speed of each work station 152, the size of the half-barrel sections 117, 127, and the takt time.

[0219]

[0235] The method according to Clause 60, further comprising using a feeder line 160 to supply auxiliary components 162 to a work station 152.

[0220]

[0236] The method of Clause 61, further comprising sending inspection data 167-1 from an exit line 169 associated with one of the work stations 152.

[0221]

[0237] The method of Clause 62, further comprising transporting the material 167-2 removed from the half-barrel sections 117, 127 away from the work station 152 using an exit line 169 associated with the work station 152.

[0222]

[0238] Clause 63. Part of an aircraft 10 assembled in accordance with the method described in Clause 54.

[0223]

[0239] Clause 64. System 150 comprising a plurality of work stations 152 arranged in series in the process direction 199, and a track 154 that moves the half-barrel sections 117, 127 of the body 12 in the process direction 199 to one or more of the workers, tools and equipment positioned in the individual work stations 152, and allows the plurality of work stations 152 to perform work on the half-barrel sections 117, 127 simultaneously.

[0224]

[0240] The system 150 as described in Clause 64, wherein the track 154 is operable to move the half-barrel sections 117, 127 in the process direction 199 through the work station 152 such that the half-barrel sections 117, 127 extend across at least a portion of the work station 152.

[0225]

[0241] The system 150 as described in Clause 65, wherein track 154 is operable to pulse-move half-barrel sections 117, 127 by a portion less than its length through a series of work stations 152, micro-pulse-move half-barrel sections 117, 127 through a range associated with one of the series of work stations 152, and to continuously move half-barrel sections 117, 127 through a series of work stations 152.

[0226]

[0242] Clause 67. The system 150 described in Clause 64, wherein the work station 152 is arranged at a work density based on the cycle time for the half-barrel sections 117, 127.

[0227]

[0243] Clause 68. The system 150 according to Clause 64, further comprising at least one exit line 169 associated with one of the work stations 152 for removing material 167-2 from the work station 152.

[0228]

[0244] Clause 69. The system 150 according to Clause 64, further comprising at least one feeder line 160 associated with one of the work stations 152 for supplying one or more of the materials and auxiliary components 162 to the work station 152.

[0229]

[0245] Clause 70. The system 150 according to Clause 69, wherein at least one feeder line 160 is configured to supply one or more of the material and auxiliary components 162 to a work station 152 based on the takt time of half-barrel sections 117, 127.

[0230]

[0246] Clause 71. Two of the multiple work stations 152 are configured such that a gap 121 separates the first half-barrel sections 117, 127 and the second half-barrel sections 117, 127 on the track 154. The system 150 as described in Clause 64, wherein the gap 121 is configured to allow access to one or more of the workers and tools for the system 150.

[0231]

[0247] Article 72. To manufacture a part of the aircraft 10 using the system 150 described in Article 64.

[0232]

[0248] Clause 73. A method for assembling an aircraft 10, comprising advancing the inverted lower half-barrel sections 118, 128 of the fuselage 12 in the process direction 199 through assembly lines 110, 120 of work stations 114, 124, and simultaneously advancing the upper half-barrel sections 116, 126 of the fuselage 12 in the process direction 199 through assembly lines 110, 120, behind the inverted lower half-barrel sections 118, 128, so that the inverted lower half-barrel sections 118, 128 and the upper half-barrel sections 116, 126 advance in parallel, and the inverted lower half-barrel... A method comprising performing work on the lower half-barrel sections 118, 128 and the upper half-barrel sections 116, 126 as they advance through assembly lines 110, 120; removing the inverted lower half-barrel sections 118, 128 from assembly lines 110, 120; removing the upper half-barrel sections 116, 126 from assembly lines 110, 120 while the inverted lower half-barrel sections 118, 128 are rotated to a keel-down orientation 563-1; and attaching the lower half-barrel sections 116, 126 to the lower half-barrel sections 118, 128.

