Methods and systems for assembling structures

Abstract

To provide a system and a method for placing a preform on a mandrel.SOLUTION: One of exemplary methods includes: moving a mandrel 140 in a process direction 14 with respect to a station 100 equipped with multiple pick and place (PNP) machines 130; identifying a tray 190 that stores a preform containing an uncured fiber-reinforced material 152; placing a strongback 180 on the preform via at least one of the PNP machines; applying a vacuum to hold the preform in contact with the strongback; conveying the preform to the mandrel via the PNP machine; and placing the preform on the mandrel.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to the field of assembly, and more particularly, to the placement of preforms (pre-formed parts) for assembling composite parts.

Background Art

[0002] Multilayer preforms of constituent materials (e.g., carbon fiber reinforced polymer (CFRP)) can be formed into any of a variety of shapes and solidified into composite parts. When manufacturing complex composite parts, multiple preforms can be placed together on a mandrel and cured together to form a single integral part. However, placing multiple preforms together for curing, whether done manually or automatically, is a substantially time-consuming process that reduces the speed of manufacturing composite parts.

[0003] Therefore, in addition to at least some of the above problems, it would be desirable to have a method and system that also takes into account other possible problems.

[0004] Patent document WO 2020 / 263093 A1, according to its abstract, describes as follows. A preforming system for automatically and sequentially placing plies (specifically fiber reinforced plies) at desired locations in a preselected arrangement for preforming a composite structure includes at least one buffer provided with two or more carriers, a controller, a placement robot provided with a ply operation unit, and a substrate. Each carrier is configured to carry at least one preclassified ply. The controller tracks changes in the position, type, and order of at least one preclassified ply for each carrier. The controller further controls the placement robot to operate at least one ply from a selected carrier among the two or more carriers by the ply operation unit, convey it to the substrate, and place this at least one ply at a desired location in a preselected arrangement.

[0005] According to its abstract, patent document US 2019 / 047158 A1 describes a system and method for enhancing the picking and placing of plies of material. The apparatus includes a robotic end effector. The end effector includes a frame and a cup assembly mounted on the frame. Each cup assembly includes a shaft and a head. The end effector also includes a Bernoulli cup mounted on the head of the cup assembly and a gripping portion mounted on the head of the cup assembly.

[0006] According to its abstract, patent document US 9 873 230 B1 describes a mobile vehicle used to place, compress, and inspect composite plies at selected locations on a tool. The vehicle comprises a mounted composite ply feeder, a transfer platen for transporting the plies to the tool, a compression device for compressing the plies on the tool, and an inspection device for inspecting the plies on the tool, each of which is operated and controlled by a mounted operating device (such as a robot).

[0007] According to its abstract, patent document DE 42 26 822 A1 describes the following: A suction panel bonded to a backing pad, the backing pad being fixed to a reinforcing plate. The suction panel has several suction positions, at which through-holes extend to a main channel connected to a lateral channel system and a vacuum source. Each of the air holes is surrounded by a raised ring located at a certain radial distance from the hole. This creates a closed suction area around each of the holes on the working surface of the panel. The raised ring has sides that are tapered in thickness from its base to its top on the panel surface. [Overview of the project]

[0008] The embodiments described in this book provide a system and method for performing coordinated control of pick-and-place (PNP) machines to place preforms onto a mandrel. The PNP machines operate in conjunction when placing large objects but independently when placing smaller objects. This allows for an improvement in the overall preform placement speed, and consequently, can accelerate the layup (and thus manufacturing) speed of composite parts.

[0009] One embodiment is a method for placing a preform on a mandrel. This method includes moving a mandrel in the process direction with respect to a station having a plurality of pick-and-place (PNP) machines; identifying a tray containing a preform containing unsolidified fiber-reinforced material; placing a strongback on the preform via at least one of the PNP machines; applying a vacuum to hold the preform in contact with the strongback; transporting the preform to the mandrel via the PNP machines; and placing the preform on the mandrel.

[0010] Further embodiments include a non-transient computer-readable medium that embodies programmed instructions, which, when executed by a processor, may function to carry out a method for assembling a structure. This method includes moving a mandrel in the process direction to a station comprising a plurality of pick-and-place (PNP) machines; identifying a tray containing a preform containing unsolidified fiber-reinforced material; placing a strongback on the preform via at least one of the PNP machines; applying a vacuum to hold the preform in contact with the strongback; transporting the preform to a mandrel via the PNP machines; and placing the preform on the mandrel.

[0011] A further embodiment is a placement system for manufacturing structures. This placement system includes a pick-and-place (PNP) machine in a station within a cell and a cell controller. The cell controller is operable to move a mandrel in the process direction relative to the station, identify a tray containing a preform containing unsolidified fiber-reinforced material, place a strongback on the preform via at least one of the PNP machines, apply a vacuum to hold the preform in contact with the strongback, transport the preform to a mandrel via the PNP machine, and place the preform on the mandrel.

[0012] Other exemplary embodiments (e.g., methods and computer-readable media related to the embodiments described above) may also be described later. The features, functions, and advantages described above may be realized individually in various embodiments or in combination in yet another embodiment, the further details of which can be understood by referring to the following description and drawings.

[0013] Hereafter, some embodiments of the present disclosure will be described for illustrative purposes only, with reference to the accompanying drawings. In all drawings, the same reference numerals represent the same or similar elements. [Brief explanation of the drawing]

[0014] [Figure 1] This is a schematic block diagram showing a manufacturing line having a mounting system in an exemplary embodiment. [Figure 2] This is a schematic block diagram of a mounting station that may be used in the mounting system of the manufacturing line shown in Figure 2, in one exemplary embodiment. [Figure 3] Figure 2 is a perspective view of the mounting system shown in one exemplary embodiment. [Figure 4] This is a perspective view of a first exemplary tray, which may be used with the mounting system shown in Figures 1 and 3, in an exemplary embodiment. [Figure 5] Figures 1 and 3 show a perspective view of a second exemplary tray that can be used with the mounting system and includes an exemplary preform that can be mounted by the mounting system. [Figure 6] These are side cross-sectional views of the tray shown in Figures 4 and 5, cut along line 6-6, without any preforms. [Figure 7] This is a side cross-sectional view of the tray shown in Figure 6, which has a preform (for example, the preform(s) shown in Figure 5). [Figure 8] Figures 6 and 7 show a tray, and Figures 1 to 3 show a strongback that can be used with the mounting system. These are side cross-sectional views of the strongback. [Figure 9] This is a side cross-sectional view of the strongback in Figure 8, engaged with the tray in Figure 8. [Figure 10] These are side cross-sectional views of the strongback shown in Figures 8 and 9, which have a preform. [Figure 11] This is a side cross-sectional view of a mandrel that can be used with the mounting system shown in Figures 1 to 3 and / or with the manufacturing line shown in Figure 1. [Figure 12] Figures 6 to 11 show side cross-sectional views of the mandrel, strongback, and preform in an exemplary embodiment. [Figure 13] Figure 12 shows a side section of the mandrel, strongback, and preform, in which the strongback and / or preform are placed on the mandrel. [Figure 14] Figures 12 and 13 show side cross-sectional views of the mandrel, strongback, and preform, where the preform is placed on the mandrel. [Figure 15] This is an end view of a mandrel that can be used as the mandrel shown in Figures 11 to 14 in an exemplary embodiment, and / or can be used in conjunction with the mounting system shown in Figures 1 to 3 and / or the manufacturing line shown in Figure 1. [Figure 16] An end view of the mandrel of FIG. 15, with a strongback assembly that can be used as a strongback as shown in FIGS. 8 to 10 and FIGS. 12 to 14 in an exemplary embodiment. [Figure 17] A bottom view of a strongback on which preform(s) are placed, cut along line 17-17 of FIG. 16, in an exemplary embodiment. [Figure 18] An end cross-sectional view of the mandrel and preform(s) shown in FIG. 17. [Figure 19] A perspective view of a first example of a plurality of placement stations that can be used with the placement system shown in FIG. 1. [Figure 20] A perspective view of a second example of a plurality of placement stations that can be used with the placement system shown in FIG. 1. [Figure 21] A perspective view showing the configuration of a placement station, an assembly station, and a mandrel segment that can be used in the placement system of FIG. 1 in an exemplary embodiment. [Figure 22] A flowchart showing a method for assembling a structure using the placement system of FIGS. 1 to 3 in an exemplary embodiment. [Figure 23] A message diagram that can be used in the method shown in FIG. 22 in an exemplary embodiment. [Figure 24A] A flowchart showing a placement method for operating the placement system shown in FIGS. 1 to 21 in an exemplary embodiment. [Figure 24B] A flowchart showing a placement method for operating the placement system shown in FIGS. 1 to 21 in an exemplary embodiment. [Figure 25] A flowchart showing a method for operating the placement system and / or manufacturing line shown in FIG. 1 to perform a post-placement method before or during the placement method shown in FIGS. 24A and 24B in an exemplary embodiment. [Figure 26]This flowchart shows how to prepare the mandrels shown in Figures 2 to 21, which can be used to carry out the reuse shown in the method in Figure 25. [Figure 27] This is a flowchart of an aircraft manufacturing and maintenance method, in an exemplary embodiment in which the system and / or manufacturing line shown in Figures 1 to 21 and / or the method shown in Figures 22 to 26 may be used. [Figure 28] This is a schematic block diagram of an aircraft, which in one exemplary embodiment may be manufactured using the systems and / or production lines shown in Figures 1 to 21 and / or the methods shown in Figures 22 to 26. [Figure 29] Figure 28 is a perspective view of the aircraft shown. [Modes for carrying out the invention]

[0015] Specific and exemplary embodiments of the Disclosure are provided by the figures and the following description. Therefore, those skilled in the art will recognize that various configurations within the scope of the Disclosure, embodying the principles of the Disclosure, can be devised (even those not explicitly described or illustrated herein). Furthermore, any examples provided herein should be understood as being for the purpose of understanding the principles of the Disclosure and not as limiting to the examples and conditions specifically listed. Consequently, the Disclosure is limited by the scope of the claims and their equivalents, and not by the specific embodiments or examples described below.

[0016] Composite parts (such as carbon fiber reinforced polymer (CFRP) parts) are first laid up into a multi-layer structure collectively called a preform. While the individual fibers within each layer of the preform are aligned parallel to one another, separate layers may exhibit different fiber orientations to improve the strength along various dimensions of the resulting composite part. The preform may contain a viscous resin that solidifies it into a composite part (e.g., used in aircraft). Carbon fibers impregnated with uncured thermosetting or thermoplastic resins are called "prepregs." Other types of carbon fibers include "dry fibers," which are not impregnated with thermosetting resins but may contain viscosity modifiers or binders. Dry fibers may be injected with resin before curing. With thermosetting resins, solidification is a unidirectional process called curing, while with thermoplastic resins, the resin can reach a viscous state upon reheating.

[0017] The embodiments described herein provide pulsed or moving line designs and systems, as well as methods for coordinating and synchronously assisting pick-and-place (PNP) machines in placing preforms onto stationary or moving mandrels. In one example having moving segments (e.g., mandrel segments) or full tools (e.g., mandrels) that move continuously or pulsed along the production line, the systems and methods described herein can increase the work density on the mandrel (for example, by having more stations and / or a larger zone coverage area, and by allowing more parallel processing steps to be performed simultaneously in the supply lines to the stations). The systems and methods described herein can provide orders of magnitude reductions in work density and increases in parallel processing steps by maintaining a similar level of dense packing density in the production facility. All processes (both automatic and manual) can be synchronized to support line speed.

[0018] Figure 1 is a schematic block diagram showing a manufacturing line 10 having a mounting system 50 for manufacturing or assembling a structure 12. In the examples in this book, the structure 12 moves along the manufacturing line 10 in a process direction 14, and becomes a composite part 16 after the unsolidified fiber-reinforced material 152 constituting the structure 12 is solidified. Solidification includes curing thermosetting materials or solidifying thermoplastic materials. The structure 12 may be a section 768 (e.g., a half-barrel section 770) of a fuselage 766 that can be used in an aircraft 750 (see Figures 28 and 29).

[0019] To move the structure 12 along the production line 10, the mandrel 140 moves along the production line 10, at least through the mounting system 50. In some examples, the mandrel 140 includes mandrel segments 235 (detailed in relation to Figure 21).

[0020] The loading system 50 manufactures or assembles a structure 12 from objects 18. Each object 18 may include a preform 150 (see Figures 2 and 5) of unsolidified fiber-reinforced material 152. The loading system 50 loads the preforms 150 onto a mandrel 140 to solidify into a composite component 16. One or more of the objects 18 may be a first type of object 18 (e.g., a discrete object 20) and / or a second type of object 18 (e.g., a large object 22). The large object 22 is larger than the discrete object 20. Thus, the loading system 50 can manufacture or assemble a structure 12 from objects 18, including discrete objects 20 and one or more large objects 22. In the example described later, the large objects 22 span multiple pick-and-place (PNP) machines 130.

[0021] Referring to Figures 1, 5, and 18, if object 18 is a preform 150, the preform 150 may be a first type of preform (e.g., a discrete preform 154 such as a frame filler preform 158) and / or a second type of preform (e.g., a large preform 156 such as a stringer preform 159). Thus, in some examples, the mounting system 50 assembles a structure 12 from a preform 150 that includes a discrete preform 154 and one or more large preforms 156. If the mounting system 50 is used to fabricate a portion 768 of a fuselage 766 as a structure 12, the discrete object 20 may be a frame filler preform 158 (also known as “postage stamps”) and / or a short stringer, and the large object 22 may be a medium stringer preform or a long stringer preform 159. Since the large preform 156 is an example of a large object 22, it spans multiple PNP machines 130.

[0022] Referring again to Figure 1, the mounting system 50 includes at least a mounting station 100. The mounting system 50 may optionally also include at least one assembly station 105. The production line 10 may further include a solidification system 60, a separation system 70, a washing system 80, and / or other suitable systems (e.g., a lamination system or a fastener installation system, not shown). The mounting system 50, the solidification system 60, the separation system 70, and / or the washing system 80 may be configured in series or in parallel, depending on the structure to be assembled and the manufacturing processes used along the production line 10. In Figure 1, the mounting system 50, the solidification system 60, the separation system 70, and the washing system 80 are shown in this order, but the solidification system 60 may also be positioned after the separation system 70, as detailed in relation to Figure 25.

[0023] The solidification system 60 is configured to solidify an unsolidified material (e.g., an unsolidified fiber-reinforced material 152) into a solidified material. The solidification system 60 is capable of curing thermosetting materials and / or solidifying thermoplastic materials. For example, the solidification system 60 includes an autoclave. The solidification system 60 may further be configured to add a release film 62 to the structure 12 and / or the mandrel 140 prior to the solidification of the structure 12. The release film 62 may include bagging material, release ply, separation membrane, etc. In one example, a release film 62 such as a separation membrane and / or release ply is added to the mandrel 140, and a release film 62 such as bagging material is added to the structure 12. The release film 62 may be added to the mandrel 140 before the mandrel 140 enters the mounting system 50.

[0024] Structure 12 can become a solidified structure 64 after being solidified by the solidification system 60. If structure 12 is formed from unsolidified fiber-reinforced material 152, the solidified structure 64 can be a composite component 16. For example, the solidified structure 64 is a hardened structure that forms the composite component 16. The solidified structure 64 or the composite component 16 moves along the production line 10 to undergo additional manufacturing processes. For example, the composite component 16 and / or the solidified structure 64 move to a new location (e.g., a different system) within the production line 10 to undergo further manufacturing processes. The various systems may be manufacturing systems or assembly systems, and further manufacturing processes may assemble the composite component 16 into a final product (e.g., the aircraft 750 shown in Figures 28 and 29).

[0025] The separation system 70 is configured to separate (e.g., demold) the solidified structure 64 from the mandrel 140. In one example, the separation system 70 is configured to separate the solidified structure 64 from the mandrel 140 by moving it vertically. If the mandrel 140 is formed from mandrel segments 235, the separation system 70 is configured to separate the solidified structure 64 from the mandrel segments 235 individually, or from the mandrel 140 after they have been assembled together. The separation system 70 is further configured to separate the mandrel segments 235 from each other. If a release film 62 is added in the solidification system 60, the separation system 70 removes the release film 62 from the solidified structure 64 and / or the mandrel 140. When the mandrel 140 is formed from the mandrel segments 235, the release film 62 is removed from the mandrel segments 235 after the solidified structure 64 has been separated from the mandrel 140 and before the mandrel segments 235 are separated from each other.

[0026] If the mandrel 140 is to be reused at the loading station 100, the mandrel 140 is moved in the reverse process direction 24 to be reused in the loading station 50 after being separated from the structures 12, 64. More specifically, the mandrel 140 is transported to the starting position 52 of the loading system 50 and / or loading station 100. Alternatively, the mandrel 140 may remain with the structures 12, 64 and continue to support the structures 12, 64 along the production line 10 as additional assembly and manufacturing processes are carried out on the structures 12, 64 until the mandrel 140 no longer needs to support the structures 12, 64.

[0027] The cleaning system 80 is configured to clean the mandrel 140 and / or the mandrel segment 235. For example, the cleaning system 80 is configured to apply at least one cleaning agent 82 to the mandrel 140 and / or the mandrel segment 235. This at least one cleaning agent 82 may be a solvent, water, and / or soap. In one example, the at least one cleaning agent 82 is selected from the group consisting of solvents, water, and soap. If the at least one cleaning agent 82 includes multiple different cleaning agents 82 applied by the cleaning system 80, the cleaning system 80 may apply the multiple different cleaning agents 82 sequentially and / or simultaneously.

[0028] The cleaning system 80 additionally or alternatively includes components for polishing, scrubbing, or other cleaning processes, such as using a mobile brush or scrubber. These cleaning devices may be used before, during, or after the application of at least one cleaning agent 82. In an alternative embodiment, the mandrel segments 235 are separated from each other after the mandrel 140 has been cleaned. However, if the mandrel segments 235 are separated from each other initially, they can be cleaned more thoroughly and / or in parallel.

[0029] The placement system 50 includes a pick-and-place (PNP) machine 130 at a placement station 100 and a cell controller 120 operable to perform the methods described herein. More specifically, the placement station 100 includes the PNP machine 130 and the cell controller 120. The cell controller 120 communicates with the PNP machine 130 to perform the placement process at the placement station 100. For example, the cell controller 120 is operablely connected to the PNP machine 130 to place an object 18 onto a mandrel 140 using the PNP machine 130. The placement station 100 may further include a strongback 180 and / or a tray 190. The tray 190 is configured to hold one type of object 20 or 22, or both types of objects 20 and 22, as detailed in relation to Figures 4 and 5.

[0030] The mounting system 50 includes one or more mounting stations 100. If the mounting system 50 includes more than one number of mounting stations 100, 100', the PNP machines 130, 130' may be distributed across multiple mounting stations 100, 100'. The multiple mounting stations 100, 100' may be programmed and / or configured to perform parallel processes, or to perform a series of processes. As detailed in relation to Figure 22, the PNP machines 130, 130' within the multiple mounting stations 100, 100' may operate in the same mode or in different modes.

[0031] If the mounting system 50 includes a first mounting station 100 and a second mounting station 100', each of the mounting stations 100 and 100' may include its own cell controllers 120 and 120' that control multiple mounting stations 100 and 100', or may have a common cell controller 120. In one example, mounting stations 100 and 100' have a common cell controller 120 when they are located in the same manufacturing cell 110 (see Figure 2), but mounting stations 100 and 100' in separate manufacturing cells 110 may also be operated by the same cell controller 120. If each of the mounting stations 100 and 100' includes a corresponding cell controller 120 or 120', the cell controllers 120 and 120' are configured to communicate with each other to coordinate the operation of PNP machines 130 and 130' in different mounting stations 100 and 100'.

[0032] The mounting system 50 may further include one or more assembly stations 105. If the mandrel 140 includes mandrel segments 235, the mounting system 50 includes an assembly station 105. The assembly station 105 is configured to assemble the mandrel segments 235 together to form the mandrel 140. The assembly station 105 includes a mandrel support structure 106. The mandrel support structure 106 is configured to support the mandrel segments 235 before, during, or after they are assembled together. Even if the mandrel 140 is not formed from mandrel segments 235, the mandrel support structure 106 may be attached to the mandrel 140 to provide support for the mandrel 140 in the manufacturing process. The mandrel support structure 106 is further configured to move with the mandrel 140 along the production line 10 to subsequent systems. The mandrel support structure 106 can be removed from the mandrel 140 and / or mandrel segment 235 when support is no longer needed (wherever this occurs on the production line 10). The assembly station 105 is shown as being after the loading station 100, but may be before the loading station 100 if the mandrel 140 is to be supported by the mandrel support structure 106 during the loading process performed at the loading station 100.

[0033] If the mounting system 50 includes more than one assembly station 105, 105', the assembly stations 105, 105' may be programmed and / or configured to perform parallel processes, or to perform a series of processes. If assembly station 105 is omitted from the mounting system 50, the mounting system 50 may be considered to include the PNP machine 130 and cell controller 120 of mounting station 100.

[0034] The mandrel 140 is configured to move relative to the loading station 100 (and consequently through the loading system 50). More specifically, the mandrel 140 moves relative to the loading station 100 in the process direction 14. The process direction 14 is the direction in which the mandrel 140 and subassemblies move along the production line 10 as the material (e.g., unsolidified fiber-reinforced material 152) and subassemblies (e.g., structures 12, 64) become the final assembly (e.g., the aircraft 750 shown in Figure 28). The mandrel 140 may sometimes move in the reverse process direction 24. The reverse process direction 24 is either opposite to the process direction 14 or at an angle to the process direction 14, depending on which manufacturing process should be completed along the production line 10. When the mandrel 140 is in the mounting system 100, the mounting system 100 is considered to include the mandrel 140, but the mounting system 50 may sometimes not have the mandrel 140 inside it. Furthermore, the cell controller 120 communicates with the mandrel 140 in order to move it relative to the mounting station 100.

[0035] Figure 2 is a schematic block diagram of a mounting station 100 that may be used in the mounting system 50 shown in Figure 1. In one exemplary embodiment, the mounting station 100 is configured to coordinate the actions of a PNP machine 130. The mounting station 100 includes any system device or component that can operate to mount a preform (e.g., a stringer) onto a mandrel 140 for later solidification into a single composite component (e.g., composite component 16 shown in Figure 1). In this embodiment, the mounting station 100 is enhanced to selectively synchronize the actions of the PNP machine 130 in order to increase the speed at which the preform 150 is mounted onto the mandrel 140.

[0036] The loading station 100 includes a PNP machine 130 and a cell controller 120. More specifically, the loading station 100 includes a plurality of (i.e., two or more) PNP machines, for example, three or more PNP machines 130a, 130b, and 130c. The PNP machine 130 can be divided into subsets, each having one or more PNP machines 130. For example, the PNP machine 130 can be divided into a first subset 126 of the PNP machine 130 and a second subset 128 of the PNP machine 130. As shown in Figure 2, the first subset 126 includes the first PNP 130a, and the second subset 128 includes the second PNP machine 130b and the third PNP machine 130c. Although the first subset 126 and the second subset 128 are illustrated for the sole purpose of clarity as having one and two PNP machines respectively, each subset 126 and 128 may contain any number of PNP machines 130, whether adjacent or not. The PNP machines 130 in the first subset 126 are separate from the PNP machines 130 in the second subset 128. However, the PNP machines 130 may be reassigned between the first subset 126 and the second subset 128 depending on the structure 12 being assembled (see Figure 1) and / or the mounting method being implemented.

[0037] The cell controller 120 operates to control the PNP machine 130. More specifically, the cell controller 120 and the PNP machine 130 are connected to communicate with each other such that commands 124 are communicated from the cell controller 120 to the PNP machine 130 (or more) and data 137 is communicated from the PNP machine 130 (or more) to the cell controller 120. For example, if the mounting station 100 includes three PNP machines 130a, 130b, and 130c, the cell controller 120 receives first data 137a, second data 137b, and third data 137c from each of the PNP machines 130a, 130b, and 130c.

[0038] The loading station 100 and / or PNP machine 130 are located within the manufacturing cell 110. The cell controller 120 is configured to control the processes (such as the loading process) performed in the manufacturing cell 110. The cell controller 120 also operates to assign each PNP machine 130 within the manufacturing cell 110 to either the first subset 126 or the second subset 128. The cell controller 120 also operates to reassign the PNP machines 130 to other subsets 126 and / or 128 as needed.

