Method and system for fabricating a pressure bulkhead assembly

Abstract

To provide a method for making a pressure bulkhead assembly of an aircraft.SOLUTION: A method of making a pressure bulkhead assembly of an aircraft includes determining 1024 an optimized position of splice angles such that splice surfaces of the splice angles will form a circumferential splice surface of the pressure bulkhead assembly. The method further includes performing 1026 a virtual fit between the plurality of splice angles at the optimized position and an aft pressure bulkhead. The method also includes determining 1032 splice-angle-hole positions of splice-angle holes to be drilled in each of the splice angles such that the splice-angle holes will correspond to aft-pressure-bulkhead holes, pre-drilled in the aft pressure bulkhead. The method further includes drilling 1034 the splice-angle holes in each of the splice angles at the splice-angle-hole positions. The method also includes joining 1038 each one of the splice angles to the aft pressure bulkhead such that the splice surfaces form the circumferential splice surface with the optimized shape.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present disclosure generally relates to methods and systems for joining structural components to each other, and more particularly, to methods and systems for positioning structural components associated with an aircraft pressure bulkhead assembly.

Background Art

[0002] Pressure bulkheads are often used in aircraft to separate pressurized sections of the fuselage from unpressurized sections. In some applications, the pressure bulkhead may be installed inside the fuselage and attached to the outer skin of one or more sections of the fuselage. In some cases, the pressure bulkhead is attached to the aircraft using a plurality of angle members (referred to as "splice angles").

[0003] The angle splices and pressure bulkheads are typically assembled into a drill jig using complex and expensive assembly tooling. For example, the pressure bulkhead is first joined to the angle splice. Then, while holes are drilled through the pressure bulkhead and the angle splice, the two are temporarily joined to each other. However, using a drill jig for drilling such major structural joints can result in holes being too large, requiring multiple measurement and alignment steps, and / or repeatedly placing the pressure bulkhead and angle splice in the jig and removing them from the jig, any or all of which can cause manufacturing delays. Using a drill jig can also result in the pressure bulkhead having an undesirably large joint surface and / or shim design incompatibility. Also, due to the flexibility of the carbon fiber material that makes up part of the pressure bulkhead components, it can be difficult to machine the pressure bulkhead surface and holes when the pressure bulkhead is attached to the jig.

[0004] Therefore, there is a need for a pressure bulkhead assembly method that reduces installation time, improves the accuracy of hole size and location, improves the accuracy of the position of the crescent splice, reduces labor, is easily automated, and minimizes waste of parts. Accordingly, those skilled in the art continue their research and development efforts in the field of pressure bulkhead assembly. [Overview of the Initiative]

[0005] Disclosed are a method for manufacturing a pressure bulkhead assembly, a system for manufacturing a pressure bulkhead assembly, and examples of pressure bulkhead assemblies for aircraft. The following is a non-exclusive list of examples of subject matter covered by this disclosure, which may or may not be claimed.

[0006] In one example, the method of the present disclosure includes: (1) determining the optimal positions of a plurality of crescent splices such that the splice surfaces of the plurality of crescent splices form a periphery-direction splice surface of a pressure bulkhead assembly having an optimal shape; (2) performing a virtual fit between the plurality of crescent splices at the optimal positions and a tail pressure bulkhead; (3) determining the positions of crescent splice holes such that the crescent splice holes to be drilled in each of the plurality of crescent splices correspond to tail pressure bulkhead holes pre-drilled in the tail pressure bulkhead; (4) drilling crescent splice holes at the positions of the crescent splice holes of each of the plurality of crescent splices; and (5) joining each of the plurality of crescent splices to the tail pressure bulkhead such that the splice surfaces form a periphery-direction splice surface having an optimal shape.

[0007] In one example, the system of the present disclosure includes a measuring machine configured to acquire measurements of a tail pressure bulkhead and a plurality of crescent splices. The system also includes a computer system having memory and a processor for storing a program. The processor is configured to execute a program to: (1) determine the optimal positions of the plurality of crescent splices such that the plurality of splice surfaces of the plurality of crescent splices form a periphery-direction splice surface having an optimal shape; (2) perform a virtual fit between the plurality of crescent splices at the optimal positions and the tail pressure bulkhead; and (3) determine the positions of the crescent splice holes such that, with the plurality of crescent splices at the optimal positions, the crescent splice holes to be drilled in each of the plurality of crescent splices correspond to pre-drilled tail pressure bulkhead holes in the tail pressure bulkhead. The system includes a computer numerical control machine configured to drill crescent splice holes at the positions of each of the plurality of crescent splices. When multiple V-shaped splices are joined to the tail pressure bulkhead at the optimal position, the multiple splice surfaces form a periphery-direction splice surface with an optimal shape.

[0008] In one example, the pressure bulkhead assembly of the present disclosure includes a tail pressure bulkhead comprising a bulkhead interface and a tail pressure bulkhead hole pre-drilled through the bulkhead interface, and a plurality of crescent splices configured to connect to the tail pressure bulkhead. Each of the plurality of crescent splices comprises a flange surface configured to engage with the bulkhead interface, a crescent splice hole drilled through the flange surface, and a splice surface extending from the flange surface. With the crescent splice hole aligned with the tail pressure bulkhead hole, the plurality of splice surfaces form a periphery-direction splice surface having an optimal shape.

[0009] Other examples of the methods, systems, and structural assemblies of this disclosure will also be apparent from the embodiments for carrying out the inventions described below, the accompanying drawings, and the accompanying claims. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic perspective view of an example of a pressure bulkhead assembly. [Figure 2] This is a schematic diagram of an example aircraft including a pressure bulkhead assembly. [Figure 3] This is a schematic cutaway perspective view of an example of a portion of a pressure bulkhead assembly connected to the fuselage of an aircraft. [Figure 4] This is a flowchart illustrating an example of a method for fabricating a pressure bulkhead assembly. [Figure 5] This is a schematic block diagram of an example system for fabricating a pressure bulkhead assembly. [Figure 6] This is a schematic cutaway perspective view of an example of a portion of the first bulkhead surface of the aft pressure bulkhead of a pressure bulkhead assembly. [Figure 7] This is a schematic cutaway perspective view of an example of a portion of the second bulkhead surface of the aft pressure bulkhead of a pressure bulkhead assembly. [Figure 8] This is a schematic perspective view of an example of a V-shaped splice configured to be attached to the tail pressure bulkhead to form a pressure bulkhead assembly. [Figure 9] This is a schematic perspective view of an example of a V-shaped splice configured to be attached to the tail pressure bulkhead to form a pressure bulkhead assembly. [Figure 10] This is a schematic diagram of multiple vertex splice scan images representing multiple splice surfaces in their initial position, where the circumferential splice surfaces of the pressure bulkhead assembly have their initial shape. [Figure 11] Figure 10 is a schematic perspective view of a portion of the bell-shaped splice scan image. [Figure 12] Figure 10 shows a schematic perspective view of a portion of the bell-shaped splice scan image, which is adjusted from its initial position to the optimal position. [Figure 13] This is a schematic diagram of multiple ridge splice scan images representing multiple ridge splices in optimal positions, where the circumferential splice surface of the pressure bulkhead assembly has the optimal shape. [Figure 14]Figure 13 is a schematic perspective view of a portion of the bell-shaped splice scan image. [Figure 15] This is a schematic diagram of an example of a three-dimensional virtual overlay between a tail pressure bulkhead scan image and one of several vertex splice scan images. [Figure 16] Figures 8 and 9 show schematic perspective views of an example of a crescent splice with multiple crescent splice holes drilled. [Figure 17] This is a schematic cross-sectional view of an example of a pressure bulkhead assembly. [Figure 18] This is a schematic plan view of an example of a shim for a pressure bulkhead assembly with shim holes drilled. [Figure 19] This is a flowchart illustrating the manufacturing and maintenance methods for aircraft. [Modes for carrying out the invention]

[0011] Modes for carrying out the following inventions are referenced in the accompanying drawings, which illustrate specific examples described herein. Other examples having various structures and processes do not deviate from the scope of this disclosure. Similar reference numerals may refer to the same feature, element, or component in separate drawings. Throughout this disclosure, any of multiple items may be referred to individually as that item, multiple items may be referred to collectively as that item, or referred to together with multiple similar reference numerals. Furthermore, as used herein, features, elements, components, or steps following the word "one (a or an)" should be understood as not being subject to any exclusion of the plural form of feature, element, component, or step unless such exclusion is explicitly stated herein.

[0012] The following provides illustrative and non-exclusive examples of the subject matter of this disclosure. Such examples may be claimed, but are not necessarily claimed. References to “example” in this document mean that one or more features, structures, elements, components, characteristics, and / or process steps described in association with an example are included in at least one aspect, embodiment, and / or embodiment of the subject matter of this disclosure. Thus, expressions such as “one example,” “another example,” “one or more examples,” and similar phrases throughout this disclosure may, but are not necessarily, refer to the same example. Furthermore, the subject matter characterizing any one example may, but are not necessarily, include the subject matter characterizing any of the other examples. Furthermore, the subject matter characterizing any one example may, but are not necessarily, be combined with the subject matter characterizing any of the other examples.

[0013] Referring to Figure 1 as an example, this disclosure relates to a pressure bulkhead assembly 100 including a tail pressure bulkhead 108 and a plurality of crescent splices 102. Referring schematically to Figure 4 as an example, this disclosure relates to a method 1000 for fabricating the pressure bulkhead assembly 100 by positioning and attaching a plurality of crescent splices 102 to the tail pressure bulkhead 108. Referring schematically to Figure 5 as an example, this disclosure also relates to a system 200 for fabricating the pressure bulkhead assembly 100. In one or more examples, the method 1000 is implemented using the system 200.

[0014] In an example of the system 200 and method 1000, measurements of the aft pressure bulkhead 108 are used to determine the surface profile of the aft pressure bulkhead 108 and to determine the positions of the full-size holes pre-drilled in the aft pressure bulkhead 108. In an example of the system 200 and method 1000, measurements of the plurality of chevron splices 102 are used to determine the surface profile of each of the plurality of chevron splices 102. In an example of the system 200 and method 1000, the determined surface profile of the aft pressure bulkhead 108 and the surface profiles of the plurality of chevron splices 102 are used to virtually fit the plurality of chevron splices 102 in an optimal position around the aft pressure bulkhead 108 in order to assemble the pressure bulkhead assembly 100. In an example of the system 200 and method 1000, virtual fitting and the determined positions of the full-size holes pre-drilled in the aft pressure bulkhead 108 are used to determine the positions of the full-size holes to be drilled in each of the plurality of chevron splices 102 so that the plurality of chevron splices 102 are positioned in an optimal position when joined to the aft pressure bulkhead 108.

[0015] Examples of the system 200 and method 1000 facilitate drilling full-size holes at the determined positions of each of the plurality of chevron splices 102 such that the full-size holes drilled in the chevron splices 102 correspond to the full-size holes pre-drilled in the aft pressure bulkhead 108. Examples of the system 200 and method 1000 also facilitate attaching the chevron splices 102 to the aft pressure bulkhead 108 using a plurality of fasteners inserted through the aligned pairs of the full-size holes of the chevron splices 102 and the full-size holes of the aft pressure bulkhead 108 so that the plurality of chevron splices 102 are joined to the aft pressure bulkhead 108 in an optimal position.

[0016] Examples of the system 200 and method 1000 facilitate identifying the dimensions of the gaps formed between the aft pressure bulkhead 108 and the plurality of chevron splices 102, and forming a plurality of shims 128 based on the dimensions of these gaps. Examples of the system 200 and method 1000 also facilitate determining the positions of the current size holes to be drilled in the shims 128, and drilling the current size holes at the determined positions of the shims 128. Examples of the system 200 and method 1000 further facilitate attaching a plurality of shims 128 between the aft pressure bulkhead 108 and the plurality of chevron splices 102 such that the plurality of chevron splices 102 are joined to the aft pressure bulkhead 108 at an optimal position.

[0017] Referring now to FIG. 1, this figure schematically shows an example of a pressure bulkhead assembly 100. The pressure bulkhead assembly 100 includes or is composed of an aft pressure bulkhead 108 and chevron splices 102. The chevron splices 102 are positioned adjacent to each other and joined to the aft pressure bulkhead 108. The plurality of chevron splices 102 form a circumferential splice surface 106. The circumferential splice surface 106 has an optimal shape 136.

[0018] In the present disclosure, the optimal shape 136 of the circumferential splice surface 106 refers to an optimized shape of the circumferential splice surface 106 that is as circular as possible within the manufacturing tolerances. As will be described in detail later in this document, the optimal shape 136 of the circumferential splice surface 106 is achieved by determining the optimal position of each of the chevron splices 102 such that the step or offset between the engagement edges of directly adjacent ones of the chevron splices 102 is minimized. In one or more examples, the optimal shape 136 is approximately circular, and in this circular shape, the step dimension 116 (see, for example, FIG. 12) between each engagement edge 118 of the plurality of chevron splices 102 and the engagement edge 118 of directly adjacent ones of the plurality of chevron splices 102 is minimized (see, for example, FIGS. 13 and 14).

[0019] In one or more examples, the tail pressure bulkhead 108 includes a bulkhead interface 126 (see, for example, Figures 7 and 9) and a plurality of tail pressure bulkhead holes 114 (see, for example, Figures 6 to 9). The tail pressure bulkhead holes 114 are pre-drilled through the bulkhead interface 126.

[0020] In one or more examples, the crescent splice 102 is configured to connect to (e.g., attach to or otherwise fix to) the tail pressure bulkhead 108. Each crescent splice 102 includes a flange surface 130, a plurality of crescent splice holes 112, and a splice surface 104 (see, for example, Figures 8, 9, and 16). The flange surface 130 is configured to engage with the bulkhead interface 126. The crescent splice holes 112 are drilled through the flange surface 130. The splice surface 104 extends from the flange surface 130. With the crescent splice holes 112 aligned with the tail pressure bulkhead holes 114, the plurality of splice surfaces 104 form a periphery-direction splice surface 106 having an optimal shape 136.