[0233]

[0249] The method according to Clause 73, further comprising installing the floor grid 365 within the inverted lower half-barrel sections 118, 128 after the inverted lower half-barrel sections 118, 128 have been removed from the assembly line 110, 120, and while the upper half-barrel sections 116, 126 continue to pass through the assembly line 110, 120.

[0234]

[0250] Clause 75. The method according to Clause 73, comprising advancing the upper half-barrel sections 116, 126 while maintaining a distance between the upper half-barrel sections 116, 126 and the inverted lower half-barrel sections 118, 128 such that the distance between them is less than the length of the inverted lower half-barrel sections 118, 128.

[0235]

[0251] Clause 76. The method according to Clause 73, comprising maintaining a distance between the upper half-barrel sections 116, 126 and the inverted lower half-barrel sections 118, 128 such that the upper half-barrel sections 116, 126 are greater than or equal to the distance between the work stations 114, 124 of the assembly line 110, 120.

[0236]

[0252] The method according to Clause 77, wherein advancing the inverted lower half-barrel sections 118, 128 and advancing the upper half-barrel sections 116, 126 is performed, and the lower half-barrel sections 118, 128 and the upper half-barrel sections 116, 126 are moved continuously in the process direction 199 through the assembly line 110, 120.

[0237]

[0253] Clause 78. The method according to Clause 73, which includes advancing the upper half-barrel sections 116, 126 to maintain the spacing between work stations 114, 124 performing work on assembly lines 110, 120, which is between the frame pitch 147 of the fuselage 12 and the length of the half-barrel section 44.

[0238]

[0254] The method according to Clause 79, wherein the gap 131 between the upper half-barrel sections 116, 126 and the inverted lower half-barrel sections 118, 128 in assembly lines 110, 120 is greater than the spacing between the work stations 114, 124 in assembly lines 110, 120, thereby allowing the work stations 114, 124 to idle when positioned between adjacent half-barrel sections 118, 128 and the corresponding upper half-barrel sections 116, 126 during manufacturing.

[0239]

[0255] The method according to Clause 80, comprising removing the upper half-barrel sections 116, 126 from assembly line 110, 120 while the inverted lower half-barrel sections 118, 128 are rotated to keel-down orientation 563-1, installing the floor grid 365 into the inverted lower half-barrel sections 118, 128 while the upper half-barrel sections continue to advance along assembly line 110, 120, and installing the crown module 364 into the upper half-barrel sections 116, 126 after they have been removed from assembly line 110, 120 and while the inverted lower half-barrel sections 118, 128 are rotated to keel-down orientation 563-1.

[0240]

[0256] Clause 81. Part of an aircraft 10 assembled in accordance with the method described in Clause 73.

[0241]

[0257] Clause 82. A method for assembling the airframe of an aircraft 10, comprising: assembly lines 110, 120 that advance inverted lower half-barrel sections 118, 128 and upper half-barrel sections 116, 126 of the fuselage 12 in a process direction 199, and including a plurality of work stations 114, 124 positioned in a process direction 199 for performing work on the inverted lower half-barrel sections 118, 128 and upper half-barrel sections 116, 126; a reversing station 560 that is operable to rotate the lower half-barrel sections 118, 128 from a keel-up orientation 563-3 to a keel-down orientation 563-1; and joining stations 184, 194 for attaching the lower half-barrel sections 118, 128 to the upper half-barrel sections 116, 126, a system 100.

[0242]

[0258] The system 100 as described in Clause 82, wherein the work at the lower half-barrel sections 118, 128 at the reversing station 560 has a cycle time such that the upper half-barrel sections 116, 126 and the lower half-barrel sections 118, 128 arrive synchronously at the joining stations 184, 194.

[0243]

[0259] The system 100 as described in Clause 82, further comprising floor grid assembly stages 330, 331, which receive inverted lower half-barrel sections 118, 128 from assembly lines 110, 120 and mount floor grids 365 inside the inverted lower half-barrel sections 118, 128.