[0039] During the assembly of the structure 12, the PNP machine 130 picks up an object 18 (e.g., a preform 150) and places it on a mandrel 140. Each preform 150 may be formed from unsolidified fiber-reinforced material 152. The preforms 150 described herein may solidify to become short stringers, medium stringers spanning multiple PNP machines 130, or even long stringers spanning numerous PNP machines 130. Figure 1 shows an object 18 in the form of a stringer preform 159 (e.g., having internal bladder, gap filler, and other components not shown), but in further embodiments, the object 18 may include any preferred components (e.g., other preforms, frame fillers, separation plies, etc.). In short, the PNP machine 130 is positioned within range of discrete objects 20 (e.g., small preforms such as the frame filler preform 158 shown in Figure 5 and / or discrete preform 154), mandrels 140, and larger objects 22 (e.g., large preform 156) spanning multiple PNP machines 130. Alternatively, the PNP machine 130 is positioned within range of objects 18 and mandrels 140. If object 18 is a preform 150, the PNP machine 130 is positioned within reach of the mandrel 140 and the preform 150. The mandrel 140 also moves relative to the PNP machine 130, for example, in the process direction 14.

[0040] Each PNP machine 130 may be similarly configured and include a body 131 having a lower end 133. The main body 131 is configured to house the components of the PNP machine 130. Furthermore, each PNP machine 130 includes a PNP controller 132, a sensor(s) 136, and an end effector 134. The PNP controller 132, the sensor(s) 136, and the end effector 134 are located within and / or mounted on the main body 131. In some embodiments, the sensor(s) 136 are contained within the main body 131 and the end effector 134.

[0041] If the mounting station 100 includes three PNP machines 130a, 130b, and 130c, the first PNP machine 130a includes a first body 131a, a first lower end 133a, one or more first sensors 136a, and a first end effector 134a. Similarly, the second PNP machine 130b includes a second body 131b, a second lower end 133b, one or more second sensors 136b, and a second end effector 134b, and the third PNP machine 130c includes a third body 131c, a third lower end 133c, one or more third sensors 136c, and a third end effector 134c.

[0042] The end effector 134 may optionally move along the body 131 of the PNP machine 130 and / or extend and retract from the body 131 of the PNP machine 130. In one example, the body 131 includes a track or other device that enables the end effector 134 to move at least vertically along the body 131. Additionally or alternatively, the end effector 134 may be positioned near the lower end 133 of the body 131, with at least a portion of the end effector 134 extending vertically from the body 131. For example, the end effector 134 may move vertically relative to the lower end 133 of the body 131, and a portion of the end effector 134 (e.g., a gripping system 139) may extend vertically from the body 131 and retract vertically to the body 131.

[0043] The end effector 134 includes at least a gripping system 139 (e.g., a vacuum system 138). In an alternative embodiment, the gripping system 139 and / or the vacuum system 138 are contained within the PNP machine 130, separately from the end effector 134. In a particular example, the PNP machine 130 includes a vacuum system 138 for applying a vacuum pressure 160 (see Figures 10 and 12) to hold the large preform 156 and the discrete preform 154. The PNP machine 130 has a distal end 135. If the end effector 134 is located near or below the lower end 133 of the PNP machine 130, and / or extends from the PNP machine 130, the distal end 135 may be defined by the end effector 134 and / or the gripping system 139.

[0044] If the mounting station 100 includes three PNP machines 130a, 130b, and 130c, the first PNP machine 130a includes a first distal end 135a, a first gripping system 139a, and / or a first vacuum system 138a. Similarly, the second PNP machine 130b includes a second distal end 135b, a second gripping system 139b, and / or a second vacuum system 138b, and the third PNP machine 130c includes a third distal end 135c, a third gripping system 139c, and / or a third vacuum system 138c.

[0045] The end effector 134 may include additional components for performing operations other than gripping, or it may be removable and replaceable in the PNP machine 130 to allow a different type of end effector to be connected to the PNP machine 130. Sensors 136 are configured to supply data 137 to the cell controller 120 to enable control of the associated PNP machine 130. Sensors 136 may be position sensors (for example, for measuring or determining the position of the end effector 134 and / or the PNP machine 130). Alternatively or additionally, the sensors may include pressure sensors (for example, to measure the vacuum pressure applied by the vacuum system 138), open-circuit sensors, hydraulic sensors, image sensors (such as cameras), radio frequency sensors (such as RFID and / or RADAR), optical sensors (such as LIDAR), barcode readers or QR code readers, etc.

[0046] The PNP machine 130 may operate the gripping system 139 of the end effector 134 to place the strongback 180 on top of the object 18 placed in the tray 190 during the picking and placing process. The PNP machine 130 may move the object 18 to the appropriate place on the mandrel 140 via the strongback 180 (for example, into a notch 142 of the mandrel 140 sized to receive the object 18). The gripping system 139 may be a vacuum system 138 configured to apply a vacuum pressure 160. For example, the vacuum system 138 selectively applies the vacuum pressure 160. The vacuum pressure 160 is applied to or through the strongback 180 to grip the object 18. Alternatively, if the placing station 100 does not include a strongback 180, the vacuum pressure 160 is applied to the object 18. The tray 190 may be a vacuum tray configured to maintain the position of the object(s) 18 relative to the tray 190 by applying vacuum pressure to the object(s) 18.

[0047] The cell controller 120 coordinates the actions of the PNP machine 130 by selectively operating it in synchronous and asynchronous modes, as detailed in relation to Figures 22 and 23. The periodic loading process (process 352 shown in Figure 23) includes a series of phases, and the PNP machine 130 operates in a specific mode in each phase. When the PNP machine 130 performs the periodic loading process, it operates in synchronous mode during the synchronous phase of the period and in asynchronous mode during the asynchronous phase of the period.

[0048] In synchronous mode, the cell controller 120 coordinates the provision of commands 124 from program 122 to multiple PNP machines 130. In one example, program 122 is a numerical control (NC) program 123, and command 124 is an NC command 125. Command 124 is a series of commands sent to each PNP machine 130 from time to time. Thus, command 124 can be formatted as a series of commands (for example, the series of commands shown in Figure 23) that include a previous command 124 and a new command 124 sent after the previous command 124. Program 122 includes a set of commands 124 corresponding to various types of objects 18 placed on various types of mandrels 140 and / or mandrel segments 235 (see Figure 21) by the PNP machines 130. Furthermore, the vacuum system 138 selectively applies a vacuum pressure 160 according to program 122.

[0049] In one embodiment, the cell controller 120 refrains from sending new commands 124 to the PNP machines 130 until each of the PNP machines 130 has completed its current command. This allows the PNP machines 130 to lift, carry, and transport the large object 22 (e.g., stringer preforms 159 for forming medium stringers, long stringers, etc.) in a coordinated manner. In asynchronous mode, the cell controller 120 provides commands from the program 122 to each of the PNP machines 130 as soon as each PNP machine 130 has completed its process (without waiting for progress reports from any other of the PNP machines 130a, 130b, or 130c).

[0050] A first subset 126 of the PNP machine 130 may operate in synchronous mode, and a second subset 128 of the PNP machine 130 may operate in asynchronous mode. Alternatively, all of the PNP machine 130 may operate in either synchronous or asynchronous mode. In some examples, subsets 126 and / or 128 are distributed across multiple mounting stations 100, 100'. For example, the first PNP machine 130 of subset 126 may be located in the first mounting station 100, and the second PNP machine 130' of subset 126 may be located in the second mounting station 100'.

[0051] If the mounting system 50 includes multiple mounting stations (for example, a first mounting station 100 and a second mounting station 100'), the cell controller 120 and / or 120' may operate the PNP machine 130 in the first mounting station 100 in synchronous mode or asynchronous mode so that each mounting station 100, 100' operates in a different mode, and the cell controller 120' may operate the PNP machine 130' in the second mounting station 100' in the other mode. Alternatively, the cell controller 120 and / or 120' may operate the PNP machines 130, 130' in multiple mounting stations 100, 100' in the same mode.

[0052] The PNP controller 132 manages the operation of each PNP machine 130 and interprets received instructions 124 to control the end effector 134. The PNP controller 132 can receive input from sensors 136 (e.g., vacuum sensors, position sensors, open-circuit sensors, hydraulic sensors, LiDAR sensors, etc.) and report data 137 to the cell controller 120 for interpretation. Based on the data 137 from the sensor(s) 136, the cell controller 120 can stop the process, notify a technician, or modify the instructions 124 provided to the PNP machine 130. The cell controller 120 and PNP controller 132 can be implemented, for example, as a custom network, as a hardware processor that executes programmed instructions, or as any combination thereof.

[0053] The loading station 100 may further include a tray 190. The tray 190 may be moved out of the loading station 100 to load preforms 150 into the tray 190, or the preforms 150 may be loaded into the tray 190 while the tray 190 is inside the loading station 100. The loading station 100 may further include a strongback 180. In embodiments in which a PNP machine 130 directly holds the preforms 150, the strongback 180 may be moved out of the loading station 100. The vacuum system 138 selectively applies a vacuum pressure 160 (e.g., suction force) to the strongback 180 and / or to the preforms 150 (e.g., directly or via the strongback 180) according to instructions 124 in the program 122.

[0054] The mandrel 140 is movable into and through the mounting station 100, and therefore movable through the manufacturing cell 110 relative to the PNP machine 130. Such movement is described in detail with reference to Figure 3. The mandrel 140 has a contoured cross section 143 (shown in detail in Figure 3). More specifically, the mandrel 140 includes notches 142 that define the contoured cross section 143 of the mandrel 140. The notches 142 may be channels, grooves, recesses, or other protrusions corresponding to an object 18 to be mounted on the mandrel 140, manufactured on the mandrel 140, and / or assembled on the mandrel 140. Optionally, the mandrel 140 may have an associated vacuum system 144 for securing a preform 150 within the notches 142. A vacuum channel 146 may be defined through the mandrel 140 to provide flow to the vacuum system 144, thereby allowing the vacuum system 144 to apply a vacuum pressure 147 to the notch 142 through the corresponding vacuum channel 146.

[0055] The optional vacuum system 144 is included in the mounting system 50, the mounting station 100, and / or the mandrel 140. If the vacuum system 144 is included in the mounting station 100, the mandrel 140 is connected to the vacuum system after being positioned within the mounting station 100 and disconnected from the vacuum system 144 when it is moved out of the mounting station 100. If the mounting system 50 includes the assembly station 105, the mounting system 50 includes the vacuum system 144, so a vacuum pressure 147 may be applied in the mounting station 100 and the assembly station 105 until the mandrel 140 is moved out of the mounting system 50 and disconnected from the vacuum system 144. However, the mounting system 50 may include separate vacuum systems 144 for mounting station 100 and for assembly station 105, so that the mandrel 140 is disconnected and reconnected from the vacuum system 144 as it moves from mounting station 100 to assembly station 105. As an alternative for connecting and disconnecting the mandrel 140 and the vacuum system 144, the vacuum system 144 may be integrated with the mandrel 140 and move with the mandrel 140 as it passes through various systems along the production line 10.

[0056] If the mandrel 140 includes mandrel segments 235, each of the mandrel segments 235 may be connected to and disconnected from the respective vacuum systems 144 or a common vacuum system 144 in the mounting system 50 and / or mounting station 100. Alternatively, each of the mandrel segments 235 may include a corresponding vacuum system 144 that moves with each of the mandrel segments 235.

[0057] To assist in the alignment of the strongback 180 with the tray 190 and mandrel 140, the strongback 180 includes a strongback positioning element 182, the tray 190 includes a tray positioning element 192, and the mandrel 140 includes a mandrel positioning element 148. The strongback positioning element 182 is configured to align with the tray positioning element 192 and the mandrel positioning element 148. In certain embodiments, the strongback positioning element 182 engages with (e.g., mates with) the mandrel positioning element 148 and the tray positioning element 192.

[0058] Figure 3 is a perspective view of a mounting system 100 in an exemplary embodiment, showing a PNP machine 130 located within a manufacturing cell 110. The manufacturing cell 110 includes a frame 112 and a plurality of supports 114. The supports 114 are connected to the frame 112 and are configured to support the PNP machine 130. As shown in Figure 3, the PNP machine 130 is supported by the frame 112 and the plurality of supports 114. The PNP machine 130 moves along the frame 112 and supports 114 to retrieve a preform 150 (see Figure 2) from a tray 190, transport it, and place it on a mandrel 140 having a convex cross section 143 and notches 142 for receiving stringers.

[0059] More specifically, the PNP machine 130 moves in the Y direction along the support 114. The support 114 may optionally move in the X direction along the frame 112. If the support 114 can move in the X direction on the frame 112, the program 122 in the cell controller 120 includes an instruction 124 to avoid collisions between the PNP machine 130 and / or the end effector 134. Furthermore, the PNP machine 130 and / or the end effector 134 are configured to move in the Z direction perpendicular to the support 114. In one example, the PNP machine 130 moves in the Z direction along a trajectory or other device that can move the PNP machine 130 vertically. Alternatively or additionally, the end effector 134 and / or gripping system 139 extend and retract in the Z direction relative to the PNP machine 130 as described above. As detailed in relation to Figures 24A and 24B, at least the distal end 135 of the PNP machine 130 and / or end effector 134 moves in the Y and Z directions, and optionally in the X direction, to position itself on the tray 190 and to transport the object 18 from the tray 190 to the mandrel 140.

[0060] Figure 4 is a perspective view of a first exemplary tray 190 that may be used with the mounting system 50 shown in Figures 1 and 3 in an exemplary embodiment. The tray 190 is configured to hold at least one preform 150 (see Figure 2) before being attached to the mandrel 140 (see Figures 1 to 3). The tray 190 stores the preform 150 of the stringer 778 (see Figure 29) or other object 18 that is to be placed on the mandrel 140.

[0061] The tray 190 includes a body 194 having a surface 196 and one or more recesses 198 defined in the surface 196. The recesses 198 are configured to hold objects 18. The tray 190 further includes a positioning cup 193 as a tray positioning element 192. The positioning cup 193 facilitates the alignment of the strongback 180 and the tray 190. The recesses 198 have a length L. In some embodiments, a layer of fluorinated ethylene propylene (FEP) or another release film 26 (see Figure 6) is positioned within the recesses 198 to facilitate the separation of the preform 150 from the tray 190.

[0062] Tray 190 may be a first type of tray 190a, which includes a plurality of recesses 198. Each recess 198 is configured to hold a corresponding preform 150. Even if each recess 198 is the same depth, at least one recess 198 may be deeper or shallower than the others. In the example shown in Figure 4, the plurality of recesses 198 are similarly configured to hold a plurality of identical preforms 150. For example, tray 190a includes a plurality of recesses 198 to hold a plurality of large preforms 156, each of which is configured to hold a corresponding large preform 156 (see Figure 5). Alternatively, tray 190 may be a second type of tray 190b, which includes a single recess 198. The recess 198 may hold one or more preforms 150. When the recess 198 stores multiple preforms 150, the preforms 150 may be multiple discrete preforms 154 (see Figure 5), multiple large preforms 156, or a combination of discrete preforms 154 and large preforms 156. For example, tray 190b can store an array of discrete preforms 154 within the same recess 198.

[0063] The two types of trays 190a and 190b may constitute a set 191 of trays 190 that can be used with the mounting station 100. When this set 191 is used, the first type of tray 190a may contain multiple stringer preforms 159 (see Figure 5), and the second type of tray 190b may contain multiple frame filler preforms 158 (see Figure 5).

[0064] Figure 5 is a perspective view of a second exemplary tray 190 that may be used with the mounting system 50 shown in Figures 1 to 3, and includes an exemplary preform 150 that may be mounted by the mounting station 100. The preform 150 includes a large preform 156, exemplified as a stringer preform 159, and a discrete preform 154, exemplified as a frame filler preform 158. The tray 190 in Figure 5 is a third type of tray 190c that includes recesses 198 configured to accommodate one or more large preforms 156 and discrete preforms 154. More specifically, the third type of tray 190c includes a plurality of recesses 198 having first shapes 197 and second shapes 199. The first shape 197 corresponds to the discrete preform 154, and the second shape 199 corresponds to the large preform 156.

[0065] Having recesses of two different shapes (e.g., a first shape 197 and a second shape 199) makes it possible to accommodate a kitted preform 150 of a third type of tray 190c. When kitted, the discrete preform 154 is positioned so as to rest on the location 781 where the frame 780 (see Figure 29) should be installed relative to the large preform 156 (i.e., relative to the stringer 778 shown in Figure 29, formed from the stringer preform 159). In other words, the discrete object 20 is positioned in the tray 190c together with the large object 22, at the location 195 where the frame 780 should be installed relative to the large object 22. Location 781 of the fuselage 766 corresponds to location 195 in the tray 190, either full size or scaled down. If the correspondence is life-size, preforms 154 and 156 remain stationary relative to each other while being transported from tray 190 to mandrel 140. If the correspondence is scaled, preforms 154 and 156 may be separated so that they become life-size when moved from tray 190 to mandrel 140.

[0066] In the example in Figure 5, the discrete preform 154 is positioned in place 195 relative to the large preform 156 where the frame 780 will be installed. More specifically, the frame filler preform 158 is positioned in place 195 within a recess 198, corresponding to where the frame 780 will be placed relative to the stringer 778 formed from the stringer preform 159. For example, the stringer preform 159 is housed in each recess 198 having a second shape 199, and the frame filler preform 158 is housed in a recess 198 having a first shape 197 in place 195.

[0067] If the preform 150 is equipped, the cell controller 120 operates the PNP machine 130 to transport the large preform(s) 156 and the discrete preform 154 while maintaining their relative positions to each other. Thus, the equipped arrangement on tray 190c is maintained from tray 190c to placement on mandrel 140.

[0068] One alternative to equipping is that an array of discrete preforms 154 fills a recess 198 having a first shape 197, and the PNP machine 130 picks up each discrete preform 154 from the tray 190c and places it at a specific position on the mandrel 140 relative to the large preform 156 and other discrete preforms 154. In this example, more discrete preforms 154 can be stored in the tray 190c compared to when the discrete preforms 154 are spaced apart at multiple locations 195 within the recess 198. However, equipping the preforms 150 can ensure that a suitable number of preforms 150 for a particular part of the structure 12 currently being assembled are present at the placement station 100.

[0069] Figures 6 to 14 illustrate the transfer of the preform 150 from the tray 190 to the strongback 180 and from the strongback 180 to the mandrel 140 in an exemplary embodiment.

[0070] Figure 6 is a side cross-sectional view of the tray 190 shown in Figures 4 and 5, cut along line 6-6, without the preform(s) 150. In Figure 6, the tray 190 is awaiting the loading of object 18 (see Figures 1 and 2). Figure 6 also shows optional tray vacuum channels 200. Each recess 198 of the tray 190 may have one or more vacuum channels 200 extending from the recess 198 through the body 194. The vacuum channels 200 are configured to provide flow between the corresponding recess 198 and the vacuum system 202 in order to apply vacuum pressure 204 (see Figure 7). Figure 6 also shows an optional release film 26 which may be positioned within the recess(s) 198 to facilitate the removal of the preform(s) 150 (see Figure 7) from the tray 190.

[0071] Figure 7 is a side cross-sectional view of the tray 190 shown in Figure 6, which has a preform 150 (for example, the preform(s) shown in Figure 5). In Figure 7, the preform 150 is loaded into the recess 198 (for example, by an end effector of an automated machine or by a technician). This can be done by laying up the preform 150 into the recess 198 via the operation of a tape laying machine, physically picking up the preform 150 from the layup mandrel, and placing the preform 150 into the recess 198. Figure 7 also shows a vacuum pressure 204 which may be optionally applied to the preform 150 positioned in the recess 198. The vacuum pressure 204, if used, is applied by a vacuum system 202 (see Figure 2) through a vacuum channel 200.

[0072] Figure 8 is a side cross-sectional view of a strongback 180 that can be used with the tray 190 shown in Figures 6 and 7, and the mounting system 50 shown in Figures 1 to 3. In Figure 8, the strongback 180 is positioned above the tray 190. The strongback 180 includes recesses 184 for receiving preforms 150. More specifically, the strongback 180 includes a body 186 having a surface 185 and one or more recesses 184 defined on the surface 185. The strongback 180 may include one recess 184 for each preform 150 to be removed from the tray 190, and / or may include the same number of recesses 184 as the number of recesses 198 in the tray. In a particular example, the tray 190 contains multiple preforms 150, and the strongback 180 contains multiple recesses 184. An example of a strongback 180 containing multiple recesses 184 is shown in Figure 17. An optional release film 26 may be loaded into the recess 184. In a further embodiment, the strongback 180 may be sized to carry multiple preforms 150 at once from the tray 190.

[0073] The strongback 180 further includes positioning pins 183 as strongback positioning elements 182. The positioning pins 183 are for aligning the strongback 180 with the tray 190. Each of the positioning pins 183 has a shape corresponding to the shape of the positioning cup 193 of the tray 190. For example, if the cup 193 is a conical hole, each of the positioning pins 183 may be configured as a cone. Thus, when the strongback 180 engages with the tray 190 (see Figure 9), each of the positioning pins 183 may be received within the corresponding positioning cup 193.

[0074] A vacuum channel 188 is defined to extend from the recess 184 and pass through the body 186. The vacuum channel 188 is configured to provide flow between the recess 184 and the vacuum system 138 (see Figure 2) of the PNP machine 130. The strongback 180 may include one or more vacuum channels 188 for each recess 184. If the strongback 180 includes more than one recess 184, it also includes more than one vacuum channel 188, so that at least one vacuum channel 188 is associated with each recess 184. The vacuum channels 188 are connected to the recess 184. The vacuum channels 188 allow the vacuum pressure 160 (see Figure 10) applied by the end effector 134 (see Figure 2) of the PNP machine 130 to suction the preform 150 into place in the strongback 180. Depending on the type, number, and / or size of preforms 150 picked up by the strongback 180, each vacuum channel 188 may be operated individually or in conjunction with other vacuum channels 188. For example, only the vacuum channel 188 to which a preform 150 is held may be operated, while the vacuum channels 188 to which no preform 150 is associated may not be operated.

[0075] Figure 9 is a side cross-sectional view of the strongback 180 of Figure 8 engaged with the tray 190 of Figure 8. The strongback positioning element 182 is configured to engage with the tray positioning element 192 as the strongback 180 moves toward the tray 190. More specifically, the positioning pins 183 of the strongback 180 are shaped to contact the positioning cups 193 of the tray 190 to guide the strongback 180 toward the tray 190 in order to align the recess(s) 184 of the strongback 180 with the recess(s) 198 of the tray 190.

[0076] For example, the positioning pin 183 and the positioning cup 193 are tapered (for example, to be conical in shape). Therefore, initially, a relatively large tolerance is allowed in the misalignment between the strongback 180 and the tray 190, and the misalignment decreases as the strongback 180 and the tray 190 move closer to each other until the positioning pin 183 is centered on the positioning cup 193 (at which point the strongback 180 is in a fixed position relative to the tray 190 and begins to hold and lift the preform 150). Alternatively, the tray 190 may include a positioning pin and the strongback 180 may include a positioning cup, which function to align the tray 190 and the strongback 180 as described above.

[0077] When the strongback 180 and the preform 150 and / or tray 190 are aligned, a vacuum pressure 160 is applied through the vacuum channel 188. For example, the cell controller 120 commands the vacuum system 138 to activate and apply the vacuum pressure 160. Once the vacuum pressure 160 is applied, the preform 150 is held in contact with the strongback 180. If an optional vacuum pressure 204 was applied to the preform 150 through the tray 190, the cell controller 120 commands the vacuum system 202 to deactivate and stop applying the vacuum pressure 204. Stopping the vacuum pressure 204 in the tray 190 facilitates the transfer of the preform 150 from the tray 190 to the strongback 180.

[0078] Figure 10 is a side cross-sectional view of the strongback 180 shown in Figures 8 and 9, having a preform 150. In Figure 10, the strongback 180 is lifted while a vacuum pressure 160 is applied, holding the preform 150, as well as any other large preforms 156 and / or discrete preforms 154, in contact with the strongback 180 (also when the strongback 180 and preforms 150 are lifted away from the tray 190, although this is not shown in Figure 10). As the strongback 180 is lifted away from the tray 190, the positioning pin 183 is disengaged from the positioning cup 193 (see Figure 9).

