Note: Descriptions are shown in the official language in which they were submitted.
CA 02895735 2015-06-25
CLAMPING FEET FOR AN END EFFECTOR
RELATED PROVISIONAL APPLICATION
This application claims the benefit of U.S. Provisional Patent Application
Serial
No. 62/022,641, filed July 9, 2014, and entitled "Automated Flexible
Manufacturing
System for Building a Fuselage."
BACKGROUND INFORMATION
1. Field:
The present disclosure relates generally to clamps and, in particular, to
clamps
attached to end effectors associated with robotic devices. Still more
particularly, the
present disclosure relates to a method and apparatus for attaching elastomeric
clamping feet to the edges of clamps.
2. Background:
Building a fuselage may include assembling skin panels and a support structure
for the fuselage. The skin panels and support structure may be joined together
to form
a fuselage assembly. For example, without limitation, the skin panels may have
support members, such as frames and stringers, attached to the surface of the
skin
panels that will face the interior of the fuselage assembly. These support
members
may be used to form the support structure for the fuselage assembly. The skin
panels
may be positioned relative to each other and the support members may be tied
together to form this support structure.
Fastening operations may then be performed to join the skin panels and the
support members together to form the fuselage assembly. These fastening
operations
may include, for example, riveting operations, interference-fit bolting
operations, other
types of attachment operations, or some combination thereof. The fuselage
assembly
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may need to be assembled in a manner that meets outer mold line (OML)
requirements and inner mold line (IML) requirements for the fuselage assembly.
With some currently available methods for building a fuselage assembly, the
fastening operations performed to assemble the skin panels and the support
members
together may be performed manually. For example, without limitation, a first
human
operator positioned at an exterior of the fuselage assembly and a second human
operator positioned at an interior of the fuselage assembly may use handheld
tools to
perform these fastening operations. In some cases, this type of manual
fastening
process may be more labor-intensive, time-consuming, ergonomically
challenging, or
expensive than desired. Further, some current assembly methods used to build
fuselages that involve manual fastening processes may not allow fuselages to
be built
in the desired assembly facilities or factories at desired assembly rates or
desired
assembly costs.
Some current assembly methods may use clamps to perform certain types of
fastening processes. For example, without limitation, clamps may be used to
hold two
parts in place relative to each other such that the two parts may be fastened
together.
In some cases, a clamp may be comprised of a material that may have an
undesired
effect on the surface of a part when the clamp is used to apply a clamping
force on the
part. For example, the clamp may be comprised of a material, such as a
metallic
material, that may scratch, mar, bend, or otherwise affect the surface of a
part in an
undesired manner. Consequently, it may be desirable to have a clamp that can
apply
a clamping force to a part without having an undesired effect on the surface
of the
part. Therefore, it would be desirable to have a method and apparatus that
take into
account at least some of the issues discussed above, as well as other possible
issues.
SUMMARY
In one illustrative embodiment, an apparatus may comprise a clamp and a foot
adhesively bonded to an edge of the clamp and having a set of interlocking
features
that form a mechanical interlock with the clamp.
7
In another illustrative embodiment, an apparatus may comprise an interface
between a first element and a second element. The second element may have a
set
of interlocking features that mechanically interlock the second element with
the first
element to form the interface.
.J In another illustrative embodiment, an attachment for an end effector
may
comprise a first element and a second element. The first element may have a
complementary set of interlocking features along an edge of the first element.
The
second element may be adhesively bonded to the first element such that a set
of
interlocking features of the second element mate with the complementary set of
interlocking features along the edge of the first element to form a mechanical
interlock
between the first element and the second element.
In another illustrative embodiment, a method for mating a first element with a
second element may be presented. An edge of the first element may be shaped to
have a complementary set of interlocking features. A second element may be
shaped
to have a set of interlocking features. The set of interlocking features of
the second
element may be interfaced with the complementary set of interlocking features
along
the edge of the first element.
In another illustrative embodiment, a method for attaching a foot to a clamp
may
be presented. An edge of the clamp may be shaped to have a complementary set
of
interlocking features. A mold may be positioned relative to the edge of the
clamp. A
plastic material may be poured in liquid form into the mold such that the
plastic
material contacts the mold and the complementary set of interlocking features.
The
plastic material may be hardened to form the foot having a set of interlocking
features
that are adhesively bonded and mechanically interlocked with the complementary
set
of interlocking features along the edge of the clamp.
According to another embodiment, an apparatus includes a clamp, and a foot
attached to an edge of the clamp and having a set of interlocking features,
each of the
interlocking features having a geometric shape that forms a mechanical
interlock with
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the clamp. The clamp is comprised of a first material and the foot is
comprised of a
second material different from the first material.
In another embodiment, an apparatus comprises an interface between a first
element and a second element in which the second element has a set of
interlocking
features that mechanically interlock the second element with the first element
to form
the interface. Each of the interlocking features has a geometric shape for
forming the
mechanical interlock with the first element.
In another embodiment, an attachment for an end effector comprises a first
element having a complementary set of interlocking features along an edge of
the first
element. The attachment for an end effector further comprises a second element
attached to the first element such that a set of interlocking features of the
second
element mate with the complementary set of interlocking features of the first
element
to form a mechanical interlock between the first element and the second
element.
Each interlocking feature of the set of interlocking features has a geometric
shape.
The first element is comprised of a first material and the second element is
comprised
of a second material different from the first material.
In another embodiment, a method for attaching a foot to a clamp to
manufacture a clamping device involves shaping the foot to have a set of
interlocking
features, each of the interlocking features having a geometric shape for
forming a
mechanical interlock with the clamp. The method further involves shaping an
edge of
the clamp to have a complementary set of interlocking features, and
interfacing the set
of interlocking features of the foot with the complementary set of
interlocking features
along the edge of the clamp. The clamp is comprised of a first material and
the foot is
comprised of a second material different from the first material.
In another embodiment, a method for attaching a foot to a clamp involves
shaping an edge of the clamp to have a complementary set of interlocking
features,
and positioning a mold relative to the edge of the clamp. The method further
involves
pouring a plastic material in liquid form into the mold such that the plastic
material
contacts the mold and the complementary set of interlocking features, and
hardening
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the plastic material to form the foot having a set of interlocking features
that are
adhesively bonded and mechanically interlocked with the complementary set of
interlocking features along the edge of the clamp. Each of the interlocking
features in
the set of interlocking features has a geometric shape for forming a
mechanical
interlock with the clamp. The clamp is comprised of a different material than
the
plastic material.
The features, functions, and advantages can be achieved independently in
various embodiments of the present disclosure or may be combined in yet other
embodiments in which further details can be seen with reference to the
following
description and drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative embodiments, as well as a preferred mode of use, further
objectives
and features thereof, will best be understood by reference to the following
detailed
description of an illustrative embodiment of the present disclosure when read
in
conjunction with the accompanying drawings, wherein:
Figure 1 is an illustration of a manufacturing environment in the form of a
block
diagram in accordance with an illustrative embodiment;
Figure 2 is an illustration of a fuselage assembly in the form of a block
diagram
in accordance with an illustrative embodiment;
Figure 3 is an illustration of a plurality of mobile systems of a flexible
manufacturing system within a manufacturing environment in the form of a block
diagram in accordance with an illustrative embodiment;
Figure 4 is an illustration a plurality of mobile platforms in the form of a
block
diagram in accordance with an illustrative embodiment;
Figure 5 is an illustration of a flow of a number of utilities across a
distributed
utility network in the form of a block diagram in accordance with an
illustrative
embodiment;
Figure 6 is an illustration of an attachment for an end effector for a robotic
device in the form of a block diagram in accordance with an illustrative
embodiment;
Figure 7 is an illustration of an isometric cutaway view of a plurality of
mobile
platforms performing fastening processes within an interior of a fuselage
assembly in a
manufacturing environment in accordance with an illustrative embodiment;
Figure 8 is an illustration of a cross-sectional view of a flexible
manufacturing
system and a fuselage assembly in accordance with an illustrative embodiment;
Figure 9 is an illustration of a side view of robotic device in accordance
with an
illustrative embodiment;
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Figure 10 is an illustration of an isometric view of a clamping device in
accordance with an illustrative embodiment;
Figure 11 is an illustration of an enlarged front view of an interlocking
feature in
accordance with an illustrative embodiment;
Figure 12 is an illustration of a cross-sectional view of an interlocking
feature of
a foot in accordance with an illustrative embodiment;
Figure 13 is an illustration of an isometric view of another attachment in
accordance with an illustrative embodiment;
Figure 14 is an illustration of yet another type of attachment in accordance
with
an illustrative embodiment;
Figure 15 is an illustration of a cross-sectional view of an interlocking
feature in
accordance with an illustrative embodiment;
Figure 16 is an illustration of a clamping device in accordance with an
illustrative embodiment;
Figure 17 is an illustration of a clamping device in accordance with an
illustrative embodiment;
Figure 18 is an illustration of a clamping device in accordance with an
illustrative embodiment;
Figure 19 is an illustration of an enlarged front view of an interlocking
feature in
accordance with an illustrative embodiment;
Figure 20 is an illustration of a cross-sectional view of an interlocking
feature of
a foot in accordance with an illustrative embodiment;
Figure 21 is an illustration of a clamping device in accordance with an
illustrative embodiment;
Figure 22 is an illustration of an enlarged front view of an interlocking
feature in
accordance with an illustrative embodiment;
Figure 23 is an illustration of a clamping device in accordance with an
illustrative embodiment;
Figure 24 is an illustration of a cross-sectional view of a clamping device in
accordance with an illustrative embodiment;
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Figure 25 is an illustration of a cross-sectional view of a clamping device in
accordance with an illustrative embodiment;
Figure 26 is an illustration of a clamping device in accordance with an
illustrative embodiment;
Figure 27 is an illustration of an enlarged front view of an interlocking
feature in
accordance with an illustrative embodiment;
Figure 28 is an illustration of process for interfacing a first element with a
second element in the form of a flowchart in accordance with an illustrative
embodiment;
Figure 29 is an illustration of a process for attaching a foot to a clamp in
the
form of a flowchart in accordance with an illustrative embodiment;
Figure 30 is an illustration of an aircraft manufacturing and service method
in
the form of a block diagram in accordance with an illustrative embodiment; and
Figure 31 is an illustration of an aircraft in the form of a block diagram in
which
an illustrative embodiment may be implemented.
DETAILED DESCRIPTION
The illustrative embodiments recognize and take into account different
considerations. For example, the illustrative embodiments recognize and take
into
account that it may be desirable to automate the process of building a
fuselage
assembly for an aircraft. Automating the process of building a fuselage
assembly for
an aircraft may improve build efficiency, improve build quality, and reduce
costs
associated with building the fuselage assembly. The illustrative embodiments
also
recognize and take into account that automating the process of building a
fuselage
assembly may improve the accuracy and precision with which assembly operations
are performed, thereby ensuring improved compliance with outer mold line (OML)
requirements and inner mold line (IML) requirements for the fuselage assembly.
Further, the illustrative embodiments recognize and take into account that
automating the process used to build a fuselage assembly for an aircraft may
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significantly reduce the amount of time needed for the build cycle. For
example,
without limitation, automating fastening operations may reduce and, in some
cases,
eliminate, the need for human operators to perform these fastening operations
as well
as other types of assembly operations.
Further, this type of automation of the process for building a fuselage
assembly
for an aircraft may be less labor-intensive, time-consuming, ergonomically
challenging,
and expensive than performing this process primarily manually. Reduced manual
labor may have a desired benefit for the human laborer. Additionally,
automating the
fuselage assembly process may allow fuselage assemblies to be built in desired
assembly facilities and factories at desired assembly rates and desired
assembly
costs.
The illustrative embodiments also recognize and take into account that it may
be desirable to use equipment that can be autonomously driven and operated to
automate the process of building a fuselage assembly. In particular, it may be
desirable to have an autonomous flexible manufacturing system comprised of
mobile
systems that may be autonomously driven across a factory floor, autonomously
positioned relative to the factory floor as needed for building the fuselage
assembly,
autonomously operated to build the fuselage assembly, and then autonomously
driven
away when building of the fuselage assembly has been completed.
As used herein, performing any operation, action, or step autonomously may
mean performing that operation substantially without any human input. For
example,
without limitation, a platform that may be autonomously driven is a platform
that may
be driven substantially independently of any human input. In this manner, an
autonomously drivable platform may be a platform that is capable of driving or
being
driven substantially independently of human input.
Thus, the illustrative embodiments provide a method, apparatus, and system for
building a fuselage assembly for an aircraft. In particular, the illustrative
embodiments
provide an autonomous flexible manufacturing system that automates most, if
not all,
of the process of building a fuselage assembly. For example, without
limitation, the
autonomous flexible manufacturing system may automate the process of
installing
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fasteners to join fuselage skin panels and a fuselage support structure
together to
build the fuselage assembly.
However, the illustrative embodiments recognize and take into account that
automating the process for building a fuselage assembly using an autonomous
flexible
manufacturing system may present unique technical challenges that require
unique
technical solutions. For example, the illustrative embodiments recognize and
take into
account that it may be desirable to provide utilities to all of the various
systems within
the autonomous flexible manufacturing system. In particular, it may be
desirable to
provide these utilities in a manner that will not disrupt or delay the process
of building
the fuselage assembly or restrict the movement of various mobile systems
within the
autonomous flexible manufacturing system over a factory floor.
For example, without limitation, it may be desirable to provide a set of
utilities,
such as power, communications, and air, to the autonomous flexible
manufacturing
system using an infrastructure that includes only a single direct connection
to each of
a set of utility sources providing the set of utilities. These direct
connections may be
above-ground, in-ground, or embedded. These direct connections may be
established
using, for example, without limitation, a utility fixture. Thus, the
infrastructure may
include a utility fixture that provides a direct connection to each of the set
of utility
sources and an assembly area with a floor space sufficiently large to allow
the various
systems of an autonomous flexible manufacturing system to be coupled to the
utility
fixture and each other in series. In this manner, the set of utilities may
flow from the
set of utility sources to the utility fixture and then downstream to the
various systems of
the autonomous flexible manufacturing system within the assembly area.
Thus, the illustrative embodiments provide a distributed utility network that
may
be used to provide utilities to the various systems of the autonomous flexible
manufacturing system. The distributed utility network may provide these
utilities in a
manner that does not restrict or impede movement of the various mobile systems
of
the autonomous flexible manufacturing system. The different mobile systems of
the
autonomous flexible manufacturing system may be autonomously coupled to each
other to create this distributed utility network.
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Referring now to the figures and, in particular, with reference to Figures 1-
6,
illustrations of a manufacturing environment are depicted in the form of block
diagrams
in accordance with an illustrative embodiment. In particular, in Figures 1-6,
a fuselage
assembly, a flexible manufacturing system, the various systems within the
flexible
manufacturing system that may be used to build the fuselage assembly, and a
distributed utility network are described.
Turning now to Figure 1, an illustration of a manufacturing environment is
depicted in the form of a block diagram in accordance with an illustrative
embodiment.
In this illustrative example, manufacturing environment 100 may be an example
of one
environment in which at least a portion of fuselage 102 may be manufactured
for
aircraft 104.
Manufacturing environment 100 may take a number of different forms. For
example, without limitation, manufacturing environment 100 may take the form
of a
factory, a manufacturing facility, an outdoor factory area, an enclosed
manufacturing
area, an offshore platform, or some other type of manufacturing environment
100
suitable for building at least a portion of fuselage 102.
Fuselage 102 may be built using manufacturing process 108. Flexible
manufacturing system 106 may be used to implement at least a portion of
manufacturing process 108. In one illustrative example, manufacturing process
108
may be substantially automated using flexible manufacturing system 106. In
other
illustrative examples, only one or more stages of manufacturing process 108
may be
substantially automated.
