Note: Descriptions are shown in the official language in which they were submitted.
CA 02895737 2015-06-25
ASSEMBLY FIXTURE FOR SUPPORTING A FUSELAGE ASSEMBLY
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 aircraft and, in particular, to
building
the fuselage of an aircraft. Still more particularly, the present disclosure
relates to a
method, apparatus, and system for building an assembly fixture and supporting
a
fuselage assembly using the assembly fixture while building the fuselage
assembly.
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.
In some cases, the current assembly methods and systems used to build
fuselages may require that these fuselages be built in facilities or factories
specifically
designated and permanently configured for building fuselages. These current
assembly methods and systems may be unable to accommodate different types and
shapes of fuselages. For example, without limitation, large and heavy
equipment
needed for building fuselages may be permanently affixed to a factory and
configured
for use solely with fuselages of a specific type.
Further, with some current assembly methods, supporting a fuselage during
building of the fuselage may be more difficult than desired. With some current
assembly systems, the structures used to support a fuselage during the
building of the
fuselage may be permanent fixtures and unable to be moved from one location to
another location. 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.
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SUMMARY
In one illustrative embodiment, a method for building an assembly fixture may
be provided. A number of cradle fixtures may be driven across a floor to an
assembly
area. The number of cradle fixtures may be configured to form the assembly
fixture.
In another illustrative embodiment, an apparatus may comprise a number of
cradle fixtures. The number of cradle fixtures may be coupleable to form an
assembly
fixture.
In another illustrative embodiment, an apparatus may comprise a cradle fixture
and a vehicle coupleable to the cradle fixture.
In accordance with one disclosed aspect there is provided a method for
building
an assembly fixture for supporting a fuselage. The method involves driving a
number
of cradle fixtures across a floor to an assembly area, each cradle fixture in
the number
of drivable cradle fixtures including a number of retaining structures for
engaging with
and supporting one or more of a plurality of panels of the fuselage. The
method
further involves configuring the number of cradle fixtures to form the
assembly fixture
by coupling the number of cradle fixtures to each other, and positioning the
number of
retaining structures of the number of cradle fixtures for engaging a plurality
of fuselage
sections for forming the fuselage.
The method may involve positioning the number of retaining structures for
supporting the fuselage assembly such that the fuselage meets outer mold line
requirements and inner mold line requirements within selected tolerances.
Positioning the number of retaining structures may involve positioning each of
the number of retaining structures associated with the each of the number of
cradle
fixtures using data acquired from a laser tracking system.
Driving the number of cradle fixtures may involve autonomously driving the
number of cradle fixtures into a number of selected cradle positions.
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Autonomously driving the number of cradle fixtures may involve autonomously
driving the number of cradle fixtures into the number of selected cradle
positions
relative to a tower.
Autonomously driving the number of cradle fixtures into the number of selected
cradle positions may involve using a number of radar sensors to position the
number
of cradle fixtures.
Autonomously driving the number of cradle fixtures into the number of selected
cradle positions may involve driving a first cradle fixture in the number of
cradle
fixtures into a first selected cradle position relative to the tower using a
number of
radar targets associated with the tower.
Autonomously driving the number of cradle fixtures into the number of selected
cradle positions may further involve driving a second cradle fixture in the
number of
cradle fixtures into a second selected cradle position relative to the first
cradle fixture
using the number of radar targets associated with the first cradle fixture.
The method may involve coupling the number of cradle fixtures to a tower in
series.
Coupling the number of cradle fixtures to the tower in series may involve
coupling the number of cradle fixtures to the tower in series autonomously to
enable a
flow of a number of utilities downstream from the tower to each of the number
of cradle
fixtures.
The method may involve coupling a number of utilities between the tower and a
utility fixture, and coupling the number of utilities between the tower and
the number of
cradle fixtures.
Coupling the number of cradle fixtures to each other may involve connecting a
first coupling unit associated with a first cradle fixture in the number of
cradle fixtures
to a second coupling unit associated with a second cradle fixture in the
number of
cradle fixtures to couple the first cradle fixture to the second cradle
fixture.
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The method may involve connecting a tower coupling unit associated with a
cradle fixture in the number of cradle fixtures to a cradle coupling unit
associated with
the tower to couple a first cradle fixture to the tower.
The method may involve coupling an external mobile platform to a utilities
unit
associated with one of the number of cradle fixtures.
The method may involve autonomously driving a number of corresponding
autonomous vehicles across the floor of a manufacturing environment to
position each
of the number of corresponding autonomous vehicles under a corresponding one
of
the number of cradle fixtures.
The method may involve controlling movement of the number of corresponding
autonomous vehicles across the floor of the manufacturing environment using
data
generated by a number of radar sensors associated with the each of the number
of
corresponding autonomous vehicles.
Controlling the movement of the number of corresponding autonomous vehicles
may involve controlling the movement of the number of corresponding autonomous
vehicles using the data generated by the number of radar sensors associated
with the
each of the number of corresponding autonomous vehicles to avoid obstacles.
The method may involve coupling an autonomous vehicle in the number of
corresponding autonomous vehicles with a corresponding cradle fixture in the
number
.. of cradle fixtures, and driving the autonomous vehicle having the
corresponding cradle
fixture associated with the autonomous vehicle to move the corresponding
cradle
fixture across the floor.
Coupling the autonomous vehicle in the number of corresponding autonomous
vehicles with the corresponding cradle fixture in the number of cradle
fixtures may
involve transferring a load of the corresponding cradle fixture to the
autonomous
vehicle.
The method may involve decoupling the autonomous vehicle from the
corresponding cradle fixture, and driving the autonomous vehicle away from the
cradle
fixture.
3b
The method may involve coupling a number of utilities between the assembly
fixture and a first tower.
The method may involve decoupling the number of utilities between the
assembly fixture and the first tower, and coupling the number of utilities
between the
.. assembly fixture and a second tower.
The method may involve decoupling the number of utilities between the second
tower and the assembly fixture.
In accordance with another disclosed aspect there is provided an apparatus.
The apparatus includes a number of drivable cradle fixtures that are
coupleable to
form an assembly fixture, each cradle fixture in the number of drivable cradle
fixtures
includes a number of retaining structures for engaging with and supporting one
or
more of a plurality of panels for forming a fuselage, and each retaining
structure is
adjustable.
The number of retaining structures may be configured to hold a corresponding
fuselage section of a fuselage.
Each retaining structure in the number of retaining structures may have a
curved shape that substantially matches an outer mold line of a panel to be
engaged
with the number of retaining structures.
Each retaining structure in the number of retaining structures may have a
curved shape that substantially matches a curvature of a portion of a panel of
a
fuselage section to be engaged with the each retaining structure.
Each retaining structure in the number of retaining structures may include a
number of beams, each of the number of beams having a substantially same
radius of
curvature as a portion of a keel panel that is to be engaged with the each of
the
number of beams.
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The features and functions 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,
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the illustrative embodiments are
set forth in the appended claims. The illustrative embodiments, however, 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;
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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 a cradle system in the form of a block diagram
in
accordance with an illustrative embodiment;
Figure 7 is an illustration of an isometric view of a manufacturing
environment
in accordance with an illustrative embodiment;
Figure 8 is an illustration of a first tower coupled to a utility fixture in
accordance with an illustrative embodiment;
Figure 9 is an illustration of an isometric view of a cradle system in
accordance
with an illustrative embodiment;
Figure 10 is an illustration of an isometric view of an assembly fixture
formed
using a cradle system and coupled to a first tower in accordance with an
illustrative
embodiment;
Figure 11 is an illustration of an isometric view of one stage in the assembly
process for building a fuselage assembly that is being supported by an
assembly
fixture in accordance with an illustrative embodiment;
Figure 12 is an illustration of an isometric view of another stage in the
assembly process for building a fuselage assembly being supported by an
assembly
fixture in accordance with an illustrative embodiment;
Figure 13 is an illustration of an isometric view of another stage in the
assembly process for building a fuselage assembly being supported by an
assembly
fixture in accordance with an illustrative embodiment;
Figure 14 is an illustration of an isometric view of another stage in the
assembly process for building a fuselage assembly in accordance with an
illustrative
embodiment;
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Figure 15 is an illustration of an isometric view of a second tower coupled to
a
utility fixture and an assembly fixture supporting a fuselage assembly in
accordance
with an illustrative embodiment;
Figure 16 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
accordance with an illustrative embodiment;
Figure 17 is an illustration of a cross-sectional view of a flexible
manufacturing
system performing operations on a fuselage assembly in accordance with an
illustrative embodiment;
Figure 18 is an illustration of an isometric view of a fully assembled
fuselage in
accordance with an illustrative embodiment;
Figure 19 is an illustration of an isometric view of fuselage assemblies being
built within a manufacturing environment in accordance with an illustrative
embodiment;
Figure 20 is an illustration of an isometric view of a cradle fixture in
accordance
with an illustrative embodiment;
Figure 21 is an illustration of an enlarged isometric view of a retaining
member
and a movement system in accordance with an illustrative embodiment;
Figure 22 is an illustration of an enlarged isometric view of a retaining
structure,
a movement system, and a movement system in accordance with an illustrative
embodiment;
Figure 23 is an illustration of an enlarged isometric view of a retaining
structure
and a movement system in accordance with an illustrative embodiment;
Figure 24 is an illustration of an isometric view of a cradle fixture with a
utilities
unit associated with the cradle fixture in accordance with an illustrative
embodiment;
Figure 25 is an illustration of an enlarged isometric view of a cradle fixture
in
accordance with an illustrative embodiment;
Figure 26 is an illustration of an enlarged isometric view of a retaining
structure
in accordance with an illustrative embodiment;
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Figure 27 is an illustration of an enlarged isometric view of a retaining
structure
in accordance with an illustrative embodiment;
Figure 28 is an illustration of a side view of a retaining structure and a
movement system in accordance with an illustrative embodiment;
Figure 29 is an illustration of a front view of a retaining structure with a
movement system and another movement system in accordance with an illustrative
embodiment;
Figure 30 is an illustration of an isometric view of a cradle fixture with a
utilities
unit associated with a cradle fixture in accordance with an illustrative
embodiment;
Figure 31 is an illustration of an enlarged isometric view of a cradle fixture
in
accordance with an illustrative embodiment;
Figure 32 is an illustration of an isometric view of a cradle fixture with a
utilities
unit associated with a cradle fixture in accordance with an illustrative
embodiment;
Figure 33 is an illustration of a process for configuring an assembly fixture
in
the form of a flowchart in accordance with an illustrative embodiment;
Figure 34 is an illustration of a process for configuring an assembly fixture
in
the form of a flowchart in accordance with an illustrative embodiment;
Figure 35 is an illustration of a process for adjusting a retaining structure
of a
cradle fixture in the form of a flowchart in accordance with an illustrative
embodiment;
Figure 36 is an illustration of adjusting an adjustable retaining structure in
the
form of a flowchart in accordance with an illustrative embodiment;
Figure 37 is an illustration of a data processing system in the form of a
block
diagram in accordance with an illustrative embodiment;
Figure 38 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 39 is an illustration of an aircraft in the form of a block diagram in
which
an illustrative embodiment may be implemented.
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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
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
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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
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
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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.
Further, the illustrative embodiments recognize and take into account that it
may be desirable to have an apparatus and method for supporting a fuselage
assembly during building of the fuselage assembly in a manner that meets
desired
tolerances. In particular, it may be desirable to have a method and apparatus
for
supporting a fuselage assembly that allows the fuselage assembly to be built
within
selected tolerances of outer mold line requirements and inner mold line
requirements
for the fuselage assembly. Thus, the illustrative embodiments provide a cradle
system
that may be used to form an assembly fixture for supporting and holding a
fuselage
assembly.
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.
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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.
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
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CA 02895737 2015-06-25
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
to the
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
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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 or 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.
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.
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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.
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
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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.
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,
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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
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
CA 02895737 2015-06-25
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.
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
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CA 02895737 2015-06-25
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
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
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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
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
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CA 02895737 2015-06-25
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.
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.
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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.
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.
CA 02895737 2015-06-25
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
aftrnost 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.
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
25' 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
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CA 02895737 2015-06-25
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
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
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CA 02895737 2015-06-25
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.
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.
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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.
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
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CA 02895737 2015-06-25
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.
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
CA 02895737 2015-06-25
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
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
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CA 02895737 2015-06-25
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.