[0244]

[0260] The system 100 as described in Clause 85, further comprising crown module assembly stages 320, 321, which receive upper half-barrel sections 116, 126 from assembly lines 110, 120 and install crown modules 364 into the upper half-barrel sections 116, 126.

[0245]

[0261] Clause 86. System 100 as described in Clause 82, wherein work stations 114, 124 perform work selected from the group consisting of installing window frames 145, installing door frames 145-1, trimming excess production, installing frames 146, cutting windows, and cutting doors.

[0246]

[0262] System 100 as described in Clause 82, including tracks 112, 122, which periodically pulse-move the inverted lower half-barrel sections 118, 128 and the upper half-barrel sections 116, 126 in the process direction 199, so that the assembly lines 110, 120 and the work stations 114, 124 perform work on the inverted lower half-barrel sections 118, 128 and the upper half-barrel sections 116, 126 during pauses between pulses 123.

[0247]

[0263] System 100 as described in Clause 82, wherein assembly lines 110, 120 include tracks 112, 122 that move the inverted lower half-barrel sections 118, 128 and the upper half-barrel sections 116, 126 in a process direction 199 so that work stations 114, 124 perform work on the inverted lower half-barrel sections 118, 128 and the upper half-barrel sections 116, 126 during continuous movement.

[0248]

[0264] Article 89. To manufacture a part of an aircraft using the systems described in Article 82.

[0249]

[0265] Any of the various control elements (e.g., electrical components or electronic components) shown in the diagrams or described herein may be implemented as hardware, processor-implemented software, processor-implemented firmware, or any combination thereof. For example, some elements may be implemented as dedicated hardware. Dedicated hardware elements may be referred to as “processors,” “controllers,” or some similar terminology. If functions are provided by processors, they may be provided by a single dedicated processor, a single shared processor, or a number of separate processors, some of which may be shared. Furthermore, the explicit use of the terms “processor” or “controller” should not be interpreted as referring only to software-executable hardware, but implicitly includes, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuits, field-programmable gate arrays (FPGAs), read-only memory (ROM) for software storage, random-access memory (RAM), non-volatile storage, logic, or any other physical hardware components or modules.

[0250]

[0266] Furthermore, control elements may be implemented as instructions that can be executed by a processor or computer to perform the function of that element. Some examples of instructions are software, program code, and firmware. When executed by a processor, instructions are operable to instruct the processor to perform the function of that element. Instructions may be stored in a processor-readable storage device. Some examples of storage devices are digital or solid-state memory, magnetic storage media such as magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media.

[0251]

[0267] While specific embodiments are described herein, the scope of this disclosure is not limited to those specific embodiments. The scope of this disclosure is defined by the following claims:

Claims

1. A method for assembling aircraft, In an assembly line with multiple work stations arranged in series, the lower half-barrel section of the fuselage is received in a keel-up orientation, In the assembly line, the upper half-barrel section of the fuselage corresponding to the lower half-barrel section is received after the lower half-barrel section, The lower half-barrel section and the upper half-barrel section are advanced in the process direction through the assembly line such that each of them extends across at least a portion of the work station. Using the aforementioned part of the work station, work is performed simultaneously on the lower half-barrel section and the upper half-barrel section, The lower half-barrel section, which exited the assembly line prior to the upper half-barrel section, is inverted to a keel-down orientation. The lower half-barrel section, which has been inverted to the keel-down orientation, is joined to the upper half-barrel section that has come out of the assembly line. Methods that include...