Flexible manufacturing system 106 may be configured to perform at least a
portion of manufacturing process 108 autonomously.
In this manner, flexible
manufacturing system 106 may be referred to as autonomous flexible
manufacturing
system 112. In other illustrative examples, flexible manufacturing system 106
may be
referred to as an automated flexible manufacturing system.
As depicted, manufacturing process 108 may include assembly process 110 for
building fuselage assembly 114.
Flexible manufacturing system 106 may be
configured to perform at least a portion of assembly process 110 autonomously.
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Fuselage assembly 114 may be fuselage 102 at any stage during
manufacturing process 108 prior to the completion of manufacturing process
108. In
some cases, fuselage assembly 114 may be used to refer to a partially
assembled
fuselage 102. Depending on the implementation, one or more other components
may
need to be attached to fuselage assembly 114 to fully complete the assembly of
fuselage 102. In other cases, fuselage assembly 114 may be used to refer to
the fully
assembled fuselage 102. Flexible manufacturing system 106 may build fuselage
assembly 114 up to the point needed to move fuselage assembly 114 to a next
stage
in the manufacturing process for building aircraft 104. In some cases, at
least a
portion of flexible manufacturing system 106 may be used at one or more later
stages
in the manufacturing process for building aircraft 104.
In one illustrative example, fuselage assembly 114 may be an assembly for
forming a particular section of fuselage 102. As one example, fuselage
assembly 114
may take the form of aft fuselage assembly 116 for forming an aft section of
fuselage
102. In another example, fuselage assembly 114 may take the form of forward
fuselage assembly 117 for forming a forward section of fuselage 102. In yet
another
example, fuselage assembly 114 may take the form of middle fuselage assembly
118
for forming a center section of fuselage 102 or some other middle section of
fuselage
102 between the aft and forward sections of fuselage 102.
As depicted, fuselage assembly 114 may include plurality of panels 120 and
support structure 121. Support structure 121 may be comprised of plurality of
members 122. Plurality of members 122 may be used to both support plurality of
panels 120 and connect plurality of panels 120 to each other. Support
structure 121
may help provide strength, stiffness, and load support for fuselage assembly
114.
Plurality of members 122 may be associated with plurality of panels 120. As
used herein, when one component or structure is "associated" with another
component
or structure, the association is a physical association in the depicted
examples.
For example, a first component, such as one of plurality of members 122, may
be considered to be associated with a second component, such as one of
plurality of
panels 120, by being at least one of secured to the second component, bonded
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CA 02895735 2015-06-25
second component, mounted to the second component, attached to the component,
coupled to the component, welded to the second component, fastened to the
second
component, adhered to the second component, glued to the second component, or
connected to the second component in some other suitable manner. The first
component also may be connected to the second component using one or more
other
components. For example, the first component may be connected to the second
component using a third component. Further, the first component may be
considered
to be associated with the second component by being formed as part of the
second
component, an extension of the second component, or both. In another example,
the
first component may be considered part of the second component by being co-
cured
with the second component.
As used herein, the phrase "at least one of," when used with a list of items,
means different combinations of one or more of the listed items may be used
and only
one of the items in the list may be needed. The item may be a particular
object, thing,
action, process, or category. In other words, "at least one of" means any
combination
of items or number of items may be used from the list, but not all of the
items in the list
may be required.
For example, "at least one of item A, item B, and item C" or "at least one of
item
A, item B, or item C" may mean item A; item A and item B; item B; item A, item
B, and
.. item C; or item B and item C. In some cases, "at least one of item A, item
B, and item
C" may mean, for example, without limitation, two of item A, one of item B,
and ten of
item C; four of item B and seven of item C; or some other suitable
combination.
In these illustrative examples, a member of plurality of members 122 may be
associated with at least one of plurality of panels 120 in a number of
different ways.
For example, without limitation, a member of plurality of members 122 may be
attached directly to a single panel, attached to two or more panels, attached
to another
member that is directly attached to at least one panel, attached to at least
one member
that is directly or indirectly attached to at least one panel, or associated
with at least
one of plurality of panels 120 in some other way.
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In one illustrative example, substantially all or all of plurality of members
122
may be associated with plurality of panels 120 prior to the beginning of
assembly
process 110 for building fuselage assembly 114. For example, a corresponding
portion of plurality of members 122 may be associated with each panel of
plurality of
panels 120 prior to plurality of panels 120 being joined to each other through
assembly
process 110.
In another illustrative example, only a first portion of plurality of members
122
may be associated with plurality of panels 120 prior to the beginning of
assembly
process 110. Assembly process 110 may include attaching a remaining portion of
plurality of members 122 to plurality of panels 120 for at least one of
providing support
to plurality of panels 120 or connecting plurality of panels 120 together. The
first
portion of plurality of members 122 attached to plurality of panels 120 prior
to
assembly process 110 and the remaining portion of plurality of members 122
attached
to plurality of panels 120 during assembly process 110 may together form
support
structure 121.
In yet another illustrative example, all of plurality of members 122 may be
associated with plurality of panels 120 during assembly process 110. For
example,
each of plurality of panels 120 may be "naked" without any members attached to
or
otherwise associated with the panel prior to assembly process 110. During
assembly
process 110, plurality of members 122 may then be associated with plurality of
panels
120.
In this manner, support structure 121 for fuselage assembly 114 may be built
up
in a number of different ways. Fuselage assembly 114 comprising plurality of
panels
120 and support structure 121 is described in greater detail in Figure 2
below.
Building fuselage assembly 114 may include joining plurality of panels 120
together. Joining plurality of panels 120 may be performed in a number of
different
ways. Depending on the implementation, joining plurality of panels 120
together may
include joining one or more of plurality of members 122 to one or more of
plurality of
panels 120 or to other members of plurality of members 122.
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In particular, joining plurality of panels 120 may include joining at least
one
panel to at least one other panel, joining at least one member to at least one
other
member, or joining at least one member to at least one panel, or some
combination
thereof. As one illustrative example, joining a first panel and a second panel
together
may include at least one of the following: fastening the first panel directly
to the second
panel, joining a first member associated with the first panel to a second
member
associated with the second panel, joining a member associated with the first
panel
directly to the second panel, joining one member associated with both the
first panel
and the second panel to another member, joining a selected member to both the
first
panel and the second panel, or some other type of joining operation.
Assembly process 110 may include operations 124 that may be performed to
join plurality of panels 120 together to build fuselage assembly 114. In this
illustrative
example, flexible manufacturing system 106 may be used to perform at least a
portion
of operations 124 autonomously.
Operations 124 may include, for example, but are not limited to, temporary
connection operations 125, drilling operations 126, fastener insertion
operations 128,
fastener installation operations 130, inspection operations 132, other types
of
assembly operations, or some combination thereof. Temporary connection
operations
125 may be performed to temporarily connect plurality of panels 120 together.
For
example, without limitation, temporary connection operations 125 may include
temporarily tacking plurality of panels 120 together using tack fasteners.
Drilling operations 126 may include drilling holes through one or more of
plurality of panels 120 and, in some cases, through one or more of plurality
of
members 122. Fastener insertion operations 128 may include inserting fasteners
into
the holes drilled by drilling operations 126.
Fastener installation operations 130 may include fully installing each of the
fasteners that have been inserted into the holes. Fastener installation
operations 130
may include, for example, without limitation, riveting operations,
interference-fit bolting
operations, other types of fastener installation operations, or some
combination
thereof. Inspection operations 132 may include inspecting the fully installed
fasteners.
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Depending on the implementation, flexible manufacturing system 106 may be used
to
perform any number of these different types of operations 124 substantially
autonomously.
As depicted, flexible manufacturing system 106 may include plurality of mobile
systems 134, control system 136, and utility system 138. Each of plurality of
mobile
systems 134 may be a drivable mobile system. In some cases, each of plurality
of
mobile systems 134 may be an autonomously drivable mobile system. For example,
without limitation, each of plurality of mobile systems 134 may include one or
more
components that may be autonomously driven within manufacturing environment
100
from one location to another location. Plurality of mobile systems 134 are
described in
greater detail in Figure 3 below.
In this illustrative example, control system 136 may be used to control the
operation of flexible manufacturing system 106. For example, without
limitation,
control system 136 may be used to control plurality of mobile systems 134. In
particular, control system 136 may be used to direct the movement of each of
plurality
of mobile systems 134 within manufacturing environment 100. Control system 136
may be at least partially associated with plurality of mobile systems 134.
In one illustrative example, control system 136 may include set of controllers
140. As used herein, a "set of" items may include one or more items. In this
manner,
set of controllers 140 may include one or more controllers.
Each of set of controllers 140 may be implemented using hardware, firmware,
software, or some combination thereof. In one illustrative example, set of
controllers
140 may be associated with plurality of mobile systems 134. For example,
without
limitation, one or more of set of controllers 140 may be implemented as part
of plurality
of mobile systems 134. In other examples, one or more of set of controllers
140 may
be implemented independently of plurality of mobile systems 134.
Set of controllers 140 may generate commands 142 to control the operation of
plurality of mobile systems 134 of flexible manufacturing system 106. Set of
controllers 140 may communicate with plurality of mobile systems 134 using at
least
one of a wireless communications link, a wired communications link, an optical
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communications link, or other type of communications link. In this manner, any
number of different types of communications links may be used for
communication
with and between set of controllers 140.
In these illustrative examples, control system 136 may control the operation
of
plurality of mobile systems 134 using data 141 received from sensor system
133.
Sensor system 133 may be comprised of any number of individual sensor systems,
sensor devices, controllers, other types of components, or combination
thereof. In one
illustrative example, sensor system 133 may include laser tracking system 135
and
radar system 137. Laser tracking system 135 may be comprised of any number of
laser tracking devices, laser targets, or combination thereof. Radar system
137 may
be comprised of any number of radar sensors, radar targets, or combination
thereof.
Sensor system 133 may be used to coordinate the movement and operation of
the various mobile systems in plurality of mobile systems 134 within
manufacturing
environment 100. As one illustrative example, radar system 137 may be used for
macro-positioning mobile systems, systems within mobile systems, components
within
mobile systems, or some combination thereof. Further, laser tracking system
135 may
be used for micro-positioning mobile systems, systems within mobile systems,
components within mobile systems, or some combination thereof.
Plurality of mobile systems 134 may be used to form distributed utility
network
144. Depending on the implementation, one or more of plurality of mobile
systems
134 may form distributed utility network 144. Number of utilities 146 may flow
from
number of utility sources 148 to the various mobile systems of plurality of
mobile
systems 134 that make up distributed utility network 144.
In this illustrative example, each of number of utility sources 148 may be
located with manufacturing environment 100. In other illustrative examples,
one or
more of number of utility sources 148 may be located outside of manufacturing
environment 100. The corresponding utility provided by these one or more
utility
sources may then be carried into manufacturing environment 100 using, for
example,
without limitation, one or more utility cables.
CA 02895735 2015-06-25
In one illustrative example, distributed utility network 144 may allow number
of
utilities 146 to flow directly from number of utility sources 148 to one
mobile system in
plurality of mobile systems 134 over some number of utility cables. This one
mobile
system may then distribute number of utilities 146 to other mobile systems of
plurality
of mobile systems 134 such that these other mobile systems do not need to
directly
receive number of utilities 146 from number of utility sources 148.
As depicted, distributed utility network 144 may be formed using utility
system
138. Utility system 138 may include utility fixture 150. Utility system 138
may be
configured to connect to number of utility sources 148 such that number of
utilities 146
may flow from number of utility sources 148 to utility fixture 150. Utility
fixture 150 may
be above-ground or in-ground, depending on the implementation. For example,
without limitation, utility fixture 150 may be embedded in a floor within
manufacturing
environment 100.
Utility fixture 150 may then distribute number of utilities 146 to one or more
of
plurality of mobile systems 134. In particular, one autonomous coupling of one
of
plurality of mobile systems 134 to utility fixture 150 may be followed by any
number of
autonomous couplings of mobile systems to each other in series to form
distributed
utility network 144. Utility fixture 150 may distribute number of utilities
146 to each of
plurality of mobile systems 134 downstream of utility fixture 150 in the
series of
autonomous couplings of the mobile systems.
Depending on the implementation, distributed utility network 144 may have a
chain-like configuration or a tree-like configuration.
In one illustrative example,
plurality of mobile systems 134 may include mobile systems A, B, C, and D (not
shown
in figure) with mobile system A autonomously coupled to utility fixture 150
and mobile
systems B, C, and D autonomously coupled to mobile system A and each other in
series. An example of a chain-like configuration for distributed utility
network 144 may
include number of utilities 146 flowing from number of utility sources 148
over some
number of utility cables to utility fixture 150, from utility fixture 150 to
mobile system A,
from mobile system A to mobile system B, from mobile system B to mobile system
C,
and from mobile system C to mobile system D. An example of a tree-like
configuration
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for distributed utility network 144 may include number of utilities 146
flowing from
number of utility sources 148 over some number of utility cables to utility
fixture 150,
from utility fixture 150 to mobile system A, from mobile system A to both
mobile
system B and mobile system C, and from mobile system C to mobile system D. An
example of one manner in which distributed utility network 144 may be
implemented
using plurality of mobile systems 134 is described in greater detail in Figure
5 below.
In some illustrative examples, multiple flexible manufacturing systems may be
used to build multiple fuselage assemblies concurrently.
For example, flexible
manufacturing system 106 may be a first flexible manufacturing system of many
flexible manufacturing systems.
In one illustrative example, flexible manufacturing system 106, second
flexible
manufacturing system 152, and third flexible manufacturing system 154 may be
used
to build aft fuselage assembly 116, middle fuselage assembly 118, and forward
fuselage assembly 117, respectively. Aft fuselage assembly 116, middle
fuselage
assembly 118, and forward fuselage assembly 117 may then be joined together to
form a fully assembled fuselage 102. In this manner, in this example, flexible
manufacturing system 106, second flexible manufacturing system 152, and third
flexible manufacturing system 154 may together form flexible fuselage
manufacturing
system 158.
Thus, any number of fuselage assemblies, such as fuselage assembly 114,
may be built within manufacturing environment 100 using any number of flexible
manufacturing systems implemented in a manner similar to flexible
manufacturing
system 106. Similarly, any number of full fuselages, such as fuselage 102, may
be
built within manufacturing environment 100 using any number of flexible
fuselage
manufacturing systems implemented in a manner similar to flexible fuselage
manufacturing system 158.
With reference now to Figure 2, an illustration of fuselage assembly 114 from
Figure 1 is depicted in the form of a block diagram in accordance with an
illustrative
embodiment. As described above, fuselage assembly 114 may include plurality of
panels 120 and support structure 121. Fuselage assembly 114 may be used to
refer
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to any stage in the building of fuselage assembly 114. For example, fuselage
assembly 114 may be used to refer to a single one of plurality of panels 120,
multiple
ones of plurality of panels 120 that have been or are being joined together, a
partially
built fuselage assembly, or a fully built fuselage assembly.
As depicted, fuselage assembly 114 may be built such that fuselage assembly
114 has plurality of fuselage sections 205. Each of plurality of fuselage
sections 205
may include one or more of plurality of panels 120. In this illustrative
example, each of
plurality of fuselage sections 205 may take the form of a cylindrically-shaped
fuselage
section, a barrel-shaped fuselage section, a tapered cylindrical fuselage
section, a
cone-shaped fuselage section, a dome-shaped fuselage section, or a section
having
some other type of shape. Depending on the implementation, a fuselage section
of
plurality of fuselage sections 205 may have a shape that has a substantially
circular
cross-sectional shape, elliptical cross-sectional shape, oval cross-sectional
shape,
polygon with rounded corners cross-sectional shape, or otherwise closed-curve
cross-
sectional shape.