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
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CA 02895737 2015-06-25
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
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
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CA 02895737 2015-06-25
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
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.
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CA 02895737 2015-06-25
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
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.
CA 02895737 2015-06-25
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
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
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CA 02895737 2015-06-25
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
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.
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CA 02895737 2015-06-25
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
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
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CA 02895737 2015-06-25
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.
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
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CA 02895737 2015-06-25
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
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.
CA 02895737 2015-06-25
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.
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
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CA 02895737 2015-06-25
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
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
37
CA 02895737 2015-06-25
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
1 5 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
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.
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CA 02895737 2015-06-25
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
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.
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CA 02895737 2015-06-25
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
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.
CA 02895737 2015-06-25
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
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.
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CA 02895737 2015-06-25
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
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
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CA 02895737 2015-06-25
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
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
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CA 02895737 2015-06-25
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.
With reference now to Figure 6, an illustration of cradle system 308 from
Figure 3 is depicted in the form of a block diagram in accordance with an
illustrative
embodiment. As depicted, cradle system 308 includes number of fixtures 313
shown
in Figure 3. In this illustrative example, number of fixtures 313 may include
number of
cradle fixtures 314 also shown in Figure 3.
Cradle fixture 600 may be an example of one of number of cradle fixtures 314.
For example, cradle fixture 600 may be an example of one implementation for
cradle
fixture 322 in Figure 3.
Cradle fixture 600 may have base 602. Base 602 may have plurality of
stabilizing members 604 that support base 602 and the various components
associated with base 602. In particular, plurality of stabilizing members 604
may be
used to stabilize base 602 relative to floor 300. In one illustrative example,
plurality of
stabilizing members 604 may take the form of plurality of legs 601. Depending
on the
implementation, plurality of stabilizing members 604 may take the form of
plurality of
hydraulic legs 603.
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In some cases, plurality of stabilizing members 604 may be used to adjust
cradle fixture 600 to align number of floors 266 of fuselage assembly 114
shown in
Figure 2 with a number of platform levels of, for example, tower 332 in Figure
3. For
example, without limitation, plurality of stabilizing members 604 may adjust
cradle
fixture 600 by at least one of raising, lowering, or tilting cradle fixture
600. Further,
plurality of stabilizing members 604 may be used to adjust cradle fixture 600
to align a
coupling unit associated with cradle fixture 600 with a corresponding coupling
unit
associated with tower 332 such that cradle fixture 600 may be coupled to tower
332.
In some illustrative examples, plurality of leveling members 606 may be
optionally associated with plurality of stabilizing members 604. Plurality of
leveling
members 606 may be used to level base 602 such that, if desired, base 602 may
be
leveled substantially parallel to floor 300. In other illustrative examples,
plurality of
leveling members 606 may be used to level base 602 such that base 602 is
substantially aligned with a true horizontal plane. For example, without
limitation,
plurality of leveling members 606 may be used to level base 602 such that a
selected
point on base 602 is substantially perpendicular to the gradient of the
gravity field at
that point. The selected point may be, for example, without limitation, a
center of base
602 or a center of cradle fixture 600.
Plurality of stabilizing members 604 may be used to compensate for
unevenness of one or more portions of floor 300. For example, without
limitation,
plurality of leveling members 606 may be used to align base 602 with a
horizontal
plane when base 602 is over an uneven or sloped portion of floor 300.
In other illustrative examples, plurality of stabilizing members 604 may be
used
to adjust cradle fixture 600 such that a panel being supported by cradle
fixture 600
may be substantially aligned with another panel being supported by another one
of
number of cradle fixtures 314. For example, plurality of stabilizing members
604 may
be used to ensure that these panels are substantially aligned prior to the
panels being
temporarily connected together using, for example, without limitation,
temporary
fasteners 328 in Figure 3.
CA 02895737 2015-06-25
Further, plurality of stabilizing members 604 may be configured to provide
clearance 605 between bottom side 617 of base 602 and floor 300. For example,
each of plurality of stabilizing members 604 may have a height that provides
clearance
605. Clearance 605 may be selected such that one of plurality of autonomous
vehicles 306 in Figure 3, such as autonomous vehicle 607, may be autonomously
driven under base 602 without contacting bottom side 617 of base 602.
Autonomous
vehicle 607 may be an example of one of number of corresponding autonomous
vehicles 316 in Figure 3.
For example, cradle fixture 600 and autonomous vehicle 607 may be located in
holding area 318 from Figure 3. Autonomous vehicle 607 may be driven to a
position
under bottom side 617 of base 602. Autonomous vehicle 607 may then be
associated
with cradle fixture 600. For example, without limitation, autonomous vehicle
607 may
couple to cradle fixture 600. In other illustrative examples, a vehicle other
than
autonomous vehicle 607 may be coupleable to cradle fixture 600.
In one illustrative example, load 621 of cradle fixture 600 may be transferred
to
autonomous vehicle 607. For example, without limitation, autonomous vehicle
607
may use load transfer system 623 to transfer load 621 of cradle fixture 600
onto
autonomous vehicle 607. As one illustrative example, load transfer system 623
may
include number of lift devices 625 associated with autonomous vehicle 607.
Number
of lift devices 625 may include at least one of, for example without
limitation, a lift
beam, a lift arm, a vertically mobile platform, or some other type of lift
device.
Number of lift devices 625 may be used to lift base 602 vertically relative to
floor
300 such that the entire load 621 of cradle fixture 600 is completely
supported by
autonomous vehicle 607. For example, base 602 may be lifted such that
plurality of
stabilizing members 604 do not contact floor 300.
Once the entire load 621 of cradle fixture 600 is supported by autonomous
vehicle 607, autonomous vehicle 607 may enable autonomous driving of cradle
fixture
600 freely across floor 300. For example, autonomous vehicle 607 may drive
cradle
fixture 600 from holding area 318 in Figure 3, across floor 300, to selected
cradle
position 631, which may be located within assembly area 304 in Figure 3.
Selected
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CA 02895737 2015-06-25
cradle position 631 may be an example of one of number of selected cradle
positions
320 in Figure 3.
Autonomous vehicle 607 may use number of radar sensors 609 associated with
autonomous vehicle 607 to position cradle fixture 600 in selected cradle
position 631
within selected tolerances. This positioning of cradle fixture 600 may be
referred to as
a rough positioning or macro-positioning, depending on the implementation.
Autonomous vehicle 607 may also use number of radar sensors 609 to avoid
obstacles while autonomous vehicle 607 drives across floor 300.
Once cradle fixture 600 is in selected cradle position 631, autonomous vehicle
607 may be disassociated from cradle fixture 600 such that the entire load of
cradle
fixture 600 is no longer supported by autonomous vehicle 607. For example,
without
limitation, once cradle fixture 600 is in selected cradle position 631, load
transfer
system 623 may be used to lower cradle fixture 600 towards floor 300 to put
plurality
of stabilizing members 604 back in contact with floor 300. Autonomous vehicle
607
may decouple, or disassociate, from cradle fixture 600 such that autonomous
vehicle
607 may be driven away from cradle fixture 600. In one illustrative example,
autonomous vehicle 607 may be driven back into holding area 318 in Figure 3.
Plurality of stabilizing members 604 may then be used to at least one of
stabilize or
position cradle fixture 600 relative to floor 300.
In other illustrative examples, some other type of movement system may be
used to move cradle fixture 600 into selected cradle position 631. For
example,
without limitation, two autonomous vehicles may be used to move cradle fixture
600
into selected cradle position 631. In another illustrative example, a crane
system may
be used to autonomously pick up cradle fixture 600 from holding area 318 and
place
cradle fixture 600 into selected cradle position 631.
As depicted, set of coupling units 608 may be associated with base 602. Set of
coupling units 608 may include at least one of robotics coupling unit 610,
number of
fixture coupling units 611, and tower coupling unit 613. Robotics coupling
unit 610
may be used to form an interface between cradle fixture 600 and a mobile
platform,
such as, for example, without limitation, external mobile platform 404 in
Figure 4. For
47
CA 02895737 2015-06-25
example, robotics coupling unit 610 may be configured to connect to a
corresponding
cradle coupling unit (not shown) associated with external mobile platform 404
in
Figure 4.
Number of fixture coupling units 611 may include, for example, cradle coupling
unit 612. Cradle coupling unit 612 may be used to form an interface between
cradle
fixture 600 and another one of number of cradle fixtures 314 using another
cradle
coupling unit associated with the other cradle fixture.
Tower coupling unit 613 may be used to form an interface between cradle
fixture 600 and one of number of towers 330 in Figure 3 using a cradle
coupling unit
associated with the tower. In this illustrative example, tower coupling unit
613 may be
used to autonomously couple cradle fixture 600 to one of number of towers 330
in
Figure 3 such that number of utilities 146 in Figure 1 may be received at
cradle fixture
600 from the tower. For example, tower coupling unit 613 may be used to
autonomously couple cradle fixture 600 to tower 332 in Figure 3. In other
illustrative
examples, tower coupling unit 613 may be used to manually couple cradle
fixture 600
to tower 332.
In this illustrative example, each of set of coupling units 608 may be used to
couple number of utilities 146 between cradle fixture 600 and a corresponding
system.
In this manner, number of utilities 146 may be distributed from a system to
cradle
fixture 600 or from cradle fixture 600 to a system through each coupling unit
in set of
coupling units 608.
In this illustrative example, number of retaining structures 614 may be
associated with base 602. Each of number of retaining structures 614 may be
comprised of one or more beams. Number of retaining structures 614 may be an
example of one implementation for number of retaining structures 326 in Figure
3.
Number of retaining structures 614 may be used to support one or more panels
of one or more different types, depending on the implementation. For example,
number of retaining structures 614 may be used to support one, two, or some
other
number of keel panels 222 in Figure 2.
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CA 02895737 2015-06-25
As depicted, retaining structure 616 may be an example of one of number of
retaining structures 614. Retaining structure 616 may have curved shape 618.
Curved shape 618 may substantially match a curvature of a corresponding
fuselage
section in plurality of fuselage sections 268 in Figure 2 to be received by
and engaged
with retaining structure 616. In particular, curved shape 618 may
substantially match
the curvature for a corresponding portion of the outer mold line (OML) for
fuselage
assembly 114, and thereby, fuselage 102 in Figure 1. This portion may be, for
example, without limitation, the portion of the outer mold line corresponding
to the
bottom, or keel, of fuselage assembly 114. For example, retaining structure
616 may
have curved shape 618 that substantially matches a curvature of one of
plurality of
panels 120 in Figures 1-4 to be received by and engaged with retaining
structure 616.
In one illustrative example, retaining structure 616 may include number of
beams 620. Each of number of beams 620 may have a curved shape such that
retaining structure 616 may have the overall curved shape 618. In particular,
each of
number of beams 620 may have a radius of curvature substantially equal to the
radius
of curvature of the portion of a corresponding one of keel panels 222 in
Figure 2 that
is to be engaged with that particular beam. In other words, each of number of
beams
620 may be shaped such that the portion of a keel panel that is engaged with
each of
number of beams 620 may mate with the beam with a desired contact fit. In some
illustrative examples, number of beams 620 may be referred to as number of
hoop
beams 622.
Each beam in number of beams 620 may have any shape or configuration that
allows the beam to engage a corresponding panel in a manner that allows
fuselage
assembly 114 to be built in accordance with outer mold line requirements. For
example, a beam in number of beams 620 may be comprised of a plurality of
members angled relative to each other in a manner that forms a shape that
substantially matches to an outer mold line of fuselage assembly 114. The
plurality of
members may include any number of linear members, curved members, or
combination thereof. Further, each beam in number of beams 620 may have any
position or orientation relative to base 602 of cradle fixture 600, relative
to one or more
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CA 02895737 2015-06-25
other beams in number of beams 620, or relative to fuselage assembly 114 that
allows
the beam to engage a corresponding panel in a manner that allows fuselage
assembly
114 to be built in accordance with outer mold line requirements.
Configuring number of cradle fixtures 314 to form assembly fixture 324 may
include configuring the retaining structures associated with number of cradle
fixtures
314. Configuring these retaining structures may include positioning a number
of
retaining structures associated with each of number of cradle fixtures 314
relative to
the base of each of number of cradle fixtures 314 with respect to a reference
coordinate system. The reference coordinate system may be a fuselage
coordinate
system, an aircraft coordinate system, a manufacturing environment coordinate
system, or some other type of coordinate system.