2. A method for assembling an aircraft, An assembly line having multiple work stations arranged in series, receiving a half-barrel section of the fuselage, The half-barrel section is advanced through the assembly line in the process direction such that it extends across at least a portion of the work station. Using the aforementioned part of the work station, to simultaneously perform work on the half-barrel section and Includes, A method wherein advancing the half-barrel section includes moving the half-barrel section through the series-arranged work stations, the work stations being separated from each other by a distance less than the length of the half-barrel section, and / or advancing the half-barrel section includes micropulse movement of the half-barrel section through the series-arranged work stations, the length of the micropulse movement being equal to a multiple of the frame pitch for the half-barrel section, and the work stations being separated by the frame pitch for the half-barrel section.

3. The method according to claim 1 or 2, wherein advancing the half-barrel section includes pulse-moving the half-barrel section through the assembly line, and the portion of the work station performs work on the half-barrel section during pauses between pulses.

4. The method according to any one of claims 1 to 3, wherein advancing the half-barrel section includes micropulsing the half-barrel section through a range of at least one of the series-arranged work stations, the portion of the series-arranged work stations performing work on the half-barrel section during pauses between micropulses.

5. The method according to any one of claims 1 to 4, wherein advancing the half-barrel section includes continuously moving the half-barrel section through the assembly line or pulse-moving the half-barrel section through the assembly line according to a common takt time, the common takt time being based on a desired number of half-barrel sections per month.

6. The method according to any one of claims 1 to 5, further comprising indexing the half-barrel section to at least one of the series-arranged work stations during a pause between pulses.

7. When the half-barrel section moves pulse-moving toward or through the work station via micro-pulse movement, the components are transported to one of the work stations. At the aforementioned work station, the components are joined to the half-barrel section. The method according to any one of claims 1 to 6, further comprising joining the components, wherein joining the components to the half-barrel section during a pause between pulses.

8. Performing work on the aforementioned half-barrel section To operate the aforementioned series-arranged work stations independently of each other, To remove material from the aforementioned half-barrel section, some of the multiple work stations arranged in series are operated, To add components to the half-barrel section, operate some of the multiple work stations arranged in series, To non-destructively inspect the half-barrel section and non-destructively inspect the trimmed edges of the half-barrel section, by operating some of the series-arranged work stations and cleaning some of the half-barrel section. The method according to any one of claims 1 to 7, comprising at least one of the following.

9. A system for handling the half-barrel section of the fuselage, Multiple work stations arranged in series, separated from each other by a distance less than the length of the half-barrel section, A track configured to receive the half-barrel section and advance the half-barrel section in the process direction through the plurality of work stations, so that at least two of the work stations can perform work on the half-barrel section simultaneously. Equipped with, A system in which the track is configured to move the half-barrel sections continuously through the plurality of work stations, and / or the distance between the work stations is equal to the frame pitch associated with the half-barrel sections, and / or the track is configured to pulse-move the half-barrel sections through the plurality of work stations according to a common takt time, the common takt time being based on a desired number of half-barrel sections per month.

10. The system according to claim 9, wherein the track is configured to pulse-move the half-barrel section through the plurality of work stations, and the work stations are operated to perform work on the half-barrel section during pauses between pulses.

11. The system according to claim 9 or 10, wherein the track is configured to move the half-barrel section in micropulses through a range of at least one of the work stations, and the work station is operated to perform work on the half-barrel section during pauses between micropulses.

12. The system according to any one of claims 9 to 11, wherein at least one of the work stations includes an indexing component, the indexing component is configured to operate in relation to the half-barrel section and the indexing feature on the track, to position the half-barrel section within the work station.

13. The system according to any one of claims 9 to 12, wherein the plurality of work stations are separately configured to perform tasks from a group consisting of frame mounting, window mounting, window excess trimming, door mounting, door excess trimming, trimming of the bearing edge of the half-barrel section, cleaning, sealing, non-destructive testing (NDI) of the half-barrel section, and non-destructive testing (NDI) of the trimmed edge.

14. A method for manufacturing a part of an aircraft using the method according to any one of claims 1 to 8 and / or the system according to any one of claims 9 to 13.

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