[0021] In one or more examples, the position 110 of the crescent splice hole 112 (see, for example, Figure 16) is determined based on (1) a virtual fit between a plurality of optimally positioned crescent splices 102 and the tail pressure bulkhead 108, and (2) the measured position 132 of the tail pressure bulkhead hole 114 (see, for example, Figures 6 and 7).

[0022] In this disclosure, the “position” of a hole means the location of the hole in three-dimensional space (for example, along the X, Y, and Z axes with respect to a three-dimensional coordinate system) and its angular orientation (for example, around the X, Y, and Z axes).

[0023] In one or more examples, the pressure bulkhead assembly 100 includes a plurality of fasteners 134 (see, for example, Figures 5 and 17). The fasteners 134 are inserted through the crescent splice holes 112 and the tail pressure bulkhead holes 114 to secure the plurality of crescent splices 102 to the tail pressure bulkhead 108.

[0024] In one or more examples, the pressure bulkhead assembly 100 includes a shim 128 (see, for example, Figures 17 and 18). The shim 128 is positioned between one flange surface 130 of the crescent splice 102 and the bulkhead interface 126 of the tail pressure bulkhead 108 (see, for example, Figure 17).

[0025] In one or more examples, the tail pressure bulkhead 108 takes the form of a panel, disc, or dome (e.g., a dome shape). Thus, the tail pressure bulkhead 108 is also referred to as the tail pressure bulkhead dome or pressure bulkhead panel. The tail pressure bulkhead is sometimes referred to as "APB" for brevity in this document or the accompanying drawings. Generally, the pressure bulkhead assembly 100 is sized and shaped so that the pressure bulkhead 108 is mounted inside the fuselage 1202 (see, for example, Figure 2) of the aircraft 1200 such that the pressure bulkhead 108 separates the pressurized portion (e.g., pressurized cabin) of the interior 1204 (Figure 2) of the aircraft 1200 from the unpressurized portion of the interior 1204, and the V-splice 102 forms a pressure seal. In one or more examples, the pressure bulkhead assembly 100 is attached to the outer skin 1206 (Figure 2) of the fuselage 1202 via the V-splice 102.

[0026] The tail pressure bulkhead 108 and the crescent splice 102 are formed from any suitable material. In one or more examples, the tail pressure bulkhead 108 and the crescent splice 102 are formed from a composite material. In one or more examples, the tail pressure bulkhead 108 and the crescent splice 102 are formed from a metallic material, a polymer material, another suitable material, or a combination of materials. The material of the tail pressure bulkhead 108 and the material of the crescent splice 102 may be the same or different.

[0027] Referring here to Figure 2, this figure schematically shows an example of an aircraft 1200 in which a pressure bulkhead assembly 100 is used. The pressure bulkhead assembly 100 separates the pressurized side of the aircraft 1200 from the unpressurized side of the aircraft 1200. A V-shaped splice 102 (Figure 1) is attached to the tail pressure bulkhead 108 (Figure 1) on the pressurized side of the tail pressure bulkhead 108. As an example, the aircraft 1200 includes a fuselage 1202 and wings 1208 attached to the fuselage 1202 and extending outward from the fuselage 1202. The fuselage 1202 includes a plurality of fuselage sections (e.g., barrel sections). The fuselage 1202 (e.g., each fuselage section) has outer skin 1206 connected to the airframe 1210, forming the outside of the aircraft 1200. The pressure bulkhead assembly 100 separates the first fuselage section 1212 (e.g., the pressurized side) from the second fuselage section 1214 (e.g., the unpressurized side) at the tail portion of the fuselage 1202. For example, in Figure 3, arrow 1216 indicates the direction of the nose portion (e.g., the pressurized side) of the aircraft 1200.

[0028] Referring now to Figure 3, this figure schematically shows an example of a portion of a pressure bulkhead assembly 100 attached to the first fuselage section 1212 and the second fuselage section 1214, as seen from inside the fuselage 1202. The V-splice 102 overlaps with the first outer skin portion 1218 of the outer skin 1206 of the first fuselage section 1212 and the second outer skin portion 1220 of the outer skin 1206 of the second fuselage section 1214. The V-splice 102 is attached to the first outer skin portion 1218 and the second outer skin portion 1220 (for example, by being fastened with multiple fasteners). In this configuration, the V-splice 102 joins the tail pressure bulkhead 108, the first fuselage section 1212, and the second fuselage section 1214 to each other. Therefore, the V-splice 102 is also referred to as an outer skin V-splice.

[0029] For example, the pressure bulkhead assembly 100 is attached to the second fuselage section 1214 during the manufacture of the aircraft 1200 by securing the crescent splice 102 to the second skin section 1220. The first fuselage section 1212 is then positioned adjacent to the second fuselage section 1214 such that the crescent splice 102 overlaps with the first skin section 1218. The pressure bulkhead assembly 100 is attached to the first fuselage section 1212 by securing the crescent splice 102 to the first skin section 1218. The optimal shape 136 (Figure 1) of the periphery splice surface 106 formed by the multiple crescent splices 102 roughly complements the barrel (e.g., circular) shape of the skin 1206 of the first and second fuselage sections 1212 and 1214. Therefore, the V-shaped splice 102 is positioned on the pressurized side of the tail pressure bulkhead 108 and is configured to form a pressure seal of the fuselage 1202 (Figure 2) between the first fuselage section 1212 (e.g., the pressurized section) and the second fuselage section 1214 (e.g., the non-pressurized section).

[0030] In one or more examples, if there is a gap between the crescent splice 102 and the first outer panel portion 1218 and / or the second outer panel portion 1220, one or more splice-to-outer panel shims (not shown in Figure 3) are positioned between the periphery splice surface 106 of the crescent splice 102 and the outer panel 1206, for example, in an area where the periphery splice surface 106 is not in contact with the outer panel 1206 of the first fuselage section 1212 and / or the second fuselage section 1214 (for example, the optimal shape 136 (Figure 1) of the periphery splice surface 106 does not match the barrel shape of the first fuselage section 1212 and / or the second fuselage section 1214).

[0031] Referring now to Figure 4, this figure shows an example of Method 1000. In one or more examples, Method 1000 includes the step of fabricating or forming a tail pressure bulkhead 108 (block 1002). In one or more examples, Method 1000 includes the step of drilling a tail pressure bulkhead hole 114 through the tail pressure bulkhead 108 (block 1004).

[0032] Referring here to Figures 6 and 7, these drawings schematically show examples of portions of the first bulkhead surface 138 and the second bulkhead surface 140 of the tail pressure bulkhead 108, respectively. In one or more examples, the tail pressure bulkhead 108 is first manufactured (or otherwise manufactured) with a plurality of tail pressure bulkhead holes 114. For example, the tail pressure bulkhead 108 can be mounted on an assembly jig or support tool to drill the tail pressure bulkhead holes 114.

[0033] The tail pressure bulkhead hole 114 is a full-size hole pre-drilled in the tail pressure bulkhead 108 and configured to receive a corresponding fastener 134 (see, for example, Figure 17). Therefore, the tail pressure bulkhead hole 114 is also referred to as a pre-drilled full-size hole or a tail pressure bulkhead fastener hole. The tail pressure bulkhead hole 114 is drilled at a predetermined location in the tail pressure bulkhead 108. Each predetermined location of the tail pressure bulkhead hole 114 refers to the actual (e.g., physical, real-world) predetermined location of the tail pressure bulkhead hole 114 drilled in the tail pressure bulkhead 108.

[0034] In one or more examples, the tail pressure bulkhead 108 includes a first bulkhead surface 138 (see, for example, Figure 6) and a second bulkhead surface 140 (see, for example, Figure 7) opposite the first bulkhead surface 138. The tail pressure bulkhead 108 also has a thickness 142 (Figure 6) defined between the first bulkhead surface 138 and the second bulkhead surface 140.

[0035] In one or more examples, the first bulkhead surface 138 is or forms the outer mold line (OML) of the tail pressure bulkhead 108, and the second bulkhead surface 140 is or forms the inner mold line (IML) of the tail pressure bulkhead 108. Thus, the first bulkhead surface 138 is also referred to as the outer surface, and the second bulkhead surface 140 is also referred to as the inner surface. When the pressure bulkhead assembly 100 is installed inside the fuselage 1202 of the aircraft 1200 (see Figure 3), the first bulkhead surface 138 is on the non-pressurized side of the tail pressure bulkhead 108, and the second bulkhead surface 140 is on the pressurized side of the tail pressure bulkhead 108.

[0036] The second bulkhead surface 140 includes a bulkhead interface 126 (e.g., a tail pressure bulkhead interface) (for example, a portion of the second bulkhead surface 140 forms the bulkhead interface 126). The bulkhead interface 126 is located adjacent to the periphery of the tail pressure bulkhead 108 and extends along an approximately circular path. The bulkhead interface 126 is configured to engage with the crescent splice 102 when the crescent splice 102 is attached to the tail pressure bulkhead 108. In other words, the bulkhead interface 126 acts as a faying surface that contacts the crescent splice 102 at the joint between the crescent splice 102 and the tail pressure bulkhead 108 during the assembly of the pressure bulkhead assembly 100 (Figure 1).

[0037] The tail pressure bulkhead hole 114 is drilled through the thickness 142 of the tail pressure bulkhead 108 (for example, extending between the first bulkhead surface 138 and the second bulkhead surface 140). Due to the predetermined position of the tail pressure bulkhead hole 114, it is positioned through the bulkhead interface 126 along an approximately circular path, for example, proximal to the periphery of the tail pressure bulkhead 108 (for example, on or near the periphery of the tail pressure bulkhead 108).

[0038] For clarity, Figures 6 and 7 show only a portion of the tail pressure bulkhead hole 114 (for example, the tail pressure bulkhead hole 114 in one section of the tail pressure bulkhead 108). Although not explicitly shown in Figures 6 and 7, it should be understood that the tail pressure bulkhead hole 114 extends along the entire tail pressure bulkhead 108 (see, for example, Figure 1).

[0039] Referring again to Figure 4, in one or more examples, method 1000 includes a step (block 1006) of producing a crescent splice 102 (Figures 8 and 9). The crescent splice 102 is first produced (or otherwise manufactured) without having multiple holes (e.g., pre-drilled full-size holes).

[0040] Referring now to Figures 8 and 9, these drawings schematically show examples of a first and second crest splice surface 144 and a second crest splice surface 146 of a crest splice 102, respectively, to the tail pressure bulkhead 108. The crest splice 102 shown in Figures 8 and 9 represents one of several crest splices 102.

[0041] In one or more examples, the crescent splice 102 includes a first crescent splice surface 144 (see, for example, Figure 8) and a second crescent splice surface 146 (see, for example, Figure 9) opposite the first crescent splice surface 144. The crescent splice 102 also has a defined thickness between the first crescent splice surface 144 and the second crescent splice surface 146.

[0042] In one or more examples, the first crest splice surface 144 is or forms the outer mold line (OML) of the crest splice 102, and the second crest splice surface 146 is or forms the inner mold line (IML) of the crest splice. Thus, the first crest splice surface 144 is also referred to as the outer surface, and the second crest splice surface 146 is also referred to as the inner surface. When the pressure bulkhead assembly 100 is installed inside the fuselage 1202 of the aircraft 1200 (see, for example, Figure 3), the first crest splice surface 144 generally faces radially outward, and the second crest splice surface 146 generally faces radially inward.

[0043] In one or more examples, the crescent splice 102 includes a flange 148. The flange 148 includes a flange surface 130 (e.g., a crescent splice interface) (e.g., a portion of the first crescent splice surface 144 forms the flange surface 130). The flange surface 130 is configured to engage with the bulkhead interface 126 of the tail pressure bulkhead 108 when the crescent splice 102 is attached to the tail pressure bulkhead 108. In other words, the flange surface 130 acts as a joint surface that contacts the bulkhead interface 126 at the joint between the crescent splice 102 and the tail pressure bulkhead 108 during the assembly of the pressure bulkhead assembly 100 (Figure 1).

[0044] In one or more examples, the crescent splice 102 includes an outer plate splice 150 extending from the flange 148 at an oblique angle. The outer plate splice 150 includes a splice surface 104 (for example, a portion of the first crescent splice surface 144 forms the splice surface 104). The splice surface 104 forms an arc-shaped segment of the periphery splice surface 106 (see Figure 1).

[0045] The crescent splice 102 includes a pair of engaging edges 118 on both sides (for example, identified as the first engaging edge 118a and the second engaging edge 118b in Figures 1, 8, and 9). When the crescent splice 102 is attached to the tail pressure bulkhead 108, one of the engaging edges 118 of the crescent splice 102 (e.g., the first engaging edge 118a) abuts against one of the engaging edges 118 of the directly adjacent crescent splice 102 (e.g., the second engaging edge 118b) (see, for example, Figure 1).

[0046] In one or more examples, the crescent splice 102 is manufactured with a pilot hole 152, which is drilled through the outer plate splice 150. The pilot hole 152 is drilled in a location that roughly corresponds to where a full-size hole will be drilled through the outer plate splice 150, the first outer plate portion 1218, and the second outer plate portion 1220 (see, for example, Figure 3) of the crescent splice 102 when the pressure bulkhead assembly 100 is attached to the fuselage 1202.

[0047] Referring again to Figure 4, in one or more examples, method 1000 includes a step (block 1008) of measuring the tail pressure bulkhead 108. In one or more examples, the step (block 1008) of measuring the tail pressure bulkhead 108 provides (e.g., generates) 3D measurement data representing the three-dimensional (3D) geometry of the tail pressure bulkhead 108.