In this illustrative example, each of number of retaining structures 614 may
be
at least one of translatable or rotatable relative to base 602. For example,
without
limitation, retaining structure 616 may be associated with base 602 through
number of
movement systems 628. Each of number of movement systems 628 may be
configured to provide movement with at least one degree of freedom.
As one illustrative example, number of movement systems 628 may be used to
at least one of translationally or rotationally move retaining structure 616
relative to
base 602. In one illustrative example, number of movement systems 628 may be
used to horizontally and vertically move retaining structure 616.
Movement system 630 is an example of one of number of movement systems
628. Movement system 630 may be coupled to at least a portion of retaining
structure
616 and used to move at least that portion of retaining structure 616
horizontally and
vertically.
As one illustrative example, movement system 630 may take the form of XYZ
movement system 632. XYZ movement system 632 may be capable of moving a
corresponding portion, which may be some or all of retaining structure 616, in
directions substantially parallel to X-axis 634, Y-axis 636, and Z-axis 638.
In this
example, movement substantially parallel to an axis may be referred to as
movement
along that axis. In these illustrative examples, movement along either X-axis
634 or Y-
CA 02895737 2015-06-25
axis 636 may be considered horizontal movement. Further, movement along Z-axis
638 may be considered vertical movement.
As depicted, XYZ movement system 632 may include horizontal movement
system 640 and vertical movement system 642. In one illustrative example,
horizontal
movement system 640 may use plurality of rail systems 644 to provide
horizontal
motion along X-axis 634 and Y-axis 636. Plurality of rail systems 644 may be
motorized. As one illustrative example, horizontal movement system 640 may
take the
form of X-Y table 646.
Vertical movement system 642 may be implemented using actuator system
648. Actuator system 648 may provide, for example, without limitation,
vertical motion
relative to Z-axis 638. In one illustrative example, actuator system 648 may
be
implemented using one or more actuator devices. These actuator devices may be
implemented using, for example, without limitation, a Pogo actuator, which
may be
provided by CNA Manufacturing Systems, Inc., headquartered in Renton,
Washington,
United States. Of course, some other type of actuator device may be used to
implement actuator system 648 in other illustrative examples.
In some illustrative examples, controller 650 may be associated with base 602.
Controller 650 may be an example of one of set of controllers 140 in Figure 1.
Controller 650 may be used to control the operation of number of movement
systems
628 to control the movement of number of movement systems 628, and thereby,
the
movement of retaining structure 616. In this manner, controller 650 may
control the
movement of each of number of retaining structures 614. This type of movement
of
number of retaining structures 614 may be performed autonomously.
Each of number of retaining structures 614 may be moved into a position
relative to base 602 within selected tolerances. This position may be with
respect to a
reference coordinate system. This positioning may be performed using, for
example,
without limitation, a laser tracking system (not shown) of flexible
manufacturing system
106 in Figure 1 that includes number of laser targets 651 associated with base
602.
Number of laser targets 651 may be directly associated with base 602 or
indirectly
associated with base 602 through, for example, a mounting structure or frame.
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CA 02895737 2015-06-25
In one illustrative example, data may be received from the laser tracking
system
based on the locations of number of laser targets 651 within manufacturing
environment 100 in Figure 1. This data may be used to position number of
retaining
structures 614. For example, the data may be used to control number of
movement
systems 628 to move retaining structure 616 into selected retaining position
635
relative to base 602 with respect to the reference coordinate system. This
positioning
of number of retaining structures 614 may more precisely position number of
retaining
structures 614 as compared to the movement of base 602 using autonomous
vehicle
607.
The positioning of base 602 by autonomous vehicle 607 may be considered
macro-positioning 637 of cradle fixture 600, and thereby number of retaining
structures
614. The individual positioning of each of number of retaining structures 614
using
number of movement systems 628 associated with each retaining structure may be
considered micro-positioning 639 of each of number of retaining structures
614.
Micro-positioning 639 of each of number of retaining structures 614 may be
used to ensure that panels such as, for example, keel panels 222 in Figure 2,
may
engage number of retaining structures 614 properly. For example, without
limitation,
after cradle fixture 600 is moved into selected cradle position 631 by
autonomous
vehicle 607, plurality of stabilizing members 604 may be used to adjust at
least one of
the height of cradle fixture 600 or the tilt of cradle fixture 600 relative to
the vertical
axis, which may be Z-axis 638. Consequently, the position of one or more of
number
of retaining structures 614 may need to be adjusted to ensure that number of
retaining
structures 614 have an overall configuration that is ready to receive one of
keel panels
222 in Figure 2.
Additionally, micro-positioning 639 may be performed after one of keel panels
222 from Figure 2 has been engaged with number of retaining structures 614.
For
example, micro-positioning 639 may be used to adjust the position of the keel
panel
engaged with number of retaining structures 614 of cradle fixture 600 relative
to
another keel panel engaged with another one of number of fixtures 313. Micro-
positioning 639 may be used to align an outer mold line of a keel panel
engaged with
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CA 02895737 2015-06-25
cradle fixture 600 with the outer mold line of another keel panel engaged with
another
one of number of fixtures 313.
In one illustrative example, retaining structure 616 may take the form of
adjustable retaining structure 655. Adjustable retaining structure 655 may be
associated with number of movement systems 628 through connection member 652.
In particular, adjustable retaining structure 655 may be rotatably associated
with
connection member 652 in a manner that forms spherical interface 654.
Spherical
interface 654 may take the form of pinch point interface 656 in one specific
example.
Adjustable retaining structure 655 may be capable of passively rotating about
spherical interface 654 to rotate about X-axis 634, Y-axis 636, and Z-axis
638.
Spherical interface 654 may enable passive positioning, and thereby
adjustment, of adjustable retaining structure 655 in response to a panel, such
as one
of keel panels 222 in Figure 2, engaging adjustable retaining structure 655.
In other
words, adjustable retaining structure 655 may passively rotate about spherical
interface 654. Adjustable retaining structure 655 may be passively rotated
about
spherical interface 654 as a panel applies a load to adjustable retaining
structure 655.
The panel may be, for example, panel 216 in Figure 2, which may be one of keel
panels 222 from Figure 2 in one example.
For example, when a panel, such as one of keel panels 222 in Figure 2, is
.. engaged with adjustable retaining structure 655, contact with the panel may
cause
adjustable retaining structure 655 to passively rotate about at least one of X-
axis 634,
Y-axis 636, or Z-axis 638 to ensure that curved shape 618 of adjustable
retaining
structure 655 matches the curvature of the portion of the panel that engages
adjustable retaining structure 655. In particular, the panel may load
adjustable
retaining structure 655 in a manner that causes adjustable retaining structure
655 to
passively rotate about spherical interface 654 until a desired contact fit
between the
panel and adjustable retaining structure 655 is achieved.
In this manner, adjustable retaining structure 655 impinging on the panel may
force passive alignment of adjustable retaining structure 655. In other words,
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CA 02895737 2015-06-25
adjustable retaining structure 655 may impinge on the panel and thereby, force
alignment of adjustable retaining structure 655 with the panel.
In this illustrative example, number of movement systems 628 may be
associated with connection member 652.
In one illustrative example, vertical
movement system 642 may include at least one scissor lift mechanism 657.
Scissor
lift mechanism 657 may be used to move connection member 652, and thereby
adjustable retaining structure 655 associated with connection member 652,
relative to
Z-axis 638. For example, adjustable retaining structure 655 may be moved
vertically
substantially along Z-axis 638.
Horizontal movement system 640 may be used to move connection member
652, and thereby adjustable retaining structure 655, along at least one of X-
axis 634 or
Y-axis 636. In some cases, number of movement systems 628 may include two
horizontal movement systems that allow connection member 652, and thereby
adjustable retaining structure 655, to rotate about Z-axis 638.
In this manner, number of movement systems 628 may be used to provide
different types of movement relative to X-axis 634, Y-axis 636, Z-axis 638, or
some
combination thereof for adjustable retaining structure 655 at different times
or
simultaneously. In particular, movement along X-axis 634, about X-axis 634,
along Y-
axis 636, about Y-axis 636, along Z-axis 638, about Z-axis 638, or some
combination
thereof may be performed concurrently, at different times, or in some other
manner to
position adjustable retaining structure 655 in selected retaining position
635.
As depicted, set of sensors 658 may be associated with retaining structure
616.
Set of sensors 658 may include one or more sensors that may be used to aid in
positioning retaining structure 616 relative to a panel in plurality of panels
120 in
Figures 1-4. Set of sensors 658 may be used to guide, for example, without
limitation,
vertical movement system 642.
As one illustrative example, number of retaining structures 614 may include
two
other retaining structures in addition to retaining structure 616. These two
retaining
structures may be, for example, a forward retaining structure and an aft
retaining
structure. The forward retaining structure and the aft retaining structure may
be
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CA 02895737 2015-06-25
positioned using movement systems prior to a panel, such as one of keel panels
222
in Figure 2 being received. Once the panel has been received, number of
movement
systems 628 and set of sensors 658 may be used to move connection member 652,
and thereby retaining structure 616, into a position relative to the panel.
Retaining
structure 616 may then passively rotate into alignment with the panel such
that
retaining structure 616 is in selected retaining position 635 that will
support outer mold
line requirements for fuselage assembly 114.
Number of cradle fixtures 314 may be positioned and configured within
assembly area 304 in Figure 3 to form assembly fixture 324, as described above
in
Figure 3. In one illustrative example, number of cradle fixtures 314 includes
first
cradle fixture 660, second cradle fixture 662, and third cradle fixture 664.
First cradle
fixture 660, second cradle fixture 662, and third cradle fixture 664 may
support and
hold plurality of fuselage sections 205 for fuselage assembly 114.
In some illustrative examples, number of fixtures 313 from Figure 3 may
include fixture 665 in addition to number of cradle fixtures 314. Fixture 665
may be
used to form a part of assembly fixture 324. Fixture 665 may be used to
support and
hold one of plurality of fuselage sections 205. Depending on the
implementation,
fixture 665 may be permanently or removably associated with one of number of
cradle
fixtures 314. In other cases, fixture 665 may be separate from number of
cradle
fixtures 314.
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
CA 02895737 2015-06-25
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
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 332 may be
drivable with
human guidance.
With reference now to Figure 7, an illustration of an isometric view of a
manufacturing environment is depicted in accordance with an illustrative
embodiment.
In this illustrative example, manufacturing environment 700 may be an example
of one
implementation for manufacturing environment 100 in Figure 1.
As depicted, manufacturing environment 700 may include holding environment
701 and assembly environment 702. Holding environment 701 may be a designated
area on and over floor 703 of manufacturing environment 700 for storing
plurality of
flexible manufacturing systems 706 when plurality of flexible manufacturing
systems
706 are not in use. Each of plurality of flexible manufacturing systems 706
may be an
example of one implementation for flexible manufacturing system 106 described
in
Figures 1 and 3-5. In particular, each of plurality of flexible manufacturing
systems
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CA 02895737 2015-06-25
706 may be an example of one implementation for autonomous flexible
manufacturing
system 112 in Figure 1.
Holding environment 701 may include plurality of holding cells 704. In this
illustrative example, each of plurality of holding cells 704 may be considered
an
example of one implementation for holding area 318 in Figure 3. In other
illustrative
examples, the entire holding environment 701 may be considered an example of
one
implementation for holding area 318 in Figure 3.
Each of plurality of flexible manufacturing systems 706 may be stored in a
corresponding one of plurality of holding cells 704. In particular, each of
plurality of
holding cells 704 may be designated for a specific one of plurality of
flexible
manufacturing systems 706. However, in other illustrative examples, any one of
plurality of holding cells 704 may be used for storing any one of plurality of
flexible
manufacturing systems 706.
As depicted, flexible manufacturing system 708 may be an example of one of
plurality of flexible manufacturing systems 706. Flexible manufacturing system
708
may include plurality of mobile systems 711, which may be an example of one
implementation for plurality of mobile systems 134 in Figures 1 and 3.
Flexible manufacturing system 708 may be stored in holding cell 710 of
plurality
of holding cells 704. In this example, all of holding environment 701 may be
considered an example of one implementation for holding area 318 in Figure 3.
However, in other examples, each of plurality of holding cells 704 in holding
environment 701 may be considered an example of one implementation for holding
area 318 in Figure 3.