As one specific illustrative example, each of plurality of fuselage sections
205
may be a portion of fuselage assembly 114 defined between two radial cross-
sections
of fuselage assembly 114 that are taken substantially perpendicular to a
center axis or
longitudinal axis through fuselage assembly 114. In this manner, plurality of
fuselage
sections 205 may be arranged along the longitudinal axis of fuselage assembly
114.
In other words, plurality of fuselage sections 205 may be arranged
longitudinally.
Fuselage section 207 may be an example of one of plurality of fuselage
sections 205. Fuselage section 207 may be comprised of one or more of
plurality of
panels 120. In one illustrative example, multiple panel sections may be
arranged
circumferentially around fuselage section 207 to form the skin of fuselage
section 207.
In some cases, multiple rows of two or more longitudinally adjacent panels may
be
arranged circumferentially around fuselage section 207 to form the skin of
fuselage
section 207.
In one illustrative example, fuselage assembly 114 may have crown 200, keel
202, and sides 204. Sides 204 may include first side 206 and second side 208.
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Crown 200 may be the top portion of fuselage assembly 114. Keel 202 may be
the bottom portion of fuselage assembly 114. Sides 204 of fuselage assembly
114
may be the portions of fuselage assembly 114 between crown 200 and keel 202.
In
one illustrative example, each of crown 200, keel 202, first side 206, and
second side
208 of fuselage assembly 114 may be formed by at least a portion of at least
one of
plurality of panels 120. Further, a portion of each of plurality of fuselage
sections 205
may form each of crown 200, keel 202, first side 206, and second side 208.
Panel 216 may be an example of one of plurality of panels 120. Panel 216 may
also be referred to as a skin panel, a fuselage panel, or a fuselage skin
panel,
depending on the implementation. In some illustrative examples, panel 216 may
take
the form of a mega-panel comprised of multiple smaller panels, which may be
referred
to as sub-panels. A mega-panel may also be referred to as a super panel. In
these
illustrative examples, panel 216 may be comprised of at least one of a metal,
a metal
alloy, some other type of metallic material, a composite material, or some
other type of
material. As one illustrative example, panel 216 may be comprised of an
aluminum
alloy, steel, titanium, a ceramic material, a composite material, some other
type of
material, or some combination thereof.
When used to form keel 202 of fuselage assembly 114, panel 216 may be
referred to as a keel panel or a bottom panel. When used to form one of sides
204 of
fuselage assembly 114, panel 216 may be referred to as a side panel. When used
to
form crown 200 of fuselage assembly 114, panel 216 may be referred to as a
crown
panel or a top panel. As one illustrative example, plurality of panels 120 may
include
crown panels 218 for forming crown 200, side panels 220 for forming sides 204,
and
keel panels 222 for forming keel 202. Side panels 220 may include first side
panels
.. 224 for forming first side 206 and second side panels 226 for forming
second side 208.
In one illustrative example, fuselage section 207 of plurality of fuselage
sections
205 of fuselage assembly 114 may include one of crown panels 218, two of side
panels 220, and one of keel panels 222. In another illustrative example,
fuselage
section 207 may form an end of fuselage assembly 114.
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In some cases, fuselage section 207 may be comprised solely of a single panel,
such as panel 216. For example, without limitation, panel 216 may take the
form of
end panel 228.
End panel 228 may be used to form one end of fuselage assembly 114. For
example, when fuselage assembly 114 takes the form of aft fuselage assembly
116 in
Figure 1, end panel 228 may form the aftmost end of fuselage assembly 114.
When
fuselage assembly 114 takes the form of forward fuselage assembly 117 in
Figure 1,
end panel 228 may form the forwardmost end of fuselage assembly 114.
In one illustrative example, end panel 228 may take the form of a
cylindrically-
shaped panel, a cone-shaped panel, a barrel-shaped panel, or a tapered
cylindrical
panel. For example, end panel 228 may be a single cylindrically-shaped panel
having
a substantially circular cross-sectional shape that may change in diameter
with respect
to a center axis for fuselage assembly 114.
In this manner, as described above, fuselage section 207 may be comprised
solely of end panel 228. In some illustrative examples, fuselage section 207
may be
an end fuselage section that is comprised of only a single panel, which may be
end
panel 228. In some cases, bulkhead 272 may be associated with end panel 228
when
fuselage section 207 is an end fuselage section. Bulkhead 272, which may also
be
referred to as a pressure bulkhead, may be considered separate from or part of
end
panel 228, depending on the implementation. Bulkhead 272 may have a dome-type
shape in these illustrative examples.
When fuselage assembly 114 takes the form of aft fuselage assembly 116 in
Figure 1, bulkhead 272 may be part of fuselage section 207 located at the
aftmost end
of aft fuselage assembly 116. When fuselage assembly 114 takes the form of
forward
fuselage assembly 117 in Figure 1, bulkhead 272 may be part of fuselage
section 207
located at forwardmost end of aft fuselage assembly 116. Middle fuselage
assembly
118 in Figure 1 may not include a bulkhead, such as bulkhead 272, at either
end of
middle fuselage assembly 118. In this manner, plurality of fuselage sections
205 may
be implemented in any number of different ways.
CA 02895735 2015-06-25
Panel 216 may have first surface 230 and second surface 232. First surface
230 may be configured for use as an exterior-facing surface. In other words,
first
surface 230 may be used to form exterior 234 of fuselage assembly 114. Second
surface 232 may be configured for use as an interior-facing surface. In other
words,
second surface 232 may be used to form interior 236 of fuselage assembly 114.
Each
of plurality of panels 120 may be implemented in a manner similar to panel
216.
As described earlier, support structure 121 may be associated with a
corresponding one of plurality of panels 120. Support structure 121 may be
comprised
of plurality of members 122 that are associated with panel 216. In one
illustrative
example, corresponding portion 240 may be the portion of plurality of members
122
that correspond to panel 216. Corresponding portion 240 may form support
section
238 corresponding to panel 216. Support section 238 may form a part of support
structure 121.
Plurality of members 122 may include support members 242. Support
members 242 may include, for example, without limitation, at least one of
connecting
members 244, frames 246, stringers 248, stiffeners 250, stanchions 252,
intercostal
structural members 254, or other types of structural members.
Connecting members 244 may connect other types of support members 242
together. In some cases, connecting members 244 may also connect support
members 242 to plurality of panels 120. Connecting members 244 may include,
for
example, without limitation, shear clips 256, ties 258, splices 260,
intercostal
connecting members 262, other types of mechanical connecting members, or some
combination thereof.
In one illustrative example, when panel 216 is comprised of multiple sub-
panels,
connecting members 244 may be used to, for example, without limitation,
connect
together complementary frames of frames 246 running in the hoop-wise direction
on
adjacent sub-panels and complementary stringers of stringers 248 running in
the
longitudinal direction on adjacent sub-panels.
In other illustrative examples,
connecting members 244 may be used to connect together complementary frames,
.. stringers, or other types of support members on two or more adjacent panels
in
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plurality of panels 120. In some cases, connecting members 244 may be used to
connect together complementary support members on two or more adjacent
fuselage
sections.
Operations 124, as described in Figure 1, may be performed to join plurality
of
panels 120 together to build fuselage assembly 114. In one illustrative
example,
plurality of fasteners 264 may be used to join plurality of panels 120
together.
As described above, joining plurality of panels 120 together may be performed
in a number of different ways. Joining plurality of panels 120 together may
include at
least one of joining at least one panel in plurality of panels 120 to another
one of
.. plurality of panels 120, joining at least one panel in plurality of panels
120 to at least
one of plurality of members 122, joining at least one member in plurality of
members
122 to another one of plurality of members 122, or some other type of joining
operation. Plurality of panels 120 may be joined together such that plurality
of
members 122 ultimately form support structure 121 for fuselage assembly 114.
As depicted, number of floors 266 may be associated with fuselage assembly
114. In this illustrative example, number of floors 266 may be part of
fuselage
assembly 114. Number of floors 266 may include, for example, without
limitation, at
least one of a passenger floor, a cargo floor, or some other type of floor.
With reference now to Figure 3, an illustration of plurality of mobile systems
134 of flexible manufacturing system 106 within manufacturing environment 100
from
Figure 1 is depicted in the form of a block diagram in accordance with an
illustrative
embodiment. As depicted, flexible manufacturing system 106 may be used to
build
fuselage assembly 114 on floor 300 of manufacturing environment 100. When
manufacturing environment 100 takes the form of a factory, floor 300 may be
referred
to as factory floor 302.
In one illustrative example, floor 300 may be substantially smooth and
substantially planar. For example, floor 300 may be substantially level. In
other
illustrative examples, one or more portions of floor 300 may be sloped,
ramped, or
otherwise uneven.
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Assembly area 304 may be an area within manufacturing environment 100
designated for performing assembly process 110 in Figure 1 to build a fuselage
assembly, such as fuselage assembly 114. Assembly area 304 may also be
referred
to as a cell or a work cell. In this illustrative example, assembly area 304
may be a
designated area on floor 300. However, in other illustrative examples,
assembly area
304 may include a designated area on floor 300 as well as the area above this
designated area.
Any number of assembly areas may be present within
manufacturing environment 100 such that any number of fuselage assemblies may
be
built concurrently within manufacturing environment 100.
As depicted, plurality of mobile systems 134 may include plurality of
autonomous vehicles 306, cradle system 308, tower system 310, and autonomous
tooling system 312. Each of plurality of mobile systems 134 may be drivable
across
floor 300. In other words, each of plurality of mobile systems 134 may be
capable of
being autonomously driven across floor 300 from one location 315 to another
location
317 on floor 300.
In one illustrative example, each of plurality of autonomous vehicles 306 may
take the form of an automated guided vehicle (AGV), which may be capable of
operating independently without human direction or guidance. In some cases,
plurality
of autonomous vehicles 306 may be referred to as a plurality of automated
guided
vehicles (AGVs).
In this illustrative example, cradle system 308 may be used to support and
hold
fuselage assembly 114 during assembly process 110 in Figure 1. In some cases,
cradle system 308 may be referred to as a drivable cradle system. In still
other cases,
cradle system 308 may be referred to as an autonomously drivable cradle
system.
Cradle system 308 may include number of fixtures 313. As used herein, a
"number of" items may include one or more items. In this manner, number of
fixtures
313 may include one or more fixtures. In some illustrative examples, number of
fixtures 313 may be referred to as a number of drivable fixtures. In other
illustrative
examples, number of fixtures 313 may be referred to as a number of
autonomously
drivable fixtures.
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Number of fixtures 313 may include number of cradle fixtures 314. In some
illustrative examples, number of cradle fixtures 314 may be referred to as a
number of
drivable cradle fixtures. In other illustrative examples, number of cradle
fixtures 314
may be referred to as a number of autonomously drivable cradle fixtures.
Cradle
fixture 322 may be an example of one of number of cradle fixtures 314.
Number of retaining structures 326 may be associated with each of number of
cradle fixtures 314. Number of retaining structures 326 associated with each
of
number of cradle fixtures 314 may be engaged with and used to support fuselage
assembly 114. For example, number of retaining structures 326 associated with
cradle fixture 322 may be engaged with and used to support one or more of
plurality of
panels 120.
Number of cradle fixtures 314 may be autonomously driven across floor 300 of
manufacturing environment 100 to assembly area 304. In one illustrative
example,
each of number of cradle fixtures 314 may be autonomously driven across floor
300
using a corresponding one of plurality of autonomous vehicles 306. In other
words,
without limitation, number of corresponding autonomous vehicles 316 in
plurality of
autonomous vehicles 306 may be used to drive number of cradle fixtures 314
across
floor 300 into assembly area 304.
In this illustrative example, number of corresponding autonomous vehicles 316
may drive from, for example, without limitation, holding area 318, across
floor 300, to
assembly area 304. Holding area 318 may be an area in which at least one of
plurality
of autonomous vehicles 306, cradle system 308, tower system 310, autonomous
tooling system 312, or control system 136 from Figure 1 may be held when
flexible
manufacturing system 106 is not in use or when that particular device or
system is not
.. in use.
Holding area 318 may be referred to as a home area, a storage area, or a base
area, depending on the implementation. Although holding area 318 is depicted
as
being located within manufacturing environment 100, holding area 318 may be
located
in some other area or environment outside of manufacturing environment 100 in
other
illustrative examples.
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CA 02895735 2015-06-25
Number of corresponding autonomous vehicles 316 in plurality of autonomous
vehicles 306 may drive number of cradle fixtures 314 into number of selected
cradle
positions 320. As used herein, a "position" may be comprised of a location, an
orientation, or both. The location may be in two-dimensional coordinates or
three-
dimensional coordinates with respect to a reference coordinate system. The
orientation may be a two-dimensional or three-dimensional orientation with
respect to
a reference coordinate system. This reference coordinate system may be, for
example, without limitation, a fuselage coordinate system, an aircraft
coordinate
system, a coordinate system for manufacturing environment 100, or some other
type
of coordinate system.
When number of cradle fixtures 314 includes more than one cradle fixture such
that number of selected cradle positions 320 includes more than one cradle
position,
these cradle positions may be positions selected relative to each other. In
this
manner, number of cradle fixtures 314 may be positioned such that number of
cradle
fixtures 314 are in number of selected cradle positions 320 relative to each
other.
In these illustrative examples, number of corresponding autonomous vehicles
316 may be used to drive number of cradle fixtures 314 into number of selected
cradle
positions 320 within assembly area 304. "Driving" a component or a system
across
floor 300 may mean, for example, but not limited to, moving substantially the
entirety
of that component or system from one location to another location. For
example,
without limitation, driving cradle fixture 322 across floor 300 may mean
moving the
entirety of cradle fixture 322 from one location to another location. In other
words, all
or substantially all components that comprise cradle fixture 322 may be
simultaneously
moved together from one location to another location.
Once number of cradle fixtures 314 has been driven into number of selected
cradle positions 320 in assembly area 304, number of cradle fixtures 314 may
be
coupled to each other and to tower system 310. Number of corresponding
autonomous vehicles 316 may then drive away from number of cradle fixtures 314
to,
for example, without limitation, holding area 318, once number of cradle
fixtures 314 is
positioned in number of selected cradle positions 320 within selected
tolerances. In
CA 02895735 2015-06-25
other illustrative examples, number of corresponding autonomous vehicles 316
may
be comprised of a single autonomous vehicle that is used to drive each of
number of
cradle fixtures 314 into a corresponding selected position in number of
selected cradle
positions 320 within assembly area 304 one at a time.
In assembly area 304, number of cradle fixtures 314 may be configured to form
assembly fixture 324. Assembly fixture 324 may be formed when the different
cradle
fixtures in number of cradle fixtures 314 have been placed in number of
selected
cradle positions 320 relative to each other. In some cases, assembly fixture
324 may
be formed when number of cradle fixtures 314 have been coupled to each other
while
number of cradle fixtures 314 is in number of selected cradle positions 320
and when
number of retaining structures 326 associated with each of number of cradle
fixtures
314 has been adjusted to receive fuselage assembly 114.
In this manner, number of cradle fixtures 314 may form a single fixture
entity,
such as assembly fixture 324. Assembly fixture 324 may be used to support and
hold
fuselage assembly 114. In some cases, assembly fixture 324 may be referred to
as
an assembly fixture system or a fixture system. In some cases, assembly
fixture 324
may be referred to as a drivable assembly fixture. In other cases, assembly
fixture
324 may be referred to as an autonomously drivable assembly fixture.