[0048] In one or more examples, the step of measuring the tail pressure bulkhead 108 (block 1008) includes the steps of measuring the bulkhead interface 126 and measuring the tail pressure bulkhead hole 114. It may also be recognized that the whole or other parts of the tail pressure bulkhead 108 (e.g., the entire first bulkhead surface 138, the entire second bulkhead surface 140, and / or the periphery of the tail pressure bulkhead 108) may be measured.

[0049] In one or more examples, method 1000 includes the step (block 1010) of measuring each of the chevron splices 102 (e.g., each of the chevron splices 102). In one or more examples, the step (block 1010) of measuring the chevron splices 102 provides (e.g., generates) 3D measurement data representing the 3D geometric shape of each of the chevron splices 102.

[0050] In one or more examples, the step of measuring the crescent splice 102 (block 1010) includes measuring the first crescent splice surface 144 of the crescent splice 102 (e.g., each of the crescent splices 102) (e.g., measuring the flange surface 130 and measuring the splice surface 104). In one or more examples, the step of measuring the crescent splice 102 (block 1010) includes measuring the pilot hole 152. It may also be recognized that the whole or other parts of the crescent splice 102 (e.g., the whole first crescent splice surface 144, the whole second crescent splice surface 146, and / or the pair of engaging edges 118) may also be measured.

[0051] In one or more examples, method 1000 includes a step (block 1012) of generating a plurality of chevron splice scan images 120 (see, for example, Figure 5). In one or more examples, the chevron splice scan images 120 are generated using 3D measurement data acquired in a measurement step (e.g., block 1010). Thus, the chevron splice scan images 120 are a virtual model or 3D digital representation of the chevron splice 102 (e.g., the surface of the chevron splice 102 (e.g., a 3D surface profile), and optionally, other geometric features of the chevron splice 102). Each of the chevron splice scan images 120 represents one of the corresponding chevron splices 102 (e.g., a 3D digital representation of such corresponding chevron splice 102).

[0052] In one or more examples, the chevron splice scan image 120 represents at least a portion of the first chevron splice surface 144 (Figure 8). Optionally, the chevron splice scan image 120 represents at least a portion of the second chevron splice surface 146 of the chevron splice 102. In one or more examples, the chevron splice scan image 120 includes a splice surface scan image 158 (see, for example, Figures 10-14) representing the splice surface 104 (Figure 8). In one or more examples, the chevron splice scan image 120 includes a flange surface scan image 162 (see, for example, Figures 11, 12, and 14) representing the flange surface 130 (Figure 8). In one or more examples, the chevron splice scan image 120 includes an engagement edge scan image 160 (see, for example, Figures 11, 12, and 14) representing the engagement edge 118 (Figures 8 and 9) of the chevron splice 102. In one or more examples, the chevron splice scan image 120 includes a pilot hole scan image 164 (see, for example, Figures 11 and 14) representing the pilot hole 152 of the chevron splice 102.

[0053] In one or more examples, Method 1000 includes a step (block 1014) of aligning (e.g., virtually aligning) a chevron splice scan image 120 with a nominal model 122 (Figure 5) of a pressure bulkhead assembly 100. The nominal model 122 is a 3D design model (e.g., a computer-aided design (CAD) model) that represents a pressure bulkhead assembly 100 having a periphery splice surface 106 of a nominal shape (e.g., a design shape). The step (block 1014) of aligning the chevron splice scan images 120 with the nominal model 122 places a plurality of chevron splice scan images 120 in an initial position. In this initial position, the chevron splice scan images 120 are positioned adjacent to each other, and the plurality of splice surface scan images 158 of the chevron splice scan images 120 represent a periphery splice surface 106 (see, for example, Figures 10 and 11) having an initial shape 154.

[0054] Therefore, the initial position of the ridged splice scan image 120 is the position of the ridged splice scan image 120 after it has been aligned with the nominal model 122. The initial shape 154 of the periphery direction splice surface 106 is the shape of the periphery direction splice surface 106 represented by multiple splice surface scan images 158 after it has been aligned with the ridged splice scan image 120 with the nominal model 122.

[0055] In this disclosure, the "position" of the vertex splice 102 or the vertex splice scan image 120 (e.g., initial position, adjusted position, optimal position, etc.) refers to the location of the vertex splice 102 or the vertex splice scan image 120 in three-dimensional space (e.g., with respect to a three-dimensional coordinate system) (e.g., along the X, Y, and Z axes) and the angular orientation (e.g., around the X, Y, and X axes).

[0056] In one or more examples, the step of aligning the chevron splice scan image 120 with the nominal model 122 (block 1014) includes the step of performing a best fit between each of the multiple chevron splice scan images 120 and the nominal model 122. For example, alignment parameters are calculated by performing an optimized best fit between multiple points in the chevron splice scan image 120 and a portion of the nominal model 122 representing the chevron splice 102 of the pressure bulkhead assembly 100.

[0057] In one or more examples, Method 1000 includes a step (block 1016) in which the vertex splice scan image 120 is aligned with the nominal model 122 (block 1014) (for example, during the best fit), in which each degree of freedom of the vertex splice scan image 120 relative to the nominal model 122 is limited to a predetermined tolerance. This predetermined tolerance limits the magnitude of the motion of the vertex splice scan image 120 relative to the nominal model 122 (e.g., linear motion along the X, Y, and Z axes, and / or angular motion about the X, Y, and Z axes) during the best fit analysis. In one or more examples, the features of the vertex splice 102 represented by the vertex splice scan image 120 are used to limit the degrees of freedom. For example, the motion (e.g., linear motion and / or angular motion) of the pilot hole scan image 164 of the chevron splice scan image 120 is limited to predetermined linear and / or angular dimensions with respect to a specific coordinate system shared by the chevron splice scan image 120 and the nominal model 122.

[0058] Referring here to Figures 10 and 11, these figures schematically show an example of multiple chevron splice scan images 120 positioned (e.g., virtually positioned) in their initial locations after the step (block 1014) of aligning the chevron splice scan image 120 with the nominal model 122 (Figure 5) of the pressure bulkhead assembly 100. With the chevron splice scan images 120 in their initial positions, each engagement edge scan image 160 of the chevron splice scan image 120 is in direct contact with the engagement edge scan image 160 of the adjacent chevron splice scan image 120. The splice surface scan image 158 (e.g., 3D surface profile) representing the splice surface 104 of the chevron splice scan image 120 forms a virtual representation of the periphery direction splice surface 106 having the initial shape 154.

[0059] Referring again to Figure 4, in one or more examples, method 1000 includes the step (block 1018) of determining a step dimension 116 (see, for example, Figure 12) between each engagement edge scan image 160 of a chevron splice scan image 120 and the engagement edge scan image 160 of a directly adjacent chevron splice scan image 120. The step dimension 116 is determined using the chevron splice scan image 120 in its initial position.

[0060] Referring now to Figure 12, this figure schematically shows an example of a portion of multiple chevron splice scan images 120 initially positioned adjacent to each other. As shown in Figure 12, when the chevron splice scan images 120 are fitted to the nominal model 122 (e.g., in their initial positions), a step may occur between adjacent splice surface scan images 158 of the chevron splice scan images 120. The offset distance (e.g., step) between directly adjacent splice surface scan images 158 of the chevron splice scan images 120 is defined (e.g., calculated) by the step dimension 116 between the abutting engagement edge scan images 160 of the directly adjacent chevron splice scan images 120. For example, in the initial position, the first engagement edge scan image 160a of the first vertex splice scan image 120a is offset relative to the second engagement edge scan image 160b of the second vertex splice scan image 120b, which is directly adjacent to the first vertex splice scan image 120a. The second engagement edge scan image 160b of the first vertex splice scan image 120a is offset relative to the first engagement edge scan image 160a of the third vertex splice scan image 120c, which is directly adjacent to the first vertex splice scan image 120a on the opposite side of the second vertex splice scan image 120b.

[0061] Therefore, if the crescent splice 102 is joined to the tail pressure bulkhead 108 in its initial position, such a step will create one or more disconnections between the directly adjacent splice surfaces 104 of the crescent splice 102 along the periphery splice surface 106 (see, for example, Figures 10 to 12). Such a step can be problematic when installing the pressure bulkhead assembly 100 into the fuselage 1202 of the aircraft 1200. For example, the initial shape 154 of the periphery splice surface 106 may not engage favorably with the surface of the fuselage 1202's outer skin 1206. For example, a splice-to-skin shim (not shown) positioned between the periphery splice surface 106 formed by the crescent splice 102 and the outer skin 1206 typically extends across two or more splice surfaces 104 of the crescent splice 102. Therefore, the presence of such a step can make it difficult to manufacture a splice-to-outer plate shim for suitably filling the gap between the V-shaped splice 102 and the outer plate 1206.

[0062] Referring again to Figure 4, in one or more examples, method 1000 includes the steps of determining the angular displacement of each of the vertex splice scan images 120 to minimize the step dimension 116 (block 1020), and adjusting (repositioning) each of the vertex splice scan images 120 by its angular displacement (block 1022). By adjusting the vertex splice scan images 120 by their angular displacement, multiple vertex splice scan images 120 are moved from their initial position to an optimal position.

[0063] The displacement angle of each chevron splice scan image 120 that minimizes the step dimension 116 is used to determine the optimal position of the chevron splice scan image 120, and consequently, the optimal position of the chevron splice 102 when joined with the tail pressure bulkhead 108 to form the pressure bulkhead assembly 100. In one or more examples, the method 1000 includes a step (block 1024) of determining the optimal position of a plurality of chevron splices 102 such that the plurality of splice surfaces 104 of the plurality of chevron splices 102 form a periphery direction splice surface 106 having an optimal shape 136 (see, for example, Figures 13 and 14). The step (block 1024) of determining the optimal position of the chevron splice 102 is achieved by adjusting the chevron splice scan images 120 according to the displacement angles between directly adjacent chevron splice scan images 120 to minimize the step dimension 116.

[0064] Therefore, the optimal position of the vertex splice 102 is represented by the optimal position of the vertex splice scan image 120. The optimal position of the vertex splice scan image 120 is the position of the vertex splice scan image 120 where the step dimension 116 is minimized. The optimal positions of multiple vertex splices 102 are the positions of each vertex splice 102 where the step dimension 116 is minimized and the optimal shape 136 of the periphery direction splice surface 106 formed by the splice surface 104 of the vertex splice 102 is realized. The optimal shape 136 of the periphery direction splice surface 106 is the shape of the periphery direction splice surface 106 after optimizing the position of the vertex splice scan image 120 and minimizing the step difference between the vertex splice scan images 120 (see, for example, Figures 13 and 14).

[0065] Referring again to Figure 12, in one or more examples, the displacement angle of the chevron splice scan image 120 represents the angle of rotation performed on the chevron splice scan image 120 around the rotation axis 156, which is necessary to minimize the step dimension 116 between the chevron splice scan image 120 and the chevron splice scan image 120 directly adjacent to it. For example, as shown in Figure 12, the first vertex splice scan image 120a is adjusted by axial rotation of the first vertex splice scan image 120a around the rotation axis 156 according to the displacement angle (for example, the angle is repositioned) in order to (1) minimize the step dimension 116 between the first engagement edge scan image 160a of the first vertex splice scan image 120a and the second engagement edge scan image 160b of the second vertex splice scan image 120b and (2) minimize the step dimension 116 between the second engagement edge scan image 160b of the first vertex splice scan image 120a and the first engagement edge scan image 160a of the third vertex splice scan image 120c.

[0066] Next, each of the remaining splice scan images 120 is rotated around the rotation axis 156 according to its corresponding displacement angle, minimizing the step dimension 116 between each splice scan image 120 and its directly adjacent one. In other words, the displacement angle of each splice scan image 120 is determined to "split the difference" between the engagement edge scan images 160 on either side of each splice scan image 120 and the corresponding engagement edge scan images 160 of the pair of splice scan images 120 directly adjacent to them (for example, two adjacent splice scan images 120).

[0067] In one or more examples, the step of adjusting each of the vertex splice scan images 120 (e.g., repositioning the angle by axial rotation) is performed sequentially along the periphery splice surface 106. For example, after the first vertex splice scan image 120a has been adjusted (e.g., its angle has been repositioned), the second vertex splice scan image 120b is adjusted to minimize the step dimension 116 of the second vertex splice scan image 120b. Then, on the opposite side of the first vertex splice scan image 120a, a vertex splice scan image 120 directly adjacent to the second vertex splice scan image 120b is adjusted to minimize its step dimension 116 (e.g., its angle has been repositioned). This process is repeated for each subsequent ridge-shaped splice scan image 120 along a circular path corresponding to the periphery splice surface 106 until the third ridge-shaped splice scan image 120c is adjusted (for example, the angle is repositioned) to minimize its step dimension 116.

[0068] Referring again to Figure 4, in one or more examples, Method 1000 includes the steps of determining a step dimension 116 (block 1018), determining the displacement angle of each of the multiple chevron splices 102 (block 1020), and adjusting each of the chevron splice scan images 120 by its displacement angle (block 1022), which are repeated sequentially until the step dimension 116 between each chevron splice scan image 120 and its adjacent (e.g., directly adjacent) chevron splice scan image 120 falls below a predetermined threshold. By iteratively repeating the optimization steps described above for each chevron splice scan image 120, the position of each chevron splice scan image 120 is further optimized so that the shape of the periphery splice surface 106 approaches that of a circle.

[0069] The predetermined threshold can be any preferred default value. In one or more examples, the predetermined threshold is the maximum dimensional value within the manufacturing tolerance range of the step difference (e.g., step dimension 116) between adjacent chevron splice scan images 120. In one or more examples, the predetermined threshold is a point beyond which there is no longer a discernible deviation angle that can further minimize the step dimension 116.