Floor 703 of manufacturing environment 700 may be substantially smooth to
allow the various components and systems of plurality of flexible
manufacturing
systems 706 to be autonomously driven across floor 703 of manufacturing
environment 700 with ease. When one of plurality of flexible manufacturing
systems
706 is ready for use, that flexible manufacturing system may be driven across
floor
703 from holding environment 701 into assembly environment 702.
CA 02895737 2015-06-25
Assembly environment 702 may be the designated area on and above floor 703
for building fuselage assemblies. When none of plurality of flexible
manufacturing
systems 706 are in use, floor 703 of assembly environment 702 may be kept
substantially open and substantially clear.
As depicted, assembly environment 702 may include plurality of work cells 712.
In one illustrative example, each of plurality of work cells 712 may be an
example of
one implementation for assembly area 304 in Figure 3. Thus, each of plurality
of work
cells 712 may be designated for performing a fuselage assembly process, such
as
assembly process 110 in Figure 1, for building fuselage assembly 114 in Figure
1. In
other illustrative examples, the entire assembly environment 702 may be
considered
an example of one implementation for assembly area 304 in Figure 3.
In this illustrative example, first portion 714 of plurality of work cells 712
may be
designated for building forward fuselage assemblies, such as forward fuselage
assembly 117 in Figure 1, while second portion 716 of plurality of work cells
712 may
be designated for building aft fuselage assemblies, such as aft fuselage
assembly 116
in Figure 1. In this manner, plurality of work cells 712 may allow multiple
fuselage
assemblies to be built concurrently. Depending on the implementation, the
building of
these fuselage assemblies may begin at the same time or at different times in
plurality
of work cells 712.
In one illustrative example, plurality of mobile systems 711 that belong to
flexible manufacturing system 708 may be driven across floor 703 from holding
cell
710 into work cell 713. Within work cell 713, plurality of mobile systems 711
may be
used to build a fuselage assembly (not shown). An example of one manner in
which
this fuselage assembly may be built using flexible manufacturing system 708 is
described in greater detail in Figures 8-18 below.
In some illustrative examples, a sensor system may be associated with one or
more of plurality of work cells 712. For example, without limitation, in some
cases,
sensor system 718 may be associated with work cell 719 of plurality of work
cells 712.
Sensor data generated by sensor system 718 may be used to help drive the
various
mobile systems of the corresponding one of plurality of flexible manufacturing
systems
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706 designated for building a fuselage assembly within work cell 719. In one
illustrative example, sensor system 718 may take the form of metrology system
720.
Depending on the implementation, sensor system 718 may be optional. For
example, without limitation, other sensor systems are not depicted associated
with
.. other work cells of plurality of work cells 712. Not using sensors systems
such as
sensor system 718 may help keep floor 703 of manufacturing environment 700
more
open and clear to help the various mobile systems of plurality of flexible
manufacturing
systems 706 be driven more freely across floor 703.
As depicted, plurality of utility fixtures 724 may be permanently affixed to
floor
703. Each of plurality of utility fixtures 724 may be an example of one
implementation
for utility fixture 150 in Figure 1.
Plurality of utility fixtures 724 may be interfaced with a number of utility
sources
(not shown in this view). These utility sources (not shown) may be, for
example,
without limitation, located beneath floor 703. Utility fixture 726 may be an
example of
one of plurality of utility fixtures 724.
In this illustrative example, each of plurality of utility fixtures 724 is
located in a
corresponding one of plurality of work cells 712. Any one of plurality of
flexible
manufacturing systems 706 may be driven towards and interfaced with any one of
plurality of utility fixtures 724. In this manner, plurality of utility
fixtures 724 may be
used to provide one or more utilities to plurality of flexible manufacturing
systems 706.
Referring now to Figures 8-18, illustrations of the building of a fuselage
assembly within manufacturing environment 700 from Figure 7 are depicted in
accordance with an illustrative embodiment. In Figures 8-18, flexible
manufacturing
system 708 from Figure 7 may be used to build a fuselage assembly. The
building of
the fuselage assembly may be performed within any one of plurality of work
cells 712
in Figure 7. For example, without limitation, the building of the fuselage
assembly
may be performed within one of the work cells in second portion 716 of
plurality of
work cells 712 in Figure 7.
Turning now to Figure 8, an illustration of an isometric view of a first tower
coupled to utility fixture 726 from Figure 7 is depicted in accordance with an
illustrative
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embodiment. In this illustrative example, first tower 800 may be coupled to
utility
fixture 726. First tower 800 may be an example of one of plurality of mobile
systems
711 of flexible manufacturing system 708 in Figure 7. In particular, first
tower 800
may be an example of one implementation for first tower 334 in Figure 3.
First tower 800 may be at least one of electrically and physically coupled to
utility fixture 726 such that interface 802 is formed between first tower 800
and utility
fixture 726. Interface 802 may be an example of one implementation for
interface 342
in Figure 3.
As depicted, first tower 800 may have base structure 804. Base structure 804
may include top platform 806 and bottom platform 807. In some cases, top
platform
806 and bottom platform 807 may be referred to as top platform level and a
bottom
platform level, respectively. Top platform 806 may be used to provide a human
operator with access to a top floor of a fuselage assembly (not shown), such
as a
passenger floor inside the fuselage assembly. Bottom platform 807 may be used
to
provide a human operator with access to a bottom floor of the fuselage
assembly (not
shown), such as a cargo floor inside the fuselage assembly.
In this illustrative example, walkway 808 may provide access from a floor,
such
as floor 703 in Figure 7, to bottom platform 807. Walkway 810 may provide
access
from bottom platform 807 to top platform 806. Railing 812 is associated with
top
platform 806 for the protection of a human operator moving around on top
platform
806. Railing 814 is associated with bottom platform 807 for the protection of
a human
operator moving around on bottom platform 807.
First tower 800 may be autonomously driven across floor 703 using
autonomous vehicle 816. Autonomous vehicle 816 may be an automated guided
vehicle (AGV) in this example. Autonomous vehicle 816 may be an example of one
of
plurality of autonomous vehicles 306 in Figure 3. As depicted, autonomous
vehicle
816 may be used to drive first tower 800 from holding environment 701 in
Figure 7 to
selected tower position 818 relative to utility fixture 726. Selected tower
position 818
may be an example of one implementation for selected tower position 338 in
Figure 3.
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Once first tower 800 has been autonomously driven into selected tower position
818, first tower 800 may autonomously couple to utility fixture 726. In
particular, first
tower 800 may electrically and physically couple to utility fixture 726
autonomously to
form interface 802. This type of coupling may enable a number of utilities to
flow from
utility fixture 726 to first tower 800. In this manner, first tower 800 and
utility fixture 726
may establish at least a portion of a distributed utility network, similar to
distributed
utility network 144 described in Figures 1 and 5.
With reference now to Figure 9, an illustration of an isometric view of a
cradle
system is depicted in accordance with an illustrative embodiment. In this
illustrative
example, cradle system 900 may be an example of one implementation for cradle
system 308 in Figure 3. Further, cradle system 900 may be an example of one of
plurality of mobile systems 711 of flexible manufacturing system 708 in Figure
7. In
this manner, cradle system 900 may be an example of one of plurality of mobile
systems 711 that are stored in holding cell 710 in Figure 7.
As depicted, cradle system 900 may be comprised of number of fixtures 903.
Number of fixtures 903 may be an example of one implementation for number of
fixtures 313 in Figure 3. Number of fixtures 903 may include number of cradle
fixtures
902 and fixture 904. Number of cradle fixtures 902 may be an example of one
implementation for number of cradle fixtures 314 in Figure 3.
Number of cradle fixtures 902 may include cradle fixture 906, cradle fixture
908,
and cradle fixture 910. Fixture 904 may be fixedly associated with cradle
fixture 906.
In this illustrative example, fixture 904 may be considered part of cradle
fixture 906.
However, in other illustrative examples, fixture 904 may be considered a
separate
fixture from cradle fixture 906.
As depicted, cradle fixture 906, cradle fixture 908, and cradle fixture 910
have
base 912, base 914, and base 916, respectively. Number of retaining structures
918
may be associated with base 912. Number of retaining structures 920 may be
associated with base 914. Number of retaining structures 922 may be associated
with
base 916. Each of number of retaining structures 918, number of retaining
structures
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920, and number of retaining structures 922 may be an example of an
implementation
for number of retaining structures 326 in Figure 3.
Each retaining structure in number of retaining structures 918, number of
retaining structures 920, and number of retaining structures 922 may have a
curved
shape that substantially matches a curvature of a corresponding fuselage
section to be
received by the retaining structure. Retaining structure 923 may be an example
of one
of number of retaining structures 920. As depicted, retaining structure 923
may have
curved shape 925.
Curved shape 925 may be selected such that curved shape 925 substantially
matches a curvature of a corresponding keel panel (not shown) that is to be
engaged
with retaining structure 923. More specifically, retaining structure 923 may
have a
substantially same radius of curvature as a corresponding keel panel (not
shown) that
is to be engaged with retaining structure 923.
In this illustrative example, plurality of stabilizing members 924, plurality
of
stabilizing members 926, and plurality of stabilizing members 928 may be
associated
with base 912, base 914, and base 916, respectively. Plurality of stabilizing
members
924, plurality of stabilizing members 926, and plurality of stabilizing
members 928 may
be used to stabilize base 912, base 914, and base 916, respectively, relative
to floor
703 of manufacturing environment 700.
In one illustrative example, these stabilizing members may keep their
respective
bases substantially level relative to floor 703. Further, each of plurality of
stabilizing
members 924, plurality of stabilizing members 926, and plurality of
stabilizing
members 928 may substantially support their respective base until that base is
to be
moved to a new location within or outside of manufacturing environment 700. In
one
illustrative example, each stabilizing member of plurality of stabilizing
members 924,
plurality of stabilizing members 926, and plurality of stabilizing members 928
may be
implemented using a hydraulic leg.
Each of number of fixtures 903 may be used to support and hold a
corresponding fuselage section (not shown) for a fuselage assembly (not shown)
for
an aircraft (not shown), such as one of plurality of fuselage sections 205 for
fuselage
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assembly 114 for aircraft 104 in Figure 2. For example, without limitation,
fixture 904
may have platform 930 associated with base 932. Platform 930 may be configured
to
support and hold a forward fuselage section (not shown) or an aft fuselage
section (not
shown) for the aircraft (not shown), depending on the implementation. The
forward
fuselage section (not shown) may be the portion of the fuselage assembly (not
shown)
that is to be closest to the nose of the aircraft (not shown). The aft
fuselage section
(not shown) may be the portion of the fuselage assembly (not shown) that is to
be
closest to the tail of the aircraft (not shown).
With reference now to Figure 10, an illustration of an isometric view of an
assembly fixture formed using cradle system 900 from Figure 9 and coupled to
first
tower 800 from Figure 8 is depicted in accordance with an illustrative
embodiment. In
this illustrative example, cradle fixture 910 is coupled to first tower 800
and cradle
fixture 910, cradle fixture 906, and cradle fixture 908 are coupled to each
other.
Cradle fixture 910, cradle fixture 908, and cradle fixture 906 may have been
autonomously driven across floor 703 of manufacturing environment 700 to
selected
cradle position 1000, selected cradle position 1002, and selected cradle
position 1004,
respectively, using a number of corresponding autonomous vehicles (not shown),
such
as number of corresponding autonomous vehicles 316 from Figure 3. Driving
cradle
fixture 906 may also cause fixture 904 to be driven when fixture 904 is part
of cradle
fixture 906 as shown. Selected cradle position 1000, selected cradle position
1002,
and selected cradle position 1004 may be an example of one implementation for
number of selected cradle positions 320 in Figure 3.
After driving cradle fixture 910, cradle fixture 908, and cradle fixture 906
to
selected cradle position 1000, selected cradle position 1002, and selected
cradle
position 1004, respectively, the number of corresponding autonomous vehicles
(not
shown) may be autonomously driven away. In other illustrative examples, the
number
of corresponding autonomous vehicles (not shown) may be integrated as part of
cradle
fixture 910, cradle fixture 908, and cradle fixture 906.