Once assembly fixture 324 has been formed, number of cradle fixtures 314 may
receive fuselage assembly 114. In other words, plurality of fuselage sections
205 may
be engaged with number of cradle fixtures 314. In particular, plurality of
fuselage
sections 205 may be engaged with number of retaining structures 326 associated
with
each of number of cradle fixtures 314. Plurality of fuselage sections 205 may
be
engaged with number of cradle fixtures 314 in any number of ways.
When number of cradle fixtures 314 includes a single cradle fixture, that
cradle
fixture may be used to support and hold substantially the entire fuselage
assembly
114. When number of cradle fixtures 314 includes multiple cradle fixtures,
each of
these cradle fixtures may be used to support and hold at least one
corresponding
fuselage section of plurality of fuselage sections 205.
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CA 02895735 2015-06-25
In one illustrative example, each of plurality of fuselage sections 205 may be
engaged with number of cradle fixtures 314 one at a time. For example, without
limitation, all of the panels for a particular fuselage section in plurality
of fuselage
sections 205 may be positioned relative to each other and a corresponding
cradle
fixture in number of cradle fixtures 314 and then engaged with the
corresponding
cradle fixture. The remaining fuselage sections in plurality of fuselage
sections 205
may then be formed and engaged with number of cradle fixtures 314 in a similar
manner. In this manner, plurality of panels 120 may be engaged with number of
cradle fixtures 314 by engaging at least a portion of plurality of panels 120
with
number of retaining structures 326 associated with each of number of cradle
fixtures
314 that makes up assembly fixture 324 such that plurality of panels 120 is
supported
by number of cradle fixtures 314.
As described in Figure 2, plurality of panels 120 may include keel panels 222,
side panels 220, and crown panels 218. In one illustrative example, all of
keel panels
222 in Figure 2 used to form keel 202 of fuselage assembly 114 in Figure 2 may
first
be positioned relative to and engaged with number of cradle fixtures 314.
Next, all of
side panels 220 in Figure 2 used to form sides 204 of fuselage assembly 114 in
Figure 2 may be positioned relative to and engaged with keel panels 222. Then,
all of
crown panels 218 in Figure 2 used to form crown 200 of fuselage assembly 114
in
Figure 2 may be positioned relative to and engaged with side panels 220. In
this
manner, plurality of fuselage sections 205 may be concurrently assembled to
form
fuselage assembly 114.
In one illustrative example, each panel in plurality of panels 120 may have a
corresponding portion of plurality of members 122 fully formed and associated
with the
panel prior to the panel being engaged with one of number of cradle fixtures
314. This
corresponding portion of plurality of members 122 may be referred to as a
support
section. For example, support section 238 in Figure 2 may be fully formed and
associated with panel 216 in Figure 2 prior to panel 216 being engaged with
one of
number of cradle fixtures 314 or another panel of plurality of panels 120 in
Figure 2.
In other words, a corresponding portion of support members 242 in Figure 2 may
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CA 02895735 2015-06-25
already be attached to panel 216 and a corresponding portion of connecting
members
244 in Figure 2 already installed to connect this portion of support members
242 to
each other prior to panel 216 from Figure 2 being engaged with one of number
of
cradle fixtures 314.
In other illustrative examples, plurality of members 122 may be associated
with
plurality of panels 120 after plurality of panels 120 have been engaged with
each other
and number of cradle fixtures 314. In still other illustrative examples, only
a portion of
plurality of members 122 may be associated with plurality of panels 120 prior
to
plurality of panels 120 being engaged with each other and number of cradle
fixtures
314 and then a remaining portion of plurality of members 122 associated with
plurality
of panels 120 once plurality of panels 120 have been engaged with each other
and
number of cradle fixtures 314.
In some illustrative examples, one or more of support members 242 in Figure
2, one or more of connecting members 244 in Figure 2, or both may not be
associated
with panel 216 when panel 216 from Figure 2 is engaged with one of number of
cradle
fixtures 314 or with one of the other panels in plurality of panels 120. For
example,
without limitation, frames 246 described in Figure 2 may be added to panel 216
from
Figure 2 after panel 216 has been engaged with cradle fixture 322. In another
example, stiffeners 250 described in Figure 2 may be added to panel 216 from
Figure
2 after panel 216 has been engaged with cradle fixture 322.
Building fuselage assembly 114 may include engaging plurality of panels 120
with each other as plurality of panels 120 are built up on number of cradle
fixtures 314
of assembly fixture 324. For example, adjacent panels in plurality of panels
120 may
be connected by connecting at least a portion of the support members
associated with
the panels. Depending on the implementation, at least one of lap splices, butt
splices,
or other types of splices may be used to connect the adjacent panels in
addition to or
in place of connecting the corresponding support members of the adjacent
panels.
As one illustrative example, the support members associated with two adjacent
panels in plurality of panels 120 may be connected together using connecting
members, thereby connecting the two adjacent panels. The two support members
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CA 02895735 2015-06-25
associated with these two adjacent panels may be, for example, without
limitation,
spliced, tied, clipped, tacked, pinned, joined, or fastened together in some
other
manner. When the two adjacent panels are hoop-wise adjacent, complementary
frames may be connected in the hoop-wise direction. When the two adjacent
panels
are longitudinally adjacent, complementary stringers may be connected in the
longitudinal direction.
In some cases, connecting complementary stringers, frames, or other support
members on these two adjacent panels may be part of splicing these panels
together.
Adjacent panels may be connected together using any number of panel splices,
stringer splices, frame splices, or other types of splices.
In one illustrative example, plurality of panels 120 may be temporarily
connected to each other by temporarily fastening at least one of plurality of
panels 120
or plurality of members 122 together using temporary fasteners or permanent
fasteners. For example, without limitation, temporary clamps may be used to
temporarily connect and hold in place two of plurality of panels 120 together.
Temporarily connecting plurality of panels 120 together may be performed by at
least
one of temporarily connecting at least two plurality of panels 120 together,
temporarily
connecting at least two plurality of members 122 together, or temporarily
connecting at
least one of plurality of panels 120 to at least one of plurality of members
122 such
.. that plurality of members 122 associated with plurality of panels 120 forms
support
structure 121 in Figure 2 for fuselage assembly 114.
As one illustrative example, plurality of panels 120 may be temporarily tacked
or
pinned together using temporary fasteners 328 until plurality of fasteners 264
are
installed to join plurality of panels 120 together to form fuselage assembly
114.
Temporarily connecting plurality of panels 120 may temporarily connect
together
plurality of fuselage sections 205 from Figure 2 formed by plurality of panels
120.
Once plurality of fasteners 264 have been installed, temporary fasteners 328
may then
be removed.
In this manner, plurality of panels 120 may be connected together in a number
of different ways. Once plurality of panels 120 have been connected together,
plurality
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CA 02895735 2015-06-25
of members 122 may be considered as forming support structure 121 for fuselage
assembly 114. Connecting plurality of panels 120 together and forming support
structure 121 may maintain desired compliance with outer mold line
requirements and
inner mold line requirements for fuselage assembly 114. In other words,
plurality of
panels 120 may be held together in place relative to each other such that
fuselage
assembly 114 formed using plurality of panels 120 meets outer mold line
requirements
and inner mold line requirements for fuselage assembly 114 within selected
tolerances.
In particular, assembly fixture 324 may support plurality of panels 120 and
support structure 121 associated with plurality of panels 120 such that
fuselage
assembly 114 built using plurality of panels 120 and support structure 121 has
a shape
and a configuration that is within selected tolerances. In this manner, this
shape and
configuration may be maintained within selected tolerances while supporting
plurality
of panels 120 and plurality of members 122 associated with plurality of panels
120
during the building of fuselage assembly 114. This shape may be at least
partially
determined by, for example, without limitation, the outer mold line
requirements and
inner mold line requirements for fuselage assembly 114. In some cases, the
shape
may be at least partially determined by the location and orientation of the
frames and
stringers of fuselage assembly 114.
In some cases, when the assembly of plurality of panels 120 and support
structure 121 that comprise fuselage assembly 114 has reached a desired point,
number of corresponding autonomous vehicles 316 may drive assembly fixture 324
out of assembly area 304. For example, fuselage assembly 114 may be driven
across
floor 300 into a different area within manufacturing environment 100, from
floor 300
onto another floor in a different manufacturing environment, or from floor 300
onto
another floor in some other area or environment.
In one illustrative example, assembly fixture 324 may be driven to some other
location at which another assembly fixture is located such that the two
assembly
fixtures may be coupled to form a larger assembly fixture. As one illustrative
example,
assembly fixture 324 may be used to hold and support aft fuselage assembly 116
in
CA 02895735 2015-06-25
Figure 1, while another assembly fixture implemented in a manner similar to
assembly
fixture 324 may be used to hold and support forward fuselage assembly 117 in
Figure
1. Yet another assembly fixture implemented in a manner similar to assembly
fixture
324 may be used to hold and support middle fuselage assembly 118 in Figure 1.
Once these three fuselage assemblies have been built, the three assembly
fixtures may be brought together to form a larger assembly fixture for holding
aft
fuselage assembly 116, middle fuselage assembly 118, and forward fuselage
assembly 117 such that these three fuselage assemblies may be joined to form
fuselage 102 described in Figure 1. In particular, this larger assembly
fixture may
hold aft fuselage assembly 116, middle fuselage assembly 118, and forward
fuselage
assembly 117 in alignment with each other such that fuselage 102 may be built
within
selected tolerances.
In another illustrative example, a first assembly fixture and a second
assembly
fixture implemented in a manner similar to assembly fixture 324 may be used to
hold
and support aft fuselage assembly 116 and forward fuselage assembly 117,
respectively, from Figure 1. Once these two fuselage assemblies have been
built, the
two assembly fixtures may then be brought together to form a larger assembly
fixture
for holding the two fuselage assemblies such that these fuselage assemblies
may be
joined to form fuselage 102. The larger assembly fixture may hold aft fuselage
assembly 116 and forward fuselage assembly 117 in alignment with each other
such
that fuselage 102 may be built within selected tolerances.
As depicted, tower system 310 includes number of towers 330. Tower 332 may
be an example of one implementation for one of number of towers 330. Tower 332
may be configured to provide access to interior 236 of fuselage assembly 114
described in Figure 2. In some illustrative examples, tower 332 may be
referred to as
a drivable tower. In other illustrative examples, tower 332 may be referred to
as an
autonomously drivable tower.
In one illustrative example, tower 332 may take the form of first tower 334.
First
tower 334 may also be referred to as an operator tower in some cases. In
another
illustrative example, tower 332 may take the form of second tower 336. Second
tower
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CA 02895735 2015-06-25
336 may also be referred to as a robotics tower in some cases. In this manner,
number of towers 330 may include both first tower 334 and second tower 336.
First tower 334 may be configured substantially for use by a human operator,
whereas second tower 336 may be configured substantially for use by a mobile
.. platform having at least one robotic device associated with the mobile
platform. In
other words, first tower 334 may allow a human operator to access and enter
interior
236 of fuselage assembly 114. Second tower 336 may allow a mobile platform to
access and enter interior 236 of fuselage assembly 114.
First tower 334 and second tower 336 may be positioned relative to assembly
fixture 324 at different times during assembly process 110. As one
illustrative
example, one of plurality of autonomous vehicles 306 may be used to move or
autonomously drive first tower 334 from holding area 318 into selected tower
position
338 within assembly area 304. Number of cradle fixtures 314 may then be
autonomously driven, using number of corresponding autonomous vehicles 316,
into
number of selected cradle positions 320 relative to first tower 334, which is
in selected
tower position 338 within assembly area 304.
Second tower 336 may be exchanged for first tower 334 at some later stage
during assembly process 110 in Figure 1.
For example, one of plurality of
autonomous vehicles 306 may be used to autonomously drive first tower 334 out
of
.. assembly area 304 and back into holding area 318. The same autonomous
vehicle or
a different autonomous vehicle in plurality of autonomous vehicles 306 may
then be
used to autonomously drive second tower 336 from holding area 318 into
selected
tower position 338 within assembly area 304 that was previously occupied by
first
tower 334. Depending on the implementation, first tower 334 may be later
exchanged
for second tower 336.
In other illustrative examples, first tower 334 and second tower 336 may each
have an autonomous vehicle in plurality of autonomous vehicles 306 fixedly
associated with the tower. In other words, one of plurality of autonomous
vehicles 306
may be integrated with first tower 334 and one of plurality of autonomous
vehicles 306
may be integrated with second tower 336. For example, one of plurality of
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CA 02895735 2015-06-25
autonomous vehicles 306 may be considered part of or built into first tower
334. First
tower 334 may then be considered capable of autonomously driving across floor
300.
In a similar manner, one of plurality of autonomous vehicles 306 may be
considered
part of or built into second tower 336. Second tower 336 may then be
considered
capable of autonomously driving across floor 300.
Tower system 310 and assembly fixture 324 may be configured to form
interface 340 with each other. Interface 340 may be a physical interface
between
tower system 310 and assembly fixture 324. Tower system 310 may also be
configured to form interface 342 with utility system 138. In one illustrative
example,
interface 340 and interface 342 may be autonomously formed.
Interface 342 may be a physical interface between tower system 310 and utility
system 138. In these illustrative examples, in addition to being physical
interfaces,
interface 340 and interface 342 may also be utility interfaces. For example,
with
respect to the utility of power, interface 340 and interface 342 may be
considered
.. electrical interfaces.
Utility system 138 is configured to distribute number of utilities 146 to
tower
system 310 when tower system 310 and utility system 138 are physically and
electrically coupled through interface 342. Tower system 310 may then
distribute
number of utilities 146 to assembly fixture 324 formed by cradle system 308
when
assembly fixture 324 and tower system 310 are physically and electrically
coupled
through interface 340. Number of utilities 146 may include at least one of
power, air,
hydraulic fluid, communications, water, or some other type of utility.
As depicted, utility system 138 may include utility fixture 150. Utility
fixture 150
may be configured to receive number of utilities 146 from number of utility
sources
.. 148. Number of utility sources 148 may include, for example, without
limitation, at
least one of a power generator, a battery system, a water system, an
electrical line, a
communications system, a hydraulic fluid system, an air tank, or some other
type of
utility source. For example, utility fixture 150 may receive power from a
power
generator.
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CA 02895735 2015-06-25
In one illustrative example, utility fixture 150 may be positioned relative to
assembly area 304. Depending on the implementation, utility fixture 150 may be
positioned inside assembly area 304 or outside of assembly area 304.
In some illustrative examples, utility fixture 150 may be associated with
floor
300. Depending on the implementation, utility fixture 150 may be permanently
associated with floor 300 or temporarily associated with floor 300. In other
illustrative
examples, utility fixture 150 may be associated with some other surface of
manufacturing environment 100, such as a ceiling, or some other structure in
manufacturing environment 100. In some cases, utility fixture 150 may be
embedded
within floor 300.
In one illustrative example, first tower 334 may be autonomously driven into
selected tower position 338 with respect to floor 300 relative to utility
fixture 150 such
that interface 342 may be formed between first tower 334 and utility fixture
150. Once
interface 342 has been formed, number of utilities 146 may flow from utility
fixture 150
to first tower 334. Assembly fixture 324 may then autonomously form interface
340
with first tower 334 to form a network of utility cables between first tower
334 and
assembly fixture 324. Once both interface 342 and interface 340 have been
formed,
number of utilities 146 received at utility fixture 150 may flow from utility
fixture 150 to
first tower 334 and to each of number of cradle fixtures 314 that forms
assembly fixture
324. In this manner, first tower 334 may function as a conduit or "middleman"
for
distributing number of utilities 146 to assembly fixture 324.