[0070] Referring here to Figures 13 and 14, these figures schematically show an example of multiple chevron splice scan images 120 arranged adjacent to each other in an optimal shape after the optimization steps (e.g., blocks 1018, 1020, and 1022). With the chevron splice scan images 120 in their optimal positions, each engagement edge scan image 160 of the chevron splice scan image 120 is in direct contact with the engagement edge scan image 160 of the adjacent chevron splice scan image 120. The splice surface scan image 158 representing the splice surface 104 of the chevron splice scan image 120 forms a virtual representation of the periphery direction splice surface 106 having an optimal shape 136.

[0071] When the vertex splice scan image 120 is in the optimal position, the step difference between the splice surface scan images 158 of adjacent vertex splice scan images 120 is minimized. Therefore, when the vertex splice 102 is joined to the tail pressure bulkhead 108 in the optimal position, this minimized step difference reduces or eliminates the disconnection along the periphery direction splice surface 106 between the splice surfaces 104 of directly adjacent vertex splices 102 (see, for example, Figures 13 and 14). Minimizing such a step difference is advantageous when installing the pressure bulkhead assembly 100 inside the fuselage 1202 of the aircraft 1200. For example, the optimal shape 136 of the periphery direction splice surface 106 engages more favorably with the surface of the outer skin 1206 of the fuselage 1202. In another example, a splice-to-panel shim (not shown) positioned between the periphery splice surface 106 formed by the crescent splice 102 and the outer panel 1206 typically extends across the splice surfaces 104 of two or more crescent splices 102. Therefore, minimizing such a step reduces the difficulty in manufacturing a splice-to-panel shim to suitably fill the gap between the crescent splice 102 and the outer panel 1206.

[0072] Referring again to Example 4, in one or more examples, Method 1000 includes the step (block 1026) of performing a virtual fit between a plurality of optimally positioned crescent splices 102 and a tail pressure bulkhead 108. This virtual fit is substantially a virtual joining of the crescent splices 102 and the tail pressure bulkhead 108 using crescent splice scan images 120 and tail pressure bulkhead scan images 124 (see, for example, Figure 15). For example, the step of performing a virtual fit (block 1026) includes the step of virtually overlapping or aligning the tail pressure bulkhead scan image 124 with the crescent splice scan image 120.

[0073] In one or more examples, method 1000 includes the step of virtually positioning the chevron splice scan image 120 to an optimal position (see, for example, Figures 13 and 14) before performing virtual fitting (block 1026).

[0074] In one or more examples, Method 1000 includes the step (block 1028) of generating a tail pressure bulkhead scan image 124 (see, for example, Figure 15) representing the tail pressure bulkhead 108. In one or more examples, the tail pressure bulkhead scan image 124 is generated using 3D measurement data acquired in the measurement step (e.g., block 1008). Thus, the tail pressure bulkhead scan image 124 is a virtual model or 3D digital representation of the tail pressure bulkhead 108 (e.g., the surface of the tail pressure bulkhead 108 (such as a 3D surface profile), and optionally other geometric features of the tail pressure bulkhead 108).

[0075] For example, the tail pressure bulkhead scan image 124 represents at least a portion of the first bulkhead surface 138 of the tail pressure bulkhead 108 (Figure 8) and at least a portion of the second bulkhead surface 140 (Figure 9). In one or more examples, the tail pressure bulkhead scan image 124 includes a first bulkhead surface scan image 166 representing the first bulkhead surface 138 (see, for example, Figure 15). In one or more examples, the tail pressure bulkhead scan image 124 includes a second bulkhead surface scan image 168 representing the second bulkhead surface 140 (see, for example, Figure 15). In one or more examples, the tail pressure bulkhead scan image 124 includes a bulkhead interface scan image 170 representing the bulkhead interface 126 (Figure 9) (see, for example, Figure 15). In one or more examples, the bulkhead interface scan image 170 forms a portion of the second bulkhead surface scan image 168. In one or more examples, the tail pressure bulkhead scan image 124 includes a tail pressure bulkhead hole scan image (not shown) representing the tail pressure bulkhead hole 114 (Figures 8 and 9) of the tail pressure bulkhead 108.

[0076] In one or more examples, method 1000 includes the step (block 1030) of aligning a tail pressure bulkhead scan image 124 with a nominal model 122 in order to virtually fit the tail pressure bulkhead 108 with the optimally positioned crescent splice 102 (e.g., block 1026). For example, by aligning the tail pressure bulkhead scan image 124 with the nominal model 122, the tail pressure bulkhead scan image 124 and the crescent splice scan image 120, which is optimized for position relative to the nominal model 122, are virtually overlapped.

[0077] In one or more examples, according to Method 1000, the step of aligning the tail pressure bulkhead scan image 124 with the nominal model 122 (block 1030) includes the step of performing a best fit between the tail pressure bulkhead scan image 124 and the nominal model 122. For example, alignment parameters are calculated by performing an optimized best fit between a number of points in the second bulkhead surface scan image 168 and a portion of the nominal model 122 representing the second bulkhead surface 140 of the pressure bulkhead assembly 100.

[0078] In one or more examples, Method 1000 includes a step (block 1032) of determining the crest splice hole position 110 of the crest splice holes 112 (see, for example, Figure 16) to be drilled in each of the crest splices 102, such that the crest splice holes 112 (see, for example, Figures 8 and 9) correspond to pre-drilled tail pressure bulkhead holes 114 in the tail pressure bulkhead 108. The crest splice hole position 110 represents the determined location and orientation of the crest splice holes 112 to be drilled in each of the crest splices 102, such that the crest splice holes 112 are axially aligned with the corresponding tail pressure bulkhead holes 114 when the crest splices 102 are joined to the tail pressure bulkhead 108 in the optimal position. By aligning the V-shaped splice hole 112 with the tail pressure bulkhead hole 114, the V-shaped splice 102, which is in the optimal position, is uniquely positioned relative to the tail pressure bulkhead 108.

[0079] The position 110 of the crescent splice holes 112 is determined based on the measured 3D surface profile of the flange surface 130 of the crescent splice 102, the measured 3D surface profile of the bulkhead interface 126, and the measured position of the tail pressure bulkhead holes 114. In one or more examples, the step of determining the position 110 of the crescent splice holes 112 (block 1032) includes determining the location and orientation of the drilling axis relative to the 3D surface profile of the flange surface 130 so that the drilling axis for drilling each of the crescent splice holes 112 in the crescent splice 102 is coaxial with the central bore axis of the corresponding tail pressure bulkhead holes 114.

[0080] In one or more examples, the 3D surface profile of the flange surface 130 (Figure 8) of the crescent splice 102 joined to the bulkhead interface 126 (Figure 9) of the tail pressure bulkhead 108 is determined by measuring the crescent splice 102 (block 1010) (e.g., measuring the flange surface 130) and is represented by the flange surface scan image 162 of the crescent splice scan image 120 (see, for example, Figure 15). As described above, the crescent splice 102 is initially manufactured without pre-drilled full-size holes (e.g., without multiple crescent splice holes 112), as shown in the examples of Figures 8 and 9.

[0081] In one or more examples, the 3D surface profile of the bulkhead interface 126 (Figure 9) of the tail pressure bulkhead 108 joined to the flange surface 130 (Figure 8) of the chevron splice 102 is determined by measuring the tail pressure bulkhead 108 (e.g., block 1008) (e.g., measuring the bulkhead interface 126 (second bulkhead surface 140, etc.)) and is represented by the bulkhead interface scan image 170 of the tail pressure bulkhead scan image 124 (see, for example, Figure 15). As described above, the tail pressure bulkhead 108 is first manufactured with pre-drilled full-size holes (e.g., with multiple tail pressure bulkhead holes 114), as shown in the examples in Figures 8 and 9.

[0082] In one or more examples, method 1000 includes the step of determining the tail pressure bulkhead hole position 132 of the tail pressure bulkhead hole 114. In one or more examples, the tail pressure bulkhead hole position 132 of the tail pressure bulkhead hole 114 is determined by measuring the tail pressure bulkhead 108 (e.g., block 1008) (e.g., measuring the bulkhead interface 126 and the tail pressure bulkhead hole 114). In one or more examples, the step of determining the tail pressure bulkhead hole position 132 of the tail pressure bulkhead hole 114 includes the step of determining the location and orientation of the tail pressure bulkhead hole 114.

[0083] Referring here to Figures 6 and 7, in one or more examples, the location of each tail pressure bulkhead hole 114 is determined from a measured first location 178 (see, for example, Figure 6) of the first hole center 172 of the tail pressure bulkhead hole 114 formed on the first bulkhead surface 138, and from a measured second location 180 (see, for example, Figure 7) of the second hole center 174 of the tail pressure bulkhead hole 114 formed on the second bulkhead surface 140. For example, the first hole center 172 and the second hole center 174 are measured relative to the origin O in an exemplary three-dimensional Cartesian coordinate system XYZ (e.g., block 1008). For example, the measured first location 178 of the first hole center 172 of the tail pressure bulkhead hole 114 is measured as x1, y1, z1 in the XYZ coordinate system (see, for example, Figure 6), and the measured second location 180 of the second hole center 174 of the tail pressure bulkhead hole 114 is measured as x2, y2, z2 in the XYZ coordinate system (see, for example, Figure 7).

[0084] It can be recognized that the origin O (see, for example, Figures 6 and 7) may be selected for convenience (for example, so as to be on the outer edge of the tail pressure bulkhead 108). Without departing from the scope of this disclosure, in other cases the origin O may be selected to be in a different location, or in other cases the measurements may be performed using a different coordinate system (e.g., polar coordinates or spherical coordinates).

[0085] In one or more examples, the orientation of each tail pressure bulkhead hole 114 is determined from a first measured location 178 of the first hole center 172 and a second measured location 180 of the second hole center 174. Based on the first measured location 178 of the first hole center 172 and the second measured location 180 of the second hole center 174, the measured orientation 182 of the tail pressure bulkhead hole 114 is determined by the angle Θ formed between a plane 176 (see, for example, Figure 6) that encompasses the central bore axis extending through the thickness 142 of the tail pressure bulkhead 108 between the first hole center 172 and the second hole center 174, and a reference plane of the XYZ coordinate system (e.g., the XY plane).

[0086] In one or more examples, the step of determining the position 110 of the crescent splice hole 112 (block 1032) is performed after the step of performing a virtual fit by overlapping the tail pressure bulkhead scan image 124 with the optimally positioned crescent splice scan image 120 (block 1026). For example, the crescent splice scan image 120 is positioned adjacent to each other and determined to the optimal position such that the splice surface scan image 158 forms a virtual representation of the periphery splice surface 106 having the optimal shape 136. To optimize the engagement interface between the bulkhead interface scan image 170 and the flange surface scan image 162, the tail pressure bulkhead scan image 124 may be translated and / or rotated relative to the crescent splice scan image 120. The virtual overlap 184 (e.g., a portion of what is shown in Figure 15) between the tail pressure bulkhead scan image 124 and the chevron splice scan image 120 is determined, and the chevron splice hole position 110 is determined (e.g., calculated) based on the determined tail pressure bulkhead hole position 132 of the tail pressure bulkhead hole 114.

[0087] Referring again to Example 4, in one or more examples, Method 1000 includes the step (block 1034) of drilling a crescent splice hole 112 at each crescent splice hole position 110 of the crescent splice 102.

[0088] Referring now to Figure 16, this figure schematically shows an example of a crescent splice 102 after crescent splice holes 112 have been drilled through flange 148. Each of the crescent splice holes 112 is drilled at the corresponding crescent splice hole position 110, which is determined according to method 1000 (for example, shown by x3, y3, z3 in Figure 16).

[0089] In one or more examples, as shown in Figure 16, additional V-shaped splice holes are drilled through the outer panel splice 150 at appropriate locations to join the outer panel splice 150 to the outer panel 1206 of the fuselage 1202 when the pressure bulkhead assembly 100 is installed inside the fuselage 1202 (for example, as shown in Figure 3). In one or more examples, the additional V-shaped splice holes are full-size holes drilled through the outer panel splice 150 at the location of the pilot hole 152 (see Figures 8 and 9).

[0090] In one or more examples, Method 1000 includes a step (block 1036) of assembling a pressure bulkhead assembly 100. In one or more examples, according to Method 1000, the step (block 1036) of assembling a pressure bulkhead assembly 100 includes a step (block 1038) of joining each of the crescent splices 102 to the tail pressure bulkhead 108 such that the splice surface 104 of the crescent splice 102 forms a periphery direction splice surface 106 of the pressure bulkhead assembly 100 having an optimal shape 136 (see, for example, Figure 1).

[0091] Referring here to Figure 17, this figure schematically shows an example of a portion of a pressure bulkhead assembly 100. In one or more examples, when assembling the pressure bulkhead assembly 100, a gap may exist between the bulkhead interface 126 of the tail pressure bulkhead 108 and one or more flange surfaces 130 of the crescent splice 102. It may be recognized that such a gap may be formed by manufacturing tolerances of the tail pressure bulkhead 108 and the crescent splice 102. A shim 128 is used to fill this gap between the bulkhead interface 126 and the flange surface 130.

[0092] Referring again to Figure 4, in one or more examples, method 1000 includes the step (block 1040) of determining the shim dimensions of a shim 128 to be positioned between the bulkhead interface 126 of the tail pressure bulkhead 108 and the flange surface 130 of a single crescent splice 102.

[0093] In one or more examples, the shim dimensions of shim 128 are determined based on the gap identified in a virtual overlap 184 (Figure 15) of the bulkhead interface scan image 170 and the flange surface scan image 162. In one or more examples, method 1000 includes the step of determining (e.g., detecting or estimating) the gap between the bulkhead interface scan image 170 and the flange surface scan image 162 (which corresponds to the gap formed between the bulkhead interface 126 of the tail pressure bulkhead 108 and the flange surface 130 of the crescent splice 102 when assembling the pressure bulkhead assembly 100).