Selected cradle position 1000 may be a position relative to selected tower
position 818 of first tower 800. When cradle fixture 910 is in selected cradle
position
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1000 relative to first tower 800, cradle fixture 910 may be electrically and
physically
coupled to first tower 800 to form interface 1006. In some cases, cradle
fixture 910
may be coupled to first tower 800 autonomously to form interface 1006. In one
illustrative example, interface 1006 may be formed by autonomously coupling
cradle
fixture 910 to first tower 800. Interface 1006 may be an electrical and
physical
interface that enables a number of utilities that are flowing from utility
fixture 726 to first
tower 800 to also flow to cradle fixture 910. In this manner, interface 1006
may be
formed by autonomously coupling a number of utilities between cradle fixture
910 and
first tower 800. Interface 1006 may be an example of one implementation for
interface
340 in Figure 3. In this illustrative example, cradle fixture 910, being
coupled to first
tower 800, may be referred to as primary cradle fixture 1011.
Further, as depicted, cradle fixture 906, cradle fixture 908, and cradle
fixture
910 may be coupled to each other. In particular, cradle fixture 908 may be
coupled to
cradle fixture 910 to form interface 1008. Similarly, cradle fixture 906 may
be coupled
to cradle fixture 908 to form interface 1010. In one illustrative example,
both interface
1008 and interface 1010 may be formed by autonomously coupling these cradle
fixtures to each other.
In particular, interface 1008 and interface 1010 may take the form of
electrical
and physical interfaces that enable the number of utilities to flow from
cradle fixture
910, to cradle fixture 908, and to cradle fixture 906. In this manner,
interface 1008
may be formed by autonomously coupling the number of utilities between cradle
fixture
910 and cradle fixture 908 and interface 1010 may be formed by autonomously
coupling the number of utilities between cradle fixture 908 and cradle fixture
906. In
this manner, number of utilities 146 may be autonomously coupled between
adjacent
.. cradle fixtures in number of cradle fixtures 314.
Thus, when utility fixture 726, first tower 800, cradle fixture 910, cradle
fixture
908, and cradle fixture 906 are all coupled in series as described above, the
number of
utilities may be distributed downstream from utility fixture 726 to first
tower 800, cradle
fixture 910, cradle fixture 908, and cradle fixture 906. In this illustrative
example, any
utilities that flow to cradle fixture 906 may also be distributed to fixture
904.
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Any number of coupling units, structural members, connection devices, cables,
other types of elements, or combination thereof may be used to form interface
1008
and interface 1010. Depending on the implementation, interface 1008 and
interface
1010 may take the form of coupling units that both physically and electrically
connect
cradle fixture 910, cradle fixture 908, and cradle fixture 906 to each other.
In other
illustrative examples, interface 1008 and interface 1010 may be implemented in
some
other manner.
When cradle fixture 910, cradle fixture 908, and cradle fixture 906 are in
selected cradle position 1000, selected cradle position 1002, and selected
cradle
position 1004, respectively, and coupled to each other, these cradle fixtures
together
form assembly fixture 1012. Assembly fixture 1012 may be an example of one
implementation for assembly fixture 324 in Figure 3. In this manner, interface
1006
between first tower 800 and cradle fixture 910 may also be considered an
electrical
and physical interface between first tower 800 and assembly fixture 1012.
With reference now to Figure 11, an illustration of an isometric view of one
stage in the assembly process for building a fuselage assembly that is being
supported by assembly fixture 1012 from Figure 10 is depicted in accordance
with an
illustrative embodiment. In this illustrative example, assembly fixture 1012
may
support fuselage assembly 1100 as fuselage assembly 1100 is built on assembly
.. fixture 1012.
Fuselage assembly 1100 may be an aft fuselage assembly that is an example
of one implementation for aft fuselage assembly 116 in Figure 1. Fuselage
assembly
1100 may be partially assembled in this illustrative example. Fuselage
assembly 1100
may be at an early stage of assembly in this example.
At this stage of the assembly process, fuselage assembly 1100 includes end
panel 1101 and plurality of keel panels 1102. End panel 1101 may have a
tapered
cylindrical shape in this illustrative example. In this manner, one portion of
end panel
1101 may form part of the keel 1105 for fuselage assembly 1100, another
portion of
end panel 1101 may form part of the sides (not fully shown) for fuselage
assembly
CA 02895737 2015-06-25
1100, and yet another portion of end panel 1101 may form part of a crown (not
fully
shown) for fuselage assembly 1100.
Further, as depicted, bulkhead 1103 may be associated with end panel 1101.
Bulkhead 1103 may be a pressure bulkhead. Bulkhead 1103 may be an example of
one implementation for bulkhead 272 in Figure 2.
Plurality of keel panels 1102 include keel panel 1104, keel panel 1106, and
keel
panel 1108. End panel 1101 and plurality of keel panels 1102 have been engaged
with assembly fixture 1012. In particular, end panel 1101 has been engaged
with
fixture 904. Keel panel 1104, keel panel 1106, and keel panel 1108 have been
engaged with cradle fixture 906, cradle fixture 908, and cradle fixture 910,
respectively.
In one illustrative example, end panel 1101 is first engaged with fixture 904
with
keel panel 1104, keel panel 1106, and keel panel 1108 then being successively
engaged with cradle fixture 906, cradle fixture, 908, and cradle fixture 910,
respectively. In this manner, keel 1105 of fuselage assembly 1100 may be
assembled
in a direction from the aft end of fuselage assembly 1100 to the forward end
of
fuselage assembly 1100.
Each of cradle fixture 906, cradle fixture 908, and cradle fixture 910 may be
at
least one of autonomously or manually adjusted, as needed, to accommodate
plurality
of keel panels 1102 such that fuselage assembly 1100 may be built to meet
outer mold
line requirements and inner mold line requirements within selected tolerances.
In
some cases, at least one of cradle fixture 906, cradle fixture 908, and cradle
fixture
910 may have at least one retaining structure that can be adjusted to adapt to
the
shifting of fuselage assembly 1100 during the assembly process due to
increased
loading as fuselage assembly 1100 is built.
As depicted, members 1111 may be associated with end panel 1101 and
plurality of keel panels 1102. Members 1111 may include frames and stringers
in this
illustrative example. However, depending on the implementation, members 1111
may
also include, without limitation, stiffeners, stanchions, intercostal
structural members,
connecting members, other types of structural members, or some combination
thereof.
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The connecting members may include, for example, without limitation, shear
clips, ties,
splices, intercostal connecting members, other types of mechanical connecting
members, or some combination thereof.
The portion of members 1111 attached to end panel 1101 may form support
section 1110. The portions of members 1111 attached to keel panel 1104, keel
panel
1106, and keel panel 1108 may form support section 1112, support section 1114,
and
support section 1116, respectively.
In this illustrative example, end panel 1101 may form fuselage section 1118
for
fuselage assembly 1100. Each of keel panel 1104, keel panel 1106, and keel
panel
1108 may form a portion of fuselage section 1120, fuselage section 1122, and
fuselage section 1124, respectively, for fuselage assembly 1100. Fuselage
section
1118, fuselage section 1120, fuselage section 1122, and fuselage section 1124
may
together form plurality of fuselage sections 1125 for fuselage assembly 1100.
Each of
fuselage section 1118, fuselage section 1120, fuselage section 1122, and
fuselage
section 1124 may be an example of one implementation for fuselage section 207
in
Figure 2.
End panel 1101 and plurality of keel panels 1102 may be temporarily connected
together using temporary fasteners such as, for example, without limitation,
tack
fasteners. In particular, end panel 1101 and plurality of keel panels 1102 may
be
temporarily connected to each other as each of the panels is engaged with
assembly
fixture 1012 and other panels.
For example, without limitation, coordination holes (not shown) may be present
at the edges of end panel 1101 and each of plurality of keel panels 1102. In
some
cases, a coordination hole may pass through a panel and at least one of
members
1111 associated with the panel. Engaging one panel with another panel may
include
aligning these coordination holes such that temporary fasteners, such as tack
fasteners, may be installed in these coordination holes. In some cases,
engaging one
panel with another panel may include aligning a coordination hole through one
panel
with a coordination hole through one of members 1111 associated with another
panel.
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In yet another illustrative example, engaging a first panel with another panel
may include aligning the edges of the two panels to form a butt splice. These
two
panels may then be temporarily connected together by aligning a first number
of
coordination holes in, for example, a splice plate, with a corresponding
number of
holes on the first panel and aligning a second number of coordination holes in
that
splice plate with a corresponding number of holes on the second panel.
Temporary
fasteners may then be inserted through these aligned coordination holes to
temporarily
connect the first panel to the second panel.
In this manner, panels and members may be engaged with each other and
temporarily connected together in a number of different ways. Once end panel
1101
and plurality of keel panels 1102 have been temporarily connected together,
assembly
fixture 1012 may help maintain the position and orientation of end panel 1101
and
each of plurality of keel panels 1102 relative to each other.
Turning now to Figure 12, an illustration of an isometric view of another
stage
in the assembly process for building a fuselage assembly is depicted in
accordance
with an illustrative embodiment. In this illustrative example, cargo floor
1200 has been
added to fuselage assembly 1100. In particular, cargo floor 1200 may be
associated
with plurality of keel panels 1102.
As depicted, at least a portion of cargo floor 1200 may be substantially level
with bottom platform 807 of first tower 800. In particular, at least the
portion of cargo
floor 1200 nearest first tower 800 may be substantially aligned with bottom
platform
807 of first tower 800. In this manner, a human operator (not shown) may use
bottom
platform 807 of first tower 800 to easily walk onto cargo floor 1200 and
access interior
1201 of fuselage assembly 1100.
As depicted, first side panels 1202 and second side panels 1204 have been
added to fuselage assembly 1100. First side panels 1202 and second side panels
1204 may be an example of one implementation for first side panels 224 and
second
side panels 226, respectively, in Figure 2. First side panels 1202, second
side panels
1204, and a first and second portion of end panel 1101 may form sides 1205 of
fuselage assembly 1100. In this illustrative example, plurality of keel panels
1102, end
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panel 1101, first side panels 1202, and second side panels 1204 may all be
temporarily connected together using, for example, without limitation, tack
fasteners.
First side panels 1202 may include side panel 1206, side panel 1208, and side
panel 1210 that have been engaged with and temporarily connected to keel panel
1104, keel panel 1106, and keel panel 1108, respectively. Similarly, second
side
panels 1204 may include side panel 1212, side panel 1214, and side panel 1216
that
have been engaged with and temporarily connected to keel panel 1104, keel
panel
1106, and keel panel 1108, respectively. Further, both side panel 1206 and
side panel
1212 have been engaged with end panel 1101.
As depicted, members 1218 may be associated with first side panels 1202.
Other members (not shown) may be similarly associated with second side panels
1204. Members 1218 may be implemented in a manner similar to members 1111. In
this illustrative example, corresponding portion 1220 of members 1218 may be
associated with side panel 1206. Corresponding portion 1220 of members 1218
may
form support section 1222 associated with side panel 1206. Support section
1222 be
an example of one implementation for support section 238 in Figure 2.
With reference now to Figure 13, an illustration of an isometric view of
another
stage in the assembly process for building a fuselage assembly is depicted in
accordance with an illustrative embodiment. In this illustrative example,
passenger
floor 1300 has been added to fuselage assembly 1100. As depicted, passenger
floor
1300 may be substantially level with top platform 806 of first tower 800.
Human
operator 1302 may use top platform 806 of first tower 800 to walk onto
passenger floor
1300 and access interior 1201 of fuselage assembly 1100.
With reference now to Figure 14, an illustration of an isometric view of
another
stage in the assembly process for building a fuselage assembly is depicted in
accordance with an illustrative embodiment. In this illustrative example,
plurality of
crown panels 1400 have been added to fuselage assembly 1100. Plurality of
crown
panels 1400 may be an example of one implementation for crown panels 218 in
Figure 2.
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In this illustrative example, plurality of crown panels 1400 may include crown
panel 1402, crown panel 1404, and crown panel 1406. These crown panels along
with
a top portion of end panel 1101 may form crown 1407 of fuselage assembly 1100.
Crown panel 1402 may be engaged with and temporarily connected to end panel
1101, side panel 1206 shown in Figure 12, side panel 1212, and crown panel
1404.
Crown panel 1404 may be engaged with and temporarily connected to crown panel
1402, crown panel 1406, side panel 1208 shown in Figure 12, and side panel
1214.
Further, crown panel 1406 may be engaged with and temporarily connected to
crown
panel 1404, side panel 1210, and side panel 1216.