When interface 340 has been formed between second tower 336 and assembly
fixture 324 and interface 342 has been formed between second tower 336 and
utility
fixture 150, number of utilities 146 may be provided to second tower 336 and
assembly fixture 324 in a similar manner as described above. Thus, utility
fixture 150
may distribute number of utilities 146 to tower system 310 and assembly
fixture 324
without tower system 310 and cradle assembly fixture 324 having to separately
connect to number of utility sources 148 or any other utility sources.
Autonomous tooling system 312 may be used to assemble plurality of panels
120 and support structure 121 while fuselage assembly 114 is being supported
and
34
CA 02895735 2015-06-25
held by assembly fixture 324. Autonomous tooling system 312 may include
plurality of
mobile platforms 344. Each of plurality of mobile platforms 344 may be
configured to
perform one or more of operations 124 in assembly process 110 described in
Figure
1. In particular, plurality of mobile platforms 344 may be autonomously driven
into
selected positions relative to plurality of panels 120 within selected
tolerances to
autonomously perform operations 124 that join plurality of panels 120 together
to build
fuselage assembly 114. Plurality of mobile platforms 344 are described in
greater
detail in Figure 4 below.
In this illustrative example, set of controllers 140 in control system 136 may
generate commands 142 as described in Figure 1 to control the operation of at
least
one of cradle system 308, tower system 310, utility system 138, autonomous
tooling
system 312, or plurality of autonomous vehicles 306. Set of controllers 140 in
Figure
1 may communicate with at least one of cradle system 308, tower system 310,
utility
system 138, autonomous tooling system 312, or plurality of autonomous vehicles
306
.. using any number of wireless communications links, wired communications
links,
optical communications links, other types of communications links, or
combination
thereof.
In this manner, plurality of mobile systems 134 of flexible manufacturing
system
106 may be used to automate the process of building fuselage assembly 114.
.. Plurality of mobile systems 134 may enable fuselage assembly 114 to be
built
substantially autonomously with respect to joining together plurality of
panels 120 to
reduce the overall time, effort, and human resources needed.
Flexible manufacturing system 106 may build fuselage assembly 114 up to the
point needed to move fuselage assembly 114 to the next stage in manufacturing
process 108 for building fuselage 102 or the next stage in the manufacturing
process
for building aircraft 104, depending on the implementation. In some cases,
cradle
system 308 in the form of assembly fixture 324 may continue carrying and
supporting
fuselage assembly 114 during one or more of these later stages in
manufacturing
process 108 for building fuselage 102 and aircraft 104.
CA 02895735 2015-06-25
With reference now to Figure 4, an illustration of plurality of mobile
platforms
344 from Figure 3 is depicted in the form of a block diagram in accordance
with an
illustrative embodiment. As depicted, plurality of mobile platforms 344 may
include
number of external mobile platforms 400 and number of internal mobile
platforms 402.
In this manner, plurality of mobile platforms 344 may include at least one
external
mobile platform and at least one internal mobile platform.
In some illustrative examples, number of external mobile platforms 400 may be
referred to as a number of drivable external mobile platforms. Similarly, in
some
cases, number of internal mobile platforms 402 may be referred to as a number
of
.. drivable internal mobile platforms. In other illustrative examples, number
of external
mobile platforms 400 and number of internal mobile platforms 402 may be
referred to
as a number of autonomously drivable external mobile platforms and a number of
autonomously drivable internal mobile platforms, respectively.
External mobile platform 404 may be an example of one of number of external
mobile platforms 400 and internal mobile platform 406 may be an example of one
of
number of internal mobile platforms 402. External mobile platform 404 and
internal
mobile platform 406 may be platforms that are autonomously drivable. Depending
on
the implementation, each of external mobile platform 404 and internal mobile
platform
406 may be configured to autonomously drive across floor 300 on its own or
with the
.. assistance of one of plurality of autonomous vehicles 306 from Figure 3.
As one illustrative example, without limitation, external mobile platform 404
may
be autonomously driven across floor 300 using a corresponding one of plurality
of
autonomous vehicles 306. In some illustrative examples, external mobile
platform 404
and this corresponding one of plurality of autonomous vehicles 306 may be
integrated
with each other. For example, the autonomous vehicle may be fixedly associated
with
external mobile platform 404. An entire load of external mobile platform 404
may be
transferable to the autonomous vehicle such that driving the autonomous
vehicle
across floor 300 drives external mobile platform 404 across floor 300.
External mobile platform 404 may be driven from, for example, without
.. limitation, holding area 318 to a position relative to exterior 234 of
fuselage assembly
36
CA 02895735 2015-06-25
114 to perform one or more operations 124 in Figure 1. As depicted, at least
one
external robotic device 408 may be associated with external mobile platform
404. In
this illustrative example, external robotic device 408 may be considered part
of
external mobile platform 404. In other illustrative examples, external robotic
device
408 may be considered a separate component that is physically attached to
external
mobile platform 404. External robotic device 408 may take the form of, for
example,
without limitation, a robotic arm.
External robotic device 408 may have first end effector 410. Any number of
tools may be associated with first end effector 410. These tools may include,
for
example, without limitation, at least one of a drilling tool, a fastener
insertion tool, a
fastener installation tool, an inspection tool, or some other type of tool. In
particular,
any number of fastening tools may be associated with first end effector 410.
As depicted, first tool 411 may be associated with first end effector 410. In
one
illustrative example, first tool 411 may be any tool that is removably
associated with
first end effector 410. In other words, first tool 411 associated with first
end effector
410 may be changed as various operations need to be performed. For example,
without limitation, first tool 411 may take the form of one type of tool, such
as a drilling
tool, to perform one type of operation. This tool may then be exchanged with
another
type of tool, such as a fastener insertion tool, to become the new first tool
411
associated with first end effector 410 to perform a different type of
operation.
In one illustrative example, first tool 411 may take the form of first
riveting tool
412. First riveting tool 412 may be used to perform riveting operations. In
some
illustrative examples, a number of different tools may be exchanged with first
riveting
tool 412 and associated with first end effector 410. For example, without
limitation,
first riveting tool 412 may be exchangeable with a drilling tool, a fastener
insertion tool,
a fastener installation tool, an inspection tool, or some other type of tool.
External mobile platform 404 may be autonomously driven across floor 300 and
positioned relative to assembly fixture 324 in Figure 3 supporting fuselage
assembly
114 to position first end effector 410 and first tool 411 associated with
first end effector
410 relative to one of plurality of panels 120. For example, external mobile
platform
37
CA 02895735 2015-06-25
404 may be autonomously driven across floor 300 to external position 414
relative to
assembly fixture 324. In this manner, first tool 411 carried by external
mobile platform
404 may be macro-positioned using external mobile platform 404.
Once in external position 414, first end effector 410 may be autonomously
controlled using at least external robotic device 408 to position first tool
411 associated
with first end effector 410 relative to a particular location on an exterior-
facing side of
one of plurality of panels 120. In this manner, first tool 411 may be micro-
positioned
relative to the particular location.
Internal mobile platform 406 may be located on second tower 336 in Figure 3
when internal mobile platform 406 is not in use. When interface 342 described
in
Figure 3 is formed between second tower 336 and assembly fixture 324, internal
mobile platform 406 may be driven from second tower 336 into interior 236 of
fuselage
assembly 114 and used to perform one or more of operations 124. In one
illustrative
example, internal mobile platform 406 may have a movement system that allows
internal mobile platform 406 to move from second tower 336 onto a floor inside
fuselage assembly 114.
At least one internal robotic device 416 may be associated with internal
mobile
platform 406. In this illustrative example, internal robotic device 416
may be
considered part of internal mobile platform 406. In other illustrative
examples, internal
robotic device 416 may be considered a separate component that is physically
attached to internal mobile platform 406. Internal robotic device 416 may take
the
form of, for example, without limitation, a robotic arm.
Internal robotic device 416 may have second end effector 418. Any number of
tools may be associated with second end effector 418. For example, without
limitation, at least one of a drilling tool, a fastener insertion tool, a
fastener installation
tool, an inspection tool, or some other type of tool may be associated with
second end
effector 418. In particular, any number of fastening tools may be associated
with
second end effector 418.
As depicted, second tool 419 may be associated with second end effector 418.
In one illustrative example, second tool 419 may be any tool that is removably
38
CA 02895735 2015-06-25
associated with second end effector 418. In other words, second tool 419
associated
with second end effector 418 may be changed as various operations need to be
performed. For example, without limitation, first tool 411 may take the form
of one
type of tool, such as a drilling tool, to perform one type of operation. This
tool may
then be exchanged with another type of tool, such as a fastener insertion
tool, to
become the new first tool 411 associated with first end effector 410 to
perform a
different type of operation.
In one illustrative example, second tool 419 may take the form of second
riveting tool 420. Second riveting tool 420 may be associated with second end
effector
418. Second riveting tool 420 may be used to perform riveting operations. In
some
illustrative examples, a number of different tools may be exchanged with
second
riveting tool 420 and associated with second end effector 418. For example,
without
limitation, second riveting tool 420 may be exchangeable with a drilling tool,
a fastener
insertion tool, a fastener installation tool, an inspection tool, or some
other type of tool.
Internal mobile platform 406 may be driven from second tower 336 into fuselage
assembly 114 and positioned relative to interior 236 of fuselage assembly 114
to
position second end effector 418 and second tool 419 associated with second
end
effector 418 relative to one of plurality of panels 120. In one illustrative
example,
internal mobile platform 406 may be autonomously driven onto one of number of
floors
266 in Figure 2 into internal position 422 within fuselage assembly 114
relative to
fuselage assembly 114. In this manner, second tool 419 may be macro-positioned
into internal position 422 using internal mobile platform 406.
Once in internal position 422, second end effector 418 may be autonomously
controlled to position second tool 419 associated with second end effector 418
relative
to a particular location on an interior-facing side of one of plurality of
panels 120 or an
interior-facing side of one of plurality of members 122 in Figure 2 that make
up
support structure 121. In this manner, second tool 419 may be micro-positioned
relative to the particular location.
In one illustrative example, external position 414 for external mobile
platform
404 and internal position 422 for internal mobile platform 406 may be selected
such
39
CA 02895735 2015-06-25
that fastening process 424 may be performed at location 426 on fuselage
assembly
114 using external mobile platform 404 and internal mobile platform 406.
Fastening
process 424 may include any number of operations. In one illustrative example,
fastening process 424 may include at least one of drilling operation 428,
fastener
insertion operation 430, fastener installation operation 432, inspection
operation 434,
or some other type of operation.
As one specific example, drilling operation 428 may be performed
autonomously using first tool 411 associated with first end effector 410 of
external
mobile platform 404 or second tool 419 associated with second end effector 418
of
internal mobile platform 406. For example, without limitation, first tool 411
or second
tool 419 may take the form of a drilling tool for use in performing drilling
operation 428.
Drilling operation 428 may be autonomously performed using first tool 411 or
second
tool 419 to form hole 436 at location 426. Hole 436 may pass through at least
one of
two panels in plurality of panels 120, two members of a plurality of members
122, or a
panel and one of plurality of members 122.
Fastener insertion operation 430 may be performed autonomously using first
tool 411 associated with first end effector 410 of external mobile platform
404 or
second tool 419 associated with second end effector 418 of internal mobile
platform
406. Fastener insertion operation 430 may result in fastener 438 being
inserted into
hole 436.
Fastener installation operation 432 may then be performed autonomously using
at least one of first tool 411 associated with first end effector 410 of
external mobile
platform 404 or second tool 419 associated with second end effector 418 of
internal
mobile platform 406. In one illustrative example, fastener installation
operation 432
may be performed autonomously using first tool 411 in the form of first
riveting tool 412
and second tool 419 in the form of second riveting tool 420 such that fastener
438
becomes rivet 442 installed at location 426. Rivet 442 may be a fully
installed rivet.
Rivet 442 may be one of plurality of fasteners 264 described in Figure 2.
In one illustrative example, fastener installation operation 432 may take the
form of bolt-nut type installation process 433. First tool 411 associated with
first end
CA 02895735 2015-06-25
effector 410 may be used to, for example, without limitation, install bolt 435
through
hole 436. Second tool 419 associated with second end effector 418 may then be
used
to install nut 437 over bolt 435. In some cases, installing nut 437 may
include applying
a torque sufficient to nut 437 such that a portion of nut 437 breaks off. In
these cases,
nut 437 may be referred to as a frangible collar.
In another illustrative example, fastener installation operation 432 may take
the
form of interference-fit bolt-type installation process 439. First tool 411
associated with
first end effector 410 may be used to, for example, without limitation,
install bolt 435
through hole 436 such that an interference fit is created between bolt 435 and
hole
436. Second tool 419 associated with second end effector 418 may then be used
to
install nut 437 over bolt 435.
In yet another illustrative example, fastener installation operation 432 may
take
the form of two-stage riveting process 444. Two-stage riveting process 444 may
be
performed using, for example, without limitation, first riveting tool 412
associated with
external mobile platform 404 and second riveting tool 420 associated with
internal
mobile platform 406.
For example, first riveting tool 412 and second riveting tool 420 may be
positioned relative to each other by external mobile platform 404 and internal
mobile
platform 406, respectively. For example, external mobile platform 404 and
external
robotic device 408 may be used to position first riveting tool 412 relative to
location
426 at exterior 234 of fuselage assembly 114. Internal mobile platform 406 and
internal robotic device 416 may be used to position second riveting tool 420
relative to
the same location 426 at interior 236 of fuselage assembly 114.
First riveting tool 412 and second riveting tool 420 may then be used to
perform
two-stage riveting process 444 to form rivet 442 at location 426. Rivet 442
may join at
least two of plurality of panels 120 together, a panel in plurality of panels
120 to
support structure 121 formed by plurality of members 122, or two panels in
plurality of
panels 120 to support structure 121.
In this example, two-stage riveting process 444 may be performed at each of
plurality of locations 446 on fuselage assembly 114 to install plurality of
fasteners 264
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CA 02895735 2015-06-25
as described in Figure 2. Two-stage riveting process 444 may ensure that
plurality of
fasteners 264 in Figure 2 are installed at plurality of locations 446 with a
desired
quality and desired level of accuracy.
In this manner, internal mobile platform 406 may be autonomously driven and
operated inside fuselage assembly 114 to position internal mobile platform 406
and
second riveting tool 420 associated with internal mobile platform 406 relative
to
plurality of locations 446 on fuselage assembly 114 for performing assembly
process
110 described in Figure 1. Similarly, external mobile platform 404 may
be
autonomously driven and operated around fuselage assembly 114 to position
external
mobile platform 404 and first riveting tool 412 associated with external
mobile platform
404 relative to plurality of locations 446 on fuselage assembly 114 for
performing
operations 124.
With reference now to Figure 5, an illustration of a flow of number of
utilities
146 across distributed utility network 144 from Figure 1 is depicted in the
form of a
block diagram in accordance with an illustrative embodiment. As depicted,
number of
utilities 146 may be distributed across distributed utility network 144.
Distributed utility network 144 may include, for example, without limitation,
number of utility sources 148, utility fixture 150, number of towers 330,
assembly
fixture 324, number of external mobile platforms 400, and number of utility
units 500.
In some cases, distributed utility network 144 may also include number of
internal
mobile platforms 402. In some illustrative examples, number of utility sources
148
may be considered separate from distributed utility network 144.
In this illustrative example, only one of number of towers 330 may be included
in distributed utility network 144 at a time. When first tower 334 is used,
distributed
utility network 144 may be formed when utility fixture 150 is coupled to
number of utility
sources 148, first tower 334 is coupled to utility fixture 150, assembly
fixture 324 is
coupled to first tower 334, and number of external mobile platforms 400 is
coupled to
number of utility units 500.