[0079] Figure 11 is a side cross-sectional view of a mandrel 140, which may be used with the mounting system 50 shown in Figures 1 to 3 and / or with the manufacturing line 10 shown in Figure 1. The mandrel 140 is awaiting loading from a strongback 180 (not shown in Figure 11). The mandrel 140 includes a body 141 having an outer surface 145 of the mandrel 140. The mandrel 140 further includes notches 142 defined in the outer surface 145. The notches 142 shown in Figures 11 to 14 may be one of a number of notches 142 of the mandrel 140, each designed to receive one or more preforms 150. The outer surface 145 defines at least a portion of the uneven cross-section 143 of the mandrel 140.

[0080] The outer surface 145, or at least each notch 142, optionally includes a release film 62 to facilitate the removal of the preform(s) 150 and / or the solidified structure 64 (see Figure 1) from the mandrel 140. If a release film 62 is used on the mandrel 140, the release film 62 is added to the mandrel 140 before or when it enters the mounting system 50.

[0081] A vacuum channel 146 is defined extending from the notch 142 and / or the outer surface 145 and passing through the body 141. The vacuum channel 146 is configured to provide flow between the outer surface 145 and / or the notch 142 and the vacuum system 144 (see Figure 2). The mandrel 140 may include one or more vacuum channels 146 for each notch 142. Alternatively or additionally, the mandrel 140 may include one or more vacuum channels 146 reaching the outer surface 145 to hold a discrete preform 154 in contact with the outer surface 145. If the mandrel 140 includes more than one number of notches 142, the mandrel 140 also includes more than one number of vacuum channels 146, so that at least one vacuum channel 146 is associated with each notch 142. The vacuum channels 146 are connected to the notches 142. The vacuum channels 146 allow the vacuum pressure 147 (see Figure 13) applied by the vacuum system 144 to attract the preforms 150 into place on the mandrel 140. Depending on the type, number, and / or size of preforms 150 placed on the mandrel 140, each vacuum channel 146 may be operated individually or in conjunction with other vacuum channels 146. For example, only the vacuum channel 146 on which a preform 150 is placed may be operated, while vacuum channels 146 not associated with a preform 150 may remain inactive.

[0082] Figure 12 is a side cross-sectional view of the mandrel 140, strongback 180, and preform 150 shown in Figures 6 to 11, in an exemplary embodiment. In Figure 12, the strongback 180 is moving above the mandrel 140, which has one or more notches 142. The strongback positioning element 182 is configured to engage with the mandrel positioning element 148 as the strongback 180 moves toward the mandrel 140. More specifically, the positioning pin 183 of the strongback 180 is shaped to contact the positioning cup 149 of the mandrel 140 to guide the strongback 180 toward the mandrel 140, in order to align the recess(s) 184 of the strongback 180 with the notches 142 of the mandrel 140.

[0083] For example, the positioning cup 149 of the mandrel 140 is tapered, similar to the positioning cup 193 of the tray 190 (see Figure 9). Therefore, initially, a relatively large tolerance in the misalignment between the strongback 180 and the mandrel 140 is allowed, and the misalignment decreases as the strongback 180 and the mandrel 140 move closer to each other until the positioning pin 183 is centered on the positioning cup 149 (at which point the strongback 180 is in position relative to the mandrel 140 and begins to place the preform 150 onto the mandrel 140). Alternatively, if the tray 190 includes a positioning pin and the strongback 180 includes a positioning cup, the mandrel 140 includes a positioning pin that engages with the positioning cup of the strongback 180.

[0084] Each notch 142 may include a similar positioning cup 149 for aligning with the strongback 180, or a set of notches 142 may share one or more sets of positioning cups 149. In a further embodiment, multiple preforms 150 are placed adjacent to each other along the length L of the notches 142 and mechanically integrated via scarf joints, ply ramps, or other features.

[0085] Figure 13 is a side section view of the mandrel 140, strongback 180, and preform 150 shown in Figure 12, in which the strongback 180 and / or preform 150 are placed on the mandrel 140. When the strongback 180 and the mandrel 140 are aligned, the vacuum pressure 160 through the vacuum channel 188 is released. For example, the cell controller 120 commands the vacuum system(s) 138 to stop and release the vacuum pressure 160. When the vacuum pressure 160 is released, the preform 150 is placed in the notch 142 of the mandrel 140. Alternatively or additionally, when the vacuum pressure 160 is released, the preform 150 is placed on the outer surface 145 of the mandrel 140. If an optional vacuum pressure 147 is to be applied to the preform 150 through the mandrel 140, the cell controller 120 commands the vacuum system 144 (see Figure 2) to activate and apply the vacuum pressure 147. Applying the vacuum pressure 147 in the mandrel 140 makes it easier to fix the preform 150 to the mandrel 140.

[0086] In Figure 13, the vacuum pressure 160 is released or reversed, and the preform 150 (and any other arbitrary large preforms 156 and / or discrete preforms 154 shown in Figure 5) is positioned in place in the notch 142. In embodiments in which object 18 includes an unsolidified preform of fiber-reinforced material 152 (both see Figure 1), the strongback 180 may be operated to fix the preform 150 of the unsolidified fiber-reinforced material 152 onto the mandrel 140 (e.g., to tuck, press, consolidate, etc.). The vacuum system 144 may be operated additionally or alternatively to fix the preform 150 onto the mandrel 140 via vacuum pressure 147.

[0087] Figure 14 is a side section view of the mandrel 140, strongback 180, and preform 150 shown in Figures 12 and 13, in which the preform 150 is placed on the mandrel 140. After the vacuum pressure 160 (see Figure 12) is released to place the preform 150 on the mandrel 140, the strongback 180 is lifted away from the mandrel 140 by a PNP machine(s) 130 (see Figures 1 to 3). As the strongback 180 is lifted, the positioning pins 183 are disengaged from the positioning cups 193. The PNP machine(s) 130 moves the strongback 180 to pick up additional preforms 150 from the tray 190 and place them on the mandrel 140 until the desired number of preforms 150 are placed.

[0088] Using the components of the mounting station 100 and the techniques shown in Figures 6 to 14, an asynchronous command 124 (see Figure 2) can cause each of the PNP machines 130 to perform the following actions: to place a strongback 180 on an object 18 (e.g., a discrete object 20 shown in Figures 1 and 2); to apply a vacuum pressure 160 to hold the object 18 in the strongback 180; to lift the strongback 180 so that it is in a fixed position above the mandrel 140; and to release the vacuum pressure 160 to remove the object 18 from the strongback 180 while the object 18 is in contact with the mandrel 140. Command 124 in the synchronization phase may cause each of the PNP machines 130 to synchronously place a strongback 180 on top of the large object 22 (see Figure 1), apply a vacuum pressure 160 to hold the large object 22 across multiple PNP machines 180 in the strongback 180, lift the strongback 180 so that it is in a fixed position above the mandrel 140, and release the vacuum pressure 160 to remove the large object 22 from the strongback 180 while the large object 22 is in contact with the mandrel 140.

[0089] Figure 15 is an end view of a mandrel 140 that can be used as the mandrel 140 shown in Figures 11 to 14 in an exemplary embodiment, and / or can be used with the mounting system 50 shown in Figures 1 to 3 and / or the manufacturing line 10 shown in Figure 1. For example, Figure 15 is an end view of the mandrel 140 shown in Figure 3, and a cross-sectional view of the mandrel 140 cut at line 11 is the view of the mandrel 140 in Figures 11 to 14. For example, radial zone Z1 shows the stringer preform 159 and layer 206 after the strong back 180 has been lifted away from the mandrel 140, and radial zones Z2 and Z3 show the mandrel 140 before the preform 150 is placed on the mandrel 140.

[0090] The mandrel 140 has a notch 142 (e.g., in the form of a channel) for receiving a preform 150 in an exemplary embodiment. The notch 142 and / or the outer surface 145 define the uneven cross section 143 of the mandrel 140. In the examples of Figures 3 and 15 to 21, the uneven cross section 143 is arc-shaped. In Figure 15, each of the notches 142 along the outer surface 145 is for receiving a stringer preform 159. The plies of material forming the outer skin 782 of the aircraft 750 are then laid up as a layer(s) 206 on top of the stringer preform 159 and solidified to form a half-barrel section 770 (or full-barrel section 776). The half-barrel section 770 (or full-barrel section 776) is a single, integrated piece containing both the outer skin 782 and the stringer 778 (see Figure 29) to be co-cured.

[0091] To facilitate the loading process, the mandrel 140 is divided into radial sections 208, 210, and 212 (corresponding to radial zones Z1, Z2, and Z3, respectively). The preforms 150 can be loaded sequentially or in parallel onto radial zones Z1, Z2, and Z3 and / or radial sections 208, 210, and 212 on the mandrel 140 at the loading station 100. Alternatively, the mandrel 140 can receive multiple preforms 150 from separate loading stations 100, 100', and 100'' onto separate radial sections 208, 210, and 212, as shown in Figure 19. The example in Figure 19 can be modified to place preforms 150 in parallel across multiple zones Z1, Z2, and / or Z3 by using one or more placement stations 100 to operate multiple PNP machines 130 simultaneously in separate radial sections 208, 210, and 212. One or more radial sections 208, 210, and / or 212 may also be assigned to technicians for manual placement of preforms 150. This coordinated placement across multiple radial sections 208, 210, and 212 provides a technical benefit by increasing the speed at which multiple preforms 150 are placed on a single mandrel 140.

[0092] When mandrel 140 is assembled from mandrel segment 235 (see Figure 21), each of mandrel segments 236, 238, and 240 becomes a different radial portion 208, 210, or 212 of mandrel 140. Furthermore, when mandrel 140 is assembled from mandrel segment 235, each of mandrel segments 236, 238, and 240 is positioned in a different radial zone Z1, Z2, or Z3. Further details regarding assembly 504 and positioning 508 are shown in Figure 25.

[0093] Figure 16 is an end view of a mandrel 140 with a strongback in an exemplary embodiment. In this example, the strongback 180 includes strongback segments 181 and can be used as the strongback in Figures 8 to 10 and Figures 12 to 14. For example, the strongback 180 includes a first strongback segment 181a, a second strongback segment 181b, and a third strongback segment 181c. However, the strongback 180 may include any preferred number of strongback segments 181. For example, the strongback 180 includes a single strongback segment 181 that is repositioned relative to the mandrel 140 when the preform 150 is placed on the mandrel. The strongback segment 181 is moved through radial zones Z1, Z2, and Z3 so that it is positioned in each of the radial portions 208, 210, and 212 of the mandrel 140 (for example, via the transport 408 shown in Figures 24A and 24B). Alternatively, the strongback 180 is continuous along the mandrel 140 and does not include the strongback segment 181.

[0094] The cross-sectional shape of the strongback 180 corresponds to (e.g., complements) the cross-sectional shape of the mandrel 140. Furthermore, the mandrel 140 and strongback 180 are shaped to correspond to the structure 12 assembled by the mounting system 50. More specifically, as shown in Figure 16, the mandrel 140 is arc-shaped, and the strongback 180 is also arc-shaped. If the strongback 180 includes strongback segments 181, each of the strongback segments 181 is arc-shaped. The mandrel 140 (which may be shaped into an arc) and the strongback 180 (which may also be shaped into an arc) can be used to assemble and / or manufacture parts 768 of the fuselage 766 (see Figure 29).

[0095] As shown in Figure 16, the strongback 180 and / or each strongback segment 181 includes a plurality of preforms 150. For example, the strongback 180 includes a plurality of large preforms 156 that are placed in the corresponding notches 142. Furthermore, in the placement process, the strongback 180 and / or each strongback segment 181 includes discrete preforms 154 on the inner surface 185 of the strongback 180. In one exemplary embodiment, each of the discrete preforms 154 is a set of buffer plies (e.g., a plurality of layers 216 of unsolidified fiber-reinforced material 152 shown in Figure 18) that form a preform pad-up (i.e., a lamination of multi-layer plies) known as a “postage stamp” or “frame filler” 784, which facilitates the placement of the frame 780 (see Figure 29). In such an embodiment, the large preforms 156 are stringer preforms 159, and the discrete preforms 154 are frame filler preforms 158.

[0096] Figure 17 is a bottom view of a strongback 180 on which a preform(s) 150 is placed, cut along line 17-17 of Figure 16, in an exemplary embodiment. Figure 17 is an internal diameter view of the strongback 180 and / or strongback segment 181 having discrete preforms 154 and a large preform 156. In this example, the strongback 180 includes a plurality of recesses 184. More specifically, the strongback 180 includes recesses 184 corresponding to each of the plurality of preforms 150 that are picked up and placed using the strongback 180. Thus, each preform 150 is fitted into a particular recess 184 of the plurality of recesses 184 of the strongback 180.

[0097] The frame filler preform 158 is positioned along the length L of the strong back 180 at locations on the inner surface 185 that are separated from each other (for example, in recesses 184), while the stringer preform 159 is positioned parallel to the length L. In the above embodiment, the associated tray 190 for holding the stringer preform 159 and the frame filler preform 158 (as shown in the tray 190c and preforms 158, 159 in Figure 5) may include recesses 198 for both the stringer preform 159 and the frame filler preform 158.

[0098] When a vacuum pressure of 160 is applied, each of the discrete preforms 154 is held in contact with at least one larger preform 156. For example, the preforms 154 and 156 are held in contact with each other in the strongback 180 in an arrangement similar to that shown in Figure 18.

[0099] The recess 198 of the tray 190 (see Figure 4), the notch 142 of the mandrel 140 (see Figure 11), and the strong back 180 are all shown as having the same length L, however, the lengths of the recess 198, the notch 142, and the strong back 180 may differ from each other.

[0100] Figure 18 is a cross-sectional view of the end of the mandrel 140 and preform(s) 150 shown in Figure 17, with the strongback 180 separated from the mandrel 140. The example shown in Figure 18 includes a first stringer preform 159a and a second stringer preform 159b adjacent to the first stringer preform 159a. Each stringer preform 159 is positioned within a corresponding notch 142 of the mandrel 140. The frame filler preform 158 is positioned between the adjacent first stringer preform 159a and second stringer preform 159b. In this exemplary embodiment, the stringer preform 159 and the frame filler preform 158 overlap at the inclined portion 214. However, the stringer preform 159 and the frame filler preform 158 may be in contact at their planar ends, or they may be spaced apart so that a gap is defined between at least two of the preforms 150.

[0101] Each frame filler preform 158 includes a multilayer 216 of unsolidified fiber-reinforced material 152. The multilayer 216 creates pad-up areas at locations 781 (see Figure 29) where the frame 780 is to be connected to the outer panel 782. This pad-up provided by the frame filler preform 158 may allow for a more linear frame lay-up configuration because padding areas to match the frame 780 may be easier than adding flange tenons (joggles) to the frame to match the outer panel 782 or to the stringers 778.

[0102] Each of the discrete preforms 154 is held in contact with at least one large preform 156 (for example, each of the frame filler preforms 158 is held in contact with at least one stringer preform 159). The discrete preforms 154 and large preforms 156 are held in contact by gravity. If an optional vacuum system 147 is included in the mounting system 50, the discrete preforms 154 and large preforms 156 are additionally or alternatively held in contact by vacuum pressure 142 (see Figure 2). In addition to compression, gravity, and / or vacuum pressure 147, tactifier tapes and media may also be used to maintain the relative positions of the preforms 150 throughout the mounting process and subsequent processes.

[0103] The structure 12 may optionally include one or more layers 206 on top of a plurality of preforms 150 (e.g., discrete preforms 154 and / or large preforms 156) placed on the mandrel 140. As a result, one or more layers 206 will be laid up on the mandrel 140. The layers 206 are formed of unsolidified fiber-reinforced material 152. Therefore, the preform(s) 150 may be considered to include the layers 206 as a type of preform. If the structure 12 is a portion 768 of the fuselage 766, the one or more layers 206 form the outer skin 782 of the fuselage 766 (see Figure 29). Therefore, the layers 206 may also be referred to as “skin layers”. If the structure 12 includes the layers 206, the cell controller 120 can be operated to lay the layers 206 on top of the preforms 150 placed on the mandrel 140.

[0104] Figures 19 to 21 show the configuration of mounting stations (e.g., a first mounting station 100, a second mounting station 100', and a third mounting station 100'') for mounting multiple preforms 150 to different parts of a mandrel 140 in an exemplary embodiment. In the following description, the PNP machine 130 may be distributed across multiple mounting stations 100, 100', 100'', and cell controllers 120, 120', and / or 120'' cause the PNP machines 130, 130', 130'' at each of the mounting stations 100, 100', 100'' to operate iteratively in synchronous and asynchronous phases. In one example, each of the placement stations 100, 100', and 100'' operates the PNP machines 130, 130', and 130'' to place multiple objects 18 onto different radial portions 208, 210, 212, or 213 of the uneven cross-section 143 of the mandrel 140. In another example, each of the placement stations 100, 100', and 100'' may operate the PNP machines 130, 130', and 130'' to place multiple objects 18 onto different longitudinal portions or longitudinal sections 224, 226, and 228 (see Figure 20) of the mandrel 140.

[0105] Figure 19 is a perspective view of a first example of a plurality of mounting stations 100, 100', and 100'' that can be used with the mounting system 50 shown in Figure 1. Specifically, Figure 19 shows a mounting system 50 in which mounting stations 100, 100', and 100'' operate PNP machines 130, 130', and / or 130'' to mount a plurality of preforms 150 onto different radial portions 208, 210, and 213 of a mandrel 140. As a result, the mandrel 140 has a first group 218 of stringer preforms 159 mounted by the first mounting station 100, a second group 220 of stringer preforms 159 mounted by the second mounting station 100', and a third group 222 of stringer preforms 159 mounted by the third mounting station 100''. The frame filler preform 158 may optionally be placed together with each of the stringer preforms 159, groups 218, 220, and 222.

[0106] In this embodiment, as the mandrel 140 moves in the process direction 14 relative to the mounting stations 100, 100', and 100'', separate mounting stations 100, 100', and 100'' positioned in the process direction 14 can mount separate preforms 150 (e.g., stringer preforms 159) on separate radial portions 210, 212, and 213 of the mandrel 140, thereby facilitating pulse-operated line manufacturing or continuous-movement manufacturing.

[0107] Figure 20 is a perspective view of a second example of multiple mounting stations 100, 100', 100'' that can be used with the mounting system 50 shown in Figure 1. In this example, the mandrel 140 is divided into a first longitudinal section 224, a second longitudinal section 226, and a third longitudinal section 228. However, the mandrel 140 may be divided into any number of suitable longitudinal sections depending on the size of the mandrel 140, the size of the objects 18, and / or the number and location of the objects 18. The objects 18 (e.g., preform 150) may be mounted on the longitudinal sections 224, 226, and / or 228 if the objects 18 (e.g., preform 150 or large preform 156) are shorter than the length of the mandrel 140, or may be divided into multiple longitudinal segments shorter than the length of the mandrel 140 so as to fit the lengths of the relevant longitudinal sections 224, 226, or 228.

[0108] More specifically, Figure 20 shows a mounting system 50 in which stations 100, 100', and 100'' operate PNP machines 130, 130', and / or 130'' to mount multiple objects 18 (e.g., preforms 150) onto different longitudinal sections 224, 226, or 228 of a mandrel 140. For example, the first mounting station 100 mounts the first group 230 of preforms 150 onto the first longitudinal section 224, the second mounting station 100' mounts the second group 232 of preforms 150 onto the second longitudinal section 226, and the third mounting station 100'' mounts the third group 234 of preforms 150 onto the third longitudinal section 228. Each of the preform groups 230, 232, and / or 234 includes a large preform 156 (e.g., a stringer preform 159). Alternatively or additionally, each of the preform groups 230, 232, and / or 234 includes one or more large preforms 156 (e.g., a stringer preform 159) and one or more discrete preforms 154 (e.g., a frame filler preform 158). Thus, each of the mounting stations 100, 100', and 100'' can mount the stringer preform 159 and the frame filler preform 158 on one or more longitudinal sections 224, 226, and / or 228, depending on the structure 12 to be assembled (see Figure 1).

[0109] Furthermore, any of the large preforms 156 may span more than one number of longitudinal sections 224, 226, and / or 228. If the large preform 156 extends to or through different longitudinal sections 224, 226, and / or 228, any suitable mounting station 100, 100', or 100'' may mount the large preform 156. For example, if the large preform 156 spans a first longitudinal section 224 and a second longitudinal section 226, the first mounting station 100 or the second mounting station 100' may mount the large preform 156.

[0110] In this example, the mandrel 140 may have a first group 230 of stringer preforms 159 placed by the first mounting station 100, a second group 232 of stringer preforms 159 placed by the second mounting station 100', and a third group 234 of stringer preforms 159 placed by the third mounting station 100'' for assembling the stringer 778 (see Figure 29). The preforms 150 beyond different longitudinal portions 224, 226, and / or 228 may be joined together by any preferred splice joining technique (e.g., scarf splice, lap splice, or step lap splice). This segmental method is useful in pulsed or continuous moving manufacturing environments, as each of the first group 230, second group 232, and third group 234 of the stringer preform 159 can be added to a series of mounting stations 100, 100', and 100'' of the manufacturing line 10 (see Figure 1).

[0111] Figure 21 is a perspective view showing the configuration of mounting stations 100, 100', and 100'', and assembly station 105, which may be used in the mounting system 50 of Figure 1 in an exemplary embodiment. Figure 21 is also a perspective view of a mandrel segment 235, which may be used with any of the mandrels 140 in the preceding figures. The mandrel 140 includes a plurality of mandrel component segments 235. The mandrel segment 235 includes a first mandrel segment 236, a second mandrel segment 238, and a third mandrel segment 240. Although three mandrel segments 236, 238, and 240 are described in this document, the mandrel 140 may include any preferred number of mandrel segments 235. Each of the mandrel segments 235 includes the aforementioned components and features of the mandrel 140 (for example, mandrel positioning elements 148 such as the notches 142, uneven cross section 143, optional vacuum system 144, outer surface 145, optional vacuum channel 146, and / or positioning cup 149 shown in Figures 2, 3, and 11 to 16).

[0112] More specifically, Figure 21 shows a mounting system 50 in which mounting stations 100, 100', and 100'' operate to mount an object 18 (e.g., a preform 150) onto mandrel segments 236, 238, and 240 of a mandrel 140. At mounting stations 100, 100', and 100'', the object 18 (e.g., a preform 150) is mounted onto the corresponding mandrel segment 235 by PNP machines 130; 130', and 130''. More specifically, the first mounting station 100 places the first group 218 of the preform 150 on the first mandrel segment 236, the second mounting station 100' places the second group 220 of the preform 150 on the second mandrel segment 238, and the third mounting station 100'' places the third group 222 of the preform 150 on the third mandrel segment 240. As described above, each of groups 218, 220, and 222 may include one or more stringer preforms 159 and / or one or more frame filler preforms 158.

[0113] Each of the mandrel segments 236, 238, and 240 corresponds to a radial portion 208, 210, or 212 of the mandrel 140, respectively. For example, the first mandrel segment 236 corresponds to the third radial portion 212, the second mandrel segment 238 corresponds to the first radial portion 208, and the third mandrel segment 240 corresponds to the second radial portion 210. However, the correspondence between each mandrel segment 236, 238, or 240 and the radial portions 208, 210, or 212 can be any preferred assignment depending on the process carried out by the assembled structure 12 (see Figure 1) and the mounting system 50. Therefore, placing multiple objects 18 on separate mandrel segments (e.g., a first mandrel segment 236, a second mandrel segment 238, and / or a third mandrel segment 240) can be considered as placing multiple objects 18 on separate radial portions 208, 210, and 212 of the mandrel 140.

[0114] One or more cell controllers 120, 120', and / or 120'' include all or part of a program 122 (see Figure 2) having instructions 124. Program 122 includes instructions 124 corresponding to each of the mandrel segments 236, 238, and 240. PNP machines 130, 130', and 130'' receive instructions 124 from program 122 corresponding to a particular mandrel segment 236, 238, or 240 at the mounting station 100, 100', or 100'' in which the PNP machine 130, 130', or 130'' is operating.

[0115] The mandrel segments 235 (also known as "segments" or "segmented mandrels") are assembled to form a mandrel 140 having separate radial sections 208, 210, and 212 (each corresponding to one of the mandrel segments 238, 240, and 236). In other words, the mandrel segments 236, 238, and 240 can be fastened together using fasteners 242 to form the mandrel 140.