Together, end panel 1101, plurality of keel panels 1102, first side panels
1202,
second side panels 1204, and plurality of crown panels 1400 may form plurality
of
panels 1408 for fuselage assembly 1100. Plurality of panels 1408 may be an
example
of one implementation for plurality of panels 120 in Figure 1.
Plurality of panels 1408 may all be temporarily connected to each other such
that desired compliance with outer mold line requirements and inner mold line
requirements may be maintained during the building of fuselage assembly 1100.
In
other words, temporarily connecting plurality of panels 1408 to each other may
enable
outer mold line requirements and inner mold line requirements to be met within
selected tolerances during the building of fuselage assembly 1100 and, in
particular,
the joining of plurality of panels 1408 together.
Members (not shown) may be associated with plurality of crown panels 1400 in
a manner similar to the manner in which members 1218 are associated with first
side
panels 1202. These members associated with plurality of crown panels 1400 may
be
implemented in a manner similar to members 1218 and members 1111 as shown in
Figures 12-13. The various members associated with end panel 1101, plurality
of
keel panels 1102, plurality of crown panels 1400, first side panels 1202, and
second
side panels 1204 may form plurality of members 1410 for fuselage assembly
1100.
When plurality of panels 1408 are joined together, plurality of members 1410
may form
a support structure (not yet shown) for fuselage assembly 1100, similar to
support
structure 131 in Figure 1.
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After plurality of crown panels 1400 have been added to fuselage assembly
1100, first tower 800 may be autonomously decoupled from assembly fixture 1012
and
utility fixture 726. First tower 800 may then be autonomously driven away from
utility
fixture 726 using, for example, without limitation, autonomous vehicle 816 in
Figure 8.
In one illustrative example, first tower 800 may be autonomously driven back
to
holding environment 701 in Figure 7.
When first tower 800 is decoupled from assembly fixture 1012 and utility
fixture
726, a gap is formed in the distributed utility network. This gap may be
filled using a
second tower (not shown), implemented in a manner similar to second tower 336
in
Figure 3.
With reference now to Figure 15, an illustration of an isometric view of a
second tower coupled to utility fixture 726 and assembly fixture 1012
supporting
fuselage assembly 1100 from Figure 14 is depicted in accordance with an
illustrative
embodiment. In this illustrative example, second tower 1500 has been
positioned
relative to assembly fixture 1012 and utility fixture 726. Second tower 1500
may be an
example of one implementation for second tower 336 in Figure 3.
Second tower 1500 may be autonomously driven across floor 703 using an
autonomous vehicle (not shown), similar to autonomous vehicle 816 in Figure 8.
Second tower 1500 may be autonomously driven into selected tower position 1518
relative to utility fixture 726. Selected tower position 1518 may be an
example of one
implementation for selected tower position 338 in Figure 3.
In this illustrative
example, selected tower position 1518 may be substantially the same as
selected
tower position 818 in Figure 8.
Once second tower 1500 has been autonomously driven into selected tower
position 1518, second tower 1500 may autonomously couple to utility fixture
726. In
particular, second tower 1500 may electrically and physically couple to
utility fixture
726 autonomously to form interface 1502. Interface 1502 may be another example
of
one implementation for interface 342 in Figure 3. This type of coupling may
enable a
number of utilities to flow from utility fixture 726 to second tower 1500.
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CA 02895737 2015-06-25
Further, second tower 1500 may autonomously couple to cradle fixture 910,
thereby autonomously coupling to assembly fixture 1012, to form interface
1505.
Interface 1505 may enable the number of utilities to flow downstream from
second
tower 1500. In this manner, the number of utilities may flow from second tower
1500
to cradle fixture 910, to cradle fixture 908, and then to cradle fixture 906.
In this
manner, second tower 1500 may fill the gap in the distributed utility network
that was
created when first tower 800 in Figure 14 was decoupled from assembly fixture
1012
and utility fixture 726 and driven away.
Similar to first tower 800 in Figure 8, second tower 1500 may include base
structure 1504, top platform 1506, and bottom platform 1507. However, top
platform
1506 and bottom platform 1507 may be used to provide internal mobile platforms
with
access to interior 1201 of fuselage assembly 1100 instead of human operators.
In this illustrative example, internal mobile platform 1508 may be positioned
on
top platform 1506. Top platform 1506 may be substantially aligned with
passenger
floor 1300 such that internal mobile platform 1508 may be able to autonomously
drive
across top platform 1506 onto passenger floor 1300.
Similarly, an internal mobile platform (not shown in this view) may be
positioned
on bottom platform 1507. Bottom platform 1507 may be substantially aligned
with
cargo floor 1200 (not shown in this view) from Figure 12 such that this other
internal
mobile platform (not shown in this view) may be able to autonomously drive
across
bottom platform 1507 onto the cargo floor. Internal mobile platform 1508 and
the other
internal mobile platform (not shown in this view) may be examples of
implementations
for internal mobile platform 406 in Figure 4.
As depicted, internal robotic device 1510 and internal robotic device 1512 may
be associated with internal mobile platform 1508. Although internal robotic
device
1510 and internal robotic device 1512 are shown associated with the same
internal
mobile platform 1508, in other illustrative examples, internal robotic device
1510 may
be associated with one internal mobile platform and internal robotic device
1512 may
be associated with another internal mobile platform. Each of internal robotic
device
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CA 02895737 2015-06-25
1510 and internal robotic device 1512 may be an example of one implementation
for
internal robotic device 416 in Figure 4.
Internal robotic device 1510 and internal robotic device 1512 may be used to
perform operations within interior 1201 of fuselage assembly 1100 for joining
plurality
of panels 1408. For example, without limitation, internal robotic device 1510
and
internal robotic device 1512 may be used to perform fastening operations, such
as
riveting operations, within interior 1201 of fuselage assembly 1100.
In one illustrative example, utility box 1520 may be associated with base
structure 1504. Utility box 1520 may manage the number of utilities received
from
utility fixture 726 through interface 1502 and may distribute these utilities
into utility
cables that are managed using cable management system 1514 and cable
management system 1516.
As depicted in this example, cable management system 1514 may be
associated with top platform 1506 and cable management system 1516 may be
associated with bottom platform 1507. Cable management system 1514 and cable
management system 1516 may be implemented similarly.
Cable management system 1514 may include cable wheels 1515 and cable
management system 1516 may include cable wheels 1517. Cable wheels 1515 may
be used to spool utility cables that are connected to internal mobile platform
1508. For
example, without limitation, cable wheels 1515 may be biased in some manner to
substantially maintain a selected amount of tension in the utility cables.
This biasing
may be achieved using, for example, one or more spring mechanisms.
As internal mobile platform 1508 moves away from second tower 1500 along
passenger floor 1300, the utility cables may extend from cable wheels 1515 to
maintain utility support to internal mobile platform 1508 and manage the
utility cables
such that they do not become tangled. Cable wheels 1517 may be implemented in
a
manner similar to cable wheels 1515.
By using cable wheels 1515 to spool the utility cables, the utility cables may
be
kept off of internal mobile platform 1508, thereby reducing the weight of
internal mobile
platform 1508 and the load applied by internal mobile platform 1508 to
passenger floor
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CA 02895737 2015-06-25
1300. The number of utilities provided to internal mobile platform 1508 may
include,
for example, without limitation, electricity, air, water, hydraulic fluid,
communications,
some other type of utility, or some combination thereof.
With reference now to Figure 16, an illustration of an isometric cutaway view
of
a plurality of mobile platforms performing fastening processes within interior
1201 of
fuselage assembly 1100 is depicted in accordance with an illustrative
embodiment. In
this illustrative example, plurality of mobile platforms 1600 may be used to
perform
fastening processes to join plurality of panels 1408 together.
In particular, plurality of panels 1408 may be joined together at selected
locations along fuselage assembly 1100. Plurality of panels 1408 may be joined
to
form at least one of lap joints, butt joints, or other types of joints. In
this manner,
plurality of panels 1408 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 1408.
As depicted, plurality of mobile platforms 1600 may include internal mobile
platform 1508 and internal mobile platform 1601. Internal mobile platform 1508
and
internal mobile platform 1601 may be an example of one implementation for
number of
internal mobile platforms 402 in Figure 4. Internal mobile platform 1508 may
be
configured to move along passenger floor 1300, while internal mobile platform
1601
may be configured to move along cargo floor 1200.
As depicted, internal robotic device 1602 and internal robotic device 1604 may
be associated with internal mobile platform 1601. Each of internal robotic
device 1602
and internal robotic device 1604 may be an example of one implementation for
internal
robotic device 416 in Figure 4. Internal robotic device 1602 and internal
robotic
device 1604 may be similar to internal robotic device 1510 and internal
robotic device
1512.
Plurality of mobile platforms 1600 may also include external mobile platform
1605 and external mobile platform 1607. External mobile platform 1605 and
external
mobile plafform 1607 may be an example of one implementation for at least a
portion
of number of external mobile platforms 400 in Figure 4. External mobile
platform 1605
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CA 02895737 2015-06-25
and external mobile platform 1607 may be examples of implementations for
external
mobile platform 404 in Figure 4.
External robotic device 1606 may be associated with external mobile platform
1605. External robotic device 1608 may be associated with external mobile
platform
1607. Each of external robotic device 1606 and external robotic device 1608
may be
an example of one implementation for external robotic device 408 in Figure 4.
As depicted, external robotic device 1606 and internal robotic device 1512 may
work collaboratively to install fasteners autonomously in fuselage assembly
1100.
These fasteners may take the form of, for example, without limitation, at
least one of
rivets, interference-fit bolts, non-interference-fit bolts, or other types of
fasteners or
fastener systems. Similarly, external robotic device 1608 and internal robotic
device
1604 may work collaboratively to install fasteners autonomously in fuselage
assembly
1100. As one illustrative example, end effector 1610 of internal robotic
device 1512
and end effector 1612 of external robotic device 1606 may be positioned
relative to a
same location 1620 on fuselage assembly 1100 to perform a fastening process at
location 1620, such as fastening process 424 in Figure 4.
The fastening process may include at least one of, for example, without
limitation, a drilling operation, a fastener insertion operation, a fastener
installation
operation, an inspection operation, or some other type of operation. The
fastener
installation operation may take the form of, for example, without limitation,
two-stage
riveting process 444 described in Figure 4, interference-fit bolt-type
installation
process 439 described in Figure 4, bolt-nut type installation process 433
described in
Figure 4, or some other type of fastener installation operation.
In this illustrative example, autonomous vehicle 1611 may be fixedly
associated
with external mobile platform 1605. Autonomous vehicle 1611 may be used to
drive
external mobile platform 1605 autonomously. For example, autonomous vehicle
1611
may be used to autonomously drive external mobile platform 1605 across floor
703 of
manufacturing environment 700 relative to assembly fixture 1012.
Similarly, autonomous vehicle 1613 may be fixedly associated with external
mobile platform 1607. Autonomous vehicle 1613 may be used to drive external
mobile
CA 02895737 2015-06-25
platform 1607 autonomously. For example, autonomous vehicle 1613 may be used
to
autonomously drive external mobile platform 1607 across floor 703 of
manufacturing
environment 700 relative to assembly fixture 1012.
By being fixedly associated with external mobile platform 1605 and external
mobile platform 1607, autonomous vehicle 1611 and autonomous vehicle 1613 may
be considered integral to external mobile platform 1605 and external mobile
platform
1607, respectively.
However, in other illustrative examples, these autonomous
vehicles may be independent of the external mobile platforms in other
illustrative
examples.
Once all fastening processes have been completed for fuselage assembly
1100, internal mobile platform 1508 and internal mobile platform 1601 may be
autonomously driven across passenger floor 1300 back onto top platform 1506
and
bottom platform 1507, respectively, of second tower 1500. Second tower 1500
may
then be autonomously decoupled from both utility fixture 726 and assembly
fixture
1012. Autonomous vehicle 1614 may then be used to autonomously drive or move
second tower 1500 away.
In this illustrative example, building of fuselage assembly 1100 may now be
considered completed for this stage in the overall assembly process for the
fuselage.
Consequently, assembly fixture 1012 may be autonomously driven across floor
703 to
move fuselage assembly 1100 to some other location. In other illustrative
examples,
first tower 800 from Figure 8 may be autonomously driven back into selected
tower
position 818 in Figure 8 relative to utility fixture 726. First tower 800 from
Figure 8
may then be autonomously recoupled to utility fixture 726 and assembly fixture
1012.