[0094] Referring to Figure 15, this figure schematically shows an example of a portion of the virtual overlap 184 between the tail pressure bulkhead scan image 124 and the chevron splice scan image 120 (for clarity, only one chevron splice scan image 120 is shown in Figure 15). In one or more examples, when the tail pressure bulkhead scan image 124 and the chevron splice scan image 120 are virtually overlapped, any discrepancy between the bulkhead interface scan image 170 and the flange surface scan image 162 is identified as a gap. If the calculated deviation exceeds the design tolerance, it is identified as a gap requiring filling with shim 128 (see, for example, Figure 17), and this is used to determine the shim dimensions.

[0095] In one or more examples, this misalignment is used to determine the shim outline 186 and 3D shim surface profile 188 of the shim 128 to be used to fill the gap between the partition interface 126 and the flange surface 130. The shim outline 186 and shim surface profile 188 represent the shim dimensions.

[0096] Referring again to Figure 4, in one or more examples, Method 1000 includes the step (block 1042) of manufacturing (e.g., fabricating) a shim 128 used to fill the gap between the tail pressure bulkhead 108 and the crescent splice 102, based on shim dimensions. The shim outline 186 and shim surface profile 188 of the shim 128 (see, for example, Figure 15) are determined based on dimensional data of the deviation between the bulkhead interface scan image 170 and the flange surface scan image 162. The shim outline 186 and shim surface profile 188 represent the length, width, thickness, and surface geometry of the shim 128.

[0097] In one or more examples, the step of manufacturing the shim 128 (block 1042) includes machining the shim 128 from a stock shim (not shown) to have determined shim dimensions (for example, to form a shim outline 186 and a shim surface profile 188). The shim 128 is machined to fill the gap between the tail pressure bulkhead 108 and the crescent splice 102 according to the shim dimensions (see, for example, Figure 17).

[0098] In one or more examples, method 1000 includes the step of determining a plurality of shim hole positions 192 (see, for example, Figure 18) of a plurality of shim holes 190 to be drilled in each of the shims 128. In one or more examples, the shim hole positions 192 of the shim holes 190 are determined based on a virtual overlap 184 (Figure 15) and the determined shim dimensions. For example, the shim hole positions 192 are determined (e.g., calculated) based on the determined tail pressure bulkhead hole position 132 of the tail pressure bulkhead hole 114 and the crescent splice hole position 110 of the crescent splice hole 112, with the virtual overlap 184 of the tail pressure bulkhead scan image 124 and the crescent splice scan image 120 determined.

[0099] In one or more examples, the step of manufacturing the shim 128 (block 1042) includes drilling shim holes 190 through the shim 128 at determined shim hole locations 192. Each of the shim holes 190 is drilled at the corresponding shim hole location 192 (indicated, for example, by y4, z4 in Figure 18).

[0100] In one or more examples, shim holes 190 are drilled in shim 128 before shim 128 is machined to shim dimensions. For example, shim holes 190 are drilled in a stock shim having a roughly flat configuration (e.g., a flat stock shim). In such an example, the shim surface profile 188 is converted to a virtual (e.g., flat or planar) profile corresponding to the flat surface of the stock shim, and the shim hole location 192 is converted to a corresponding virtual location on the stock shim. Shim holes 190 are drilled at the virtual location on the stock shim so that after the stock shim is machined to shim dimensions, the shim holes 190 will be at a suitable shim hole location 192.

[0101] In one or more examples, shim holes 190 are drilled in shim 128 after it has been machined to shim dimensions. In such examples, shim holes 190 are drilled at determined shim hole positions 192 in shim 128.

[0102] Referring here to Figure 18, this figure schematically shows an example of a shim 128. The shim hole position 192 of the shim hole 190 corresponds to the tail pressure bulkhead hole position 132 of the tail pressure bulkhead hole 114 of the tail pressure bulkhead 108, and the crest splice hole position 110 of the crest splice hole 112 of the crest splice 102. The shim hole 190 is positioned between the bulkhead interface 126 and the flange surface 130, so that when the crest splice 102 is joined to the tail pressure bulkhead 108 in the optimal position, it will be axially aligned with the corresponding tail pressure bulkhead hole 114 and the corresponding crest splice hole 112 (see, for example, Figure 17). By filling the gap between the tail pressure bulkhead 108 and the flange 148 with the shim 128, the crest splice 102 is maintained in the optimal position relative to the tail pressure bulkhead 108.

[0103] Referring again to Figure 4, in one or more examples, according to Method 1000, step (block 1036) includes a step (block 1044) of positioning a shim 128 between the bulkhead interface 126 and the flange surface 130 such that the shim hole 190 is axially aligned with the corresponding tail pressure bulkhead hole 114 and the corresponding crest splice hole 112, prior to step (block 1038) of joining the crest splice 102 and the tail pressure bulkhead 108.

[0104] In one or more examples, method 1000 includes the step (block 1046) of moving the tail pressure bulkhead scan image 124 over a plurality of crescent splice scan images 120 such that the shim dimensions of the shim 128 are greater than the minimum manufacturing dimensions. In one or more examples, when the tail pressure bulkhead scan image 124 and the crescent splice scan image 120 are virtually overlapped, the calculated misalignment between the bulkhead interface scan image 170 and the flange surface scan image 162 defines a gap that exceeds the design tolerance but is less than the minimum manufacturing dimensions of the shim 128. In one or more examples, after the step of performing a virtual fit (block 1026), the tail pressure bulkhead scan image 124 is moved away from the crescent splice scan image 120 along the axis circumscribing the periphery splice surface 106, so that the bulkhead interface scan image 170 is moved away from the flange surface scan image 162 until the shim dimensions of the shim 128 are greater than the minimum manufacturing dimensions of the shim 128. In such examples, the crescent splice hole positions 110, the shim hole positions 192, and the shim dimensions are determined after the tail pressure bulkhead scan image 124 has been moved away from the crescent splice scan image 120 (e.g., separated).

[0105] Referring to Figures 1 and 17, in one or more examples, after a crescent splice hole 112 is drilled in the crescent splice 102, each crescent splice 102 is joined to the tail pressure bulkhead 108 so that the crescent splice hole 112 is aligned with the corresponding tail pressure bulkhead hole 114. A fastener 134 (Figure 17) is attached through the aligned tail pressure bulkhead hole 114 of the tail pressure bulkhead 108 and the crescent splice hole 112 of the crescent splice 102 to fix the crescent splice 102 and the tail pressure bulkhead 108 in the optimal position. By drilling the crescent splice hole 112 at the crescent splice hole position 110 as described in this document, the fastener 134 can position the crescent splice 102 in the optimal position. Furthermore, by assembling the pressure bulkhead assembly 100 according to method 1000, the amount of assembly tools required to position and hold the V-shaped splice 102 in place relative to the rear pressure bulkhead 108 during assembly of the pressure bulkhead assembly 100 is reduced, or such assembly tools are eliminated. This advantageously improves cycle time and reduces manufacturing costs.

[0106] In one or more examples, shims 128 are used as needed to fill the gap between the bulkhead interface 126 and the flange surface 130. After the shims 128 are machined to shim dimensions and shim holes 190 are drilled in the shims 128, the crisscross splice 102 and shims 128 are joined to the tail pressure bulkhead 108 so that the shim holes 190 and the crisscross splice holes 112 are aligned with the corresponding holes among the tail pressure bulkhead holes 114 of the tail pressure bulkhead 108. The fastener 134 (Figure 17) is attached through the tail pressure bulkhead hole 114 of the aligned tail pressure bulkhead 108, the shim hole 190 of the shim 128, and the crescent splice hole 112 of the crescent splice 102, and the crescent splice 102 and shim 128 are fixed to the tail pressure bulkhead 108 with the crescent splice 102 in the optimal position.

[0107] Each of the crescent splices 102 is joined to the tail pressure bulkhead 108 at the optimal position as described above, so that the flange surface 130 engages with the corresponding portion (e.g., section) of the bulkhead interface 126 to form a periphery splice surface 106 of the pressure bulkhead assembly 100 having the optimal shape 136 (Figure 1). Shims 128 are used as needed to fill the gap between the flange surface 130 and the bulkhead interface 126. Fasteners 134 are routed through a set of aligned holes to join the tail pressure bulkhead 108 and the crescent splices 102 (and shims 128 as needed) to each other, forming the pressure bulkhead assembly 100. Fasteners 134 can take any desired form (e.g., a permanent fastener).

[0108] Fasteners 134 and shims 128 maintain the optimal shape 136 when the crescent splice 102 is joined to the tail pressure bulkhead 108. The pressure bulkhead assembly 100 may include any number of crescent splices 102 necessary to form the periphery splice surface 106 and to attach the pressure bulkhead assembly 100 to the fuselage 1202. In one example, 32 crescent splices 102 are joined to the tail pressure bulkhead 108 to form the pressure bulkhead assembly 100.

[0109] Referring here to Figure 5, which schematically illustrates an example of system 200. In one or more examples, system 200 is configured to accurately measure the tail pressure bulkhead 108 and the crescent splice 102, process the measurements, and generate, for example, a tail pressure bulkhead scan image 124 and a crescent splice scan image 120. System 200 is also configured to determine the optimal position of the crescent splice 102 from the measurements of the tail pressure bulkhead 108 and the crescent splice 102. System 200 is further configured to determine the crescent splice hole position 110 of the crescent splice hole 112 so that the optimal position of the crescent splice 102 is maintained when the crescent splice 102 is joined to the tail pressure bulkhead 108. In addition, system 200 is configured to machine the crescent splice 102 (for example, by drilling a crescent splice hole 112 in the crescent splice 102). System 200 is further configured to machine shims 128 to match the required tolerances, if necessary.

[0110] In one or more examples, the system 200 includes a measuring machine 202 configured to obtain measurements of the tail pressure bulkhead 108 and a number of crescent splices 102. In one or more examples, the measuring machine 202 is a coordinate measuring machine (CMM).

[0111] In one or more examples, the measuring machine 202 (e.g., CMM) is configured to measure an object in a three-dimensional (3D) coordinate system (this is often compared to a computer-aided design (CAD) model of the object). For example, the measuring machine 202 measures the tail pressure bulkhead 108 and the tail splice 102 in order to drill a tail splice hole 112 in the tail splice 102 (and optionally, to add a shim 128 as needed to fill the gap between the tail pressure bulkhead 108 and the tail splice 102, and to drill a shim hole 190 in the shim 128).

[0112] The measuring machine 202 is any suitable measuring machine. In one or more examples, the measuring machine 202 is a portable coordinate measuring machine. In one or more examples, the measuring machine 202 includes an articulated measuring arm (not shown), such as a ROMER arm machine. For example, the measuring machine 202 includes a robotic arm with six degrees of freedom that operates in 3D space with six or seven joints (i.e., this robotic arm can move forward and backward, up and down and left and right in three-dimensional space, combined with rotations around three vertical axes: roll, yaw, and pitch). The movement along each of the three axes is independent of each other and of rotations around any of these axes, resulting in six degrees of freedom.

[0113] In one or more examples, the measuring machine 202 is configured to acquire measurements of a selected area of ​​the tail pressure bulkhead 108 (e.g., the tail pressure bulkhead hole 114 and the bulkhead interface 126). In one or more examples, the measuring machine 202 is positioned adjacent to the tail pressure bulkhead 108 to be measured so that the articulated measuring arm can acquire measurements of the location and orientation of the tail pressure bulkhead hole 114 and the bulkhead interface 126. In one or more examples, the tail pressure bulkhead 108 is mounted on an assembly jig or support tool for measurement acquisition by the measuring machine 202.

[0114] In one or more examples, the measuring machine 202 is configured to obtain measurements of a selected area of ​​the crescent splice 102 (e.g., the flange surface 130 and the splice surface 104). In one or more examples, the measuring machine 202 is positioned adjacent to the crescent splice 102 to be measured so that the articulated measuring arm can obtain measurements of the flange surface 130 and the splice surface 104. In one or more examples, one or more of the crescent splices 102 may be mounted on an assembly jig or support tool so that the measuring machine 202 can obtain measurements of each of the crescent splices 102.

[0115] It should be recognized that other suitable types of coordinate measuring instruments with sufficient accuracy (such as handheld measuring devices or laser scanners) may also be used to obtain measurements of selected areas of the structures being measured (e.g., the tail pressure bulkhead 108 and the crescent splice 102). Furthermore, it should be recognized that the system 200 may use various coordinate measuring instruments to obtain measurements of the tail pressure bulkhead 108 and the crescent splice 102.

[0116] In one or more examples, system 200 includes computer system 204. In one or more examples, system 200 includes measuring device 220. In one or more examples, measuring device 220 includes or takes the form of spatial-related device. Measuring device 220 includes measuring machine 202 and computer system 204 (such as a controller). Measurements taken by measuring machine 202 are transmitted to computer system 204. Computer system 204 provides an interface for the user to execute a measurement plan, processes the measurements taken by measuring machine 202, and provides the processed measurements to an on-demand emergent manufacturing (ODEM) application 222 in .XML format.

[0117] The computer system 204 includes a processor 210 and memory 206. Memory 206 stores one or more programs 208. In one or more examples, the computer system 204 includes a measurement software platform. The measurement software platform is any preferred type, including a program 208 adapted to acquire and process measurement values. An exemplary measurement software platform (e.g., program 208) is a spatial analyzer program 224. In one or more examples, the computer system 204 includes an optimization software platform. The optimization software platform is any preferred type, including a program 208 adapted to process measurement data and execute an optimization algorithm on such data. An exemplary optimization software platform (e.g., program 208) is a best fit optimizer program 226.