[0116] Furthermore, seals may be installed between adjacent mandrel segments 235. For example, seals between mandrel segments 235 are installed last. In one example, mandrel segments 236 and 238 are positioned before being assembled into mandrel segment 240, so that the seals are pressed perpendicularly without tilting.

[0117] For example, after the PNP machines 130, 130', and 130'' complete instruction 124 in program 122, mandrel segment 235 moves from mounting stations 100, 100', and 100'' to assembly station 105. As mandrel segments 236, 238, and 240 move from mounting stations 100, 100', and 100'', each of the mandrel segments 236, 238, and 240 moves to the corresponding radial zone Z3, Z1, or Z2. More specifically, when the mandrel 140 is assembled from mandrel segments 236, 238, and 240, each of the mandrel segments 236, 238, and 240 is positioned in the corresponding radial zone Z3, Z1, or Z2, depending on the correspondence between the mandrel segments 236, 238, and 240 and the radial portions 212, 208, and 210. The mandrel segments 236, 238, and 240 can be moved in any order to any preferred radial zone Z1, Z2, or Z3 in order to assemble the mandrel 140.

[0118] In one embodiment, the mandrel segments 235 are used as a tray-shaped transport device. The mandrel segments 235 are then connected to each other, for example, by fastening, bolting, or gluing. For example, mandrel segments 236, 238, and 240 are assembled to each other by adding fasteners 242 to the mandrel segments 236, 238, and 240. More specifically, the second mandrel segment 238 is connected to one side of the third mandrel segment 240 using fasteners 242, and the first mandrel segment 236 is connected to the other side of the third mandrel segment 240 using fasteners 242. In this configuration, by assembling the mandrel segments 236, 238, and 240, each mandrel segment 235 is placed on a different radial portion 212, 208, or 210 of the mandrel 140. The fastener 242 may be added after all the mandrel segments 235 have been positioned relative to each other, or it may be added as each mandrel segment 235 is positioned. A seal may be installed between adjacent mandrel segments 235 before or after the fastener 242 is added to the mandrel segments 235.

[0119] If the assembly station 105 includes a mandrel support structure 106, the mandrel segments 235 are attached to the mandrel support structure 106. For example, the mandrel segments 235 are individually or joined together to form a mandrel 140, which is then connected to the mandrel support structure 106 using fasteners 244. In one example, the mandrel segments 235 are joined together, and then the mandrel 140 formed from the mandrel segments 235 is attached to the mandrel support structure 106. In another example, the mandrel segments 235 are connected to the mandrel support structure 106, and then connected to adjacent mandrel segments 235. Although fasteners 242 and 244 are assigned different reference numbers, fasteners 242 and 244 may be of the same type or different types.

[0120] In some embodiments, after the PNP machine 130 completes instructions 124 in program 122 (e.g., NC program 123) relating to mandrel segments 235 for placing the preform 150 in a desired location, the PNP machine 130 assembles multiple mandrel segments 235 together to form a half-barrel section 770 (or a full-barrel section 776, or a barrel section less than half the length, such as a quarter panel) (see Figure 29). This segmental technique is useful in pulsed-operation manufacturing environments because each of the groups 218, 220, and 222 of stringer preforms 159 can be placed on the mandrel segments 235 which are moving in a pulsed or continuously manner, and then the mandrel 140 formed into the half-barrel section 770 or full-barrel section 776 can be assembled from the mandrel segments 235. This design concept may also be implemented to form a full-barrel section 776, if desired.

[0121] In relation to Figures 22 to 26, illustrative details of the operation of the mounting system 50 will be described. As a prerequisite, a wide variety of objects 18 (e.g., one or more stringer preforms 159) to be placed on the mandrel 140 are prepared on the tray 190 and awaiting placement. Furthermore, unless a mandrel segment 235 is specified, the method described below can be used with the mandrel 140 or one or more mandrel segments 235 (when referring to the mandrel 140).

[0122] The method described in relation to Figures 22 to 26 may be carried out by the cell controller 120. For example, referring to Figures 1 and 2, the steps of the method are contained in a program 122 embodied in the cell controller 120, which is transmitted from the cell controller 120 to the PNP machine 130 in an instruction 124 and / or to the mandrel 140 in an instruction to carry out the method(s). Thus, the cell controller 120 is operable to carry out the methods 300, 400, 500, and 600 described herein, as well as the steps. If the method steps are carried out by a system other than the loading system 50 in the production line 10, the cell controller 120 communicates with the controller(s) in such other system (e.g., the solidification system 60, the separation system 70, and / or the washing system 80) to move the mandrel 140 to carry out the remainder of the method(s).

[0123] The steps of the method will be described later with reference to the mounting system 50 in Figure 1, but those skilled in the art will recognize that the methods described herein can also be implemented in other systems. The steps in the flowcharts described herein are not exhaustive and may include other steps not shown, as well as optional steps that may be performed in some examples. The steps described herein may be performed in an alternative order and / or may be omitted. Furthermore, the operations and / or mounting operations described herein may be performed synchronously or asynchronously.

[0124] Figure 22 is a flowchart showing a method 300 for assembling a structure 12 using the mounting system 50 of Figures 1 to 3. Method 300 operates the mounting system 50 to coordinate the actions of the PNP machine 130. As described above, the picking step and / or mounting step may be performed synchronously or asynchronously, depending on the structure 12 being assembled. The picking and / or mounting operations may occur between pulse movements while the mandrel 140 is stopped at the mounting station 100, and the cell controller 120 may stop the mandrel 140 while at least a portion of the mandrel 140 is positioned at the mounting station 100.

[0125] Referring to Figures 1, 2, and 22, method 300 includes operating in an asynchronous phase 302 and operating in a synchronous phase 304. When operating in the asynchronous phase 302, the mounting system 50 operates in asynchronous mode. Similarly, while operating in the synchronous phase 304, the mounting system 50 operates in synchronous mode. Figures 24A and 24B show an example of mode 412. The mounting of the object 18 (e.g., discrete object 20 and large object 22) will be described later, but if object 18 is a preform 150, the discrete object 20 includes a discrete preform 154 (e.g., frame filler preform 158), and the large object 22 includes a large preform 156 (e.g., stringer preform 159). Therefore, the method 300 described later is equally applicable to placing the preform 150, the discrete preform 154, the frame filler preform 158, the large preform 156, and the stringer preform 159.

[0126] In step 302 of the operation, the cell controller 120 initiates an asynchronous phase in which each of the PNP machines 130 of the loading station 100 operates independently to place an object 18 (such as a discrete object 20) onto the mandrel 140. To initiate this asynchronous phase, the cell controller 120 sends a command 124 to the PNP machines 130 to operate in asynchronous mode. The asynchronous phase is an operation phase in which the cell controller 120 does not perform coordination between the PNP machines 130, and each PNP machine 130 places the object 18 at its fastest speed.

[0127] Instruction 124 for operation in the asynchronous phase causes each of the PNP machines 130 to perform the following: 404 to place a strongback 180 on at least one discrete object 20; 406 to apply a vacuum pressure 160 to hold at least one discrete object 20 in the strongback 180; 454 to lift the strongback 180 so that it is in a fixed position above the mandrel 140; and 470 to release the vacuum pressure 160 to remove at least one discrete object 20 from the strongback 180 while at least one discrete object 20 is in contact with the mandrel 140. The placing step 404, the applying step 406, the lifting step 454, and the releasing step 470 are shown in mode 412 of Figures 24A and 24B.

[0128] In the asynchronous phase operation 302, the cell controller 120 provides a new instruction 124 for each of the PNP machines 130 306. The new instruction 124 is defined by the program 122 and is provided by the cell controller 120 to a PNP machine 130 in response to the detection that a previous instruction 124 from the program 122 has been completed by that PNP machine 130, regardless of the progress of the other PNP machines 130 in the loading station 100 306. Thus, each PNP machine 130 receives the instruction 124 independently of the other PNP machines 130 in the loading station 100. This allows each PNP machine 130 to operate efficiently independently of the other PNP machines 130.

[0129] Instructions 124 from program 122, preferably from NC program 123, when used in this document in particular in connection with steps 302 and 304 to be performed, may include commands to move the end effector 134 to a specific location to physically grasp the strongback 180 (and the corresponding preform 150, if any) to place an object 18 carried by the strongback 180, or to apply vacuum pressure 160 to them, to control the operation of the vacuum system 138 and / or gripping system 139 of the end effector 134, and / or to control actuators. In response to each instruction 124, the PNP machine 130 performs the requested action, and the PNP controller 132 generates an authentication to be received by the cell controller 120. Upon receiving each authentication from the PNP machine 130, the cell controller 120 provides the PNP machine 130 with a new instruction 124 from program 122 306.

[0130] The PNP controller 132 may use data 137 to verify that instruction 124 was executed in the desired manner. If data 137 indicates a situation in which the PNP machine 130 was unable to complete instruction 124 (for example, due to a delay exceeding a threshold amount or an error code), the PNP controller 132 reports this situation to the cell controller 120 for interpretation and correction.

[0131] Referring to Figures 19 and 22, the asynchronous operation 302 may include placing a discrete object 20 on different radial portions 208, 210, 212, or 213 of the mandrel 140. If the mandrel 140 includes mandrel segments 235, the discrete object 20 is placed on one or more mandrel segments (which, when assembled together, become the radial portions 208, 210, 212, and / or 213 of the mandrel 140). Referring to Figures 20 and 22, additionally or alternatively, the asynchronous operation 302 may include placing the discrete object 20 on different longitudinal portions 224, 226, or 228 of the mandrel 140.

[0132] If the PNP machine 130 is divided into a first subset 126 and a second subset 128, the asynchronous operation 302 includes operating the first subset 126 of the PNP machine 130a of the loading station 100 separately in the asynchronous phase 314 in order to load a discrete object 20 onto the mandrel 140. Instruction 124a for operation in the asynchronous phase causes each of the PNP machines 130a of the first subset 126 to perform the following: place a strongback 180 on a discrete object 20 (404); apply a vacuum pressure 160 to hold the discrete object 20 in the strongback 180 406; lift the strongback 180 so that it is in a fixed position above the mandrel 140 454; and release the vacuum pressure 160 to remove the discrete object 20 from the strongback 180 while the discrete object 20 is in contact with the mandrel 140 470.

[0133] While the first subset 126 is operating in the asynchronous phase 306, a new instruction 124 is provided to each of the PNP machines 130 in the first subset 126. More specifically, the new instruction 124 is provided from program 122 to each of the PNP machines 130 in the first subset 126, regardless of the progress of the other PNP machines 130 in the first subset 126, in response to the detection that the previous instruction 124 from program 122 has been completed by the PNP machine 130. Preferably, program 122 is NC program 123 and instruction 124 is NC instruction 125.

[0134] If the mounting system 50 includes a plurality of mounting stations 100, 100', the PNP machines 130, 130' are distributed across the plurality of mounting stations 100, 100'. In such embodiments, the operation 302 includes operating the PNP machine 130 of the first mounting station 100 in an asynchronous phase 316, or operating the PNP machine 130' of the second mounting station 100' in an asynchronous phase 316.

[0135] To operate in an asynchronous phase 302, depending on the configuration of the assembled structure 12 and / or mounting system 50, any of the mounting step 308, mounting step 310, mounting step 312, operating step 314, and / or operating step 316 may be combined.

[0136] In step 304 of the operation, the cell controller 120 initiates a synchronization phase in which the multiple PNP machines 130 work together to place the large object 22 across the multiple PNP machines 130 onto the mandrel 140. Thus, in the synchronization phase, the multiple PNP machines 130 work together to transport one or more large objects 22 to the desired position on the mandrel 140. To initiate this synchronization phase, the cell controller 120 sends a command 124 to the PNP machines 130 to operate in synchronization mode.

[0137] During operation 304 in the synchronous phase, command 124 causes each of the PNP machines 130 to synchronously place a strongback 180 on top of a large object 22 404, apply a vacuum pressure 160 to hold the large object 22 in the strongback 180 406, lift the strongback 180 454 so that it is in a fixed position above the mandrel 140, and release the vacuum pressure 160 470 to remove the large object 22 from the strongback 180 while the large object 22 is in contact with the mandrel 140. The placing step 404, the applying step 406, the lifting step 454, and the releasing step 470 are shown as steps in mode 412 in Figures 24A and 24B.

[0138] During operation 304 in the synchronization phase, the cell controller 120, in response to detecting that all of the PNP machines 130 of the mounting station 100 have completed the previous instruction 124 from program 122, provides each of the PNP machines 130 with a new instruction 124 from program 122 (e.g., NC program 123) 318. Operation 304 may result in a stepwise set of checkpointed operations performed by all of the PNP machines 130 (e.g., positioning on the strongback 180, activating the vacuum system 138 of the end effector 134 to capture the preform 150 and holding the preform 150 in contact with the strongback 180, coordinating the movement of the strongback 180 on the mandrel 140, coordinating the release of the vacuum pressure 160 to remove the preform 150 from the strongback 180, etc.).

[0139] Referring to Figures 19 and 22, the operation in the synchronous phase 304 may include 320 placing one or more large objects 22 on different radial portions 208, 210, 212, or 213 of the mandrel 140. If the mandrel 140 includes mandrel segments 235, then one or more large objects 22 are placed on one or more mandrel segments 235 (which, when assembled together, become the radial portions 208, 210, 212, and / or 213 of the mandrel 140). Referring to Figures 20 and 22, additionally or alternatively, the operation in the synchronous phase 302 may include 324 placing one or more large objects 22 on different longitudinal portions 224, 226, or 228 of the mandrel 140.

[0140] If the PNP machine 130 is divided into a first subset 126 and a second subset 128, the operation in the synchronous phase 304 includes the operation 326 of the second subset 128 of the PNP machine 130 in conjunction with the operation 314 of the first subset 126 of the PNP machine 130 in the synchronous phase to place a large object 22 on the mandrel 140. Operation 326 may be performed at the same placement station as operation 314 (e.g., first placement station 100) and / or at a different placement station (e.g., second placement station 100') than operation 314. In one embodiment, the PNP machine 130a in the first subset 126 is separate from the PNP machines 130b and 130c in the second subset 128.

[0141] In the synchronous phase operation 304 by multiple subsets 126 and 128, instructions 124b and 124c cause each of the PNP machines 130 in the second subset 128 to synchronously place the strongback 180 on the large object 22 404, apply a vacuum pressure 160 to hold the large object 22 in the strongback 180 406, lift the strongback 180 so that it is in a fixed position above the mandrel 140 454, and release the vacuum pressure 160 to remove the large object 22 from the strongback 180 while the large object 22 is in contact with the mandrel 140 470.

[0142] During the synchronization phase, while the second subset 128 is operating, a new instruction 124 is provided to the PNP machine 130 in the second subset 128. More specifically, in response to detecting that all of the PNP machines 130b and 130c in the second subset 128 have completed the previous instruction 124 from program 122, new instructions 124b and 124c are provided from program 122 to each of the PNP machines 130b and 130c in the second subset 128.

[0143] In an example where various types of objects (e.g., discrete objects 20 and large objects 22) are used to assemble the structure 12, the cell controller 120 may operate subsets 126 and 128 in separate phases 302, 304. For example, if object 18 includes discrete objects 20, the cell controller 120 is configured to operate each PNP machine 130a in the first subset 126 of PNP machines 130 independently of each other in an asynchronous phase to place the discrete objects 20 onto the mandrel 140 302. Additionally or alternatively, if object 18 includes large objects 22 spanning multiple PNP machines 130, the cell controller 120 is configured to operate PNP machines 130b, 130c in the second subset 128 of PNP machines 130 in a synchronous phase to place the large objects 22 onto the mandrel 140 304. Preferably, the cell controller 120 operates the first subset 126 and the second subset 128 simultaneously.

[0144] If the mounting system 50 includes a plurality of mounting stations 100, 100', the PNP machines 130, 130' are distributed across the plurality of mounting stations 100, 100'. In such embodiments, the operation 304 includes operating the PNP machine 130' of the second mounting station 100' in a synchronous phase 328, or operating the PNP machine 130 of the first mounting station 100 in a synchronous phase 328.

[0145] To operate in the synchronous phase 302, depending on the configuration of the assembled structure 12 and / or mounting system 50, any of the mounting step 320, mounting step 322, mounting step 324, and / or operating step 326 may be combined.

[0146] The cell controller 120 iteratively operates the PNP machine 130 in a synchronous phase or synchronous mode and in an asynchronous phase or asynchronous mode.304, 302 In a particular embodiment in which the PNP machine 130 is divided into subsets 126 and 128, the cell controller 120 iteratively operates the first subset 126 and the second subset 128 of the PNP machine 130 in a synchronous phase and asynchronous phase.304, 302 For example, referring to Figures 2 and 22, the method 300 includes iteratively operating the first subset 126 in an asynchronous phase to place discrete objects 20 on the mandrel 140,302 and then operating the first subset 126 in a synchronous phase to place one or more large objects 22 on the mandrel 140.304 Similarly, the second subset 128 can also operate iteratively between two phases 332, 302, 304 to place discrete objects 20 and large objects 22 on the mandrel 140.

[0147] More specifically, while the first subset 126 operates in an asynchronous phase 302 to place discrete objects 20, the second subset 128 operates in a synchronous phase 304 to place one or more large objects 22. When the first subset 126 changes to operate in a synchronous phase 304 to place one or more large objects 22, the second subset 128 changes to operate in a synchronous phase 302 to place discrete objects 20. The change between operations 302 and 304 may be based on which objects 18 remain in the tray 190 and / or when a used tray 190 that does not contain any objects 18 is replaced with a new tray 190 that contains objects 18. This iterative operation 332 of subsets 126 and 128 enables discrete objects 20 and large objects 22 to be placed continuously by the placement station 100.

[0148] In embodiments in which the mounting system 50 includes a plurality of mounting stations 100, 100', the method includes 304, 302 causing the PNP machines 130, 130' of each mounting station 100, 100' to operate iteratively in synchronous and and asynchronous phases. For example, referring to Figures 1 and 22, the method includes 304, 302 causing the first mounting station 100 to operate iteratively in an asynchronous phase to mount a discrete object 20 on a mandrel 140, and then 304 causing the first mounting station 100 to operate in a synchronous phase to mount one or more large objects 22 on the mandrel 140. Similarly, the second mounting station 100' may also operate iteratively between the two phases to mount objects 20, 22 on the mandrel 140.

[0149] More specifically, while the first loading station 100 operates in an asynchronous phase 302 to load discrete objects 20, the second loading station 100' operates in a synchronous phase 304 to load one or more large objects 22. When the first loading station 100 changes to operate in a synchronous phase 304 to load one or more large objects 22, the second loading station 100' changes to operate in a synchronous phase 302 to load discrete objects 20. The change between operations 302 and 304 may be based on which objects 18 remain in trays 190, 190', and / or when used trays 190, 190' that do not contain objects 18 are replaced with new trays 190, 190' that contain objects 18. This iterative operation of the mounting stations 100, 100' allows the discrete objects 20 and the larger objects 22 to be continuously mounted by the mounting stations 100, 100' as the mandrel 140 moves through the series of mounting stations 100, 100' (e.g., in pulsed or continuous motion). Strongbacks 180, 180' may be used to assist in such a process.

[0150] Furthermore, if the mounting system 50 includes a plurality of mounting stations 100, 100', 100'', each of the mounting stations 100, 100', and / or 100'' operates to mount an object 18 on different radial portions 208, 210, 212, or 213 of the mandrel 140, as shown in Figure 19. For example, method 300 includes iteratively operating the first mounting station 100 in an asynchronous phase 334 to mount a discrete object 20 on the first radial portion 208, and then operating the first mounting station 100 in a synchronous phase 304 to mount one or more large objects 22 on the first radial portion 208. Similarly, the second placement station 100' can operate iteratively between two phases to place objects 20, 22 on the second radial section 210 in either the same mode as the first placement station 100 or the opposite mode 302, 304. Alternatively, the mandrel 140 can move to the second placement station 100' so that a large object 22 is placed on the first radial section 208 while the first placement station 100 operates in asynchronous mode to place a discrete object 20 on the second radial section 210 302. Thus, as the mandrel 140 moves along multiple placement stations 100, 100', the mandrel 140 undergoes inter-phase iterations 334.

[0151] Additionally or alternatively, each of the mounting station systems 100, 100', and / or 100'' operates to mount an object 18 on different longitudinal sections 224, 226, or 228 of the mandrel 140 shown in Figure 20.312,324 For example, method 300 includes iteratively operating the first mounting station 100 in an asynchronous phase 334 to mount a discrete object 20 on the first longitudinal section 224,302 and then operating the first mounting station 100 in a synchronous phase 304 to mount one or more large objects 22 on the first longitudinal section 224. Similarly, the second mounting station 100' may also operate iteratively between two phases 302, 304 to place objects 20, 22 on the second longitudinal section 226 in either the same mode as the first mounting station 100 or the opposite mode. Alternatively, the first mounting station 100 may operate to place a discrete object 20 on the first longitudinal section 224 302, and then the mandrel 140 moves to the second mounting station 100'. The second mounting station 100' operates in asynchronous mode to place a large object 22 on the first longitudinal section 224 while the first mounting station 100 operates in asynchronous mode to place a discrete object 20 on the second longitudinal section 226 302. Therefore, as the mandrel 140 moves along the placement stations 100, 100', the mandrel 140 undergoes inter-phase iterations 334.

[0152] Additionally or alternatively, each of the mounting station systems 100, 100', and / or 100'' operates to mount an object 18 on a different mandrel segment 236, 238, or 240, as shown in Figure 21.310, 322 For example, method 300 includes iteratively operating the first mounting station 100 in an asynchronous phase 334 to mount a discrete object 20 on the first mandrel segment 236,302 and then operating the first mounting station 100 in a synchronous phase 304 to mount one or more large objects 22 on the first mandrel segment 236. Similarly, the second mounting station 100' may operate iteratively between the two phases 334 to mount objects 20, 22 on the second mandrel segment 238,302, 304 in either the same mode as the first mounting station 100 or the opposite mode.334 Alternatively, the first placement station 100 operates to place a discrete object 20 on the first mandrel segment 236 302, and then the first mandrel segment 236 moves to the second placement station 100'. The second placement station 100' operates in an asynchronous phase to place a large object 22 on the first mandrel segment 236 304, while the first placement station 100 operates in an asynchronous mode to place a discrete object 20 on the second mandrel segment 238 302. Thus, as the series of mandrel segments 235 move through the series of placement stations 100, 100', the mandrel segments 235 undergo interphase iterations 334.

[0153] Method 300 may optionally include securing the object 18 to the mandrel 140 336. For example, if the object 18 is a preform 150, the preform 150 may be secured to the mandrel 140 336. The securing 336 may be performed after each phase of operating 302 and / or operating 304, and / or after all iterations 330 of these phases have been completed. Securing the object 18 336 may include tucking the object 18 to the mandrel 140, applying a vacuum pressure 147 (see Figure 13) to the object 18, and / or pressing, compressing, and / or compacting the object 18 against the mandrel 140 using a strong back 180. One example of tack fastening is the use of tactile tape and mediating materials, in addition to compression, gravity, and / or vacuum pressure 147, to maintain the relative positions of multiple preforms 150 throughout the loading process and subsequent processes along the production line 10.

[0154] If the mandrel 140 includes mandrel segments 235, the method 300 includes assembling the multiple mandrel segments 235 together after the PNP machine 130 has completed instruction 124 in program 122 corresponding to the mandrel segments 235. In one example, the multiple mandrel segments 235 are assembled together after the PNP machine 130 has completed instruction 124 in program 122 corresponding to the mandrel segments 235 to form a half-barrel section 770 (see Figure 29). Further details of the assembly 504 (including moving the mandrel 140 to the assembly station 105 to perform the assembly 504) will be illustrated with reference to Figure 25. If an object 18 is fixed to the mandrel segments 235, then at least two mandrel segments 235 may be assembled together after the object 18 has been fixed.

[0155] Method 300 for assembling the structure 12 (see Figure 1) may offer significant advantages over existing systems because method 300 allows a single program 122 (e.g., a single NC program 123) to control the actions of multiple PNP machines 130. Since the provision of commands 124 from program 122 is synchronized across the PNP machines 130 in the synchronous phase, the PNP machines 130 can cooperate to transport objects (e.g., large objects 22) that cannot be transported by a single PNP machine 130. Furthermore, since the provision of commands 124 is not synchronized in the asynchronous phase, each PNP machine 130 can operate efficiently when transporting objects (e.g., discrete objects 20) that can only be transported by one PNP machine.