First tower 800 from Figure 8 may enable a human operator (not shown) to
access
interior 1201 of fuselage assembly 1100 to perform other operations including,
but not
limited to, at least one of inspection operations, fastening operations,
system
installation operations, or other types of operations. System installation
operations
may include operations for installing systems such as, for example, without
limitation,
at least one of a fuselage utility system, an air conditioning system,
interior panels,
electronic circuitry, some other type of system, or some combination thereof.
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CA 02895737 2015-06-25
With reference now to Figure 17, an illustration of a cross-sectional view of
flexible manufacturing system 708 performing operations on fuselage assembly
1100
from Figure 16 is depicted in accordance with an illustrative embodiment. In
this
illustrative example, a cross-sectional view of fuselage assembly 1100 from
Figure 16
is depicted taken in the direction of lines 17-17 in Figure 16.
As depicted, internal mobile platform 1508 and internal mobile platform 1601
are performing operations within interior 1201 of fuselage assembly 1100.
External
mobile platform 1605 and external mobile platform 1607 are performing assembly
operations along exterior 1700 of fuselage assembly 1100.
In this illustrative example, external mobile platform 1605 may be used to
perform operations along portion 1702 of exterior 1700 between axis 1704 and
axis
1706 at first side 1710 of fuselage assembly 1100. External robotic device
1606 of
external mobile platform 1605 may work collaboratively with internal robotic
device
1510 of internal mobile platform 1508 to perform fastening processes.
Similarly, external mobile platform 1607 may be used to perform operations
along portion 1708 of exterior 1700 of fuselage assembly 1100 between axis
1704 and
axis 1706 at second side 1712 of fuselage assembly 1100. External robotic
device
1608 of external mobile platform 1607 may work collaboratively with internal
robotic
device 1604 of internal mobile platform 1601 to perform fastening processes.
Although external mobile platform 1605 is depicted as being located at first
side
1710 of fuselage assembly 1100, external mobile platform 1605 may be
autonomously
driven by autonomous vehicle 1611 to second side 1712 of fuselage assembly
1100 to
perform operations along portion 1711 of exterior 1700 of fuselage assembly
1100
between axis 1704 and axis 1706. Similarly, external mobile platform 1607 may
be
autonomously driven by autonomous vehicle 1613 to second side 1712 of fuselage
assembly 1100 to perform operations along portion 1713 of exterior 1700 of
fuselage
assembly 1100 between axis 1704 and axis 1706.
Although not shown in this illustrative example, an external mobile platform
similar to external mobile platform 1605 may have an external robotic device
configured to work collaboratively with internal robotic device 1512 of
internal mobile
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CA 02895737 2015-06-25
platform 1508 at second side 1712 of fuselage assembly 1100. Similarly, an
external
mobile platform similar to external mobile platform 1607 may have an external
robotic
device configured to work collaboratively with internal robotic device 1602 of
internal
mobile platform 1601 at first side 1710 of fuselage assembly 1100.
These four different external mobile platforms and two internal mobile
platforms
may be controlled such that the operations performed by internal mobile
platform 1508
located on passenger floor 1300 may occur at a different location with respect
to the
longitudinal axis of fuselage assembly 1100 than the operations performed by
internal
mobile platform 1601 located on cargo floor 1200. The four external mobile
platforms
a o may
be controlled such that the two external mobile platforms located on the same
side of fuselage assembly 1100 do not collide or impede one another. The two
external mobile platforms located at the same side of fuselage assembly 1100
may be
unable to occupy the same footprint in this illustrative example.
In this illustrative example, external mobile platform 1605 may autonomously
couple to assembly fixture 1012 to form interface 1722 such that a number of
utilities
may flow from assembly fixture 1012 to external mobile platform 1605. In other
words,
the number of utilities may be autonomously coupled between external mobile
platform
1605 and assembly fixture 1012 through interface 1722. In particular, external
mobile
platform 1605 has been coupled to cradle fixture 910 through interface 1722.
Similarly, external mobile platform 1607 may autonomously couple to assembly
fixture 1012 to form interface 1724 such that a number of utilities may flow
from
assembly fixture 1012 to external mobile platform 1607. In other words, the
number of
utilities may be autonomously coupled between external mobile platform 1607
and
assembly fixture 1012 through interface 1724. In particular, external mobile
platform
1607 has been coupled to cradle fixture 910 through interface 1724.
As operations are performed along fuselage assembly 1100 by external mobile
platform 1605, external mobile platform 1607, and any other external mobile
platforms,
these external mobile platforms may be coupled to and decoupled from assembly
fixture 1012 as needed. For example, external mobile platform 1607 may
decouple
from cradle fixture 910 as external mobile platform 1607 moves aftward along
fuselage
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CA 02895737 2015-06-25
assembly 1100 such that external mobile platform 1607 may then autonomously
couple to cradle fixture 908 (not shown) from Figures 9-16. Further, these
external
mobile platforms may be coupled to and decoupled from assembly fixture 1012 to
avoid collisions and prevent the external mobile platforms from impeding each
other
during maneuvering of the external mobile platforms relative to assembly
fixture 1012
and fuselage assembly 1100.
As depicted, autonomous vehicle 1714 is shown positioned under the assembly
fixture 1012 formed by cradle system 900. In this illustrative example,
autonomous
vehicle 1714, autonomous vehicle 1611, and autonomous vehicle 1613 may have
omnidirectional wheels 1716, omnidirectional wheels 1718, and omnidirectional
wheels 1720, respectively. In some illustrative examples, metrology system
1726 may
be used to help position external mobile platform 1605 and external mobile
platform
1607 relative to fuselage assembly 1100.
Turning now to Figure 18, an illustration of an isometric view of a fully
built
fuselage assembly is depicted in accordance with an illustrative embodiment.
In this
illustrative example, fuselage assembly 1100 may be considered completed when
plurality of panels 1408 have been fully joined.
In other words, all fasteners needed to join together plurality of panels 1408
have been fully installed. With plurality of panels 1408 joined together,
support
structure 1800 may be fully formed. Support structure 1800 may be an example
of
one implementation for support structure 121 in Figure 1. Fuselage assembly
1100,
which is an aft fuselage assembly, may now be ready for attachment to a
corresponding middle fuselage assembly (not shown) and forward fuselage
assembly
(not shown).
As depicted, autonomous vehicles (not shown in this view), similar to
autonomous vehicle 1614 shown in Figure 16, may be positioned under base 912
of
cradle fixture 906, base 914 of cradle fixture 908, and base 916 of cradle
fixture 910,
respectively. Autonomous vehicles, such as number of corresponding autonomous
vehicles 316 in Figure 3, may lift up base 912, base 914, and base 916,
respectively,
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CA 02895737 2015-06-25
such that plurality of stabilizing members 924, plurality of stabilizing
members 926, and
plurality of stabilizing members 928, respectively, no longer contact the
floor.
These autonomous vehicles (not shown) may then autonomously drive cradle
system 900 carrying fuselage assembly 1100 that has been fully built away from
assembly environment 702 in Figure 7 and, in some cases, away from
manufacturing
environment 700 in Figure 7. Computer-controlled movement of these autonomous
vehicles (not shown) may ensure that number of cradle fixtures 902 maintain
their
positions relative to each other as fuselage assembly 1100 is being moved.
With reference now to Figure 19, an illustration of an isometric view of
fuselage
assemblies being built within manufacturing environment 700 is depicted in
accordance with an illustrative embodiment. In this illustrative example,
plurality of
fuselage assemblies 1900 are being built within plurality of work cells 712 in
manufacturing environment 700.
Plurality of fuselage assemblies 1900 may include plurality of forward
fuselage
assemblies 1901 being built in first portion 714 of plurality of work cells
712 and
plurality of aft fuselage assemblies 1902 being built in second portion 716 of
plurality
of work cells 712. Each of plurality of fuselage assemblies 1900 may be an
example
of one implementation for fuselage assembly 114 in Figure 1.
As depicted, plurality of fuselage assemblies 1900 are being built
concurrently.
However, plurality of fuselage assemblies 1900 are at different stages of
assembly in
this illustrative example.
Forward fuselage assembly 1904 may be an example of one of plurality of
forward fuselage assemblies 1901. Forward fuselage assembly 1904 may be an
example of one implementation for forward fuselage assembly 117 in Figure 1.
Aft
fuselage assembly 1905 may be an example of one of plurality of aft fuselage
assemblies 1902. Aft fuselage assembly 1905 may be an example of one
implementation for aft fuselage assembly 116 in Figure 1. In this illustrative
example,
aft fuselage assembly 1905 may be at an earlier stage of assembly than forward
fuselage assembly 1904.
CA 02895737 2015-06-25
Aft fuselage assembly 1906, which may be another example of an
implementation for aft fuselage assembly 116 in Figure 1, may be a fuselage
assembly with all panels joined. As depicted, aft fuselage assembly 1906 is
being
autonomously driven to some other location for a next stage in the overall
fuselage
and aircraft manufacturing process.
As described above, aft fuselage assembly 1905 may be partially assembled.
In this illustrative example, aft fuselage assembly 1905 has keel 1910, end
panel
1911, and first side 1912. End panel 1911 may form an end fuselage section of
aft
fuselage assembly 1905. As depicted, side panel 1914 may be added to aft
fuselage
assembly 1905 to build a second side of aft fuselage assembly 1905.
Forward fuselage assembly 1915 may be another example of one of plurality of
forward fuselage assemblies 1901. In this illustrative example, forward
fuselage
assembly 1915 has keel 1916 and end panel 1918. End panel 1918 may form an end
fuselage section of forward fuselage assembly 1915. As depicted, side panel
1920
may be added to forward fuselage assembly 1915 to begin building a first side
of
forward fuselage assembly 1915.
With reference now to Figure 20, an illustration of an isometric view of
cradle
fixture 906 from Figure 9 is depicted in accordance with an illustrative
embodiment.
As depicted, cradle fixture 906 may include base 912 and base 932. Base 932
may
belong to fixture 904. Base 912 and base 932 may together form overall base
2001
for cradle fixture 906.
As depicted, plurality of retaining members 2002 may be associated with base
932 of fixture 904. Plurality of retaining members 2002 may include retaining
members 2004, 2006, and 2008 that are used to fuselage section 1118 in Figure
11.
In this illustrative example, each of plurality of retaining members 2002 may
be
movable relative to X-axis 2010, Y-axis 2012, and Z-axis 2011.
Movement system 2005, movement system 2007, and movement system 2009
may be used to move retaining members 2004, 2006, and 2008, respectively,
relative
to X-axis 2010, Y-axis 2012, and Z-axis 2011. As depicted, movement system
2005
may include rail system 2014, rail system 2016, and actuator device 2018.
Movement
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CA 02895737 2015-06-25
system 2007 may include rail system 2020, rail system 2022, and actuator
device
2024. Movement system 2009 may include rail system 2026, rail system 2028, and
actuator device 2030.
Rail system 2014, rail system 2016, rail system 2020, rail system 2022, rail
system 2026, and rail system 2028 may provide movement relative to X-axis 2010
and
Y-axis 2012. In other words, these rail systems may provide horizontal X-Y
movement. Actuator device 2018, actuator device 2024, and actuator device 2030
may provide movement relative to Z-axis 2011. In other words, these actuator
devices
may provide vertical Z movement.
In this illustrative example, plurality of units 2034 may be associated with
overall
base 2001. Plurality of units 2034 may include, for example, without
limitation, a
power unit, an air supply unit, a hydraulic unit, a water supply unit, a
communications
unit, or some other type of unit.
As depicted, number of retaining structures 918 may include retaining
structures 2036, 2038, and 2040. Retaining structures 2036, 2038, and 2040 may
be
associated with base 912. Each of retaining structures 2036, 2038, and 2040
may be
an example of one implementation for retaining structure 616 in Figure 6.
As depicted, retaining structure 2036 may be moved relative to X-axis 2010, Y-
axis 2012, and Z-axis 2011 using movement system 2042 and movement system
2044. Retaining structure 2038 may be moved relative to X-axis 2010, Y-axis
2012,
and Z-axis 2011 using movement system 2046 and movement system 2048.
Retaining structure 2040 may be moved relative to X-axis 2010, Y-axis 2012,
and Z-
axis 2011 using movement system 2050.