[0118] In one or more examples, the processor 210 is configured to execute program 208 to determine the optimal position of the multiple crescent splices 102 such that the multiple splice surfaces 104 of the multiple crescent splices 102 form a periphery direction splice surface 106 having an optimal shape 136. The processor 210 is configured to execute program 208 to perform a virtual fit between the multiple crescent splices 102 at the optimal position and the tail pressure bulkhead 108. The processor 210 is configured to execute program 208 to determine the crescent splice hole position 110 of the crescent splice hole 112 to be drilled in each of the multiple crescent splices 102 such that the crescent splice hole 112 corresponds to a tail pressure bulkhead hole 114 pre-drilled in the tail pressure bulkhead 108.

[0119] In one or more examples, the processor 210 is configured to run program 208 to generate multiple chevron splice scan images 120 representing multiple splice surfaces 104 from measurements of multiple chevron splices 102 acquired by measuring machine 202. The processor 210 is configured to run program 208 to align the multiple chevron splice scan images 120 with a nominal model 122 representing a pressure bulkhead assembly 100 and position the multiple chevron splice scan images 120 in an initial position (in which the multiple splice surface scan images 158 of the multiple chevron splice scan images 120 represent periphery splice surfaces 106 having an initial shape 154).

[0120] In one or more examples, the processor 210 is configured to run program 208 to determine a step dimension 116 between each engagement edge scan image 160 of the multiple splice scan images 120 and the engagement edge scan image 160 of the directly adjacent splice scan images 120. The processor 210 is configured to run program 208 to determine the displacement angle of each of the multiple splice scan images 120 in order to minimize the step dimension 116. The processor 210 is configured to run program 208 to move the multiple splice scan images 120 to the optimal position by adjusting each of the multiple splice scan images 120 by its displacement angle.

[0121] In one or more examples, the processor 210 is configured to run program 208 to virtually position multiple splice scan images 120 in optimal locations before performing virtual fitting. The processor 210 is configured to run program 208 to generate a tail pressure bulkhead scan image 124 representing the bulkhead interface 126 of the tail pressure bulkhead 108 from measurements of the tail pressure bulkhead 108 acquired by the measuring machine 202. The processor 210 is configured to run program 208 to align the tail pressure bulkhead scan image 124 with the nominal model 122 and to virtually overlap the tail pressure bulkhead scan image 124 with multiple splice scan images 120 in optimal locations.

[0122] In one or more examples, the system 200 includes a computer numerical control (CNC) machine 212 or an equivalent, which is configured to drill crescent splice holes 112 (e.g., Figure 16) at each crescent splice hole position 110 of a plurality of crescent splices 102. For example, each of the crescent splices 102 is fixed to and positioned by a fixed drill.

[0123] In one or more examples, the computer system 204 runs a software application to generate a program for drilling crescent splice holes 112 in crescent splices 102 based on a determined crescent splice hole position 110, which is aligned with a measured crescent splice hole position 132 in the crescent splice hole 114 of the crescent splice 108. In one or more examples, the CNC machine 212 drills crescent splice holes 112 in the crescent splices 102 based on the generated program. In one or more examples, the CNC machine 212 drills crescent splice holes 112 in each of the crescent splices 102 based on the NC program 228.

[0124] In one or more examples, the CNC machine 212 includes a network computer (NC) controller 232 that receives an NC program 228. The system 200 acquires measurements and processes these measurements according to a request document in .XML format. The ODEM application 222 then updates the NC seed model with the data in .XML format and then automatically generates a valid required NC program 230.

[0125] In one or more examples, the system 200 includes an assembly jig 214 configured to restrain the tail pressure bulkhead 108 for joining each of a plurality of crescent splices 102 to the tail pressure bulkhead 108 such that the plurality of splice surfaces 104 form a periphery splice surface 106 having an optimal shape 136.

[0126] In one or more examples, the processor 210 runs program 208 (e.g., spatial analyzer program 224) to facilitate the provision of a user interface for the measuring device 220 to execute a measurement plan, process measurements, and provide the processed measurements to the ODEM application 222, as described in Method 1000. In one or more examples, the processor 210 runs program 208 (e.g., spatial analyzer program 224) to instruct the measuring machine 202 to execute the measurement steps in the process of Method 1000 (e.g., blocks 1008 and 1010).

[0127] In one or more examples, the processor 210 executes the spatial analyzer program 224 to implement process steps for implementing a first measurement model (e.g., a 3D seed model) of the tail pressure bulkhead 108, including a plurality of first measurement points for each of the tail pressure bulkhead holes 114 and for portions of the tail bulkhead interface 126 adjacent to the tail pressure bulkhead holes 114, and a second measurement model (e.g., a 3D seed model) of each of the V-shaped splices 102, including a plurality of second measurement points for a plurality of portions of the flange surface 130. The processor 210 then executes the spatial analyzer program 224 to implement further process steps of method 1000 (e.g., blocks 1012-1020, 1026-1032, and 1040).

[0128] In one or more examples, the center of each first hole 172 (Figure 6) of each tail pressure bulkhead hole 114 along the first bulkhead surface 138 of the tail pressure bulkhead 108 is measured by the measuring machine 202 with respect to the origin O in an exemplary three-dimensional Cartesian coordinate system XYZ (e.g., block 1008). The center of each second hole 174 (Figure 7) of each tail pressure bulkhead hole 114 along the second bulkhead surface 140 of the tail pressure bulkhead 108 is measured by the measuring machine 202 with respect to the origin O in this exemplary three-dimensional Cartesian coordinate system XYZ (e.g., block 1006).

[0129] In one or more examples, the computer system 204 processes the measurements to determine the tail pressure bulkhead hole positions 132 (e.g., relative location and orientation) of the tail pressure bulkhead holes 114. In one or more examples, the computer system 204 processes the measurements to determine the respective tail pressure bulkhead hole positions 132 of the tail pressure bulkhead holes 114 in the tail pressure bulkhead 108.

[0130] In one or more examples, the bulkhead interface 126 of the tail pressure bulkhead 108 is scanned by a measuring machine 202. A computer system 204 generates and stores a three-dimensional (3D) scan image of the tail pressure bulkhead 108 (e.g., tail pressure bulkhead scan image 124). In one or more examples, this 3D scan image generates surface profile data of a 3D point cloud of the tail pressure bulkhead 108.

[0131] In one or more examples, a 3D scan image of the tail pressure bulkhead 108 is compared to a corresponding 3D seed model, or a nominal model of the tail pressure bulkhead 108, or the dimensions as designed in the drawings associated with the tail pressure bulkhead 108, in order to identify the measurement capabilities of the measuring machine 202 performing the 3D scan, to confirm that the measurement process was error-free, to confirm that proper alignment was achieved, and / or to confirm that no discrepancies exist.

[0132] In one or more examples, the flange surface 130 and the splice surface 104 of the crescent splice 102 are scanned by a measuring machine 202. A computer system 204 generates and stores a three-dimensional (3D) scan image of the crescent splice 102 (e.g., crescent splice scan image 120). In one or more examples, this 3D scan image generates surface profile data of a 3D point cloud of the crescent splice 102.

[0133] In one or more examples, a 3D scan image of the chevron splice 102 is compared to a corresponding 3D seed model, or a nominal model of the chevron splice 102, or the dimensions as designed in a drawing associated with the chevron splice 102, in order to identify the measurement capabilities of the measuring machine 202 performing the 3D scan, to confirm that the measurement process was error-free, to confirm that proper alignment was achieved, and / or to confirm that no discrepancies exist.

[0134] In one or more examples, the computer system 204 runs a software application (e.g., a spatial analyzer program 224) to generate a tail pressure bulkhead scan image 124 and a splice scan image 120. For example, the tail pressure bulkhead scan image 124 is generated using 3D scan images (e.g., measurement data and / or 3D cloud surface profile data) of the tail pressure bulkhead hole 114, the tail pressure bulkhead hole position 132, the first bulkhead surface 138, the second bulkhead surface 140, and the bulkhead interface 126. The splice scan image 120 is generated using 3D scan images (e.g., measurement data and / or 3D cloud surface profile data) of the first splice surface 144 and the second splice surface 146.

[0135] In one or more examples, the processor 210 processes the step dimension 116 and displacement angle measurements as described in Method 1000 and executes program 208 (e.g., best fit optimizer program 226) to facilitate the optimization of the periphery splice surface 106. In one or more examples, the processor 210 executes program 208 (e.g., best fit optimizer program 226) to instruct the computer system 204 to execute the process optimization steps (e.g., blocks 1018-1024) of Method 1000.

[0136] One or more examples include the best fit optimizer program 226 performing a position optimization process for each of the splice scan images 120 by rotating and adjusting the angular orientation of each splice scan image 120 according to a determined deviation angle to minimize the step dimension 116 (see, for example, Figure 12) and moving the splice scan images 120 from an initial position (see, for example, Figures 10 and 11) to an optimal position (see, for example, Figures 13 and 14).

[0137] In one or more examples, the spatial analyzer program 224 performs a virtual fit by virtually aligning a tail pressure bulkhead scan image 124 (representing the bulkhead interface 126 of the tail pressure bulkhead 108) with a crescent splice scan image 120 (representing the corresponding flange surface 130 of the crescent splice 102) that is optimally positioned for, for example, a nominal model 122 (for example, generating a virtual overlap 184 shown in Figure 15). Based on the virtual overlap 184 of the tail pressure bulkhead scan image 124 and the optimally positioned crescent splice scan image 120, the spatial analyzer program 224 determines the crescent splice hole positions 110 of the crescent splice holes 112 to be drilled in each of the crescent splices 102 corresponding to the tail pressure bulkhead holes 114 of the tail pressure bulkhead 108.

[0138] Therefore, the position 110 of each crested splice hole 112 determined by the spatial analyzer program 224 provides the location and orientation of the drilling axis for drilling the crested splice hole 112. During the manufacturing (e.g., assembly) of the pressure bulkhead assembly 100 (Figure 1), the crested splice hole 112 is aligned coaxially with the tail pressure bulkhead hole 114 so that the crested splice 102 is positioned in the optimal location.

[0139] In one or more examples, the ODEM application 222, provided with a shareable formatted .XML measurement file and a 3D seed model from the spatial analyzer program 224, generates and activates a network computer (NC) program 228 to generate an effective NC program 230 that enables drilling full-size holes in the chevron splice 102, machining or manufacturing the necessary shims 128, and drilling full-size holes in the shims 128 (e.g., blocks 1034 and 1042). Each hole to be drilled will have an XYZ point to be drilled and an associated plane that determines the orientation of the hole to be drilled. Thus, the system 200 is configured to generate multiple NC programs for drilling chevron splice holes 112 in the chevron splice 102 based on acquired measurements.

[0140] In one or more examples, the spatial analyzer program 224 is adapted (e.g., programmed) to link to a three-dimensional (3D) measurement seed model. For example, the system 200 includes a 3D measurement seed model corresponding to a tail pressure bulkhead 108 and a chevron splice 102 of nominal configuration, including interfaces, nominal-size holes, and surface geometry. For example, for the tail pressure bulkhead 108, the corresponding measurement seed model identifies the first bulkhead surface 138, the second bulkhead surface 140, the bulkhead interface 126, and the tail pressure bulkhead hole 114 (see, e.g., Figures 6-9). For example, for each of the chevron splices 102, the corresponding measurement seed model may identify the flange 148, the outer splice 150, the flange surface 130, and the splice surface 104 (see, e.g., Figures 8 and 9).

[0141] In one or more examples, for each of the selected areas to be measured, the spatial analyzer program 224 operates to guide the measuring machine 202 to perform the necessary measurement and processing steps (e.g., under automatic computer control or operator control), resulting in a coordinate system transformation for each of the tail pressure bulkhead 108 and the chevron splice 102 from the Mount Street CMM coordinate system to a 3D NC seed model in the nominal coordinate system.

[0142] In one or more examples, the system 200 provides the processed measurements to the ODEM application 222 in .XML format. The ODEM application 222, if a shareable formatted .XML measurement file and an NC seed model are provided, generates and activates a network computer program (e.g., NC program 228 or an active NC program 230) for drilling a crescent splice hole 112 (e.g., a full-size hole) in the crescent splice 102, and optionally, for manufacturing a shim 128 as needed (e.g., machining the shim and drilling a full-size hole in the shim). Each hole to be drilled will have an XYZ point and associated plane to be drilled, which determines the location and orientation of the hole to be drilled. The ODEM application 222 further monitors the manufacturing status of the part being drilled or machined.

[0143] In one or more examples, the ODEM application 222 further transmits a network computer program to a server that includes a setup file reflecting acceptable tolerances for drilled holes and shims, as well as quality assurance specifications in accordance with the measurement plan, positioning plan, and mounting plan, along with product specification data.

[0144] In one or more examples, the processor 210 is configured to run a program 208 to determine the shim dimensions of a shim 128 to be positioned between the bulkhead interface 126 and the flange surface 130 of one of the multiple crescent splices 102. The shim 128 is positioned between the bulkhead interface 126 and the flange surface 130 before the rear pressure bulkhead 108 is joined to one of the multiple crescent splices 102.

[0145] In one or more examples, the spatial analyzer program 224 further estimates the gap between the bulkhead interface scan image 170 and the flange surface scan image 162 when the tail pressure bulkhead scan image 124 and the crescent splice scan image 120 are superimposed. The estimated gap represents the gap between the bulkhead interface 126 of the tail pressure bulkhead 108 and the flange surface 130 of the crescent splice 102. The estimated gap is used to determine the use of shims required to fill any gaps between the bulkhead interface 126 and the flange surface 130 during the assembly of the pressure bulkhead assembly 100.

[0146] In one or more examples, the spatial analyzer program 224 minimizes the gap, and therefore the need for shim use, by adjusting the position of the tail pressure bulkhead scan image 124 relative to the chevron splice scan image 120 in virtual overlap and alignment, as described above. This gap minimization step is performed before the step (block 1032) of determining the chevron splice hole position 110 of the chevron splice hole 112.