[0156] Figure 23 is a message diagram 350 that may be used in the method 300 shown in Figure 22. The message diagram 350 depicts communication between a cell controller 120 and a plurality of PNP controllers 132a, 132b, and 132c for selectively coordinating the operation of PNP machines 130a, 130b, and 130c in an exemplary embodiment. The PNP machine 130 performs a periodic loading process 352, which includes one or more series of asynchronous phases 354 and synchronous phases 356. In the asynchronous phase 354, the loading station 100 operates in asynchronous mode 302. Similarly, in the synchronous phase 356, the loading station 100 operates in synchronous mode 304.

[0157] As shown in Figure 23, the cell controller 120 initiates an asynchronous phase 354 for operating the PNP machine 130. In the asynchronous phase 354, the cell controller 120 immediately sends a new instruction 124a, 124b, or 124c to the PNP controllers 132a, 132b, or 132c as soon as it determines that the PNP controller 132a, 132b, or 132c has completed its most recent instruction 124. This is done regardless of the progress of the other PNP controllers 132a, 132b, and / or 132c in the mounting station 100.

[0158] However, in the synchronization phase 356, actions are synchronized among the PNP controllers 132a, 132b, and 132c. That is, the cell controller 120 waits for authentication from all the PNP controllers 132 that are working in conjunction to pick up the object 18 (e.g., the large object 22 shown in Figure 18) before sending out a new command 124. This form of checkpointing can ensure that all PNP machines 130 have reached the desired milestone before further progress is required. In a further embodiment, the cell controller 120 may implement a hybrid phase in which a subset 126 or 128 of the PNP machines 130 in the loading station 100 operates in synchronous mode, while one or more other PNP machines 130 in the loading station 100 operate in asynchronous mode.

[0159] Figures 24A and 24B are flowcharts illustrating a placement method 400 for operating the placement station 100 shown in Figures 1 to 21 in an exemplary embodiment. Method 400 operates the placement system 50 (see Figure 1) to coordinate the actions of the PNP machine 130. Various steps of Method 400 may be illustrated in relation to Figures 4 to 18. Method 400 will be described in relation to the placement of a preform 150. However, Method 400 may be used to place any suitable object 18.

[0160] Referring to Figures 22 and 23, Method 400 can be used in operation 302 in the asynchronous phase 354 and in operation 304 in the synchronous phase 356. For example, Mode 412 of Method 300 is implemented in operation 302 in the asynchronous phase 354 and in operation 304 in the synchronous phase 356. Mode 412 will be described in detail below.

[0161] Referring to Figures 1, 2, and 24, method 400 includes moving the mandrel 140 402, placing the strongback 180 on the tray 190 and / or preform(s) 150 404, applying a vacuum pressure 160 to hold the preform(s) 150 406, transporting the strongback 180 and / or preform(s) 150 onto the mandrel 140 408, and placing the preform(s) 150 onto the mandrel 140 410. Mode of operation 412 includes at least placing the strongback 180 404, applying a vacuum pressure 160 406, transporting it to the mandrel 140 408, and placing the preform(s) 150 410.

[0162] Moving the mandrel 140 402 includes moving the mandrel 140 in the process direction 14 relative to a mounting station 100 having a plurality of PNP machines 130. Moving 402 may be performed as part of a pulsed motion process or a continuous motion process along the production line 10, and the mandrel 140 is moved either by its full length or as part of a micropulse motion process to expose a new portion of the mandrel 140 on which work is performed. Moving the mandrel 140 402 may be at the direction of the cell controller 120. The mandrel 140 may be moved along a track, rail, path, etc., through the mounting system 50 and / or along the production line 10 402.

[0163] The mandrel 140 402, which is moved into the manufacturing cell 110, may include an identification device (e.g., an RFID tag and / or barcode). In such an example, moving the mandrel 140 402 into the mounting system 50 may include obtaining data from the identification device for use by the cell controller 120. For example, the data may include which mandrels 140 or mandrel segments 235 are in the mounting system 50, which parts or models are assembled by the mounting system 50, and which components were incorporated into the mandrel 140 before entering the mounting system 50. The cell controller 120 may use this data (which may be encoded in data 137 when the PNP machine 130 obtains data from the identification device) to send an appropriate command 124 to the PNP machine 130.

[0164] As shown in Figure 21, if the mandrel 140 includes multiple segments 235, moving the mandrel 140 402 includes moving the mandrel segments 235 414. More specifically, one or more mandrel segments 235 are moved 414 in the process direction 14 relative to the mounting station 100. The mandrel segments 235 may be moved along one or more tracks, rails, paths, etc. 414.

[0165] If the mounting system 50 includes multiple mounting stations 100, 100', 100'', each mandrel segment 235 is moved to a specific mounting station 100, 100', or 100'' on which a preform 150 is mounted 414. Depending on the type and number of preforms 150 mounted on the mandrel segment 235, the mandrel segment 235 may be moved at the same speed through one or more mounting stations 100, 100', and / or 100'', or it may be moved at a variable speed and / or at different speeds 414.

[0166] Method 400 optionally includes stopping the mandrel 140 416 while at least a portion of the mandrel 140 is placed at the loading station 100. The mandrel 140 may be stopped once for a period of time long enough for all of the preforms 150 to be placed on the mandrel 140 416. Alternatively, the mandrel 140 may be moved in a pulsed manner to pass through the loading station 100, stopping 416 for a shorter period of time. Stopping in such a pulsed manner 416 may be used when groups of preforms 150 230, 232, and 234 are placed on longitudinal portions 224, 226, and 228 of the mandrel 140, as shown in Figure 20. If the mandrel 140 is not stopped 416, it moves continuously through the loading station 100 during the loading process 402.

[0167] Referring to Figures 4, 5, and 24, the method 400 may further include identifying the tray 190 418. For example, the types of trays 190a, 190b, and 190c among the trays 190, the location of the trays 190 relative to the loading station 100 and / or manufacturing cell 110, and / or the number and type of preforms 150 in the tray 190 are identified 418. Identification 418 may also include identifying the tray 190 containing the preforms 150 of the unsolidified fiber-reinforced material 152 420. In identifying the tray 190 420, the type and / or number of preforms 150 contained in the tray 190 are also identified.

[0168] In one example where tray 190c of Figure 5 is used, identification 418 includes identifying tray 190c containing one or more large preforms 156 and discrete preforms 154 422. As mentioned in relation to Figure 5, the discrete preforms 154 may be placed in the location 195 where the frame 780 (see Figure 29) is to be installed relative to the large preforms 156. As described above, location 781 in the fuselage 766 corresponds to location 195 in the tray 190. Thus, the discrete preforms 154 are placed in the location 781 where the frame 780 is to be installed relative to one or more large preforms 156. In such an example, identification 418 includes identifying tray 190c equipped with discrete preforms 154 and large preforms 156 422.

[0169] In another example where the set 191 shown in Figure 4 is used, identification 418 includes identifying one or more trays 190a and 190b having different kinds of preforms 150 (e.g., one or more large preforms 156 and discrete preforms 154). Identification 420, 422 includes indicating the types of preforms 154 and 156 stored in each of the identified trays 190a and 190c. For example, step 418 includes identifying 420 that the first type of tray 190a contains discrete preforms 154 and the second type of tray 190b contains one or more large preforms 156.

[0170] Identifier 418 may further include identifying a tray 190 having one or more recesses 198 424. For example, identifier 420 may include identifying that a tray 190 includes recesses 198 for storing multiple preforms 150 424. If the set 191 in Figure 4 or the tray 190c in Figure 5 is used to store various types of preforms 150, identifier 418 may include identifying a tray 190a, 190b, or 190c that includes recesses 198 for discrete preforms 154 and one or more large preforms 156 424.

[0171] Identification 418 can be performed via a camera or other sensing component, or based on an instruction 124 in program 122. Referring to Figure 2, when identification 418 is performed by a camera or other sensing component, one or more sensors 136 of the PNP machine 130 acquire information about the tray 190 and transmit this tray information to the cell controller 120 as part of sensor data 137. The acquired information may include image data of tray 190 and / or preform(s) 150 within tray 190, radio frequency (RF) data (e.g., from RF identification tags associated with tray 190 and / or preform(s) 150 detected and / or emitted by sensor(s) 136 for detecting RF signals, data from barcodes or other codes on tray 190 and / or preform(s) 150, detection and ranging data indicating the location and / or shape of tray 190 and / or preform(s) 150 (e.g., from sensor(s) 136 configured for RADAR or LIDAR), and / or other data that enables cell controller(s) 120 to transmit appropriate commands(s) 124 to PNP(s) 130 based on the type of tray 190 and / or preform(s).

[0172] Prior to identifying the tray 190 418, the preforms 150 are placed inside the tray 190 426. The placement of the preforms 150 426 may be done when the tray 190 is positioned in the loading station 100, or it may be done in another system or station on the production line 10 before the tray 190 is moved to the loading station 100. When the tray 190c of Figure 5 is used, the discrete objects 20 are placed together with the larger objects 22 in the tray 190 in the location 195 where the frame 780 (see Figure 29) will be installed for the larger objects 22 426. In such an example, the placement of various types of objects 20 and 22 (e.g., preforms 154 and 156) 426 is considered to be equipping the objects 20 and 22 inside the tray 190c.

[0173] Placing one or more objects 18 in tray 190 426 may further include associating an identification tag (e.g., an RFID tag, a barcode, or other optical code) with tray 190 and / or preform 150. For example, the data may include which tray 190 is in the mounting system 50, which parts or models are assembled by the mounting system 50, which components were incorporated into tray 190 before entering the mounting system 50, which objects 18 are placed in tray 190 426, and where in tray 190 the objects 18 are placed. The cell controller 120 may use this data (which may be encoded in data 137 if the PNP machine 130 obtains data from the identification device) to send an appropriate command 124 to the PNP machine 130.

[0174] As shown in Figure 7, if the tray 190 includes optional vacuum channels 200 and vacuum system 202, vacuum pressure may be applied after the preform 150 is placed in the tray 190 426. If an optional release film 26 is used, the release film 26 is added to the tray 190 before the preform 150 is placed 426.

[0175] Referring to Figures 24, 1, and 2, the placement of the strongback 180 404 is carried out by at least one PNP machine 130. If an optional release film 26 is used with the strongback 180, the release film 26 is applied to the strongback 180 before the strongback 180 is placed 404. During placement 404, the strongback 180 attaches to at least one PNP machine 130, for example by attaching an end effector 134 to the strongback 180. However, the strongback 180 may also attach to the PNP machine 130 near the end effector 134. By attaching the end effector 134 and / or the PNP machine 130 to the strongback 180, the gripping system 139 and / or the vacuum system 138 can operate with the strongback 180 to pick up and place the object 18, as detailed below. The PNP machine(s) 130 is configured to move the strongback 180 to at least the tray 190 and the mandrel 140, but may have further degrees of freedom of motion within the mounting station 100 depending on the process being performed and / or the structure 12 being assembled. For example, the PNP machine 130 may further move the strongback 180 to a location within the mounting station 100 where a layer(s) 206 (see Figure 18) is provided.

[0176] In this exemplary embodiment, the cell controller 120 controls the PNP machine(s) 130 to place the strongbacks 180 onto the trays 190 and / or preforms 150.404 In some examples, tray identification 418 is used to determine where to place the strongbacks 180 relative to the trays 190 and / or preforms 150.404 For example, if the cell controller 120 identifies multiple trays 190 or multiple preforms 150 in the loading station 100,418 the cell controller 120 uses the identification 418 to place the strongbacks 180 relative to a particular tray 190 and / or preform 150.404 Even if only one tray 190 or preform 150 is identified,418 the cell controller 120 may use the positional information in the identification 418 to place the strongbacks 180 at a specific location in the loading station 100.404

[0177] Placing the strongback 180 404 includes at least one of placing the strongback 180 on the tray 190 via at least one of the PNP machines 130 428 and placing the strongback 180 on the preform 150 via at least one of the PNP machines 130 430. Placing the strongback 180 on the tray 190 428 may include aligning the strongback 180 with the tray 190 using a strongback positioning element 182 and a tray positioning element 192. When the strongback positioning element 182 engages with the tray positioning element 192, the strongback 180 is placed so as to be aligned with the tray 190 428.

[0178] Alternatively or additionally, the strongback 180 is placed on the preform 150. For example, a sensor 136 can determine where the preform 150 is located within the placement station 100 and / or tray 190, and a PNP machine(s) 130 places the strongback 180 on the preform 150 430. For example, the strongback 180 is placed on top of the object 18 (e.g., the preform 150). The determination of where the preform 150 is located may be part of the identification 418 of the tray 190, or it may be a separate step that does not depend on whether the tray 190 is identified 418. Since the preform 150 is stored within the tray 190, placing the strongback 180 on the preform 150 430 is also done by placing the strongback 180 and the tray 190 428. In another example, in which positioning elements 182, 192 are not included and / or where the tray 190 is located is not identified 418, the cell controller 120 operates the PNP machine 130 to place the strongback 180 on the preform 150 430, so that the strongback 180 is placed on the tray 190 428.

[0179] If the preform 150 is, for example, a layer(s) 206 (see Figure 18), then the layer(s) 206 (or another type of object 18 or preform 150) may not be stored in the tray 190. Therefore, the cell controller 120 can operate the PNP machine 140 so that the strongback 180 is placed on the preform 150 but not on the tray 190.

[0180] Referring to the configuration of the strongback 180 shown in Figure 16, the placement of the strongback 180 404 may include the placement of the arc-shaped strongback 180 404. Referring again to Figures 24 and 8 through 10, the placement of the strongback 180 404 may include, depending on the configuration of the strongback 180, placing the recess 184 of the strongback 180 onto the preform 150 via at least one of the PNP machines 130 432. The placement 404 and / or 432 may include covering the preform 150 with the strongback 180. This process may include positioning the strongback 180 relative to the recess 198 of the tray 190 via, for example, a cup and cone positioning system described in association with Figures 8 and 9, to ensure a known and reproducible positioning of the strongback 180 relative to the recess 198.

[0181] If the strongback 180 is configured to have a plurality of recesses 184 as shown in Figures 16 and 17, then one or more recesses 184 of the strongback 180 are placed on one or more corresponding preforms 150 432, 434. For example, the plurality of recesses 184 of the strongback 180 are placed on a plurality of preforms 150 434. In one example, each recess 184 of the plurality of recesses 184 is placed on a corresponding specific preform 150 among the plurality of preforms 150 434. In another example, one recess 184 is placed on a plurality of preforms 150 (e.g., a plurality of discrete preforms 154) 432, 434. As shown in Figure 17, each of the multiple recesses 184 of the strongback 180 may be configured to rest on a particular type of preform 150, thereby maintaining an equipped arrangement of discrete preforms 154 and large preforms 156.

[0182] In embodiments in which the PNP machine(s) 130 directly picks up the preform(s) 150 without using the strongback 180, the mounting step(s) 404 is modified by mounting the end effector 134 of the PNP machine(s) 130 (insofar as the configuration of the end effector 134 is suitable) instead of mounting the strongback 180.

[0183] If the PNP machines 130 operate in asynchronous phase 354 (see Figure 23) (see Figure 22), the mounting 404 of each PNP machine 130 may differ depending on the preform(s) 150 moved by each PNP machine 130. Furthermore, in asynchronous phase 354, one or more PNP machines 130 may also move in the X direction(s) within the mounting 404. Additionally or alternatively, if the PNP machines 130 are divided into subsets, each PNP machine 130 in the first subset 126 (see Figure 2) moves in the X direction, either moving toward or away from each other, in any part of the mounting 404 of each PNP machine 130 in the first subset 126.

[0184] When the PNP machine 130 is operating in the synchronous phase 356 (see Figure 23) 304 (see Figure 22), the PNP machine 130 is synchronously placed on the tray 190 and / or the large preform 156 404. When a subset of the PNP machine 130 (e.g., the second subset 128 shown in Figure 2) is operating in the synchronous phase 356, the PNP machines 130 may be moved relative to each other in the X direction (multiple directions) (see Figure 3) to ensure appropriate spacing for the dimensions of the large preform 156 during placement 404.

[0185] After the PNP machine 130 and / or strongback 180 are placed on the preform 150 404, the preform 150 is picked up by the PNP machine 130 and / or strongback 180. Referring to Figures 24 and 2, a vacuum pressure 160 is applied to hold the preform(s) 150 against the PNP machine 130 and / or strongback 180 406. More specifically, the cell controller 120 operates one or more vacuum systems 138 to apply a vacuum pressure 160 to hold the preform(s) 150 406 436. If the strongback 180 is not used, the vacuum system 138 operates to apply a vacuum pressure 160 directly to the preform 150 406 and hold the preform(s) 150 in the PNP machine 130 436. As shown in Figures 9 to 12, when a strongback 180 is used to hold a preform(s) 150, a vacuum pressure 160 is applied to the preform(s) 150 through the strongback 180 406. For example, a vacuum system 138 operates to apply the vacuum pressure 160 through a (e.g., flowing) vacuum channel 188 connected to at least one recess 184 of the strongback 180 406.

[0186] Referring to Figures 24, 2, and 9 through 12, applying a vacuum pressure 160 406 includes holding the preform 150 in contact with the strongback 180 438. For example, when a vacuum pressure 160 is applied 406, the preform 150 is removed from the tray 190 and attracted by the vacuum pressure 160 to come into contact with the strongback 180. Thus, the application of the vacuum pressure 160 406 lifts the preform 150. Depending on the dimensions of the strongback 180 and the tray 190, the movement of the preform 150 from the tray 190 to the strongback 180 caused by the application of the vacuum pressure 160 406 can be small or large. If an optional vacuum pressure 147 is applied through the tray 190, the vacuum system 144 is shut down to stop the vacuum pressure 147, so that the applied vacuum pressure 160 406 can begin to hold the preform 150.

[0187] If the strongback 180 includes one or more recesses 184, applying a vacuum pressure 160 406 holds the preform 150 in contact with the recesses 184 440. As shown in Figures 16 and 17, if the strongback 180 includes multiple recesses 184, applying a vacuum pressure 160 406 includes holding multiple preforms 150 in contact with multiple recesses 184 442. As described above in relation to step 434, each preform 150 may be held in contact with a particular recess 184 442, or multiple preforms 150 may be held in contact with a particular recess 184 442. Furthermore, the application of the vacuum pressure 160 406 may be selective, applied only to the recess(s) 184 in which the preform 150 is received. The selective application of vacuum pressure 160 406 in separate recesses 184 can prevent the lifting of objects that are not intended to be placed on the mandrel 140 410.

[0188] If the preform(s) 150 includes multiple types of preforms (e.g., discrete preforms 154 and one or more large preforms 156), the vacuum pressure 160 is applied to the discrete preforms 154 and one or more large preforms 156. More specifically, by applying the vacuum pressure 160, one or more large preforms 156 and the discrete preforms 154 are held in contact with the strongback 180. An example of this holding is shown in Figure 17. If, as shown in Figure 18, the discrete preforms 154 are at least partially in contact with adjacent large preforms 156, then applying the vacuum pressure 160 includes holding each of the discrete preforms 154 in contact with at least one large preform 156. If the strongback 180 is configured as shown in Figure 17, the holding steps 444 and 446 are performed simultaneously. However, if the PNP machine 130 is used to place the equipped preforms 154 and 156 (without the strongback 180), the holding step 446 may be performed without the holding step 444.

[0189] Furthermore, if various types of preforms 150 are used to assemble the structure 12, the holding step 442 may be combined with one or both of the holding steps 444 and 446. For example, at least one of the multiple recesses 184 may hold one or more discrete preforms 154 442, 444, and another of the multiple recesses 184 may hold one or more large preforms 156 442, 444. Depending on the configuration of the multiple recesses 184, the preforms 154 and 156 may be held within the multiple recesses 184 442 while also being held in contact with each other 446.

[0190] Referring again to Figures 24, 2, and 10 through 13, the strongback 180 and / or preform 150 are transported to the mandrel 140 408. More specifically, the strongback 180 and / or preform 150 are transported 406 while a vacuum pressure 160 is applied to hold the preform 150 408. During transport 408, the PNP machine 130 follows a path from the tray 190 to the mandrel 140 according to a program 122 in the cell controller 120.

[0191] Furthermore, referring to Figure 3, this path is in at least the Y and Z directions (and optionally the X direction), and at least the distal end 135 of the PNP machine 130 moves along the path to perform conveying 408. In one example, the PNP machine 130 moves in the +Y direction at the tray 190, and the PNP machine 130 or end effector 134 moves in the -Z direction toward the tray 190 and / or the preform 150 on which it is placed 404. After a vacuum pressure 160 is applied 406, conveying 408 includes moving the PNP machine 130 or end effector 134 in the +Z direction to lift the strongback 180 and / or the preform 150 454, moving the PNP machine 130 in the -Y direction toward the mandrel 140, and moving the PNP machine 130 and / or end effector 134 toward the mandrel 140 in the -Z direction.

[0192] If the PNP machines 130 are operating in the asynchronous phase 354 (see Figure 22), the paths of each PNP machine 130 may differ depending on the preform(s) 150 moved by each PNP machine 130. Furthermore, in the asynchronous phase 354, the paths of one or more PNP machines 130 may also include movement in the X direction(s) in the loading 404 and / or transport 408. Additionally or alternatively, if the PNP machines 130 are divided into subsets, each PNP machine 130 in the first subset 126 (see Figure 2) moves in the X direction, either converging or moving away, in any part of the path of each PNP machine 130 in the first subset 126 during transport 408.

[0193] If the PNP machines 130 are operating in synchronous phase 356 (see Figure 23) (see Figure 22), the paths of all PNP machines 130 will be parallel to each other in order to avoid deforming the strongback 180 and / or preform 150 when the PNP machines 130 perform transport 408. If a subset of the PNP machines 130 (for example, the second subset 128 shown in Figure 2) is operating in synchronous phase 356, all PNP machines 130 in subset 128 will follow parallel paths during transport 408, and the same applies to any optional movement in the X direction for all PNP machines 130 in subset 128.

[0194] For example, transporting to the mandrel 140 408 may include transporting the preform 150 to the mandrel 140 via the PNP machine 130 448. For example, the preform 150 is transported from where the preform 150 is picked up to where the preform 150 is placed on the mandrel 140 448. If the strongback 180 is not used, the PNP machine(s) 130 transports the preform 150 to the mandrel 140 448.

[0195] Additionally or alternatively, transporting to the mandrel 140 408 includes transporting the strongback 180 to the mandrel 140 via a PNP machine 130 450. Transporting the strongback 180 450 includes operating multiple PNP machines 130 synchronously to transport the strongback 180, or operating a single PNP machine 130 independently to transport the strongback 180. When the strongback 180 is used, the PNP machine 130(or more) 130 transports the strongback 180 and the preform 150 to the mandrel 140 450, 448. More specifically, the PNP machine 130(or more) 130 transports the strongback 180 holding the preform 150 438 for transporting the preform 150 448 450.

[0196] Transporting the strongback 180 onto the mandrel 140 450 may include positioning the strongback 180 above the mandrel 140 452. More specifically, the strongback 180 having the preform 150 is transported from the tray 190 450 and positioned above the mandrel 140 where the preform 150 is placed 410 on the mandrel 140 452. For example, the strongback 180 is moved away from the tray 190 in the -Y direction (see Figure 3) so that it is positioned above the mandrel 140 452.

[0197] In some embodiments, the strongback 180 is lifted 454 (for example, moved in the +Z direction as shown in Figure 3). For example, the strongback 180 is lifted 454 from the tray 190 to disengage the positioning elements 182 and 192 as shown in Figure 10. Lifting 454 may also include lifting 454 the strongback 180 and positioning 452 it in place above the mandrel 140. Positioning 452 and / or lifting 454 are part of a path (along which conveying 408 takes place).

[0198] The transport 408 may further include aligning the strongback 180 with the mandrel 140 456. More specifically, when the strongback 180 is positioned above the mandrel 140 452 and / or lifted above the mandrel 140 454, or thereafter, the strongback 180 is aligned with the mandrel 140 456. Alignment 456 may include moving the strongback 180 toward the mandrel 140 (e.g., lowering it). During transport 408, as the strongback 180 is moved toward the mandrel 140, the strongback positioning element 182 engages with the mandrel positioning element 148 to align the strongback 180 with the mandrel 140 456.