Number of utility units 500 may be associated with number of cradle fixtures
314 of assembly fixture 324 or separated from number of cradle fixtures 314.
For
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CA 02895735 2015-06-25
example, without limitation, a number of dual interfaces may be created
between
number of external mobile platforms 400, number of utility units 500, and
number of
cradle fixtures 314 using one or more dual-interface couplers.
When second tower 336 is used, distributed utility network 144 may be formed
when utility fixture 150 is coupled to number of utility sources 148, second
tower 336 is
coupled to utility fixture 150, assembly fixture 324 is coupled to second
tower 336,
number of internal mobile platforms 402 is coupled to second tower 336, and
number
of external mobile platforms 400 is coupled to number of utility units 500,
which may
be associated with number of cradle fixtures 314 or separated from number of
cradle
fixtures 314. Number of internal mobile platforms 402 may receive number of
utilities
146 through a number of cable management systems associated with second tower
336.
In this manner, number of utilities 146 may be distributed across distributed
utility network 144 using a single utility fixture 150. This type of
distributed utility
network 144 may reduce the number of utility components, utility cables, and
other
types of devices needed to provide number of utilities 146 to the various
components
in distributed utility network 144. Further, with this type of distributed
utility network
144, starting from at least utility fixture 150, number of utilities 146 may
be provided
completely above floor 300 of manufacturing environment in Figure 1.
The illustrative embodiments recognize and take into account that it may be
desirable to have a way of protecting a surface of a part, such as panel 216
in Figure
2, from undesired positioned effects that may occur when a clamp is used on
the part.
In particular, the illustrative embodiments recognize and take into account
that it may
be desirable to attach a foot on the clamp in which the foot is comprised of a
soft
material that will not mar, scratch, bend, or otherwise affect the part in an
undesired
manner.
However, the illustrative embodiments recognize and take into account that a
foot that is, for example, without limitation, adhesively bonded to a clamp
may peel
away, separate, or tear away from the clamp over time due to adhesive stress
caused
by bending forces. These bending forces may particularly occur with clamps
that are
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CA 02895735 2015-06-25
attached to end effectors of robotic devices. Consequently, it may be
desirable to
attach the foot to the clamp in a manner that is capable of withstanding
higher bending
forces and holding even when the adhesive bond between the foot and the clamp
has
separated or become undone in some other manner.
Thus, the illustrative embodiments provide a method and apparatus for
mechanically interlocking a foot with a clamp. In particular, the foot may be
interlocked
with the clamp through interlocking features in a manner that provides the
interface
between the foot and the clamp with a cohesive strength that may withstand
higher
levels of stress than is possible without the interlocking features.
With reference now to Figure 6, an illustration of an attachment for an end
effector for a robotic device is depicted in the form of a block diagram in
accordance
with an illustrative embodiment. In this illustrative example, attachment 600
may be
attached to end effector 602, which may be associated with robotic device 604.
Robotic device 604 may take a number of different forms. In one illustrative
example,
robotic device 604 may be internal robotic device 416 in Figure 4 and end
effector 602
may be second end effector 418 in Figure 4.
As depicted, attachment 600 may include number of tools 606. Number of tools
606 may include first tool 608. In some cases, number of tools 606 may also
include
second tool 610. In one illustrative example, second tool 610 may be
integrated with
first tool 608. First tool 608 may take a number of different forms. In one
illustrative
example, first tool 608 may take the form of clamping device 611.
Clamping device 611 may be used to apply, for example, clamping force 613
against a part, such as part 615. Part 615 may take a number of different
forms,
depending on the implementation. In one illustrative example, part 615 may
take the
form of panel 216 in Figure 2.
Second tool 610, which may be integrated with first tool 608 in some cases,
may take the form of riveting tool 636. In one illustrative example, riveting
tool 636
may take the form of bucking bar 638.
As depicted, first tool 608 may include set of first elements 612 and set of
second elements 614. First element 616 may be an example of one of set of
first
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CA 02895735 2015-06-25
elements 612 and second element 618 may be an example of one of set of second
elements 614. First element 616 may be associated with end effector 602
directly or
indirectly, depending on the implementation. Second element 618 may be
associated
with first element 616. When first tool 608 takes the form of clamping device
611,
second element 618 may be used to contact surface 617 of part 615.
First element 616 may be comprised of first material 620. Second element 618
may be comprised of second material 622. Second material 622 may be different
than
first material 620 in this illustrative example. For example, without
limitation, first
material 620 may take the form of metallic material 624 and second material
622 may
take the form of plastic material 626.
Plastic material 626 may be selected such that second element 618 does not
have an undesired effect on surface 617 of part 615 when second element 618 is
placed in contact with surface 617. Further, when first tool 608 takes the
form of
clamping device 611, plastic material 626 of second element 618 may reduce or
prevent undesired effects on surface 617 of part 615 that may result from
clamping
force 613 being applied to part 615.
Depending on the implementation, plastic material 626 may comprise at least
one of thermosetting plastic 637, thermoplastic material 639, or some other
type of
plastic material. In some cases, plastic material 626 may take the form of
polyurethane.
In one illustrative example, first element 616 may take the form of clamp 628.
In this example, second element 618 may take the form of foot 630 for clamp
628.
Foot 630 may act as a shock absorber for clamp 628 when clamp 628 is placed on
part 615. For example, foot 630 may act as a shock absorber when clamp 628 is
used
to apply clamping force 613 to part 615 during fastening operations. Further,
foot 630
may function as a protective bumper that protects surface 617 of part 615.
Each of set of first elements 612 and set of second elements 614 may be
implemented similarly. Consequently, set of first elements 612 may be set of
clamps
632 and set of second elements 614 may be set of feet 634 in some illustrative
examples.
CA 02895735 2015-06-25
In these illustrative examples, second element 618 may be associated with
edge 640 of first element 616. Interface 645 may be formed between first
element 616
and second element 618. In one example, second element 618 may be adhesively
bonded with edge 640 of first element 616. In particular, at least a portion
of second
element 618 may be adhesively bonded with at least a portion of edge 640 of
first
element 616. In this manner, interface 645 may have adhesive strength 648.
Edge 640 may be shaped to have complementary set of interlocking features
641. Second element 618 may include set of interlocking features 642. Second
element 618 may be mated with first element 616 to form interface 645. At
least a
portion of interface 645 is formed by the mating of set of interlocking
features 642 with
complementary set of interlocking features 641. When set of interlocking
features 642
is mated with complementary set of interlocking features 641, second element
618
may be considered mechanically interlocked with first element 616.
In this manner, set of interlocking features 642 may provide mechanical
interlock 644 at interface 645 between first element 616 and second element
618.
Each of set of interlocking features 642 may have a geometric shape that
enables a
mechanical interlocking with first element 616 when engaged with first element
616.
In particular, set of interlocking features 642 may have geometric pattern
646.
Geometric pattern 646 may be interfaced with complementary geometric pattern
647
of complementary set of interlocking features 641 along at least a portion of
edge 640.
When geometric pattern 646 and complementary geometric pattern 647 are mated,
mechanical interlock 644 may be formed. Mechanical interlock 644 may have
cohesive strength 651. Cohesive strength 651 may hold second element 618
together
with first element 616.
In one illustrative example, complementary geometric pattern 647 may be
machined into first element 616 to form complementary set of interlocking
features
641. Second element 618 may then be casted to first element 616. For example,
without limitation, plastic material 626 may be casted into a mold (not shown)
positioned relative to first element 616 such that second element 618 may be
formed.
In other words, plastic material 626 may be casted in liquid form and then
hardened to
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CA 02895735 2015-06-25
form second element 618 that is adhesively bonded to first element 616. This
type of
casting may create second element 618 having set of interlocking features 642
with
geometric pattern 646.
Cohesive strength 651 provided by set of interlocking features 642 may be
sufficiently high to resist bending forces within selected tolerances.
Further, cohesive
strength 651 may capable of resisting bending forces within selected
tolerances even
when adhesive strength 648 has been reduced to substantially zero. In other
words,
cohesive strength 651 may keep second element 618 mechanically interlocked
with
first element 616 even when the adhesive bond between first element 616 and
second
element 618 separates.
In one illustrative example, set of interlocking features 642 may take the
form of
set of projections 650. Second element 618 may include set of projections 650
and
base portion 652. Set of projections 650 may extend from base portion 652. In
this
illustrative example, base portion 652 may be adhesively bonded to edge 640 of
first
element 616.
Projection 655 may be an example of one of set of projections 650. Projection
655 may have elongated portion 656. When projection 655 is comprised entirely
of
elongated portion 656, projection 655 may be referred to as finger 658. In
other
illustrative examples, projection 655 may be referred to as a tab. In one
illustrative
example, elongated portion 656 may have angle 670 relative to base portion
652.
Angle 670 may be, for example, without limitation, between about 5 degrees and
about
85 degrees relative to base portion 652.
In some illustrative examples, projection 655 may have locking portion 660
that
extends past elongated portion 656. In other words, elongated portion 656 may
be
located between locking portion 660 and base portion 652. Locking portion 660
may
have first width 662 that is greater than second width 664 of elongated
portion 656. By
having first width 662 that is greater than second width 664 of elongated
portion 656,
locking portion 660 may geometrically and mechanically lock projection 655 in
place
relative to first element 616. In this manner, locking portion 660 may
increase
cohesive strength 651 of mechanical interlock 644.
47
CA 02895735 2015-06-25
As one illustrative example, locking portion 660 may take the form of circular
portion 665. Circular portion 665 may have diameter 668 that is greater than
second
width 664 of elongated portion 656. In other illustrative examples, circular
portion 665
may extend directly from base portion 652 without elongated portion 656
located
.. between circular portion 665 and base portion 652.
Of course, in other illustrative examples, locking portion 660 or projection
655 in
general may have some other type of shape. In some illustrative examples, a
cross-
sectional area of locking portion 660 of second element 618 taken along an
axis
substantially parallel to edge 640 of first element 616 may have a width that
changes
along a length of the cross-sectional area. As one illustrative example, a
cross-
sectional area of a through-thickness of locking portion 660 may appear to
have at
least one countersink portion.
The illustrations in Figures 1-6 are not meant to imply physical or
architectural
limitations to the manner in which an illustrative embodiment may be
implemented.
Other components in addition to or in place of the ones illustrated may be
used. Some
components may be optional. Also, the blocks are presented to illustrate some
functional components. One or more of these blocks may be combined, divided,
or
combined and divided into different blocks when implemented in an illustrative
embodiment.
For example, in some cases, more than one flexible manufacturing system may
be present within manufacturing environment 100.
These multiple flexible
manufacturing systems may be used to build multiple fuselage assemblies within
manufacturing environment 100. In other illustrative examples, flexible
manufacturing
system 106 may include multiple cradle systems, multiple tower systems,
multiple
utility systems, multiple autonomous tooling systems, and multiple pluralities
of
autonomous vehicles such that multiple fuselage assemblies may be built within
manufacturing environment 100.
In some illustrative examples, utility system 138 may include multiple utility
fixtures that are considered separate from flexible manufacturing system 106.
Each of
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CA 02895735 2015-06-25
these multiple utility fixtures may be configured for use with flexible
manufacturing
system 106 and any number of other flexible manufacturing systems.
Additionally, the different couplings of mobile systems in plurality of mobile
systems 134 may be performed autonomously in these illustrative examples.
However, in other illustrative example, a coupling of one of plurality of
mobile systems
134 to another one of plurality of mobile systems 134 may be performed
manually in
other illustrative examples.
Further, in other illustrative examples, one or more of plurality of mobile
systems 134 may be drivable by, for example, without limitation, a human
operator.
For example, without limitation, in some cases, first tower 334 may be
drivable with
human guidance.
With reference now to Figure 7, an illustration of an isometric cutaway view
of a
plurality of mobile platforms performing fastening processes within an
interior of a
fuselage assembly in a manufacturing environment is depicted in accordance
with an
illustrative embodiment. In this illustrative example, manufacturing
environment 701
may be an example of one implementation for manufacturing environment 100 in
Figure 1.
As depicted, flexible manufacturing system 700 may be present within
manufacturing environment 701. Flexible manufacturing system 700 may be used
to
build fuselage assembly 702. Flexible manufacturing system 700 may be an
example
of one implementation for flexible manufacturing system 106 in Figure 1.
Fuselage
assembly 702 may be an example of one implementation for fuselage assembly 84
in
Figure 1.
In this illustrative example, fuselage assembly 702 may be comprised of
plurality of panels 703 and plurality of members 704. Plurality of panels 703
and
plurality of members 704 may be examples of implementations for plurality of
panels
120 and plurality of members 122 in Figures 1 and 2. Flexible manufacturing
system
700 may be used to join plurality of panels 703 together, which may include
joining
members of plurality of members 704 to each other, to panels of plurality of
panels
703, or both.
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CA 02895735 2015-06-25
As depicted, flexible manufacturing system 700 may include plurality of
autonomous vehicles 706, cradle system 708, tower system 710, autonomous
tooling
system 712, and utility system 714. Plurality of autonomous vehicles 706,
cradle
system 708, tower system 710, autonomous tooling system 712, and utility
system 714
may be examples of implementations for plurality of autonomous vehicles 306 in
Figure 3, cradle system 308 in Figure 3, tower system 310 in Figure 3,
autonomous
tooling system 312 in Figure 3, and utility system 138 in Figure 1,
respectively.
As depicted, plurality of autonomous vehicles 706 may include autonomous
vehicle 707, autonomous vehicle 709; and autonomous vehicle 711, as well as
other
autonomous vehicles (not shown). Autonomous vehicles 707, 709, and 711 may
have
omnidirectional wheels. Plurality of autonomous vehicles 706 have been used to
move cradle system 708, tower system 710, and autonomous tooling system 712
into
selected positions relative to each other.
Cradle system 708 may form assembly fixture 713 for supporting fuselage
assembly 702 during the building of fuselage assembly 702. Assembly fixture
713
may be an example of one implementation for assembly fixture 324 in Figure 3.
Tower system 710 may include robotic tower 716, which may be an example of
one implementation for second tower 336 in Figure 3. Autonomous vehicle 707 is
shown positioned under robotic tower 716. Autonomous vehicle 707 may be used
to
move robotic tower 716 into a selected tower position relative to utility
fixture 718 of
utility system 714.
In this illustrative example, robotic tower 716 may be coupled to utility
fixture
718 of utility system 714. Cradle system 708 may be coupled to robotic tower
716.
Further, autonomous tooling system 712 may be coupled to cradle system 708 and
.. robotic tower 716. In this manner, a number of utilities may be distributed
downstream
from utility fixture 718 to robotic tower 716, to cradle system 708, and to
autonomous
tooling system 712.
In this illustrative example, autonomous tooling system 712 may include
plurality of mobile platforms 715. Plurality of mobile platforms 715 may be
used to
perform fastening processes to join plurality of panels 703 together.
Plurality of panels
CA 02895735 2015-06-25
703 may be joined to form at least one of lap joints, butt joints, or other
types of joints.
In this manner, plurality of panels 703 may be joined such that at least one
of
circumferential attachment, longitudinal attachment, or some other type of
attachment
is created between the various panels of plurality of panels 703.
As depicted, plurality of mobile platforms 715 may include internal mobile
platform 720, internal mobile platform 722, external mobile platform 724, and
external
mobile platform 726. Internal mobile platform 720 and internal mobile platform
722
may be performing operations within interior 728 of fuselage assembly 702,
while
external mobile platform 724 and external mobile platform 726 are performing
assembly operations along the exterior of fuselage assembly 702.