[0147] In one or more examples, the spatial analyzer program 224 determines a set of (gap-defining) displacements between the bulkhead interface scan image 170 and the corresponding flange surface scan image 162 when overlapping, in order to determine the need for shim use and / or separation, and compares this set of displacements with the design tolerance for displacement in the design 3D profile or nominal 3D profile of the tail pressure bulkhead 108 and the crescent splice 102. The set of displacements between the bulkhead interface scan image 170 and the flange surface scan image 162 includes, for example, dimensional data and 3D surface profile data. The set of displacements that exceeds (e.g., surpasses) the design tolerance determines the engagement surface and profile of the shim 128 that should be positioned between the tail pressure bulkhead 108 and the crescent splice 102.

[0148] In one or more examples, the processor 210 is configured to run program 208 to move the tail pressure bulkhead scan image 124 relative to a plurality of crescent splice scan images 120 such that the shim dimensions of the shim 128 are greater than the minimum manufacturing dimensions. In one or more examples, the spatial analyzer program 224 sizes the gap dimensions by adjusting the position of the tail pressure bulkhead scan image 124 relative to the crescent splice scan images 120 in a virtual overlap and alignment, and thus sizes the shim dimensions so that the shim dimensions match the minimum manufacturing dimensions. This gap sizing is performed before determining the crescent splice hole position 110 of the crescent splice hole 112.

[0149] In one or more examples, the CNC machine 212 is configured to manufacture (e.g., machine) shims 128 based on shim dimensions. The CNC machine 212 is configured to drill shim holes 190 in the shims 128 (e.g., Figure 18). For example, each of the shims 128 is fixed to a fixed drill and positioned.

[0150] In one or more examples, the computer system 204 runs a software application to generate a program for machining the shim 128 according to the determined shim dimensions and drilling shim holes 190 in the shim 128 based on the determined shim hole positions 192, which are aligned with the measured tail pressure bulkhead hole position 132 of the tail pressure bulkhead hole 114 and the determined crest splice hole position 110 of the crest splice hole 112. In one or more examples, the CNC machine 212 machines the shim 128 and drills shim holes 190 in the shim 128 based on the generated program. In one or more examples, the CNC machine 212 drills shim holes 190 in each of the shims 128 based on the NC program 228.

[0151] In one or more examples, a set of .XML measurement files is generated that includes determining the position 110 of the crescent splice hole 112 to be drilled in the crescent splice 102, the shim dimensions of the shim 128 to be machined (e.g., shim outline 186 and shim surface profile 188), and the position 192 of the shim hole 190 to be drilled in the shim 128. In one or more examples, the spatial analyzer program 224 generates a set of .XML files and sends this set of .XML files to the ODEM application 222. The ODEM application 222 then generates a set of NC programs 228 for drilling the crescent splice hole 112 in the crescent splice 102, machining the shim 128 to fill the gap, and drilling the shim hole 190 in the shim 128. After the NC program 228 is activated, the ODEM application 222 transmits a set of valid NC programs 230 to the CNC machine 212 or equivalent. The NC controller 232 receives the valid NC programs 230, and the CNC machine 212, based on the set of valid NC programs 230, drills the crescent splice holes 112 in the crescent splice 102, machines the shim 128, and drills the shim holes 190 in the shim 128.

[0152] Referring here to Figures 2 and 19, the examples of Method 1000, System 200, and Pressure Bulkhead Assembly 100 are related to, or may be used in conjunction with, the aircraft manufacturing and maintenance method 1100 shown in the flowchart of Figure 19 and the aircraft 1200 schematically shown in Figure 2. For example, the aircraft 1200 and / or the aircraft manufacturing and maintenance method 1100 may utilize a pressure bulkhead assembly 100 manufactured according to Method 1000 and / or using System 200 as described in relation to Figures 1 and 3 through 18.

[0153] Referring to Figure 2, an example of aircraft 1200 includes a fuselage 1210, which comprises wings 1208 and a fuselage 1202 having interior 1204. Aircraft 1200 also includes several high-level systems 1222. Examples of high-level systems 1222 include one or more of the propulsion system 1224, electrical system 1226, hydraulic system 1228, and environmental system 1230 (e.g., environmental control system). In other examples, aircraft 1200 may also include any number of other types of systems (e.g., communication systems, flight control systems, guidance systems, weapon systems, etc.).

[0154] Referring to Figure 19, in the pre-manufacturing stage, Method 1100 includes the specification and design of the aircraft 1200 (block 1102) and material procurement (block 1104). In the manufacturing stage of the aircraft 1200, the components and subassemblies of the aircraft 1200 are manufactured (block 1106) and system integration is performed (block 1108). Subsequently, the aircraft 1200 is licensed and delivered (block 1110) and put into operation (block 1112). Periodic maintenance and upkeep (block 1114) includes the modification, reconfiguration, and refurbishment of one or more systems of the aircraft 1200.

[0155] Each process of Method 1100 shown in Figure 19 may be carried out 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.

[0156] The examples of pressure bulkhead assembly 100, system 200, and method 1000 illustrated and described in this book may be used in one or more arbitrary stages of the manufacturing and maintenance method 1100 shown in the flowchart in Figure 19. For example, an execution of the pressure bulkhead assembly 100, system 200, and method 1000 may form part of the manufacturing of components and subassemblies (block 1106) and / or system integration (block 1108). For example, the manufacturing of a pressure bulkhead assembly 100 using system 200 or according to method 1000, or the manufacturing of an aircraft 1200 including the pressure bulkhead assembly 100, may correspond to the manufacturing of components and subassemblies (block 1106). Furthermore, the pressure bulkhead assembly 100 manufactured using system 200 or according to method 1000 may be used in the same way as components or subassemblies prepared during the operation of the aircraft 1200 (block 1112). Furthermore, the pressure bulkhead assembly 100, manufactured using System 200 or according to Method 1000, may be used in system integration (Block 1108) and in authorization and delivery (Block 1110). Similarly, the implementation of the pressure bulkhead assembly 100, manufactured using System 200 or according to Method 1000, may, but are not limited to, use during the operation of the aircraft 1200 (Block 1112) and in maintenance and servicing (Block 1114).

[0157] Furthermore, this disclosure includes embodiments as defined below.

[0158] Article 1. A method (1000) for manufacturing a pressure bulkhead assembly (100), The steps include determining the optimal position of the multiple crescent-shaped splices (102) such that the multiple splice surfaces (104) of the multiple crescent-shaped splices (102) form a periphery-direction splice surface (106) of a pressure bulkhead assembly (100) having an optimal shape (136), The steps include performing a virtual fit between multiple chevron splices (102) in optimal positions and the tail pressure bulkhead (108), The steps include determining the position (110) of the crescent splice holes (112) such that the crescent splice holes (112) to be drilled in each of the multiple crescent splices (102) correspond to the tail pressure bulkhead holes (114) that have been pre-drilled in the tail pressure bulkhead (108), The steps include drilling crescent-shaped splice holes (112) at each crescent-shaped splice hole position (110) of multiple crescent-shaped splices (102), A method (1000) comprising the step of joining each of a plurality of crescent splices (102) to a tail pressure bulkhead (108) such that the plurality of splice surfaces (104) form a periphery splice surface (106) having an optimal shape (136).

[0159] Article 2. The steps include generating multiple vertex splice scan images (120) representing multiple splice surfaces (104), The method according to Clause 1 (1000), further comprising the step of aligning the multiple chevron splice scan images (120) with a nominal model (122) representing a pressure bulkhead assembly (100) in order to position the multiple chevron splice scan images (120) at an initial position, wherein the multiple splice surface scan images (158) of the multiple chevron splice scan images (120) represent a periphery direction splice surface (106) having an initial shape (154).

[0160] Article 3. The method of Clause 2 (1000), wherein the step of aligning a plurality of chevron splice scan images (120) with a nominal model (122) includes performing a best fit between the plurality of chevron splice scan images (120) and the nominal model (122).

[0161] Article 4. The method of Clause 3 (1000), further comprising the step of limiting the degrees of freedom of each of the multiple chevron splice scan images (120) for the nominal model (122) to a predetermined tolerance range while performing best fit.

[0162] Article 5. The steps include determining the step dimension (116) between each engagement edge scan image (160) of multiple chevron splice scan images (120) and the engagement edge scan image (160) of a directly adjacent chevron splice scan image (120), A step of determining the displacement angle of each of the mountain-shaped splice scan images (120) in order to minimize the step dimension (116), The method (1000) of the clause 2, further comprising the step of adjusting each of the multiple vertex splice scan images (120) by its displacement angle in order to move the multiple vertex splice scan images (120) to an optimal position.

[0163] Article 6. The method according to Clause 5 (1000), further comprising the steps of determining a step dimension (116), determining the displacement angle of each of the multiple chevron splice scan images (120), and adjusting each of the multiple chevron splice scan images (120) by its displacement angle, repeated iteratively and sequentially until the step dimension (116) falls below a predetermined threshold.

[0164] Article 7. The method of Clause 5 (1000), further comprising virtually positioning multiple chevron splice scan images (120) in optimal locations before performing virtual fitting.

[0165] Article 8. The steps include generating a tail pressure bulkhead scan image (124) representing the tail pressure bulkhead (108), The method of Clause 5 (1000), further comprising the step of aligning the tail pressure bulkhead scan image (124) with a nominal model (122) in order to virtually overlap the tail pressure bulkhead scan image (124) with a plurality of optimally positioned chevron splice scan images (120).

[0166] Article 9. The method of Clause 8 (1000), wherein the step of aligning a tail pressure bulkhead scan image (124) with a nominal model (122) includes performing a best fit between the tail pressure bulkhead scan image (124) and the nominal model (122).

[0167] Article 10. A step of determining the shim dimensions of a shim (128) to be positioned between the bulkhead interface (126) of the tail pressure bulkhead (108) and the flange surface (130) of one of the multiple crescent splices (102), The steps include manufacturing a shim (128) based on these shim dimensions, The method according to Clause 8 (1000), further comprising the step of positioning a shim (128) between the bulkhead interface (126) and the flange surface (130) before joining one of the multiple chevron splices (102) to the tail pressure bulkhead (108).

[0168] Article 11. The method of Clause 10 (1000), further comprising moving a tail pressure bulkhead scan image (124) relative to a plurality of chevron splice scan images (120) such that the shim dimensions of the shim (128) are greater than the minimum manufacturing dimensions.

[0169] Article 12. A system (200) for manufacturing a pressure bulkhead assembly (100), A measuring machine (202) configured to acquire measurements of the tail pressure bulkhead (108) and multiple chevron splices (102), A computer system (204) having memory (206) storing a program (208) and a processor (210), wherein the processor (210) The optimal positions of the multiple crescent-shaped splices (102) are determined such that the multiple splice surfaces (104) of the multiple crescent-shaped splices (102) form a periphery direction splice surface (106) having an optimal shape (136). A virtual fit is performed between multiple chevron splices (102) in optimal positions and the tail pressure bulkhead (108), and A computer system (204) is configured to execute a program (208) to determine the position (110) of the crescent splice holes (112) such that the crescent splice holes (112) to be drilled in each of the multiple crescent splices (102) correspond to the tail pressure bulkhead holes (114) that are pre-drilled in the tail pressure bulkhead (108). A computer numerical control machine (212) configured to drill crescent splice holes (112) at each crescent splice hole position (110) of multiple crescent splices (102), A system (200) comprising an assembly jig (214) configured to restrain a tail pressure bulkhead (108) for joining each of a plurality of crescent splices (102) to the tail pressure bulkhead (108) such that the plurality of splice surfaces (104) form a periphery splice surface (106) having an optimal shape (136).

[0170] Article 13. The processor (210) Multiple ridged splice scan images (120) representing multiple splice surfaces (104) are generated from the measurements of multiple ridged splices (102) acquired by the measuring machine (202). The system (200) according to Clause 12, further configured to run a program (208) to align a plurality of chevron splice scan images (120) with a nominal model (122) representing a pressure bulkhead assembly (100) to position the plurality of chevron splice scan images (120) in an initial position, wherein at the initial position, a plurality of splice surface scan images (158) of the plurality of chevron splice scan images (120) represent a periphery direction splice surface (106) having an initial shape (154).

[0171] Article 14. The processor (210) The step dimension (116) is determined between each engagement edge scan image (160) of the multiple chevron splice scan images (120) and the engagement edge scan image (160) of the directly adjacent chevron splice scan images (120). To minimize the step dimension (116), the deviation angles of each of the mountain-shaped splice scan images (120) are determined. The system (200) described in Clause 13 is further configured to execute a program (208) to move the multiple vertex splice scan images (120) to an optimal position by adjusting each of the multiple vertex splice scan images (120) by their displacement angle.

[0172] Article 15. The system (200) described in Clause 14, further configured to execute a program (208) to virtually position multiple vertex splice scan images (120) in optimal locations before performing virtual fitting.

[0173] Article 16. The processor (210) From the measurements of the tail pressure bulkhead (108) acquired by the measuring instrument (202), a tail pressure bulkhead scan image (124) representing the bulkhead interface (126) of the tail pressure bulkhead (108) is generated. The system (200) described in Clause 14 is further configured to run a program (208) to align a tail pressure bulkhead scan image (124) with a nominal model (122) and to virtually overlap the tail pressure bulkhead scan image (124) with a plurality of optimally positioned chevron splice scan images (120).

[0174] Article 17. The processor (210) is further configured to execute a program (208) to determine the shim dimensions of a shim (128) to be positioned between the partition interface (126) and one of the flange surfaces (130) of the multiple crescent splices (102). A computer numerically controlled machine (212) is further configured to manufacture a shim (128) based on the shim dimensions. The system (200) described in Clause 15, wherein a shim (128) is positioned between the bulkhead interface (126) and the flange surface (130) before joining one of the multiple chevron splices (102) to the tail pressure bulkhead (108).