[0199] The transport 408 may be terminated when the preform 150 comes into contact with the mandrel 140. More specifically, the preform 150 may be placed so as to abut (or within tolerance of) the surface of the uneven cross section 143 (see Figure 3) of the mandrel 140 so as to come into contact with the mandrel 140. Alternatively, the strongback 180 may press the preform 150 against the mandrel 140 to terminate the transport 408. Pressing the preform 150 ensures the final shape of the preform 150 and / or fixes the preform 150 to the mandrel 140 336 (see Figure 22). To facilitate placement 410, an optional release film 26 may prevent the preform 150 from sticking to the strongback 180 even when the strongback 180 presses the preform 150 against the mandrel 140.

[0200] For example, as shown in Figures 12 and 13, transporting the strongback 180 to the mandrel 140 via the PNP machine 130 450 includes aligning the positioning elements 182 of the strongback 180 (e.g., positioning pins 183 formed into a cone) with the positioning elements 148 of the mandrel 140 (e.g., positioning cups 149 formed into a complementary cup) 456. For example, the strongback 180 is transported in the -Y and / or -Z directions (see Figure 3) so that the strongback positioning elements 182 are in contact with the mandrel positioning elements 148 450. The shapes of the positioning elements 148 and 182 guide the strongback 180 to align with the mandrel 140 as it is transported toward the mandrel 140 450. The alignment 456 may include positioning the strongback 180 in the notch 142 of the mandrel 140, for example via a positioning system of cups and cones, to ensure a known and repeatable positioning of the strongback 180 in relation to the notch 142.

[0201] In addition, referring to Figure 16, transporting the strongback 180 onto the mandrel 140 450 includes aligning the recess 184 of the strongback 180 with the notch 142 of the mandrel 140 458. Alignment of the recess 184 with the notch 142 458 may be performed in alignment of positioning elements 182 and 148 456. In addition, a program 122 in the cell controller 120 includes coordinates for the location where the recess 184 is aligned with the notch 142 458, and / or the cell controller 120 uses position information and / or image information in data 137 received from a sensor(s) to align the recess 184 with the notch 142 458. This example may be used when positioning elements 148 and / or 182 are omitted, but may also be used in addition to positioning elements 148 and 182. Alignment 456 and / or 458 allows the preform 150 to be positioned within the notch 142.

[0202] As shown in Figures 17 and 18, when multiple types of preforms 150 are assembled to form a structure 12, a first type of preform 150 (e.g., a large preform 156) is transported to the mandrel 140 408. Furthermore, a second type of preform 150 (e.g., a discrete preform 154) is transported to the mandrel 140 408 and / or 460. Various types of preforms 150 can be transported to the mandrel 140 sequentially or simultaneously 408, 460. In one example, a single PNP machine 130 transports various types of preforms 150 sequentially 408, 460. In another example, more than one PNP machine 130 transports various types of preforms 150 sequentially and / or simultaneously, depending on the preforms 150 and / or structure 12 to be assembled on the mandrel 140 408, 460. Additionally or alternatively, conveying 408 includes conveying one or more large preforms 156 and discrete preforms 154 to a mandrel 140 via a PNP machine 130 while maintaining the arrangement of the large preforms 156 and discrete preforms 154 460.

[0203] As shown in Figure 21, if the mandrel 140 includes a mandrel segment 235, transporting the preform 150 and / or strongback 180 408 includes transporting it to the mandrel segment 235 via the PNP machine 130 462. For example, the preform 150 and / or strongback 180 are transported to a specific mandrel segment 235 located within a loading station 100 462. If multiple loading stations 100, 100', 100'' perform method 400 for the corresponding mandrel segment 235, the transport 462 at each of the loading stations 100, 100', 100'' may be performed at different or the same speed.

[0204] Referring to Figures 24, 13, and 14, the preform(s) 150 is placed on the mandrel 140.410 The placement 410 is performed after the strongback 180 and / or the preform(s) 150 have been transported to the mandrel 140.408 Method 400 includes placing the preform(s) 150 on the mandrel 140.410 Preferably, the preform(s) 150 is placed on the mandrel 140 while in contact with the mandrel 140.410 More specifically, the transport of the strongback 180 and / or the preform(s) 150 408 causes the preform(s) 150 to come into contact with the mandrel 140. In a particular embodiment, the transport of the strongback 180 408 causes the strongback 180 to press the preform(s) 150 against the mandrel 140. The preform 150 is then placed while in contact with the mandrel 140 to prevent deformation of the preform 150 that may occur if the preform 150 is dropped from a certain distance away from the mandrel 140 410. However, depending on the dimensional tolerances of the strongback 180, the preform 150, and the mandrel 140, a narrow gap may exist between the preform 150 and the mandrel 140 after transport 408.

[0205] Installation 410 includes removing the preform 150 from the strongback 180 (or from the PNP machine 130 if the strongback 180 is not used) 464. The preform 150 is removed from the strongback 180 after the strongback 180 is positioned above the mandrel 140 452 and / or aligned with the mandrel 140 456, 458. More specifically, the preform 150 is removed from the recess 184 or surface 185 (see Figure 17) of the strongback 180 464 and moved to the notch 142 or surface 145 (see Figure 3) of the mandrel 140.

[0206] The placement 410 and / or removal 464 of the preform 150 may include lifting the strongback 180 and / or the PNP machine 130 away from the mandrel 140 and the preform 150, in particular if the strongback 180 is pressing the preform 150 against the mandrel 140 and if a release film 26 is applied between the surface 185 (see Figure 17) and the preform 150.

[0207] The placement 410 may additionally or alternatively include releasing the vacuum pressure 160 470 to place the preform 150 on the mandrel 140. More specifically, the cell controller 120 deactivates the vacuum system 138 to release the vacuum pressure 160 that is holding the preform 150 on the strongback 180 470. For example, the vacuum pressure 160 that was applied to the strongback 180 may be released 406 during or after placement 470 to facilitate the removal of the preform 150 from the strongback 180 464 and / or placement of the preform 150 at a desired location (e.g., a desired location on the mandrel 140). If the placement 410 includes lifting the strongback 180 468, the release of the vacuum pressure 160 470 may occur before or while the strongback 180 is being lifted 468.

[0208] If more than one type of preform 150 is placed on the mandrel 140, the placement 410 includes placing one or more large preforms 156 and discrete preforms 154 on the mandrel 140 472. The large preforms 156 may be placed separately from the discrete preforms 154 472. Alternatively, the large preforms 156 may be placed together with the discrete preforms 154 while maintaining the arrangement of the large preforms 156 and discrete preforms 154 472. For example, the large preforms 156 and discrete preforms 154 are transported from the strongback 180 to the mandrel 140 without changing the relative positions of the preforms 154 and 156 for placement 472, provided their arrangement is maintained during transport 460.

[0209] If the PNP machine(s) 130 is operating in asynchronous phase 354 (see Figure 23) 302 (see Figure 22), the mounting 410 includes releasing the vacuum pressure 160 470 in order to remove at least one discrete object 20 from the strongback 180 464 while the discrete object 20 is in contact with the mandrel 140. If the PNP machine 130 is operating in synchronous phase 356 (see Figure 23) 304 (see Figure 22), the mounting 410 includes releasing the vacuum pressure 160 470 in order to remove a large object 22 from the strongback 180 464 while the large object 22 is in contact with the mandrel 140.

[0210] If the mandrel 140 includes multiple mandrel segments 235, the placement 410 includes placing the preforms 150 on the mandrel segments 235 474. The placement 474 on the mandrel segments 235 may be performed at one or more placement stations 100, 100', and / or 100''. If the mandrel segments 235 are designed to accommodate various types of preforms 150, the placement 474 of various types of preforms 150 includes placing one or more large preforms 156 and discrete preforms 154 on the mandrel segments 235 472.

[0211] During and / or after placement 410, the strongback 180 is lifted away from the mandrel 140 (for example, by moving in the +Z direction as shown in Figure 3) 468. Mode 412 is repeated by moving the strongback 180 away from the mandrel 140 and placing it again on the tray 190 and / or preform 150 404. The placement step 404, the application step 406, the transport step 408, and the placement step 410 of Mode 412 are repeated until the asynchronous phase 354 and / or the synchronous phase 356 (see Figures 22 and 23) is completed and / or until all preforms 150 are placed on the mandrel 140 or mandrel segment 235 410.

[0212] After each or all of the preforms 150 have been placed 410, the preforms 150 may optionally be fixed to the mandrel 140 as described above in relation to Figure 22 336. For example, method 400 further includes fixing at least one large preform 156 to the mandrel 140 336. In one embodiment including an optional mandrel vacuum system 144 (see Figure 13), fixing 336 includes fixing the preforms 150 to the mandrel 140 and / or mandrel segments 235 via the vacuum system 144. If the mandrel 140 includes mandrel segments 235, fixing 336 may be performed on each of the mandrel segments 235.

[0213] Furthermore, after the final placement 410, a post-placement step may be performed as part of method 400 and / or as part of post-placement method 500 (see Figure 25). The post-placement step will be described in detail with reference to Figure 25. However, some examples of such steps are presented below in relation to Figures 24A and 24B. Furthermore, the data of the identification device on the mandrel 140 may be updated to include which one or more objects 18 were placed on the mandrel 140 for use by subsequent stations and / or systems in the production line 10.

[0214] For example, if the mandrel 140 includes mandrel segments 235, method 400 may include assembling the mandrel segments 235 together 504. More specifically, the mandrel segments 235 are assembled together 504 after the PNP machine 130 has completed instructions 124 in the program 122 corresponding to the mandrel segments 235. For example, the mandrel segments 235 are assembled together 504 to form a half-barrel section 770 (see Figure 29). Thus, method 400 includes assembling the mandrel segments 235 together 504. In a further embodiment, a vacuum pressure 147 is applied to the mandrel segments 235 to hold the preform 150 in place.

[0215] If the structure 12 includes layers 206, method 400 includes placing layers 206 on top of a number of preforms 150 placed on a mandrel 140 516. For example, a PNP machine 130 may be used to place layers 206 516, similar to how preforms 150 are placed in mode 412. Alternatively, layers 206 may be placed manually and / or by another machine within the production line 10. If the mandrel 140 includes mandrel segments 235, layers 206 are placed after the mandrel segments 235 have been assembled 504. Layers 206 and preforms 150 are solidified 520 (e.g., co-cured 524). In a further embodiment, the method 300 further includes placing a layer 206 of unsolidified fiber-reinforced material 152 on a plurality of preforms 150 arranged on a mandrel 140 516, and solidifying the layer 206 and the preforms 150 520 (e.g., co-curing 524).

[0216] The method 400 shown in Figures 24A and 24B can be customized to suit the components of the mounting system 50 and / or the specific structure 12 to be assembled by combining variations of the moving step 402, the identification step 418, the mounting step 404, the applying step 406, the transporting step 408, and / or the mounting step 410. Examples are given below, but further combinations are also possible.

[0217] If preforms 150 are equipped, method 400 may include identifying trays 190 422, placing strongbacks 180 on trays 190 428, transporting the large preforms 156 and discrete preforms 154 onto a mandrel 140 while maintaining the arrangement of the large preforms 156 and discrete preforms 154 460, and placing the large preforms 156 and discrete preforms 154 onto the mandrel 140 472. In this example, method 400 may further include holding a plurality of preforms 150 in a plurality of recesses 184 of the strongback 180 442, and / or holding a first type and a second type of preforms 150 444 and / or 446.

[0218] In another example where multiple types of preforms 150 are placed, the tray 190 houses an array of multiple preforms 154 and / or 156, as shown, for example, in Figure 5, and the strongback 180 includes multiple recesses 184 for each preform 154 or 156 in the array housed in the tray 190. In this embodiment, placing the recesses 184 of the strongback 180 onto the preforms 150 432 includes placing the multiple recesses 184 of the strongback 180 onto the multiple preforms 154 and / or 156 434, and applying a vacuum pressure 160 406 includes applying a vacuum pressure 160 through multiple vacuum channels 188 to hold the multiple preforms 154 and / or 156 in contact with the multiple recesses 184 442.

[0219] If the mandrel 140 includes a plurality of radially oriented (see Figure 21) mandrel segments 235, the method 400 includes at least moving one or more mandrel segments 235 414, transporting to one or more mandrel segments 235 462, and placing the preform 150 on one or more mandrel segments 235 474.

[0220] If the strongback 180 includes a plurality of strongback segments 181, as shown in Figure 16, the method 400 includes placing one or more strongback segments 181 on a tray 190 and / or preform 150 404, applying a vacuum pressure 160 to one or more strongback segments 181 406, transporting one or more strongback segments 181 to a mandrel 140 450, and placing the preform 150 on the mandrel 140 using each strongback segment 181 410. Each strongback segment 181 may be used by a different PNP machine 130, thereby allowing each strongback segment 181 to be used separately from one or more other strongback segments 181. Alternatively, by assigning more than one PNP machine 130 to a single strongback segment 181, multiple larger strongback segments 181 and / or preforms 150 may be moved to the mandrel 140 sequentially or simultaneously with one or more other strongback segments 181. Each strongback segment 181 may move at the same speed and in the same direction, or the movement of a strongback segment 181 may be independent of any movement of any other strongback segment 181 (unless the individual movements of the strongback segments 181 cause unintended contact).

[0221] When using a mounting system 50 that does not include a strongback 180, method 400 includes step 404, wherein mounting 404 is modified to mount the PNP machine 130 (instead of the strongback 180) onto the tray 190 and / or preform 150; step 406, wherein a vacuum pressure 160 is applied in the PNP machine 130 and / or end effector 134; transporting the preform 150 448; and placing the preform 150 from the PNP machine 130 and / or end effector 134 onto the mandrel 140 410. Similarly, in such a mounting system 50, mode 412 includes the mounting step 404, the applying step 406, the transporting step 448, and the mounting step 410, with the modifications described above.

[0222] Figure 25 is a flowchart showing a post-installation method 500 for operating the installation system 50 shown in Figures 1 to 21. More specifically, Figure 25 shows a post-installation method 500 for operating the installation system 50 and / or the production line 10 (see Figure 1) at least in part in method 400 (see Figures 24A and 24B) and / or after method 400.

[0223] Referring to Figures 25 and 21, method 500 includes an assembly process 502. Assembly method 502 is preferably performed when the mandrel 140 includes a plurality of mandrel segments 235. Assembly process 502 includes assembling the plurality of mandrel segments 235 together 504. The mandrel 140 is formed by assembling the mandrel segments 235 together 504. If the structure to be assembled 12 is a portion 768 of a fuselage 766 (see Figure 29), the plurality of mandrel segments 235 are assembled together 504 to form a half-barrel section 770.

[0224] The assembly method 502 may optionally include moving the mandrel 140 and / or mandrel segments 235 506, and / or positioning the mandrel segments 235 508. More specifically, the mandrel segments 235 may be moved to the assembly station 105 506 before being assembled to each other 504. In or after moving the mandrel segments 235 506, the mandrel segments 235 are positioned relative to each other 508 so that they may be assembled to each other 504.

[0225] If each of the mandrel segments 235 is a radial segment of the mandrel 140, each mandrel segment 235 is positioned in a different radial zone Z1, Z2, or Z3 of the mandrel 140 510. For example, when mandrel segments 236, 238, and 240 move from a loading station 100, 100', and 100'' to an assembly station 105 506, each of the mandrel segments 236, 238, and 240 is moved so as to be positioned in the corresponding radial zone Z3, Z1, or Z2 510. More specifically, before the mandrel 140 is assembled from the mandrel segments 236, 238, and 240, each of the mandrel segments 236, 238, and 240 is positioned in the corresponding radial zone Z3, Z1, or Z2, according to the correspondence between the mandrel segments 236, 238, and 240 and the radial portions 212, 208, and 210.

[0226] Assembling the mandrel segments 235 504 may include adding fasteners 242 to the mandrel segments 235 512. For example, the second mandrel segment 238 is assembled to one side of the third mandrel segment 240 by adding fasteners 242 to the second mandrel segment 238 and the third mandrel segment 240 504. Similarly, the first mandrel segment 236 is assembled to the other side of the third mandrel segment 240 by adding fasteners 242 to the first mandrel segment 236 and the third mandrel segment 240 504. The fasteners 242 may be added after all the mandrel segments 235 are positioned relative to each other 512, or they may be added as each mandrel segment 235 is positioned 512.

[0227] In a further example, assembling the mandrel segments 235 504 includes installing a seal between adjacent mandrel segments 235 either before or after the fasteners 242 are attached to the mandrel segments 235 512. In a particular example, the seal is installed such that a force acts normal to the seal.

[0228] The mandrel 140 and / or mandrel segments 235 can be attached to the mandrel support structure 106 514. More specifically, the mandrel segments 235 can be attached to the mandrel support structure 106 individually or assembled together as the mandrel 140 504. In one example, the mandrel segments 235 are assembled together 504, and the mandrel 140 formed by the mandrel segments 235 is attached to the mandrel support structure 106 using fasteners 244 514. In another example, the mandrel segments 235 are attached to the mandrel support structure 106 using, for example, fasteners 244 514, and then assembled to adjacent mandrel segments 235 using, for example, fasteners 242 504. Therefore, assembling the mandrel segments 235 together 504 may include attaching the mandrel segments 235 to the mandrel support structure 106 514.

[0229] The post-layout method 500 may further include laying layers 206 on the preform 150 and / or mandrel 140 (for example, by laying up). The laying of layers 206 516 may be by manual layup, automated layup, or a combination of both. Layers 206 may be laid before or after assembly method 502. If performed before assembly method 502, layers 206 are laid on the preform 150 which is already laid on the mandrel 140 and / or on the mandrel segments 235. For example, layers 206 are laid on each mandrel segment 235 before the mandrel segments 235 are moved to the assembly station 105. For example, layers 206 are laid at the layout station 100. The layers 206 are spliced ​​together after assembly method 502 to create, for example, an outer plate 782 (see Figure 29).516 If the layers 206 are placed after assembly method 502, the layers 206 are placed on the assembled mandrel segments and / or on the mandrels 140 attached to the mandrel support structure 106.516 The layers 206 may also be placed at assembly station 105 or at a layer placement station (not shown) after assembly station 105.516

[0230] The post-placement method 500 may further include a solidification method 520. The solidification method 520 includes solidifying at least the preform 150. To carry out the solidification method 520, the mandrel 140 and / or mandrel segment 235 are moved into the solidification system 60 (see Figure 1) 522. Since the solidification method 520 may be carried out before or after the assembly method 502, the solidification system 60 may be located along the production line 10 before or after the assembly station 105. If the structure 12 includes layers 206, the solidification method 520 includes co-curing the layers 206 and the preform 150 524.

[0231] If mandrel segments 235 are used and the curing method 520 is performed before the assembly method 502, the preform 150 and the layer 206 (if the layer 206 is included) are co-cured on each of the mandrel segments 235 524. The mandrel segments 235 are then moved to the assembly station 105 for assembly 504 506. The cured layers 206 are then spliced ​​together 518. In one example, method 500 includes laying up the outer layer 206 on each mandrel segment 235 before the mandrel segments 235 are assembled to each other 504 516, co-curing the outer layer 206 on each mandrel segment 235 together with the preform 150 on the corresponding mandrel segment 235 to create the outer layer 782 524, and splicing the outer layer 782 together 518 after the mandrel segments 235 have been assembled to each other 504.

[0232] If mandrel segments 235 are used and the solidification method 520 is performed after the assembly method 502, the mandrel segments 235 are assembled together 504 and moved to the solidification system 60 to co-cur the preform 150 and the layer 206 (if the layer 206 is included) 524 as mandrel 140 522. If the mandrel segments 235 are assembled together 504 before the solidification method 520, splicing the layer 206 is not required 518. In one example, method 500 includes laying up the outer layer 206 on the mandrel segments 235 after the mandrel segments 235 have been assembled together 504, and co-curing the outer layer 206 together with the preform 150 on the mandrel segments 235 524.

[0233] The post-placement method 500 can be carried out even if the mandrel 140 is not formed of multiple mandrel segments 235. For example, if the mandrel 140 is supported by a mandrel support structure 106, the method 500 may include moving the mandrel 140 to the assembly station 105 506 and then attaching the mandrel 140 to the mandrel support structure 106 514. If the structure 12 includes one or more layers 206, the method 500 includes placing the layers 206 before or after the mandrel 140 is attached to the mandrel support structure 106 514. The mandrel 140 (and the mandrel support structure 106) are moved to the solidification system 60 522, and the preform 150 and the layers 206 are co-cured 524.

[0234] The mandrel 140 can be reused 526 after the outer panels 782 have been spliced ​​together 518, or after the outer panel layer 206 has been co-cured with the preform 150 524. The mandrel 140 may be reused as a whole 526, or the mandrel segments 235 may be reused individually 528. Details of reuse 526, 528 will be described in relation to the preparation method 600 shown in Figure 26.

[0235] Figure 26 is a flowchart showing method 600 for preparing the mandrel 140, as shown in Figures 2 to 20. Method 600 as a whole, or parts of the steps of method 600, may be used to carry out reuse 526 and / or 528 as shown in method 500 in Figure 25. Preparation method 600 may include separation method 602 and / or washing method 604. Referring to Figures 26 and 1, method 600 may be carried out after the layup is complete and the preform 150 has solidified 520.

[0236] To carry out separation method 602, the mandrel 140 may be moved to the separation system 70 606. If the mandrel 140 includes mandrel segments 235, the mandrel 140 may be moved to the separation system 70 in which the mandrel segments 235 may be separated from each other 606. In certain examples, the mandrel 140 may move along the production line 10 in the process direction 14 from the solidification system 60 to the separation system 70 606. If the object 18 is not made from unsolidified fiber-reinforced material 152, and is placed without solidification and assembled to become a structure 12, the mandrel 140 may move along the production line 10 from the placement system 50 to the separation system 70 in order to remove the structure 12 from the mandrel 140 606.

[0237] According to method 600, separation method 602 includes separating the mandrel 140 from the solidified structure 64 608. If the mandrel 140 includes a mandrel segment 235, separation 608 includes separating the mandrel segment 235 from the solidified structure 64 610. In a particular example, separating the mandrel segment 235 from the solidified structure 64 610 includes separating the mandrel segment 235 from the hardened portion 768 of the body 766 (see Figures 28 and 29) 610. For example, separation 608 from the solidified structure 64 may include moving the mandrel segment 235 vertically 612 in order to separate the mandrel segment 235 from the solidified structure 64. In one embodiment, the mandrel segment 235 is moved vertically downward so as to move away from the solidified structure 64.

[0238] The separation method 602 may further include separating the mandrel segments 235 from each other 614. The separation of the mandrel segments 235 614 may include removing the fasteners 242 that hold the mandrel segments 235 together 616. For example, the separation of the mandrel segments 235 from each other 614 includes removing the fasteners 242 from the mandrel segments 235 616. Thus, if the mandrel 140 includes the mandrel segments 235, the separation method 602 (and by extension, the preparation method 600) includes separating the mandrel segments 235 from the solidified structure 64 610 and separating the mandrel segments 235 from each other 614.

[0239] Additionally or alternatively, the separation 614 of the mandrel segment 235 may include detaching the mandrel segment 235 from the mandrel support structure 106 618. For example, a fastener 244 may be removed to detach the mandrel segment 235 from the mandrel support structure 106 618. If the mandrel 140 does not contain the mandrel segment 235 but is supported by the mandrel support structure 106, the mandrel 140 may be detached from the mandrel support structure 106 618. Detachment 618 may be performed in the separation method 602 or after the cleaning method 604.

[0240] If a release film(s) 62 is used, the separation method 602 includes removing the release film 62 from the mandrel 140 and / or mandrel segment 235 620. For example, after the solidified structure 64 has been separated from the mandrel 140 608, the release film 62 is removed from the mandrel 140 and / or the solidified structure 64 620. If a mandrel segment 235 is used, the release film 62 is removed from the mandrel segment 235 after the mandrel segment 235 has been separated from the solidified structure 64 610, and before the mandrel segment 235 is separated from each other 614 620.

[0241] As part of the separation method 602, or after the separation method 602, the solidified structure 64 may be moved to a new location within the production line 10 to undergo further manufacturing processes 622. For example, the composite component 16 and / or the solidified structure 64 may be moved to a new location within the production line 10 (e.g., a different system) to undergo further manufacturing processes 622. Such a different system may be a manufacturing system or an assembly system, and through further manufacturing processes, the composite component 16 may be assembled into a final product (e.g., the aircraft 750 shown in Figures 28 and 29).