Internal mobile platform 720 and internal mobile platform 722 may be an
example of one implementation for at least a portion of number of internal
mobile
platforms 402 in Figure 4. External mobile platform 724 and external mobile
platform
726 may be an example of one implementation for at least a portion of number
of
external mobile platforms 400 in Figure 4.
Internal mobile platform 720 may be configured to move along passenger floor
800 while internal mobile platform 722 may be configured to move along cargo
floor
802. Internal mobile platform 720 and internal mobile platform 722 may be
coupled to
robotic tower 716 to receive the number of utilities through robotic tower
716. External
mobile platform 724 and external mobile platform 726 may be coupled to cradle
system 708 to receive the number of utilities from cradle system 708.
As depicted, internal robotic device 736 and internal robotic device 738 may
be
associated with internal mobile platform 722. Each of internal robotic device
732,
internal robotic device 734, internal robotic device 736, and internal robotic
device 738
may be an example of one implementation for internal robotic device 416 in
Figure 4.
External robotic device 740 may be associated with external mobile platform
724. External robotic device 742 may be associated with external mobile
platform
726. Each of external robotic device 740 and external robotic device 742 may
be an
example of one implementation for external robotic device 408 in Figure 4.
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CA 02895735 2015-06-25
As depicted, external robotic device 740 and internal robotic device 734 may
work collaboratively to install fasteners autonomously in fuselage assembly
702.
Similarly, external robotic device 742 and internal robotic device 738 may
work
collaboratively to install fasteners autonomously in fuselage assembly 702.
In this illustrative example, end effector 744 of external robotic device 740
and
end effector 746 of internal robotic device 734 may be positioned relative to
a same
location on fuselage assembly 702 to perform a fastening process, such as
fastening
process 424 in Figure 4, at this location. In this illustrative example, the
fastening
process may include a two-stage riveting process, such as two-stage riveting
process
444 described in Figures 4 and 6. Similarly, end effector 748 of external
robotic
device 742 and end effector 750 of internal robotic device 738 may be
positioned
relative to a same location on fuselage assembly 702 to perform a fastening
process,
which may include a two-stage riveting process, such as two-stage riveting
process
444 in Figure 4, at the location.
Although not shown, a first clamping device and a second clamping device may
be attached to end effector 748 and end effector 750, respectively. These
clamping
devices (not shown) may be implemented in a manner similar to clamping device
611
in Figure 6. These clamping devices may be used to perform at least a portion
of a
fastening process, such as fastening process 424 in Figure 4.
In this illustrative example, autonomous vehicle 709 may be fixedly associated
with external mobile platform 724. Autonomous vehicle 709 may be used to drive
external mobile platform 724 autonomously. For example, autonomous vehicle 709
may be used to autonomously drive external mobile platform 724 across floor
752 of
manufacturing environment 701 relative to assembly fixture 713.
Similarly, autonomous vehicle 711 may be fixedly associated with external
mobile platform 726. Autonomous vehicle 711 may be used to drive external
mobile
platform 726 autonomously. For example, autonomous vehicle 711 may be used to
autonomously drive external mobile platform 726 across floor 752 of
manufacturing
environment 701 relative to assembly fixture 713.
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CA 02895735 2015-06-25
By being fixedly associated with external mobile platform 724 and external
mobile platform 726, autonomous vehicle 709 and autonomous vehicle 711 may be
considered integral to external mobile platform 724 and external mobile
platform 726,
respectively. However, in other illustrative examples, these autonomous
vehicles may
be independent of the external mobile platforms in other illustrative
examples.
In these illustrative examples, a metrology system (not shown) may be used to
help position internal mobile platform 720, internal mobile platform 722,
external
mobile platform 724, and external mobile platform 726 relative to fuselage
assembly
702. In particular, the metrology system (not shown) may be used to precisely
position
internal robotic device 732 of internal mobile platform 720, internal robotic
device 734
of internal mobile platform 720, internal robotic device 736 of internal
mobile platform
722, internal robotic device 738 of internal mobile platform 722, external
robotic device
740 of external mobile platform 724, and external robotic device 742 of
external mobile
platform 726. In particular, these robotic devices may be precisely positioned
relative
to each other and to fuselage assembly 702.
With reference now to Figure 8, an illustration of a cross-sectional view of
flexible manufacturing system 700 and fuselage assembly 702 from Figure 7 is
depicted in accordance with an illustrative embodiment. In this illustrative
example, a
cross-sectional view of flexible manufacturing system 700 and fuselage
assembly 702
from Figure 7 is depicted taken in the direction of lines 8-8 in Figure 7. As
depicted,
internal mobile platform 720 may move along passenger floor 800 within
interior 728 of
fuselage assembly 702, while internal mobile platform 722 may move along cargo
floor
802 of fuselage assembly 702.
A metrology system (not shown) may be used to precisely position the various
robotic devices associated with autonomous tooling system 712 relative to each
other
and to fuselage assembly 702 such that fasteners may be installed in fuselage
assembly 702. In one illustrative example, rivets may be installed using a two-
stage
riveting process, such as two-stage riveting process 444 in Figure 4. For
example,
without limitation, internal robotic device 732 associated with internal
mobile platform
720 and external robotic device 740 associated with external mobile platform
724 may
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CA 02895735 2015-06-25
be positioned relative to a same location on fuselage assembly 702 to perform
the
two-stage riveting process.
With reference now to Figure 9, an illustration of a side view of a robotic
device
is depicted in accordance with an illustrative embodiment. Robotic device 900
may be
an example of one implementation for robotic device 604 in Figure 6. Robotic
device
900 may have end effector 902, which may be an example of one implementation
for
end effector 602 in Figure 6.
As depicted, attachment 904 is associated with end effector 902. Attachment
904 may be an example of one implementation for attachment 600 in Figure 6.
Further, attachment 904 may be an example of an attachment that may be used
with
other types of end effectors, including, but not limited to, end effector 746
in Figure 7.
In this illustrative example, attachment 904 may include clamping device 908,
which
may be an example of one implementation for clamping device 611 in Figure 6.
In this illustrative example, clamping device 908 may press against first part
910. First part 910 is positioned adjacent to second part 912. Clamping device
908
may apply first force 911 to first part 910, while another clamping device
(not shown)
may apply second force 913 to second part 912. First force 911 and second
force 913
may hold first part 910 and second part 912 together in place relative to each
other.
With reference now to Figure 10, an illustration of an isometric view of
clamping
device 908 from Figure 9 is depicted in accordance with an illustrative
embodiment.
As depicted in this example, attachment 904 may include clamping device 908
and
bucking bar 1000. Clamping device 908 and bucking bar 1000 may be an example
of
one implementation for number of tools 606 in Figure 6. In particular,
clamping device
908 and bucking bar 1000 may be examples of implementations for first tool 608
and
second tool 610, respectively, in Figure 6. Further, bucking bar 1000 may be
an
example of one implementation for bucking bar 638 in Figure 6.
In this illustrative example, clamping device 908 may have end 1001 and end
1002. Clamping device 908 may include clamp 1004 and foot 1006. Clamp 1004 may
be an example of one implementation for first element 616 in Figure 6 and, in
particular, clamp 628 in Figure 6. Foot 1006 may be an example of one
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CA 02895735 2015-06-25
implementation for second element 618 in Figure 6 and, in particular, foot 630
in
Figure 6.
Clamp 1004 may be comprised of a metallic material. For example, without
limitation, clamp 1004 may be comprised of steel. Foot 1006 may be comprised
of a
material that is soft and non-marring, such as plastic material 626 in Figure
6. For
example, without limitation, clamp 1004 may be comprised of polyurethane. Of
course, in other illustrative examples, clamp 1004 and foot 1006 may be
comprised of
other types of materials. In some illustrative examples, foot 1006 may be
comprised of
an elastomeric material.
Foot 1006 may be attached to clamp 1004 at edge 1008 of clamp 1004. As
depicted, foot 1006 may have base portion 1011 and set of interlocking
features 1010
that extend from base portion 1011. Set of interlocking features 1010 and base
portion 1011 may be examples of implementations for set of interlocking
features 642
and base portion 652, respectively, in Figure 6.
Set of interlocking features 1010 may have geometric pattern 1012. Edge 1008
may have complementary geometric pattern 1014. Geometric pattern 1012 of set
of
interlocking features 1010 may be interlocked with complementary geometric
pattern
1014 of edge 1008. Geometric pattern 1012 and complementary geometric pattern
1014 may be examples of implementations for geometric pattern 646 and
complementary geometric pattern 647, respectively, in Figure 6.
Set of interlocking features 1010 may mechanically interlock foot 1006 with
clamp 1004 such that separation of foot 1006 from clamp 1004 in the direction
of, for
example, without limitation, arrow 1016 may be difficult. In other words, set
of
interlocking features 1010 may provide cohesive strength that resists
separation of
foot 1006 from clamp 1004.
With reference now to Figure 11, an illustration of an enlarged front view of
an
interlocking feature is depicted in accordance with an illustrative
embodiment. In this
illustrative example, an enlarged front view of interlocking feature 1100 of
set of
interlocking features 1010 from Figure 10 is depicted. Interlocking feature
1100 may
include circular portion 1102 and elongated portion 1104. Elongated portion
1104
CA 02895735 2015-06-25
extends from base portion 1011 of foot 1006. Circular portion 1102 and
elongated
portion 1104 may be examples of implementations for circular portion 665 and
elongated portion 656, respectively, in Figure 6.
Foot 1006 may be bonded to edge 1008 of clamp 1004. In particular, foot 1006
may be adhesively bonded to at least a portion of edge 1008 of clamp 1004. For
example, without limitation, base portion 1011 of foot 1006 may be adhesively
bonded
to edge 1008 of clamp 1004. Further, elongated portion 1104 and circular
portion
1102 may also be adhesively bonded to edge 1008 of clamp 1004. In other
illustrative
examples, only base portion 1011 of clamp 1004 may be adhesively bonded to
edge
1008 of clamp 1004.
Foot 1006 forms interface 1110 with clamp 1004. The adhesive bond that
forms interface 1110 between foot 1006 and clamp 1004 may have an adhesive
strength capable of withstanding a certain amount of bending forces. A portion
of
interface 1110 is formed by base portion 1011 of foot 1006. Another portion of
interface 1110 is formed by elongated portion 1104 of interlocking feature
1100. Yet
another portion of interface 1110 is formed by circular portion 1102 of
interlocking
feature 1100. Circular portion 1102 of interlocking feature 1100 may
mechanically
interlock this corresponding portion of foot 1006 with clamp 1004. In
particular,
circular portion 1102 of interlocking feature 1100 may create a portion of
interface
1110 capable of withstanding a certain amount of cohesive stress.
As depicted, bending forces may act on clamping device 908 when clamping
device 908 is used in performing at least a portion of a fastening process,
such as
fastening process 424 in Figure 4. These bending forces may result in adhesive
stress 1112, cr, and cohesive stress 1114, T. Interlocking feature 1100 may
increase
the cohesive strength of interface 1110 between foot 1006 and clamp 1004.
In this example, the cohesive strength of interface 1110 may be greater than
the adhesive strength of interface 1110. In this manner, interlocking feature
1100 may
allow interface 1110 to resist greater bending forces than would be possible
without
interlocking feature 1100. Consequently, even when adhesive stress 1112 caused
by
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CA 02895735 2015-06-25
bending forces surpasses the adhesive strength of interface 1110, the cohesive
strength of interface 1110 may resist these bending forces within tolerances.
With reference now to Figure 12, an illustration of a cross-sectional view of
interlocking feature 1100 of foot 1006 from Figure 11 is depicted in
accordance with
an illustrative embodiment. In this illustrative example, a cross-sectional
view of
interlocking feature 1100 of foot 1006 may be seen taken in the direction of
lines 12-12
in Figure 11.
As depicted, bending force 1200 may cause adhesive stress 1112. The
maximum bending force that may be withstood may be the sum of the adhesive
strength of interface 1110 and the cohesive strength of interface 1110. In
other words,
the maximum bending force that may be withstood may be a combination of the
maximum adhesive stress that may be withstood and the maximum cohesive force
that may be withstood.
When adhesive stress 1112 overcomes the adhesive strength of interface 1110
such that the adhesive bonding between foot 1006 and clamp 1004 shown in
Figures
10 and 11 separates, the cohesive strength of interface 1110 may hold foot
1006 in
place relative to clamp 1004. In this manner, in the absence of adhesive
strength, the
maximum bending force that may be withstood may be equal to the maximum
cohesive stress 1114 from Figure 11 that may be withstood.
With reference now to Figure 13, an illustration of an isometric view of
another
attachment is depicted in accordance with an illustrative embodiment.
In this
illustrative example, attachment 1300 may be another example of one
implementation
for attachment 600 in Figure 6. Attachment 1300 may be used with an end
effector
for a robotic device, such as end effector 902 for robotic device 900 shown in
Figure
9.
As depicted, attachment 1300 may include set of clamping devices 1302 and
bucking bar 1301. Set of clamping devices 1302 may include clamping device
1304
and clamping device 1306. As depicted, clamping device 1304 and clamping
device
1306 may be offset from each other by distance 1305 such that bucking bar 1301
may
CA 02895735 2015-06-25
be positioned between these clamping devices. Bucking bar 1301 may be movable
in
a direction along axis 1307 relative to set of clamping devices 1302.
In this illustrative example, clamping device 1304 may include clamp 1308 and
foot 1310. Similarly, clamping device 1306 may include clamp 1312 and foot
1314.
Foot 1310 may have set of interlocking features 1316 that form geometric
pattern
1317. Foot 1314 may have set of interlocking features 1318 that form geometric
pattern 1319. As depicted, foot 1310 may be attached to edge 1320 of clamp
1308
and foot 1314 may be attached to edge 1321 of clamp 1312.
Set of interlocking features 1316 may mechanically interlock foot 1310 with
clamp 1308. Similarly, set of interlocking features 1318 may mechanically
interlock
foot 1314 with clamp 1312. This type of mechanical interlocking may increase
the
forces stabilizing foot 1310 on clamp 1308 and foot 1314 on clamp 1312. In
particular,
this type of mechanical interlocking may provide cohesive strength that
resists
separation of foot 1310 from clamp 1308 and foot 1314 from clamp 1312.
With reference now to Figure 14, an illustration of yet another type of
attachment is depicted in accordance with an illustrative embodiment.
In this
illustrative example, attachment 1400 may be another example of one
implementation
for attachment 600 in Figure 6. Attachment 1400 may be used with an end
effector
for a robotic device, such as end effector 902 for robotic device 900 shown in
Figure
9.
In this illustrative example, attachment 1400 may include bucking bar 1401 and
clamping device 1402. Clamping device 1402 may have U-shape 1405 in this
illustrative example. Clamping device 1402 may include clamp 1403 and foot
1404.
Foot 1404 may be adhesively bonded to and mechanically interlocked with clamp
1403. In particular, foot 1404 may be adhesively bonded to edge 1408 of clamp
1403.
Set of interlocking features 1406 may mechanically interlock foot 1404 with
clamp 1403. Interlocking feature 1410 may be an example of one of set of
interlocking
features 1406. In particular, this type of mechanical interlocking may provide
cohesive
strength that resists separation of foot 1404 from clamp 1403.
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With reference now to Figure 15, an illustration of a cross-sectional view of
interlocking feature 1410 from Figure 14 is depicted in accordance with an
illustrative
embodiment. In this illustrative example, a cross-sectional view of
interlocking feature
1410 from Figure 14 is taken in the direction of lines 15-15 in Figure 14.
As depicted, interlocking feature 1410 may fill hole 1500 in clamp 1403.