[0175] Article 18. The system (200) according to Clause 16 or 17, further configured to run a program (208) to move a tail pressure bulkhead scan image (124) over a plurality of chevron splice scan images (120) such that the shim dimensions of the shims (128) are greater than the minimum manufacturing dimensions.

[0176] Article 19. A pressure bulkhead assembly (100) for an aircraft (1200), A tail pressure bulkhead (108) comprising a bulkhead interface (126) and a tail pressure bulkhead hole (114) pre-drilled through the bulkhead interface (126), It comprises a plurality of V-shaped splices (102) configured to be connected to the tail pressure bulkhead (108), Each of the multiple V-shaped splices (102) A flange surface (130) configured to engage with the partition interface (126), A V-shaped splice hole (112) drilled through the flange surface (130), It comprises a splice surface (104) extending from the flange surface (130), A pressure bulkhead assembly (100) in which a mountain-shaped splice hole (112) is aligned with a tail pressure bulkhead hole (114), and multiple splice surfaces (104) form a periphery direction splice surface (106) having an optimal shape (136).

[0177] Article 20. A pressure bulkhead assembly (100) according to Clause 19, wherein the optimal shape (136) is approximately circular, and in this circular shape, the step dimension (116) between each engaging edge (118) of a plurality of crescent splices (102) and the engaging edge (118) of a directly adjacent crescent splice (102) is minimized.

[0178] Article 21. The position (110) of the crescent-shaped splice hole (112) is, Virtual fitting of multiple chevron splices (102) in optimal positions with the tail pressure bulkhead (108), and The pressure bulkhead assembly (100) described in Clause 20 is determined based on the measured position (132) of the tail pressure bulkhead hole (114).

[0179] Article 22. The pressure bulkhead assembly (100) according to Clause 20 further comprises fasteners (134) inserted through crescent splice holes (112) and tail pressure bulkhead holes (114) to secure a plurality of crescent splices (102) to the tail pressure bulkhead (108).

[0180] Article 23. A pressure bulkhead assembly (100) according to Clause 22, further comprising a shim (128) positioned between one flange surface (130) of a plurality of chevron splices (102) and the bulkhead interface (126) of a tail pressure bulkhead (108).

[0181] The features, advantages, and characteristics described in one example may be combined in any preferred manner in one or more other examples. Those skilled in the art will recognize that the examples described herein may be practiced even without one or more of the specific features or advantages of a particular example. In other examples, further features and advantages that are not present in all examples may be recognized in certain examples. Furthermore, various examples of the pressure bulkhead assembly 100, system 200, and method 1000 have been illustrated and described, and those skilled in the art will also be able to recall modifications by reading this specification. This application includes such modifications and is limited only by the claims.

Claims

1. A method (1000) for manufacturing a pressure bulkhead assembly (100), The steps include determining the optimal position of the multiple crescent-shaped splices (102) such that the multiple splice surfaces (104) of the multiple crescent-shaped splices (102) form a periphery-direction splice surface (106) of the pressure bulkhead assembly (100) having an optimal shape (136), (1024), The steps include (1026) performing a virtual fit between the plurality of V-shaped splices (102) located in the optimal positions and the tail pressure bulkhead (108), Step (1032) of determining the position (110) of the crescent splice holes (112) such that the crescent splice holes (112) to be drilled in each of the plurality of crescent splices (102) correspond to the tail pressure bulkhead holes (114) that have been pre-drilled in the tail pressure bulkhead (108), Step (1034) of drilling the crescent splice hole (112) at the crescent splice hole position (110) of each of the plurality of crescent splices (102), The process includes a step (1038) of joining each of the plurality of crescent-shaped splices (102) to the tail pressure bulkhead (108) such that the plurality of splice surfaces (104) form the periphery direction splice surface (106) having the optimal shape (136), A step (1018) to determine the step dimension (116) between each engagement edge scan image (160) of a plurality of mountain-shaped splice scan images (120) and the engagement edge scan image (160) of a directly adjacent one among the plurality of mountain-shaped splice scan images (120), A step (1020) to determine the displacement angle of each of the mountain-shaped splice scan images (120) in order to minimize the step dimension (116), A method (1000) further comprising the step (1022) of adjusting each of the plurality of ridge-shaped splice scan images (120) by the displacement angle in order to move the plurality of ridge-shaped splice scan images (120) to an optimal position.

2. A method (1000) for manufacturing a pressure bulkhead assembly (100), The steps include determining the optimal position of the multiple crescent-shaped splices (102) such that the multiple splice surfaces (104) of the multiple crescent-shaped splices (102) form a periphery-direction splice surface (106) of the pressure bulkhead assembly (100) having an optimal shape (136), (1024), The steps include (1026) performing a virtual fit between the plurality of V-shaped splices (102) located in the optimal positions and the tail pressure bulkhead (108), Step (1032) of determining the position (110) of the crescent splice holes (112) such that the crescent splice holes (112) to be drilled in each of the plurality of crescent splices (102) correspond to the tail pressure bulkhead holes (114) that have been pre-drilled in the tail pressure bulkhead (108), Step (1034) of drilling the crescent splice hole (112) at the crescent splice hole position (110) of each of the plurality of crescent splices (102), The process includes a step (1038) of joining each of the plurality of crescent-shaped splices (102) to the tail pressure bulkhead (108) such that the plurality of splice surfaces (104) form the periphery direction splice surface (106) having the optimal shape (136), A method (1000) further comprising: the step (1018) of determining a step dimension (116); the step (1020) of determining the displacement angle of each of a plurality of chevron splice scan images (120); and the step (1022) of adjusting each of the plurality of chevron splice scan images (120) by the displacement angle, repeated sequentially until the step dimension (116) falls below a predetermined threshold; and the method (1000) of virtually positioning the plurality of chevron splice scan images (120) at the optimal position before performing the virtual fitting.

3. A method (1000) for manufacturing a pressure bulkhead assembly (100), The steps include determining the optimal position of the multiple crescent-shaped splices (102) such that the multiple splice surfaces (104) of the multiple crescent-shaped splices (102) form a periphery-direction splice surface (106) of the pressure bulkhead assembly (100) having an optimal shape (136), (1024), The steps include (1026) performing a virtual fit between the plurality of V-shaped splices (102) located in the optimal positions and the tail pressure bulkhead (108), Step (1032) of determining the position (110) of the crescent splice holes (112) such that the crescent splice holes (112) to be drilled in each of the plurality of crescent splices (102) correspond to the tail pressure bulkhead holes (114) that have been pre-drilled in the tail pressure bulkhead (108), Step (1034) of drilling the crescent splice hole (112) at the crescent splice hole position (110) of each of the plurality of crescent splices (102), The process includes a step (1038) of joining each of the plurality of crescent-shaped splices (102) to the tail pressure bulkhead (108) such that the plurality of splice surfaces (104) form the periphery direction splice surface (106) having the optimal shape (136), Step (1028) of generating a tail pressure bulkhead scan image (124) representing the tail pressure bulkhead (108), The method further includes the step (1030) of aligning the tail pressure bulkhead scan image (124) with the nominal model (122) in order to virtually overlap the tail pressure bulkhead scan image (124) with the plurality of vertex splice scan images (120) located at the optimal position, A method (1000) comprising the step (1030) of aligning the tail pressure bulkhead scan image (124) with the nominal model (122), wherein the step of performing best fit between the tail pressure bulkhead scan image (124) and the nominal model (122).

4. A method (1000) for manufacturing a pressure bulkhead assembly (100), The steps include determining the optimal position of the multiple crescent-shaped splices (102) such that the multiple splice surfaces (104) of the multiple crescent-shaped splices (102) form a periphery-direction splice surface (106) of the pressure bulkhead assembly (100) having an optimal shape (136), (1024), The steps include (1026) performing a virtual fit between the plurality of V-shaped splices (102) located in the optimal positions and the tail pressure bulkhead (108), Step (1032) of determining the position (110) of the crescent splice holes (112) such that the crescent splice holes (112) to be drilled in each of the plurality of crescent splices (102) correspond to the tail pressure bulkhead holes (114) that have been pre-drilled in the tail pressure bulkhead (108), Step (1034) of drilling the crescent splice hole (112) at the crescent splice hole position (110) of each of the plurality of crescent splices (102), The process includes a step (1038) of joining each of the plurality of crescent-shaped splices (102) to the tail pressure bulkhead (108) such that the plurality of splice surfaces (104) form the periphery direction splice surface (106) having the optimal shape (136), Step (1040) of determining the shim dimensions of a shim (128) to be positioned between the bulkhead interface (126) of the tail pressure bulkhead (108) and the flange surface (130) of one of the plurality of crescent splices (102), The steps include (1042) manufacturing the shim (128) based on the shim dimensions, A method (1000) further comprising the step (1044) of positioning the shim (128) between the bulkhead interface (126) and the flange surface (130) before joining one of the plurality of chevron splices (102) to the tail pressure bulkhead (108).

5. The steps include generating a plurality of vertex-shaped splice scan images (120) representing the plurality of splice surfaces (104) (1012), The method according to any one of claims 1 to 4 (1000), further comprising the step (1014) of aligning the plurality of chevron splice scan images (120) with a nominal model (122) representing the pressure bulkhead assembly (100) in order to position the plurality of chevron splice scan images (120) at an initial position, wherein the aligning step (1014) is such that, at the initial position, a plurality of splice surface scan images (158) of the plurality of chevron splice scan images (120) represent the periphery direction splice surface (106) having an initial shape (154).

6. The method according to any one of claims 1 to 4 (1000), wherein the step (1014) of aligning a plurality of chevron splice scan images (120) with a nominal model (122) includes performing the best fit between the plurality of chevron splice scan images (120) and the nominal model (122), and limiting the degree of freedom of each of the plurality of chevron splice scan images (120) with respect to the nominal model (122) while the best fit is being performed to within a predetermined tolerance range.

7. A system (200) for manufacturing a pressure bulkhead assembly (100), A measuring machine (202) configured to acquire measurements of the tail pressure bulkhead (108) and multiple V-shaped splices (102), A computer system (204) having a memory (206) storing a program (208) and a processor (210), wherein the processor (210) The optimal positions of the plurality of mountain-shaped splices (102) are determined such that the plurality of splice surfaces (104) of the plurality of mountain-shaped splices (102) form a periphery direction splice surface (106) having an optimal shape (136). A virtual fit is performed between the plurality of V-shaped splices (102) located in the optimal position and the tail pressure bulkhead (108), and The program (208) is configured to execute in order to determine the position (110) of the crescent splice holes (112) to be drilled in each of the plurality of crescent splices (102) so that the crescent splice holes (112) to be drilled in each of the plurality of crescent splices (102) correspond to the tail pressure bulkhead holes (114) that have been pre-drilled in the tail pressure bulkhead (108). Computer system (204) and, A computer numerical control machine (212) is configured to drill the crescent splice holes (112) at the respective crescent splice hole positions (110) of the plurality of crescent splices (102), The assembly jig (214) is configured to restrain the tail pressure bulkhead (108) for joining each of the plurality of crescent-shaped splices (102) to the tail pressure bulkhead (108) such that the plurality of splice surfaces (104) form the periphery direction splice surface (106) having the optimal shape (136), The aforementioned processor (210) The step dimension (116) between each engagement edge scan image (160) of the multiple mountain-shaped splice scan images (120) and the engagement edge scan image (160) of the directly adjacent one among the multiple mountain-shaped splice scan images (120) is determined. To minimize the step dimension (116), the deviation angles of each of the mountain-shaped splice scan images (120) are determined, and The system (200) is further configured to execute the program (208) in order to adjust each of the plurality of mountain-shaped splice scan images (120) by the displacement angle and move the plurality of mountain-shaped splice scan images (120) to the optimal position.

8. The aforementioned processor (210) From the measured values ​​of the plurality of splice shapes (102) acquired by the measuring machine (202), a plurality of splice shape scan images (120) representing the plurality of splice surfaces (104) are generated. The system (200) according to claim 7, further configured to run the program (208) to align the plurality of chevron splice scan images (120) with a nominal model (122) representing the pressure bulkhead assembly (100) to position the plurality of chevron splice scan images (120) in an initial position, wherein at the initial position, the plurality of splice surface scan images (158) of the plurality of chevron splice scan images (120) represent the periphery direction splice surface (106) having an initial shape (154).

9. A method (1000) for manufacturing a pressure bulkhead assembly (100), The steps include determining the optimal position of the multiple crescent-shaped splices (102) such that the multiple splice surfaces (104) of the multiple crescent-shaped splices (102) form a periphery-direction splice surface (106) of the pressure bulkhead assembly (100) having an optimal shape (136), (1024), Step (1026) is to perform a virtual fit between the plurality of V-shaped splices (102) located in the optimal position and the tail pressure bulkhead (108), wherein the tail pressure bulkhead (108) is provided with tail pressure bulkhead holes (114) that are pre-drilled in the tail pressure bulkhead (108), Step (1032) is to determine the position (110) of the crescent splice hole (112) to be drilled in each of the multiple crescent splices (102), using the virtual fit and the position of the pre-drilled tail pressure bulkhead hole (114), such that the position (110) of the crescent splice hole (112) corresponds to the respective position of the pre-drilled tail pressure bulkhead hole (114), and Step (1034) of drilling the crescent splice hole (112) at the crescent splice hole position (110) of each of the plurality of crescent splices (102), A method (1000) comprising the step (1038) of joining each of the plurality of crescent splices (102) to the tail pressure bulkhead (108) such that the plurality of splice surfaces (104) form the periphery direction splice surface (106) having the optimal shape (136).

Images