[0242] Preparation method 600 may further include cleaning method 604. Cleaning method 604 may include moving mandrel 140 and / or mandrel segment 234 into cleaning system 80 624. Cleaning method 604 includes cleaning mandrel 140 626. If mandrel segment 235 is used, mandrel segment 235 is cleaned 626. Cleaning 626 may be done by polishing, scrubbing, or other cleaning process using movements such as brushes or scrubbers.

[0243] Washing 626 includes applying at least one cleaning agent 82 to the mandrel 140 and / or mandrel segment(s) 235 628. The cleaning agent(s) 82 may be a solvent, water, and / or soap. If more than one cleaning agent(s) 82 are applied 628, the different cleaning agents(s) 82 are applied sequentially and / or simultaneously 628. The application of the cleaning agent(s) 82 628 may be performed before, during, or after other cleaning processes (e.g., polishing or scrubbing). In an alternative embodiment, the mandrel segments 235 are separated from each other after the mandrel 140 has been washed as a whole 626 614. However, if the mandrel segments 235 are separated from each other prior to washing 626 614, they can be washed more thoroughly and / or in parallel.

[0244] Once separation method 602 (and optionally cleaning method 604) has been performed, method 600 may include transporting the mandrel 140 or mandrel segment 235 to a starting position 52 of loading stations 100, 100', and / or 100'' where the preform 150 is picked up and placed on the mandrel 140 or mandrel segment 235. Transporting the mandrel 140 630 may be the movement 402 that occurs in loading method 400 (see Figures 24A and 24B). Method 600 then includes, for example, after the mandrel segment 235 has been separated 614 and / or cleaned 626, transporting the preform 150 on the mandrel 140 or mandrel segment 235 via a PNP machine 130.

[0245] Referring to Figures 1 and 24 through 26, an overall example of the flow of a mandrel 140 (e.g., a segmented mandrel having mandrel segments 235) through the assembly environment of the manufacturing line 10 is shown. Figure 21 shows mandrel segments 235, 236, 238, and 240, along with mounting stations 100, 100', and 100'', and assembly station 105.

[0246] Referring to Figures 1, 21, and 24 to 26, the mandrel segments 236, 238, and 240 individually receive the preform 150 in the mounting system 50, in which the PNP machine 130 places the preform 150 in predetermined locations on the mandrel segments 236, 238, and / or 240 410. The mandrel segment 235 is moved to the assembly station 105 506. After the mandrel segments 235 are radially positioned 510, the mandrel segments 235 are attached to each other in their own radial positions (e.g., in assembly 504). Alternatively or additionally, the mandrel segments 235 are attached to the mandrel support structure 106 514. For example, the mandrel segments 235 are attached to the mandrel support structure 106 via fasteners 244 514.

[0247] The outer panel layer(s) 206 may be placed on the preform 150 of the mandrel segments 236, 238, and 240 and co-cured together with the preform 150 524 to form an outer panel 782 (see Figure 29) integrated with the stringer 778. This may be done prior to or after the assembly 504 of the mandrel segments 236, 238, and 240. If done after the assembly 504 of the mandrel segments 236, 238, and 240, the outer panel layer(s) 206 and the preform 150 may solidify in a single step 520 to form a single unit. However, if done prior to the assembly 504, additional splicing 518 may be performed to facilitate the assembly method 502 after the outer panel layer(s) 206 has been laid up 516 and / or solidified 520. The mandrel support structure 106 then moves 522 into the solidification system 60 in which the preform 150 is solidified. The solidification system 60 itself, or any location upstream or downstream of the solidification system 60, may form the boundary of the cleanroom environment.

[0248] The mandrel support structure 106 proceeds to the separation system 70. The separation system 70 removes or separates the hardened portion 768 of the fuselage 766 from the mandrel segment 235 by moving the hardened portion 768 of the fuselage 766 vertically 612 and separating it from the mandrel segment 235 608. The hardened portion 768 of the fuselage 766 then moves to a new location 622 so that work can be carried out (for example, attachment to another section of the fuselage 766 or installation of windows or frames).

[0249] The release film 62 (e.g., vacuum bagging material, peeling ply, separation film, etc.) is also removed from the mandrel segments 235 in either the separation system 70 or another separation station not shown 620. The mandrel segments 235 are then separated from each other 614 by removing the fasteners 242 from the mandrel segments 235 616. For example, the mandrel segments 235 are separated from each other via the separation system 70 or at another separation station not shown 614. The individual mandrel segments 235 may be cleaned in the cleaning system 80 626. The cleaning system 80 applies a cleaning agent 82 (e.g., water, solvent, soap, etc.) 628, and the application 628 may be combined with polishing, scrubbing, or other cleaning 626 (e.g., moving brushes or scrubbers, etc.). The mandrel segments 235 are returned to the loading system 50 via transport 630 to receive further preforms 150. This involves placing the preform 150 onto the mandrel segment 235 via the PNP machine 130 after the mandrel segment 235 has been cleaned 626.

[0250] example The following examples describe additional processes, systems, and methods in terms of systems that coordinate the actions of PNP machines (e.g., the PNP machine 130 described above).

[0251] With more detailed reference to the drawings, embodiments of the present disclosure may be described from the viewpoint of the manufacture and maintenance of an aircraft in Method 700 shown in Figure 27, and from the viewpoint of the aircraft 750 shown in Figures 28 and 29. In the pre-manufacturing stage, Method 700 may include the specification and design 702 of the aircraft 750 and the procurement of materials 704. In the manufacturing stage, the manufacture 706 of the components and subassemblies of the aircraft 750 and system integration 708 are carried out. The aircraft 750 may then be put into operation 712 after approval and delivery 710. During its operation by the customer, the aircraft 750 is scheduled for periodic maintenance and upkeep 714 (which may also include modifications, reconfigurations, and refurbishments).

[0252] The systems and methods embodied in this specification may be used in any preferred one or more stages of the manufacturing and maintenance described in Method 700 (e.g., manufacturing of components and subassemblies 706, system integration 708, maintenance and servicing 714), and / or in any preferred component of the aircraft 750 (e.g., airframe 752, systems 754, interior 756, propulsion system 758, electrical system 760, hydraulic system 762, environmental system 764). Each of the processes of Method 700 may be implemented or performed 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.

[0253] As shown in Figure 28, an aircraft 750 manufactured by method 700 may include a fuselage 752 having multiple systems 754 and interior 756. The fuselage 752 includes a fuselage 766 defining at least a portion of the interior 756. Examples of systems 754 include one or more of the propulsion system 758, electrical system 760, hydraulic system 762, and environmental system 764. Any number of other systems may also be included. Although examples from the aerospace industry are shown, the principles of the systems and methods described herein may be applied to other industries (such as the automotive industry).

[0254] Figure 29 is a perspective view of the aircraft 750 shown in Figure 28. The aircraft 750 includes a fuselage 766. The fuselage 766 constitutes part of the airframe 752 (see Figure 28) and may define the interior 756 of the aircraft 750. The fuselage 766 further houses at least part of the system 754. The fuselage 766 may consist of a number of parts 768 manufactured individually or as subassemblies using the manufacturing line 10, mounting system 50, and methods 300, 400, 500, and / or 600, which are described in relation to Figures 1 to 26. For example, part 768 of the fuselage 766 may be a structure 12 assembled by the mounting system 50.

[0255] As described above, the half-barrel section 770 is an example of a portion 768 of the fuselage 766 assembled using the mounting system 50 and methods 300, 400, 500, and / or 600. Since the fuselage 766 constitutes at least a portion of the airframe 752, the portion 768 and the half-barrel section 770 can be considered parts of the airframe 752. In the example of Figure 29, the fuselage 766 is manufactured from a plurality of half-barrel sections 770 by joining the upper half-barrel section 772 and the lower half-barrel section 774 to form the corresponding full-barrel sections 776-1, 776-2, 776-3, and 776-4. The full-barrel sections 776-1, 776-2, 776-3, and 776-4 are joined in series to form the fuselage 766.

[0256] Each of the fuselage 766 portions 768 or sections 770 includes a stringer 778, a frame 780, and a skin 782. The skin 782 is attached to the stringer 778 and the frame 780. In some embodiments, a frame filler 784 may be positioned between the skin 782 and the frame 780. After the solidification method 520 (see Figure 25), the stringer preform 159 (see Figures 5 and 18) becomes the stringer 778, and the frame filler preform 158 (see Figures 5 and 18) becomes the frame filler 784. If the structure 12 (see Figure 1) includes layers 206 (see Figure 18), the layers 206 laid up on the preforms 158 and 159, as described in relation to Figure 25, become the skin 782 after the solidification method 520.

[0257] In one embodiment, the part includes a portion of the airframe 752 and is manufactured in the manufacture of components and subassemblies 706. This part is then incorporated into the aircraft 750 in system integration 708 and may be used in operation 712 until it becomes unusable due to wear. Thereafter, in maintenance and servicing 714, this part may be discarded and replaced with a newly manufactured part. Novel components and methods may be used throughout the manufacture of components and subassemblies 706 to manufacture a new part.

[0258] Any of the control elements shown in the diagrams or described in this document (e.g., electrical components or electronic components) 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. When functions are provided by processors, they may be provided by a single dedicated processor, a single shared processor, or by multiple individual 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 memory, logic, or any other physical hardware components or modules.

[0259] Furthermore, control elements can 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, an instruction functions to tell the processor to perform the function of the element. Instructions can 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.

[0260] While this book describes specific embodiments, the scope of this disclosure is not limited to such specific embodiments. The scope of this disclosure is defined by the claims and, if any, by their equivalents.

[0261] This disclosure also includes the following group of clauses, but these clauses should not be confused with the accompanying claims that determine the scope of protection.

[0262] Clause Group 1: Article 1. A method (400) for placing a preform (150) containing an unsolidified fiber-reinforced material (152) on a mandrel (140), Moving a mandrel (140) in the process direction (14) relative to a loading station (100) equipped with multiple pick-and-place (PNP) machines (130) (402), Identifying the tray (190) containing the preform (150) (418), Placing the strongback (180) onto the preform (150) via at least one of the PNP machines (130) (404), In order to hold the preform (150) in contact with the strongback (180) (438), vacuum pressure (160) is applied (406), The preform (150) is transported to the mandrel (140) via at least one PNP machine (130) (448), Placing the preform 150 on the mandrel (140) (410) Method (400), including the following.

[0263] Article 2. The method according to Clause 1 (400), further comprising stopping the mandrel (140) while at least a portion of the mandrel (140) is located at the mounting station (100) (416).

[0264] Article 3. The method according to Clause 1 or 2 (400), which includes placing (410) a preform (150) and releasing (470) a vacuum pressure (160).

[0265] Article 4. The method described in any one of the clauses 1 to 3 (400), wherein placing the strongback (180) (404) includes placing the recess (184) of the strongback (180) onto the preform (150) (432).

[0266] Article 5. The tray (190) contains multiple preforms (150), and the strongback (180) includes multiple recesses (184). Placing the recesses (184) of the strongback (180) onto the preform (150) (432) includes placing multiple recesses (184) of the strongback (180) onto multiple preforms (150) (434), The method according to Clause 4 (400), which includes applying a vacuum pressure (160) (406) to hold a plurality of preforms (150) in contact with a plurality of recesses (184) (442).

[0267] Article 6. The method according to any one of clauses 1 to 5 (400), wherein the preform (150) is transported to a mandrel (140) via a PNP machine (130) (408), and the positioning elements (183) of the strongback (180) are aligned with the positioning elements (148) of the mandrel (140) (456).

[0268] Article 7. The method according to any one of the clauses 1 to 6 (400), wherein the transport of the preform (150) onto the mandrel (140) (408) includes aligning the recess (184) of the strongback (180) with the notch (142) of the mandrel (140) (458).

[0269] Article 8. Placing (516) a layer (206) of uncured fiber reinforced material (152) on a plurality of preforms (150) disposed on a mandrel (140); The method (400) according to any one of clauses 1 to 7, further comprising co-curing (524) the layer (206) and the preform (150).

[0270] Clause 9. The method (400) according to any one of clauses 1 to 8, wherein applying (406) a vacuum pressure (160) includes operating (436) a vacuum system (138) to apply the vacuum pressure (160) through a vacuum channel (188) connected to a recess (184) of a strongback (180).

[0271] Clause 10. A portion (768) of an aircraft (750) assembled according to the method (400) according to any one of clauses 1 to 9.

[0272] Clause 11. A non-transitory computer-readable medium embodying programmed instructions (124), the instructions (124) being operative, when executed by a processor, to perform the method (400) according to any one of clauses 1 to 9 for assembling a structure.

[0273] Clause 12. A portion (768) of an aircraft (750) assembled according to the method (400) defined by instructions (124) stored in the computer-readable medium according to claim 11.

[0274] Clause 13. A placement system (50) for manufacturing a structure (12), A pick and place (PNP) machine (130) in a manufacturing cell (110), A cell controller (120), Moving the mandrel (140) in the process direction (14) relative to the PNP machine (130) (402), Identifying (418) a tray (190) containing a preform (150) containing unsolidified fiber-reinforced material (152), Placing the strongback (180) onto the preform (150) via at least one of the PNP machines (130) (404), In order to hold the preform (150) in contact with the strongback (180), vacuum pressure (160) is applied (406), The preform (150) is transported to the mandrel (140) via at least one PNP machine (130) (448), A mounting system (50) comprising a cell controller (120) that is operable to perform the following: placing a preform 150 on a mandrel (140) (410).

[0275] Article 14. The mounting system (50) according to Clause 13, wherein the cell controller (120) is operable to stop (416) the mandrel (140) while a portion of the mandrel (140) is located in a mounting station (100) having a PNP machine (130).

[0276] Article 15. The mounting system (50) according to Clause 13 or 14, wherein the cell controller (120) is operable to mount (410) the preform (150) by releasing (470) the vacuum pressure (160).

[0277] Article 16. A mounting system (50) according to any one of clauses 13 to 15, wherein the cell controller (120) is operable to mount (404) the strongback (180) by placing (432) the recess (184) of the strongback (180) onto the preform (150).

[0278] Article 17. A mounting system (50) according to Clause 16, wherein a tray (190) houses a number of preforms (150) and a strongback (180) includes a number of recesses (184).

[0279] Article 18. A mounting system (50) according to any one of clauses 13 to 17, wherein the cell controller (120) is operable to transport (408) the preform (150) to the mandrel (140) via the PNP machine (130) by aligning (456) the positioning element (183) of the strongback (180) with the positioning element (148) of the mandrel (140).

[0280] Article 19. A mounting system (50) according to any one of clauses 13 to 18, wherein the cell controller (120) is operable to transport (408) the preform (150) by aligning (458) the recess (184) of the strongback (180) with the notch (142) of the mandrel (140).

[0281] Article 20. A mounting system (50) according to any one of Clauses 13 to 19, wherein the cell controller (120) is operable to place (516) a layer (206) of unsolidified fiber-reinforced material (152) on a plurality of preforms (150) arranged on a mandrel (140), and to co-cur (524) the layer (206) and the preforms (150).

[0282] Article 21. Manufacture of a portion (768) of an aircraft (750) using a mounting system (50) as described in any one of clauses 13 to 20.

[0283] Clause Group 2: Article 1. A method (300) for assembling a structure (12) formed of an object (18) including discrete objects (20) and a larger object (22) larger than the discrete objects (20), In an asynchronous phase (354), the pick-and-place (PNP) machines (130) of the placement station (100) are each individually operated to place discrete objects (20) on a mandrel (140), and an operation (302) of causing them to operate, In a synchronous phase (356), a method (300) includes causing a plurality of PNP machines (130) to operate in cooperation to place a large object (22) spanning the plurality of PNP machines (130) on a mandrel (140), and an operation (304) of causing them to operate.

[0284] Clause 2. In response to detecting that a previous instruction (124) from a program (122) has been completed by a PNP machine (130) during the operation (302) in the asynchronous phase (354), a new instruction (124) from the program (122) is provided to each of the PNP machines (130) regardless of the progress status of other PNP machines (130), preferably, the method (300) according to Clause 1, wherein the program (122) is a numerical control (NC) program (123) and the instruction (124) is an NC instruction (125).

[0285] Clause 3. In response to detecting that all PNP machines (130) have completed a previous instruction (124) from a program (122) during the operation (304) in the synchronous phase (356), a new instruction (124) from the program (122) is provided to each of the PNP machines (130), preferably, the method (300) according to Clause 1 or 2, wherein the program (122) is an NC program (123) and the instruction (124) is an NC instruction (125).

[0286] Clause 4. The mandrel (140) has a concavo-convex cross-section (143), and the PNP machines (130, 130') are separately arranged across a plurality of placement stations (100, 100'), The method according to any one of the clauses 1 to 3 (300), further comprising operating the PNP machines (130, 130') in each of the mounting stations (100, 100') iteratively (334) in a synchronous phase (356) and an asynchronous phase (354) (304, 302).

[0287] Article 5. The method according to Clause 4 (300), wherein each of the placement stations (100, 100') operates the PNP machine (130, 130) (316, 328) to place (308, 320) an object (18) on different radial portions (208, 210, 212, 213) of the mandrel (140).

[0288] Article 6. The method according to Clause 4 or 5 (300), wherein each of the loading stations (100, 100') operates the PNP machine (130, 130) (316, 328) to load (312, 324) an object (18) onto different longitudinal portions (224, 226, 228) of the mandrel (140).

[0289] Article 7. The method (300) described in any one of the clauses 1 to 6, further comprising the PNP machine (130) completing instructions (124) in a program (122) corresponding to each of the multiple mandrel segments (235), and then assembling (504) the multiple mandrel segments (235) together to form a half-barrel section (770).

[0290] Article 8. Each of the objects (18) comprises a preform (150) of an unsolidified fiber-reinforced material (152), The method according to any one of the clauses 1 to 7 (300), further comprising fixing the preform 150 to a mandrel (140) (336).

[0291] Article 9. An instruction (124) in the asynchronous phase (354) causes each of the PNP machines (130) to perform the following: to place a strongback (180) on at least one discrete object (20) (404); to apply vacuum pressure (160) (406) to hold at least one discrete object (20) in the strongback (180); to lift the strongback (180) (454) so ​​that it is in a fixed position above the mandrel (140); and to release the vacuum pressure (160) (470) to remove at least one discrete object (20) from the strongback (180) (464) while at least one discrete object (20) is in contact with the mandrel (140). The method according to any one of clauses 1 to 8 (300), wherein a command (124) in the synchronization phase (356) causes each of the PNP machines (130) to synchronously place a strongback (180) on a large object (22) (404), apply vacuum pressure (160) (406) to hold the large object (22) across multiple PNP machines (130) in the strongback (180), lift the strongback (180) (454) to position it above the mandrel (140), and release the vacuum pressure (160) (470) to remove the large object (22) from the strongback (180) (464) while the large object (22) is in contact with the mandrel (140).

[0292] Article 10. A portion (768) of an aircraft (750) assembled in accordance with the method (300) described in any one of the clauses 1 to 9.

[0293] Article 11. A non-transient computer-readable medium for embodying programmed instructions (124), the instructions (124), when executed by a processor, can function to carry out the method (300) described in any one of clauses 1 to 9 to assemble a structure (12).

[0294] Article 12. A portion (768) of an aircraft (750) assembled in accordance with the method (300) specified by the instructions (124) stored in a computer-readable medium as described in Article 11.

[0295] Article 13. A mounting system (50) for manufacturing a structure (12) from an object (18) which includes discrete objects (20) and a larger object (22) that is larger than the discrete objects (20), A pick-and-place (PNP) machine (130) located within a loading station (100) in a manufacturing cell (110), within reach of an object (18) and a mandrel (140), wherein the large object (22) spans multiple PNP machines (130), and the mandrel (140) moves relative to the PNP machines (130), A mounting system (50) comprising a cell controller (120) which is operable to initiate (302) an asynchronous phase (354) in which each of the PNP machines (130) is operated individually to place discrete objects (20) on a mandrel (140), and further operable to initiate (304) a synchronous phase (356) in which the PNP machines (130) are operated in conjunction to place a large object (22) on the mandrel (140).

[0296] Article 14. The mounting system (50) according to Clause 13, wherein each PNP machine (130) comprises a controller (132), an end effector (134), and a sensor (136), preferably the sensor (136) being a position sensor.

[0297] Article 15. The mounting system (50) according to Clause 14, wherein each end effector (134) of the PNP machine (130) includes a vacuum system (138) that selectively applies a vacuum pressure (160) according to a program (122), preferably the program (122) is a numerically controlled (NC) program (123).

[0298] Article 16. Manufacture of a portion (768) of an aircraft (750) using a mounting system (50) as described in any one of clauses 13 to 15.

[0299] Clause Group 3: Article 1. A method (300) for assembling a structure (12) from an object (18) which includes discrete objects (20) and a larger object (22) that is larger than the discrete objects (20), The first subset (126) of the pick-and-place (PNP) machine (130) of the loading station (100) is operated individually in an asynchronous phase (354) to place discrete objects (20) on the mandrel (140) (314), While the first subset (126) is operating in the asynchronous phase (354) (314), in response to detecting that a previous instruction (124) from the program (122) has been completed by a PNP machine (130a) in the first subset (126), a new instruction (124) from the program (122) is provided to each of the PNP machines (130a) (306), regardless of the progress of the other PNP machines (130) in the first subset (126). Simultaneously with the operation (314) of the first subset (126) of the PNP machine (130), the second subset (128) of the PNP machine (130) is operated in a synchronized phase (356) (326) to place a large object (22) on the mandrel (140), wherein the large object (22) is operated in a synchronized manner across multiple PNP machines (130b, 130c), A method (300) comprising, while operating the second subset (128) in the synchronization phase (356) (326), detecting that all PNP machines (130b, 130c) in the second subset (128) have completed the previous instruction (124) from the program (122), providing each of the PNP machines (130b, 130c) in the second subset (128) with a new instruction (124) from the program (122) (318).

[0300] Article 2. The method according to Clause 1 (300), further comprising operating a first subset (126) and a second subset (128) of the PNP machine (130) iteratively (332) in a synchronous phase (356) and an asynchronous phase (354) (326, 314).

[0301] Article 3. The method according to Clause 1 or 2 (300), wherein the PNP machines (130a) in the first subset (126) are distinct from the PNP machines (130b, 130c) in the second subset (128).

[0302] Article 4. The method (300) described in any one of the clauses 1 to 3, further comprising assembling (504) a plurality of mandrel segments (235) into a half-barrel section (770) after the PNP machine (130) has completed instructions (124) in a program (122) corresponding to a mandrel segment (235).

[0303] Article 5. Each of the objects (18) comprises a preform (150) of an unsolidified fiber-reinforced material (152), The method according to any one of the clauses 1 to 4 (300), further comprising fixing the preform 150 to a mandrel (140) (336).

[0304] Article 6. An instruction (124) in the asynchronous phase (354) causes each of the PNP machines (130a) in the first subset (126) to perform the following: to place a strongback (180) on a discrete object (20) (404); to apply vacuum pressure (160) to hold the discrete object (20) in the strongback (180) (406); to lift the strongback (180) so that it is in a fixed position above the mandrel (140) (454); and to release the vacuum pressure (160) to remove the discrete object (20) from the strongback (180) (464) while the discrete object (20) is in contact with the mandrel (140) (470) The method according to any one of clauses 1 to 5 (300), wherein an instruction (124) in the synchronization phase (356) causes each of the PNP machines (130b, 130c) in the second subset (128) to synchronously place a strongback (180) on a large object (22) (404), apply vacuum pressure (160) to hold the large object (22) in the strongback (180) (406), lift the strongback (180) to a fixed position above the mandrel (140) (454), and release the vacuum pressure (160) to remove the large object (22) from the strongback (180) (464) while the large object (22) is in contact with the mandrel (140).

[0305] Article 7. A portion (768) of an aircraft (750) assembled in accordance with the method (300) described in any one of the clauses 1 to 6.

[0306] Article 8. A non-transient computer-readable medium for embodying programmed instructions (124), the instructions (124), when executed by a processor, can function to carry out the method (300) described in any one of clauses 1 to 6 to assemble a structure (12).

[0307] Article 9. A portion (768) of an aircraft (750) assembled in accordance with the method (300) specified by the instructions (124) stored in a computer-readable medium as described in Article 8.