Interlocking feature 1410 may include countersink portion 1502, elongated
portion
1504, and countersink portion 1506. Countersink portion 1502 may be present at
first
side 1508 of clamp 1403 and countersink portion 1506 may be present at second
side
1510 of clamp 1403. Countersink portion 1502 and countersink portion 1506 may
provide cohesive strength in the direction of Y-axis 1512.
With reference now to Figure 16, an illustration of a clamping device is
depicted
in accordance with an illustrative embodiment. In this illustrative example,
clamping
device 1600 includes clamp 1602 and foot 1604. Foot 1604 may include set of
interlocking features 1608 and base portion 1610. Foot 1604 may be adhesively
bonded to edge 1606 of clamp 1602. Further, foot 1604 may be mechanically
interlocked with clamp 1602 through set of interlocking features 1608. Set of
interlocking features 1608 may provide cohesive strength to help resist
separation of
foot 1604 from clamp 1602.
With reference now to Figure 17, an illustration of a clamping device is
depicted
in accordance with an illustrative embodiment. In this illustrative example,
clamping
device 1700 may be smaller than clamping device 1600 in Figure 16, which may
enable clamping device 1700 to be used in hard-to-reach areas.
Clamping device 1700 includes clamp 1702 and foot 1704. Foot 1704 may
include set of interlocking features 1708 and base portion 1710. Foot 1704 may
be
adhesively bonded to edge 1706 of clamp 1702. Further, foot 1704 may be
mechanically interlocked with clamp 1702 through set of interlocking features
1708.
Set of interlocking features 1708 may provide cohesive strength to help resist
separation of foot 1704 from clamp 1702.
With reference now to Figure 18, an illustration of a clamping device is
depicted
in accordance with an illustrative embodiment. In this illustrative example,
clamping
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CA 02895735 2015-06-25
device 1800 includes clamp 1802 and foot 1804. Foot 1804 may include set of
interlocking features 1808 and base portion 1810. Foot 1804 may be adhesively
bonded to edge 1806 of clamp 1802. Further, foot 1804 may be mechanically
interlocked with clamp 1802 through set of interlocking features 1808.
Interlocking feature 1812 may be an example of one of set of interlocking
features 1808. Interlocking feature 1812 may be comprised entirely of locking
portion
1814. Locking portion 1814 may have dove-tail shape 1816 that mechanically
interlocks interlocking feature 1812 with clamp 1802. Set of interlocking
features 1808
may provide cohesive strength to help resist separation of foot 1804 from
clamp 1802.
With reference now to Figure 19, an illustration of an enlarged front view of
interlocking feature 1812 from Figure 18 is depicted in accordance with an
illustrative
embodiment. An enlarged front view of interlocking feature 1812 from Figure 18
is
depicted.
In this illustrative example, bending forces may result in adhesive stress
1900
and cohesive stress 1902. The adhesive bonding of foot 1804 to edge 1806 of
clamp
1802 and the mechanical interlocking of interlocking feature 1812 with clamp
1802
may resist these bending forces. In this manner, interlocking feature 1812 may
help
resist separation of foot 1804 from clamp 1802.
In some cases, bending forces may produce adhesive stress 1900 greater than
the adhesive strength of interface 1904 formed between foot 1804 and clamp
1802.
However, cohesive strength provided by interlocking feature 1812 may be
greater than
adhesive strength provided by the adhesive bonding of foot 1804 to edge 1806
of
clamp 1802. Consequently, the cohesive strength of interface 1904 provided by
interlocking feature 1812 may be sufficiently high to resist these bending
forces.
With reference now to Figure 20, an illustration of a cross-sectional view of
interlocking feature 1812 of foot 1804 from Figure 19 is depicted in
accordance with
an illustrative embodiment. In this illustrative example, a cross-sectional
view of
interlocking feature 1812 of foot 1804 may be seen taken in the direction of
lines 20-20
in Figure 19.
CA 02895735 2015-06-25
As depicted, bending force 2000 may cause adhesive stress 1900. The
maximum bending force that may be withstood may be the sum of the adhesive
strength of interface 1904 and the cohesive strength of interface 1904. When
adhesive stress 1900 overcomes the adhesive strength of interface 1904 such
that the
adhesive bonding between foot 1804 and clamp 1802 separates, the cohesive
strength of interface 1904 may hold foot 1804 in place relative to clamp 1802.
In this
manner, in the absence of adhesive strength, the maximum bending force that
may be
withstood may be equal to the maximum cohesive stress 1902 from Figure 19 that
may be withstood.
With reference now to Figure 21, an illustration of a clamping device is
depicted
in accordance with an illustrative embodiment. In this illustrative example,
clamping
device 2100 includes clamp 2102 and foot 2104. Foot 2104 may include set of
interlocking features 2108 and base portion 2110. Foot 2104 may be adhesively
bonded to edge 2106 of clamp 2102. Further, foot 2104 may be mechanically
interlocked with clamp 2102 through set of interlocking features 2108.
Interlocking feature 2112 may be an example of one of set of interlocking
features 2108. Interlocking feature 2112 may be comprised entirely of
elongated
portion 2114. Elongated portion 2114 may have angle 2116 relative to base
portion
2110. Set of interlocking features 2108 may provide cohesive strength to help
resist
separation of foot 2104 from clamp 2102.
With reference now to Figure 22, an illustration of an enlarged front view of
interlocking feature 2112 from Figure 21 is depicted in accordance with an
illustrative
embodiment. In this illustrative example, an enlarged front view of
interlocking feature
2112 from Figure 21 is depicted. As depicted, foot 2104 may be bonded to clamp
2102 such that interface 2200 is formed.
In this illustrative example, interlocking feature 2112 may mechanically
interlock
with clamp 2102 in a manner that provides cohesive strength to resist bending
forces
that cause adhesive stress 2202 and cohesive stress 2204. In this illustrative
example, interlocking feature 2112 may enable interface 2200 to withstand
higher
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CA 02895735 2015-06-25
levels of cohesive stress 2204 than the levels of adhesive stress 2202 that
may be
withstood based on the adhesive bonding of foot 2104 to clamp 2102.
With reference now to Figure 23, an illustration of a clamping device is
depicted
in accordance with an illustrative embodiment. In this illustrative example,
clamping
device 2300 includes clamp 2302 and foot 2304. Foot 2304 may include set of
interlocking features 2308 (shown in phantom) and base portion 2310. Foot 2304
may
be adhesively bonded to edge 2306 of clamp 2302. Further, foot 2304 may be
mechanically interlocked with clamp 2302 through set of interlocking features
2308.
With reference now to Figure 24, an illustration of a cross-sectional view of
clamping device 2300 from Figure 23 is depicted in accordance with an
illustrative
embodiment. In this illustrative example, a cross-sectional view of clamping
device
2300 from Figure 23 may be depicted taken in the direction of lines 24-24 in
Figure
23. As depicted, foot 2304 may be comprised of material that substantially
surrounds
end 2400, side 2402, and side 2404 of clamp 2302.
With reference now to Figure 25, an illustration of a cross-sectional view of
clamping device 2300 from Figures 23-24 is depicted in accordance with an
illustrative embodiment. In this illustrative example, a different
configuration for foot
2304 may be shown as compared to foot 2304 in Figure 24. In this illustrative
example, foot 2304 may be comprised of a material that substantially surrounds
end
2400 and side 2404 of clamp 2302 but not side 2402 of clamp 2302.
With reference now to Figure 26, an illustration of a clamping device is
depicted
in accordance with an illustrative embodiment. In this illustrative example,
clamping
device 2600 includes clamp 2602 and foot 2604. Foot 2604 may include set of
interlocking features 2608 (shown in phantom) and base portion 2610. Foot 2604
may
be adhesively bonded to edge 2606 of clamp 2602. Further, foot 2604 may be
interlocked with clamp 2602 through set of interlocking features 2608.
Interlocking
feature 2612 may be an example of one of set of interlocking features 2608.
With reference now to Figure 27, an illustration of an enlarged front view of
interlocking feature 2612 from Figure 26 is depicted in accordance with an
illustrative
embodiment. In this illustrative example, an enlarged front view of
interlocking feature
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CA 02895735 2015-06-25
2612 from Figure 26 is depicted. As depicted, foot 2604 may be bonded to clamp
2602 such that interface 2700 is formed.
In this illustrative example, interlocking feature 2612 may provide additional
adhesive strength. In particular, interlocking feature 2612 may provide
adhesive
strength greater than the adhesive strength provided by the adhesive bonding
between base portion 2610 and edge 2606 of clamp 2602 in Figure 26.
The illustrations of flexible manufacturing system 700 in Figures 7-8 and the
various types of attachments and clamps in Figures 9-27 are not meant to imply
physical or architectural limitations to the manner in which an illustrative
embodiment
may be implemented. Other components in addition to or in place of the ones
illustrated may be used. Some components may be optional.
The different components shown in Figures 7-27 may be illustrative examples
of how components shown in block form in Figures 1-6 can be implemented as
physical structures. Additionally, some of the components in Figures 7-27 may
be
combined with components in Figures 1-6, used with components in Figure 1-6,
or a
combination of the two.
With reference now to Figure 28, an illustration of a process for interfacing
a
first element with a second element is depicted in the form of a flowchart in
accordance with an illustrative embodiment. The process illustrated in Figure
28 may
be performed to interface, for example, without limitation, first element 616
with
second element 618 in Figure 6.
The process may begin by shaping edge 640 of first element 616 to have
complementary set of interlocking features 641 (operation 2800). In one
illustrative
example, operation 2800 may be performed by, for example, without limitation,
machining complementary set of interlocking features 641 having complementary
geometric pattern 647 along edge 640 of first element 616.
Next, second element 618 may be shaped to have set of interlocking features
642 (operation 2802). In one illustrative example, second element 618 may be
cast
using a mold positioned at edge 640 of first element 616 such that the casting
material
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CA 02895735 2015-06-25
fills the mold and contacts complementary set of interlocking features 641.
The
casting material may be, for example, plastic material 626 in liquid form.
Thereafter, set of interlocking features 642 of second element 618 may be
interlocked with complementary set of interlocking features 641 along edge 640
of first
element 616 (operation 2804), with the process terminating thereafter.
Operation
2804 may result in first element 616 and second element 618 being both
mechanically
interlocked and adhesively bonded to each other.
With reference now to Figure 29, an illustration of a process for attaching a
foot
to a clamp is depicted in the form of a flowchart in accordance with an
illustrative
embodiment. The process illustrated in Figure 29 may be implemented to attach,
for
example, without limitation, foot 630 to clamp 628 in Figure 6.
The process may begin by shaping edge 640 of clamp 628 to have
complementary set of interlocking features (operation 2900). In one
illustrative
example, operation 2902 may be performed by machining edge 640 of clamp 628 to
have complementary set of interlocking features 641 with complementary
geometric
pattern 647.
Next, a mold may be positioned relative to edge 640 of clamp 628 (operation
2902). Plastic material 626 may then be poured in liquid form into the mold
such that
plastic material 626 contacts the mold and complementary set of interlocking
features
641 (operation 2904). Then, plastic material 626 may be hardened to form foot
630
having set of interlocking features 642 that is adhesively bonded and
mechanically
interlocked with complementary set of interlocking features 641 along edge 640
of
clamp 628 (operation 2906), with the process terminating thereafter.
The flowcharts and block diagrams in the different depicted embodiments
illustrate the architecture, functionality, and operation of some possible
implementations of apparatuses and methods in an illustrative embodiment. In
this
regard, each block in the flowcharts or block diagrams may represent a module,
a
segment, a function, a portion of an operation or step, some combination
thereof.
In some alternative implementations of an illustrative embodiment, the
function
or functions noted in the blocks may occur out of the order noted in the
figures. For
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CA 02895735 2015-06-25
example, in some cases, two blocks shown in succession may be executed
substantially concurrently, or the blocks may sometimes be performed in the
reverse
order, depending upon the functionality involved. Also, other blocks may be
added in
addition to the illustrated blocks in a flowchart or block diagram.
The illustrative embodiments of the disclosure may be described in the context
of aircraft manufacturing and service method 3000 as shown in Figure 30 and
aircraft
3100 as shown in Figure 31. Turning first to Figure 30, an illustration of an
aircraft
manufacturing and service method is depicted in the form of a block diagram in
accordance with an illustrative embodiment.
During pre-production, aircraft
manufacturing and service method 3000 may include specification and design
3002 of
aircraft 3100 in Figure 31 and material procurement 3004.
During production, component and subassembly manufacturing 3006 and
system integration 3008 of aircraft 3100 in Figure 31 takes place. Thereafter,
aircraft
3100 in Figure 31 may go through certification and delivery 3010 in order to
be placed
in service 3012. While in service 3012 by a customer, aircraft 3100 in Figure
31 is
scheduled for routine maintenance and service 3014, which may include
modification,
reconfiguration, refurbishment, and other maintenance or service.
Each of the processes of aircraft manufacturing and service method 3000 may
be performed or carried out by at least one of a system integrator, a third
party, or an
operator. In these examples, the operator may be a customer. For the purposes
of
this description, a system integrator may include, without limitation, any
number of
aircraft manufacturers and major-system subcontractors; a third party may
include,
without limitation, any number of vendors, subcontractors, and suppliers; and
an
operator may be an airline, a leasing company, a military entity, a service
organization,
and so on.
With reference now to Figure 31, an illustration of an aircraft is depicted in
the
form of a block diagram in which an illustrative embodiment may be
implemented. In
this example, aircraft 3100 is produced by aircraft manufacturing and service
method
3000 in Figure 30 and may include airframe 3102 with plurality of systems 3104
and
interior 3106. Examples of systems 3104 include one or more of propulsion
system
CA 02895735 2015-06-25
3108, electrical system 3110, hydraulic system 3112, and environmental system
3114.
Any number of other systems may be included. Although an aerospace example is
shown, different illustrative embodiments may be applied to other industries,
such as
the automotive industry.
Apparatuses and methods embodied herein may be employed during at least
one of the stages of aircraft manufacturing and service method 3000 in Figure
30. In
particular, flexible manufacturing system 106 from Figure 1 may be used to
build at
least a portion of airframe 3102 of aircraft 3100 during any one of the stages
of aircraft
manufacturing and service method 3000. For example, without limitation,
flexible
manufacturing system 106 from Figure 1 may be used during at least one of
component and subassembly manufacturing 3006, system integration 3008, or some
other stage of aircraft manufacturing and service method 3000 to form a
fuselage for
aircraft 3100.
In one illustrative example, components or subassemblies produced in
component and subassembly manufacturing 3006 in Figure 30 may be fabricated or
manufactured in a manner similar to components or subassemblies produced
while aircraft 3100 is in service 3012 in Figure 30. As yet another example,
one or
more apparatus embodiments, method embodiments, or a combination thereof may
be
utilized during production stages, such as component and subassembly
manufacturing
3006 and system integration 3008 in Figure 30. One
or more apparatus
embodiments, method embodiments, or a combination thereof may be utilized
while
aircraft 3100 is in service 3012, during maintenance and service 3014 in
Figure 30, or
both. The use of a number of the different illustrative embodiments may
substantially
expedite the assembly of and reduce the cost of aircraft 3100.
The description of the different illustrative embodiments has been presented
for
purposes of illustration and description, and is not intended to be exhaustive
or limited
to the embodiments in the form disclosed. Many modifications and variations
will be
apparent to those of ordinary skill in the art. Further, different
illustrative embodiments
may provide different features as compared to other desirable embodiments. The
embodiment or embodiments selected are chosen and described in order to best
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CA 02895735 2015-06-25
explain the principles of the embodiments, the practical application, and to
enable
others of ordinary skill in the art to understand the disclosure for various
embodiments
with various modifications as are suited to the particular use contemplated.
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