[0308] Article 10. A mounting system (50) for manufacturing a structure (12) formed of multiple objects (18), A pick-and-place (PNP) machine (130) located within a manufacturing cell (110) within reach of an object (18) and a mandrel (140), wherein the mandrel (140) moves relative to the PNP machine (130), A placement system (50) comprising a cell controller (120) operably connected to a PNP machine (130) for placing an object (18) on a mandrel (140) using the PNP machine (130).

[0309] Article 11. The mounting system (50) according to Clause 10, wherein the PNP machines (130) are divided into a first subset (126) and a second subset (128), and preferably the cell controller (120) operates to assign each PNP machine (130) to either the first subset (126) or the second subset (128).

[0310] Article 12. The object (18) includes a discrete object (20) and a larger object (22) that is larger than the discrete object (20), and the cell controller (120) is The first subset (126) of the PNP machine (130) is operated individually in an asynchronous phase (354) to place a discrete object (20) on a mandrel (140) (314), While the first subset (126) is operating in the asynchronous phase (354) (314), in response to detecting that a previous instruction (124) from the program (122) has been completed by a PNP machine (130a) in the first subset (126), a new instruction (124) from the program (122) is provided to each of the PNP machines (130a) (306), regardless of the progress of the other PNP machines (130) in the first subset (126). Simultaneously with the operation (314) of the first subset (126) of the PNP machine (130), the second subset (128) of the PNP machine (130) is operated in a synchronized phase (356) (326) to place a large object (22) on the mandrel (140), wherein the large object (22) is operated in a synchronized manner across multiple PNP machines (130b, 130c), The mounting system (50) according to Clause 10 or 11 is configured to, while operating the second subset (128) in the synchronization phase (356) (326), provide each of the PNP machines (130b, 130c) in the second subset (128) with a new instruction (124) from the program (122) (318), in response to detecting that all of the PNP machines (130b, 130c) in the second subset (128) have completed a previous instruction (124) from the program (122).

[0311] Article 13. A mounting system (50) according to any one of clauses 10 to 12, wherein the cell controller (120) is operable to operate a first subset (126) and a second subset (128) of the PNP machine (130) iteratively (332) in synchronous (356) and asynchronous (354) phases (326, 314).

[0312] Article 14. The mounting system (50) described in any one of clauses 10 to 13, wherein the PNP machine (130a) in the first subset (126) is distinct from the PNP machines (130b, 130c) in the second subset (128).

[0313] Article 15. Each object (18) is a mounting system (50) according to any one of clauses 10 to 14, each including a preform (150) of an unsolidified fiber-reinforced material (152).

[0314] Article 16. The object (18) includes a discrete object (20) and a large object (22) spanning multiple PNP machines (130), and the cell controller (120) is a program (122), Each of the PNP machines (130a) in the first subset (126) is given an asynchronous phase (354) command (124) to perform the following: placing a strongback (180) on a discrete object (20) (404); applying vacuum pressure (160) (406) to hold the discrete object (20) in the strongback (180); lifting the strongback (180) so that it is in a fixed position above the mandrel (140) (454); and releasing the vacuum pressure (160) (470) to remove the discrete object (20) from the strongback (180) (464) while the discrete object (20) is in contact with the mandrel (140); A mounting system (50) according to any one of clauses 10 to 15, comprising a program (122) having commands (124) in a synchronous phase (356) to cause each of the PNP machines (130b, 130c) in the second subset (128) to synchronously place a strongback (180) on a large object (22), apply vacuum pressure (160) (406) to hold the large object (22) in the strongback (180), lift the strongback (180) (454) to position it above the mandrel (140), and release the vacuum pressure (160) (470) to remove the large object (22) from the strongback (180) (464) while the large object (22) is in contact with the mandrel (140).

[0315] Article 17. Object (18) includes discrete object (20), A mounting system (50) according to any one of clauses 10 to 16, wherein the cell controller (120) is configured to cause each PNP machine (130a) in a first subset (126) of PNP machines (130) to operate independently of each other (314) in an asynchronous phase (354) for mounting discrete objects (20) on a mandrel (140).

[0316] Article 18. The object (18) includes a large object (22) that spans multiple PNP machines (130), The cell controller (120) is configured to cause the PNP machines (130b, 130c) in the second subset (128) of the PNP machine (130) to operate in a synchronized phase (356) (326) to place a large object (22) on the mandrel (140), preferably the cell controller (120) operates the first subset (126) and the second subset (128) simultaneously, in the placement system (50) according to any one of the clauses 10 to 17.

[0317] Article 19. Manufacturing of a portion (768) of an aircraft (750) using a mounting system (50) as described in any one of clauses 10 to 18.

[0318] Clause Group 4: Article 1. A method (400) for assembling a structure (12) from a preform (150) comprising discrete preforms (154) and one or more large preforms (156), each preform (150) comprising an unsolidified fiber-reinforced material (152), Moving a mandrel (140) in the process direction (14) relative to a loading station (100) equipped with multiple pick-and-place (PNP) machines (130) (402), Identifying (422) a tray (190) containing one or more large preforms (156) and discrete preforms (154), wherein the discrete preforms (154) are positioned to be placed on the tray (190) where the frame (780) is to be installed (781) relative to the large preforms (156), Placing the strongback (180) on the tray (190) via at least one of the PNP machines (130) (428), Applying vacuum pressure (160) (406) in order to hold (444) one or more large preforms (156) and discrete preforms (154) in contact with a strong back (180), The process involves transporting one or more large preforms (156) and discrete preforms (154) to a mandrel (140) via at least one PNP machine (130) (460), while maintaining the arrangement of one or more large preforms (156) and discrete preforms (154). This includes (472) placing one or more large preforms (156) and discrete preforms (154) on a mandrel (140), Preferably, the discrete preform 154 is a frame filler preform (158) and the large preform (156) is a stringer preform (159), in the method (400).

[0319] Article 2. Identifying a tray (190) (422) includes identifying a tray (190) that includes recesses (198) for discrete preforms (154) and for one or more large preforms (156), Preferably, the recess (198) has a first shape (197) and a second shape (199), the first shape (197) corresponds to a discrete preform (154) and the second shape (199) corresponds to one or more large preforms (156), according to the method of Clause 1 (400).

[0320] Article 3. The method of Clause 1 or 2 (400), wherein placing a strongback (180) (428) includes placing an arc-shaped strongback (180) (404).

[0321] Article 4. The method (400) of any one of the clauses 1 to 3, further comprising assembling (504) a plurality of mandrel segments (235) together (504) after the PNP machine (130) has completed instructions (124) in a program (122) corresponding to a mandrel segment (235).

[0322] Article 5. The method according to any one of the clauses 1 to 4 (400), further comprising fixing (336) at least one or more large preforms (156) to a mandrel (140).

[0323] Article 6. Applying a vacuum pressure (160, 147) (406) includes holding each of the discrete preforms (154) in contact with at least one large preform (156) (446), Preferably, each of the discrete preforms (154) is held in contact with at least one large preform (156) in a strongback (180) and / or mandrel (140) (446), as described in any one of the claims 1 to 5 (400).

[0324] Article 7. A portion (768) of an aircraft (750) assembled in accordance with the method (400) described in any one of the clauses 1 to 6.

[0325] Article 8. A non-transient computer-readable medium for embodying programmed instructions (124), the instructions (124), when executed by a processor, can function to carry out the method (400) described in any one of clauses 1 to 6 to assemble a structure (12).

[0326] Article 9. A portion (768) of an aircraft (750) assembled in accordance with the method (400) specified by the instructions (124) stored in a computer-readable medium as described in Article 8.

[0327] Article 10. A mounting system (50) for manufacturing a structure (12) from a preform (150) comprising a discrete preform (154) and a large preform (156), each preform (150) comprising an unsolidified fiber-reinforced material (152), A tray (190) containing a large preform (156) and a discrete preform (154), wherein the discrete preform (154) is positioned relative to the large preform (156) at a location (195) where a frame (780) should be installed, and the tray (190) A pick-and-place (PNP) machine (130) located within a loading station (100) of a manufacturing cell (110), within reach of a mandrel (140) and a preform (150), comprising a vacuum system (138) for applying vacuum pressure (160) to hold a large preform (156) and a discrete preform (154), wherein the mandrel (140) moves relative to the PNP machine (130), A loading system (50) comprising a cell controller (120) which is operable to move a mandrel (140) in the process direction (14) relative to a loading station (100) (402), identify a tray (190) (422), place a strongback (180) on the tray (190) via at least one of the PNP machines (130) (428), transport the large preform (156) and discrete preform (154) to the mandrel (140) via at least one PNP machine (130) while maintaining the arrangement of the large preform (156) and discrete preform (154) (460), and place the large preform (156) and discrete preform (154) on the mandrel (140) (472).

[0328] Article 11. The tray (190) includes recesses (198) for discrete preforms (154) and for large preforms (156). Preferably, the mounting system (50) according to Clause 10, wherein the recess (198) has a first shape (197) and a second shape (199), the first shape (197) corresponding to a discrete preform (154) and the second shape (199) corresponding to one or more large preforms (156).

[0329] Article 12. A mounting system (50) according to clause 10 or 11, wherein the strongback (180) is arc-shaped.

[0330] Article 13. Each of the discrete preforms (154) is held in contact with at least one large preform (156), Preferably, the mounting system (50) according to any one of the clauses 10 to 12, wherein each of the discrete preforms (154) is held in contact with at least one large preform (156) in a strongback (180) and / or mandrel (140).

[0331] Article 14. A mounting system (50) according to any one of clauses 10 to 13, wherein each of the discrete preforms (154) is a frame filler preform (158) comprising multiple layers (216) of unsolidified fiber-reinforced material (152).

[0332] Article 15. Manufacture of a portion (768) of an aircraft (750) using a mounting system (50) as described in any one of clauses 10 to 14.

[0333] Article 16. A method (400) for assembling a structure (12) from a preform (150) comprising discrete preforms (154) and one or more large preforms (156), each preform (150) comprising an unsolidified fiber-reinforced material (152), Moving a mandrel segment (235) in the process direction (14) relative to a loading station (100) equipped with multiple pick-and-place (PNP) machines (130) (414), Identifying (422) a tray (190) containing one or more large preforms (156) and discrete preforms (154), wherein the discrete preforms (154) are arranged to be placed on the tray (190) where the frame (780) is to be installed (781) relative to one or more large preforms (156), Placing the strongback (180) on the tray (190) via at least one of the PNP machines (130) (428), Applying vacuum pressure (160) (406) in order to hold (444) one or more large preforms (156) and discrete preforms (154) in contact with a strong back (180), The process involves transporting one or more large preforms (156) and discrete preforms (154) to a mandrel segment (235) via a PNP machine (130) while maintaining the arrangement of the large preforms (156) and discrete preforms (154) (460, 462), A method (400) comprising placing one or more large preforms (156) and discrete preforms (154) on a mandrel segment (235) (472, 474).

[0334] Article 17. The method according to Clause 16 (400), further comprising (336) securing (400) a preform (150) to a mandrel segment (235) via a vacuum system (144).

[0335] Article 18. A portion (768) of an aircraft (750) assembled in accordance with the method (400) described in Article 16 or 17.

[0336] Clause Group 5: Article 1. A method (400) for placing a preform (150) on a mandrel (140) including a mandrel segment (235) in order to solidify it into a composite component (16), Moving a mandrel segment (235) in the process direction (14) relative to a loading station (100) which includes multiple pick-and-place (PNP) machines (130) (414), Placing the strongback (180) onto the preform (150) via at least one of the PNP machines (130) (430), In order to hold the preform (150) in contact with the strongback (180) (438), vacuum pressure (160) is applied (406), The preform (150) is transported to the mandrel segment (235) via at least one PNP machine (130) (448, 462), A method (400) comprising placing a preform (150) on a mandrel segment (235) (474).

[0337] Article 2. The method according to Clause 1 (400), further comprising identifying (420) a tray (190) containing a preform (150) comprising an unsolidified fiber-reinforced material (152).

[0338] Article 3. Preform (150) is the first type of preform, The method according to Clause 1 or 2 (400), further comprising conveying a second type of preform (150), which is a discrete preform (154), into a mandrel segment (235) (460, 462).

[0339] Article 4. The first type of preform is a large preform (156), The method of Clause 3 (400), further comprising placing a discrete preform (154) together with a large preform (156) in a tray (190c) in a location (195) where a frame (780) should be installed relative to the large preform (156) (426).

[0340] Article 5. The method according to any one of the clauses 1 to 4 (400), further comprising releasing the vacuum pressure (160) (470) to facilitate the removal (464) of the preform (150) from the strongback (180) (452) after the strongback (180) has been positioned (435).

[0341] Article 6. The method described in any one of the clauses 1 to 5 (400, 500), further comprising assembling multiple mandrel segments (235) together (504).

[0342] Article 7. The method according to Clause 6 (400, 500), wherein assembling the mandrel segments (235) together (504) includes attaching fasteners (242) to the mandrel segments (235) (512).

[0343] Article 8. The method according to Clause 6 or 7 (400, 500), wherein assembling the mandrel segments (235) to one another (504) includes attaching the mandrel segments (235) to a mandrel support structure (106) (514).

[0344] Article 9. After the mandrel segments (235) are assembled together (504), the outer layer (206) is laid up (516) on the mandrel segments (235), The method according to any one of the clauses 6 to 8 (400, 500), further comprising co-curing (524) an outer layer (206) together with a preform (150) on a mandrel segment (235).

[0345] Article 10. Before the mandrel segments (235) are assembled together (504), lay up (516) an outer layer (206) on each mandrel segment (235), To manufacture at least the outer panel (782), the outer panel layer (206) on each mandrel segment (235) is co-cured (524) together with the preform (150) on the corresponding mandrel segment (235), The method according to any one of the clauses 6 to 8 (400, 500), further comprising splicing together (518) the outer plates (782) on the mandrel segments (235) after they have been assembled (504).

[0346] Article 11. The method according to any one of the clauses 6 to 10 (400, 500), further comprising positioning each mandrel segment (235) in different radial zones (Z1, Z2, Z3) of the mandrel (140) (510).

[0347] Article 12. A portion (768) of an aircraft (750) assembled in accordance with the method described in any one of the clauses 1 to 11 (400, 500).

[0348] Article 13. A method (600) for preparing a mandrel (140) formed from a mandrel segment (235) to receive a preform (150) in a manufacturing line (10), The mandrel segment (235) is separated (610) from the solidified structure (64), A method (600) comprising separating mandrel segments (235) from each other (614).

[0349] Article 14. The method according to Clause 13 (600), further comprising cleaning the mandrel segment (235) (626).

[0350] Article 15. The method (600) of clause 13 or 14, further comprising moving (624) a mandrel segment (235) into a cleaning system (80).

[0351] Article 16. The method according to clause 14 or 15 (600), wherein cleaning (626) includes applying (628) at least one cleaning agent (82) selected from the group consisting of solvents, water, and soap to the mandrel segment (235).

[0352] Article 17. The method (600) described in any one of the clauses 13 to 16, further comprising moving (622) the solidified structure (64) to a new location within the manufacturing line (10) for further manufacturing processes.

[0353] Article 18. The method (600) described in any one of the clauses 13 to 17, further comprising moving a mandrel (140) into a separation system (70) in which the mandrel segments (235) are separated (614) from one another (606).

[0354] Article 19. The method (600) of any one of the clauses 13 to 18, further comprising transporting (630) the mandrel segment (235) to a starting position (52) of a loading station (100) that picks up the preform (150) and places it on the mandrel segment (235).

[0355] Article 20. The method described in any one of the clauses 13 to 19 (600), wherein separating the mandrel segments (235) from each other (614) includes removing the fasteners (242) from the mandrel segments (235) (616).

[0356] Article 21. The method according to any one of the claims 13 to 20 (600), further comprising removing the release film (620) from the mandrel segments (235) after separating the mandrel segments (235) from the solidified structure (64) (610) and before separating the mandrel segments (235) from each other (614).

[0357] Article 22. The method(600) described in any one of the clauses 13 to 21, wherein separating the mandrel segment(235) from the solidified structure(64)(610) includes moving the solidified structure(64) vertically(612) in order to separate the mandrel segment(235)(610).

[0358] Article 23. The method according to any one of the clauses 14 to 16 (600), further comprising placing a preform (150) on the mandrel segment (235) via a pick-and-place (PNP) machine (130) after the mandrel segment (235) has been cleaned (604).

[0359] Article 24. The method (600) described in any one of the clauses 13 to 23, wherein separating the mandrel segment (235) from the solidified structure (64) (610) includes separating the mandrel segment (235) from the hardened portion (768) of the fuselage (750).

[0360] Article 25. A portion (768) of an aircraft (750) assembled in accordance with the method (600) described in any one of clauses 13 to 24.

Claims

1. A method (400) for placing a preform (150) containing an unsolidified fiber-reinforced material (152) on a mandrel (140), Moving the mandrel (140) in the process direction (14) relative to a mounting station (100) equipped with multiple pick-and-place (PNP) machines (130) (402), Identifying the tray (190) containing the preform (150) (418), Placing the strongback (180) onto the preform (150) via at least one of the PNP machines (130) (404), which includes placing the recess (184) of the strongback (180) onto the preform (150) (432), In order to hold the preform (150) in contact with the strong back (180) (438), a vacuum pressure (160) is applied (406), Conveying the preform (150) to the mandrel (140) via at least one PNP machine (130) (408), including aligning the recess (184) of the strongback (180) with the notch (142) of the mandrel (140) (458), A method (400) comprising placing the preform (150) on the mandrel (140) (410).

2. The method according to claim 1 (400), further comprising stopping the mandrel (140) while a portion of the mandrel (140) is placed in the aforementioned placement station (100) (416).

3. The method according to claim 1 (400), wherein placing the preform (150) (410) includes releasing the vacuum pressure (160) (470).

4. Placing the recess (184) of the strongback (180) onto the preform (150) (432) includes placing a plurality of recesses (184) of the strongback (180) onto a plurality of preforms (150) (434), The method according to claim 1 (400), wherein applying the vacuum pressure (160) (406) includes holding the plurality of preforms (150) in contact with the plurality of recesses (184) (442).

5. The method according to claim 1 (400), wherein transporting the preform (150) to the mandrel (140) via the PNP machine (130) (408) includes aligning the positioning element (183) of the strongback (180) with the positioning element (148) of the mandrel (140) (456).

6. A method (400) for placing a preform (150) containing an unsolidified fiber-reinforced material (152) on a mandrel (140), Moving the mandrel (140) in the process direction (14) relative to a mounting station (100) equipped with multiple pick-and-place (PNP) machines (130) (402), Identifying the tray (190) containing the preform (150) (418), Placing the strongback (180) onto the preform (150) via at least one of the PNP machines (130) (404), In order to hold the preform (150) in contact with the strong back (180) (438), a vacuum pressure (160) is applied (406), Conveying the preform (150) to the mandrel (140) via at least one PNP machine (130) (408), including aligning the recess (184) of the strongback (180) with the notch (142) of the mandrel (140) (458), Placing the preform (150) on the mandrel (140) (410), A layer (206) of unsolidified fiber-reinforced material (152) is placed (516) on top of a plurality of preforms (150) arranged on a mandrel, Co-curing the aforementioned layer (206) and the aforementioned preform (150) (524), Method (400), including.

7. A method (400) for placing a preform (150) containing an unsolidified fiber-reinforced material (152) on a mandrel (140), Moving the mandrel (140) in the process direction (14) relative to a mounting station (100) equipped with multiple pick-and-place (PNP) machines (130) (402), Identifying the tray (190) containing the preform (150) (418), Placing the strongback (180) onto the preform (150) via at least one of the PNP machines (130) (404), Applying a vacuum pressure (160) (406) to hold (438) the preform (150) in contact with the strongback (180), wherein the application of the vacuum pressure (160) (406) includes operating a vacuum system (138) to apply the vacuum pressure (160) through a vacuum channel (188) connected to a recess (184) of the strongback (180), Conveying the preform (150) to the mandrel (140) via at least one PNP machine (130) (408), including aligning the recess (184) of the strongback (180) with the notch (142) of the mandrel (140) (458), Placing the preform (150) on the mandrel (140) (410), Method (400), including.

8. A method for assembling a part (768) of an aircraft (750) according to the method (400) of claim 1.

9. A mounting system (50) for manufacturing a structure (12), A pick-and-place (PNP) machine (130) inside a manufacturing cell (110), A cell controller (120), Moving the mandrel (140) in the process direction (14) relative to the PNP machine (130) (402), Identifying (418) a tray (190) containing a preform (150) containing unsolidified fiber-reinforced material (152), Placing the recess (184) of the strongback (180) onto the preform (150) via at least one of the PNP machines (130), thereby placing the strongback (180) onto the preform (150) (404), In order to hold the preform (150) in contact with the strong back (180), a vacuum pressure (160) is applied (406), The preform (150) is conveyed to the mandrel (140) by aligning the recess (184) of the strongback (180) with the notch (142) of the mandrel via at least one PNP machine (130) (408), The device is operable to perform the following actions: placing the preform (150) on the mandrel (140) (410), Cell controller (120) and A mounting system (50) is provided.

10. The mounting system (50) according to claim 9, wherein the cell controller (120) is operable to stop (416) the mandrel (140) while a portion of the mandrel (140) is located in a mounting station (100) having the PNP machine (130).

11. The mounting system (50) according to claim 9, wherein the cell controller (120) is operable to place (410) the preform (150) by releasing (470) the vacuum pressure (160).

12. The mounting system (50) according to claim 9, wherein the tray (190) stores a plurality of preforms (150), and the strongback (180) includes a plurality of recesses (184).

13. The mounting system (50) according to claim 9, wherein the cell controller (120) is operable to transport the preform (150) to the mandrel (140) via the PNP machine (130) (408) by aligning the positioning element (183) of the strongback (180) with the positioning element (148) of the mandrel (140) (456).

14. A mounting system (50) for manufacturing a structure (12), A pick-and-place (PNP) machine (130) inside a manufacturing cell (110), A cell controller (120), Moving the mandrel (140) in the process direction (14) relative to the PNP machine (130) (402), Identifying (418) a tray (190) containing a preform (150) containing unsolidified fiber-reinforced material (152), Placing the strongback (180) onto the preform (150) via at least one of the PNP machines (130) (404), In order to hold the preform (150) in contact with the strong back (180), a vacuum pressure (160) is applied (406), By aligning the recess (184) of the strongback (180) with the notch (142) of the mandrel (140) (458), the preform (150) is conveyed (408) to the mandrel (140) via the at least one PNP machine (130), The process involves placing the preform (150) on the mandrel (140) (410) The device is operable to place (516) a layer (206) of unsolidified fiber-reinforced material (152) on a plurality of preforms (150) arranged on the mandrel (140), and to co-cur (524) the layer and the preforms (150). Cell controller (120) and A mounting system (50) is provided.

15. Multiple pick-and-place (PNP) machines (130) located within the manufacturing cell (110), A cell controller (120) coupled to a plurality of the aforementioned PNP machines (130), A mandrel (140) including a notch (142) that is movable in the process direction relative to a plurality of the PNP machines (130), Tray (190) and A preform (150) containing a layer (206) of unsolidified fiber-reinforced material (152) stored on the tray, A strong back (180) including a recess is held in contact with the preform (150) by vacuum. A device equipped with, The tray (190) is identified by the cell controller (120), The preform (150) and the strongback (180) are transported to the mandrel (140) via at least one of the plurality of PNP machines (130) and placed on the mandrel. The recess (184) of the strongback (180) aligns with the notch (142) of the mandrel (140). Device.

16. The apparatus according to claim 15, wherein the tray (190) stores a plurality of preforms (150), and the strongback (180) includes a plurality of recesses (184).

17. The apparatus according to claim 16, wherein a layer (206) of unsolidified fiber-reinforced material (152) is placed on a plurality of preforms (150) and co-cured together with the plurality of preforms (150) (524).

18. Placing a layer (206) of unsolidified fiber-reinforced material (152) on a plurality of preforms (150) arranged on the mandrel (140) (516), Co-curing the layer (206) and the preform (150) (524) The method according to claim 1, further comprising (400).

19. The method according to claim 1 (400), further comprising: applying the vacuum pressure (160) (406) by operating the vacuum system (138) (436) to apply the vacuum pressure (160) through a vacuum channel (188) connected to a recess (184) of the strongback (180);

20. The placement system (50) according to claim 9, wherein the cell controller (120) is operable to place (516) a layer (206) of the unsolidified fiber-reinforced material (152) on a plurality of preforms (150) arranged on the mandrel (140), and to co-cur (524) the layer (206) and the preforms (150).

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