As depicted, bracket 2052 may be associated with base 912 and used to hold a
rail system (not shown) for a utilities unit (not shown). This utilities unit
(not shown)
may be used to couple an external mobile platform, such as external mobile
platform
404 described in Figure 4, to cradle fixture 906. As used herein, a utilities
unit may
also be referred to as a utility unit in some cases.
In this illustrative example, plurality of stabilizing members 924 may take
the
form of plurality of hydraulic legs 2054. Each of plurality of hydraulic legs
2054 may be
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CA 02895737 2015-06-25
capable of adjusting in height. In this manner, plurality of stabilizing
members 924
may be used to adjust at least one of a height of cradle fixture 906 or the
tilt of cradle
fixture 906 relative to Z-axis 2011.
With reference now to Figure 21, an illustration of an enlarged isometric view
of
retaining member 2004 and movement system 2005 from Figure 20 is depicted in
accordance with an illustrative embodiment. Rail system 2014, rail system
2016, and
actuator device 2018 from Figure 20 are more clearly depicted in Figure 21.
As depicted, rail system 2014 may include rail 2100, rail 2102, and motor
2104.
Motor 2104 may be used to provide movement of retaining member 2004 along rail
2100 and rail 2102. For example, retaining member 2004 may be indirectly
associated
with plate 2105 that is configured to move along rail 2100 and rail 2102.
Motor 2104
may be used to move plate 2105 along these rails to move retaining member 2004
in a
direction along X-axis 2010.
In this illustrative example, rail system 2016 may include rail 2106, rail
2108,
and motor 2110. Motor 2110 may be used to provide movement of retaining member
2004 along rail 2106 and rail 2108. For example, retaining member 2004 may be
indirectly associated with plate 2111 that is configured to move along rail
2106 and rail
2108. Motor 2110 may be used to move plate 2111 along these rails to move
retaining member 2004 in a direction along Y-axis 2012.
Actuator device 2018 may include telescoping device 2112. Telescoping
device 2112 may include base 2114, element 2116, element 2118, and element
2120.
Motor 2122 may be used to move each of element 2116, element 2118, and element
2120 along Z-axis 2011 relative to base 2114. In this manner, movement system
2005
may provide movement of retaining member 2004 relative to X-axis 2010, Y-axis
2012,
and Z-axis 2011.
Turning now to Figure 22, an illustration of an enlarged isometric view of
retaining structure 2038, movement system 2046, and movement system 2048 from
Figure 20 is depicted in accordance with an illustrative embodiment. Movement
system 2046 and movement system 2048 may be more clearly seen in Figure 22.
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CA 02895737 2015-06-25
In this illustrative example, movement system 2048 and movement system
2046 may include X-Y table 2200 and X-Y table 2202, respectively. X-Y table
2200
and X-Y table 2202 may be examples of implementations for X-Y table 646 in
Figure
6.
Movement system 2048 may also include motor 2204, motor 2208, motor 2209,
and actuator device 2212. Motor 2204 may be configured to move X-Y table 2200
in a
direction along X-axis 2010. Motor 2208 may be configured to move X-Y table
2200 in
a direction along Y-axis 2012. Motor 2209 may be configured to operate
actuator
device 2212 to move the portion of retaining structure 2038 associated with
actuator
device 2212 along Z-axis 2214.
Similarly, movement system 2046 may also include motor 2216, motor 2218,
motor 2220, and actuator device 2221. Motor 2216 may be configured to move X-Y
table 2200 in a direction along X-axis 2010. Motor 2218 may be configured to
move
X-Y table 2200 in a direction along Y-axis 2210. Motor 2220 may be configured
to
operate actuator device 2221 to move the portion of retaining structure 2038
associated with actuator device 2221 along Z-axis 2214.
As depicted, retaining structure 2038 may include beam 2222 and beam 2224
connected by set of connecting elements 2226. Beam 2222 and beam 2224 may
have curved shape 2223 and curved shape 2225, respectively. Curved shape 2223
and curved shape 2225 may substantially match the curvature of the portion of
keel
panel 1104 shown in Figure 11 that is received by retaining structure 2038.
More
specifically, beam 2222 and beam 2224 may have radii of curvature that
substantially
match an outer mold line of the portion of keel panel 1104 shown in Figure 11
that is
engaged with retaining structure 2038. With beam 2222 and beam 2224 having
curved shape 2223 and curved shape 2225, respectively, retaining structure
2038 may
also have an overall curved shape.
Retaining structure 2036 in Figure 20 may be implemented in a manner similar
to retaining structure 2038. Further, movement system 2042 and movement system
2044 associated with retaining structure 2036 in Figure 20 may be implemented
in a
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CA 02895737 2015-06-25
manner similar to movement system 2046 and movement system 2048, respectively,
associated with retaining structure 2038.
With reference now to Figure 23, an illustration of an enlarged isometric view
of
retaining structure 2040 and movement system 2050 from Figure 20 is depicted
in
accordance with an illustrative embodiment. In this illustrative example,
movement
system 2050 may be more clearly seen.
Retaining structure 2040 may include beam 2300 and beam 2302 connected by
set of connecting elements 2304. In this illustrative example, both beam 2300
and
beam 2302 may be curved such that retaining structure 2040 has curved shape
2305
that may substantially match the curvature of keel panel 1104 shown in Figure
11 to
be received by retaining structure 2040. More specifically, beam 2300 and beam
2302
may have radii of curvature that substantially match an outer mold line of the
portion of
keel panel 1104 shown in Figure 11 that is to be engaged with retaining
structure
2040.
As depicted, movement system 2050 may include scissor lift mechanism 2306,
motor 2308, rail 2312, and rail 2314. Motor 2308 may be used to operate
scissor lift
mechanism 2306, which may be configured to move retaining structure 2040 along
Z-
axis 2310. Motor 2308 may cause scissor lift mechanism 2306 to expand and
retract
along rail 2312 and rail 2314.
With reference now to Figure 24, an illustration of an isometric view of
cradle
fixture 906 from Figure 9 with a utilities unit associated with cradle fixture
906 is
depicted in accordance with an illustrative embodiment. In this illustrative
example,
rail system 2400 has been coupled to bracket 2052.
In this illustrative example, cable management system 2402 may be associated
with base 912. In this illustrative example, cable management system 2402 may
include cable track 2404 and cable support arm 2405. Cable track 2404 and
cable
support arm 2405 may be used to manage a number of utility cables associated
with
cradle fixture 906.
As depicted, utilities unit 2406 may be associated with rail system 2400. In
this
illustrative example, utilities unit 2406 may be coupled to rail system 2400
such that
CA 02895737 2015-06-25
utilities unit 2406 may be moved along rail system 2400 in a direction along X-
axis
2010. Utilities unit 2406 may be used to provide a number of utilities from
cradle
fixture 906 to an external mobile platform (not shown) that couples to
utilities unit
2406.
As one illustrative example, one of external mobile platform 1605 and external
mobile platform 1607 in Figure 16 may be coupled to utilities unit 2406. The
coupled
external mobile platform may then be configured to receive a number of
utilities from
cradle fixture 906 through utilities unit 2406.
With reference now to Figure 25, an illustration of an enlarged isometric view
of
cradle fixture 908 from Figure 9 is depicted in accordance with an
illustrative
embodiment. As depicted, plurality of stabilizing members 926 associated with
base
914 of cradle fixture 908 may take the form of plurality of hydraulic legs
2500.
In this illustrative example, cradle fixture 908 may include retaining
structure
923, retaining structure 2502, and retaining structure 2504. As depicted,
retaining
structure 923 may include beam 2506 and beam 2508 connected by set of
connecting
elements 2510 and beam 2512 and beam 2514 connected by set of connecting
elements 2516. In this illustrative example, beams 2506, 2508, 2512, and 2514
may
be rotatably associated with set of connection beams 2518.
Retaining structure 923 may be moved relative to base 914 in one or more
directions relative to X-axis 2520, Y-axis 2522, and Z-axis 2524. In
particular,
retaining structure 923 may be rotated relative to set of connection beams
2518 in a
direction about Z-axis 2524. Further, retaining structure 923 may be
associated with
movement system 2526 and movement system 2528. Each of movement system
2526 and movement system 2528 may be implemented in a manner similar to
movement systems 2042, 2044, 2046, and 2048 in Figure 20.
Retaining structure 2502 may be moved relative to base 914 using movement
system 2530. Retaining structure 2504 may be moved relative to base 914 using
movement system 2532 and movement system 2534, which may be implemented in a
manner similar to movement systems 2042, 2044, 2046, and 2048 in Figure 20. In
this illustrative example, retaining structure 2502 may be moved relative to
base 914
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along X-axis 2520 using rail system 2535 and rail system 2533. Rail system
2535
may be part of movement system 2532. Rail system 2533 may be part of movement
system 2534.
In this illustrative example, plurality of units 2536 may be associated with
base
914. Plurality of units 2536 may include, for example, without limitation, a
power unit,
an air supply unit, a hydraulic unit, a water supply unit, a communications
unit, or
some other type of unit. Further, as depicted, bracket 2538 may be associated
with
base 914 and used to hold a rail system (not shown) for a utilities unit (not
shown).
In this illustrative example, number of radar targets 2540 is shown associated
with base 914. Number of radar targets 2540 may be used to position an
external
mobile platform (not shown) relative to cradle fixture 908. For example,
autonomous
vehicle 1611 from Figure 16 may use number of radar targets 2540 to position
external mobile platform 1605 in Figure 16 relative to cradle fixture 908.
With reference now to Figure 26, an illustration of an enlarged isometric view
of
retaining structure 923 from Figure 25 is depicted in accordance with an
illustrative
embodiment. In this illustrative example, movement system 2526 and movement
system 2528 may be more clearly seen. This view of retaining structure 923 may
be
shown from the direction of lines 26-26 in Figure 25. As depicted, movement
system
2526 and movement system 2528 may be implemented in a manner similar to
movement system 2042 and movement system 2046 and movement system 2048,
respectively, shown in Figure 22.
With reference now to Figure 27, an illustration of an enlarged isometric view
of
retaining structure 2502 from Figure 25 is depicted in accordance with an
illustrative
embodiment. In this illustrative example, movement system 2528 and movement
system 2530 are shown more clearly. This view of retaining structure 2502 may
be
shown from the direction of lines 27-27 in Figure 25.
As depicted, movement system 2528 may include scissor lift mechanism 2702,
motor 2704, rail 2706, and rail 2708. Motor 2704 may be used to expand and
retract
scissor lift mechanism 2702 in a direction along Y-axis 2522 along rail 2706
and rail
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2708 such that retaining structure 2502 may be moved in a direction along Z-
axis
2705.
Further, movement system 2530 may include scissor lift mechanism 2712,
motor 2714, rail 2716, and rail 2718. Motor 2714 may be used to expand and
retract
.. scissor lift mechanism 2712 in a direction along Y-axis 2522 along rail
2716 and rail
2718 such that retaining structure 2502 may be moved in a direction along Z-
axis
2705.
In this illustrative example, retaining structure 2502 may be moved in the
direction along X-axis 2520 by moving along rail system 2535 and rail system
2533. In
some cases, rail system 2535 may be considered part of movement system 2528
and
rail system 2533 may be considered part of movement system 2530.
Retaining structure 2502 may include beam 2720 and beam 2722. Connection
beam 2724 may be associated with beam 2720 and beam 2722. Movement system
2528 and movement system 2530 may be associated with connection beam 2724.
Retaining structure 2502 may be rotatably associated with connection beam
2724. In
particular, retaining structure 2502 may be rotatably associated with
connection beam
2724 through spherical interface 2726. Spherical interface 2726 may be an
example
of one implementation for spherical interface 654 in Figure 6. Retaining
structure
2502 may be configured to passively rotate about spherical interface 2726 in a
direction about X-axis 2520, a direction about Y-axis 2522, and a direction
about Z-
axis 2524.
With reference now to Figure 28, an illustration of a side view of retaining
structure 2502 and movement system 2530 from Figure 25 is depicted in
accordance
with an illustrative embodiment. In this illustrative example, the view of
retaining
structure 2502 may be shown from the direction of lines 28-28 in Figure 25.
With reference now to Figure 29, an illustration of a front view of retaining
structure 2502 from Figure 26 with movement system 2530 and movement system
2528 is depicted in accordance with an illustrative embodiment. In this
illustrative
example, the view of retaining structure 2502 may be shown from the direction
of lines
.. 29-29 in Figure 25.
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With reference now to Figure 30, an illustration of an isometric view of
cradle
fixture 908 from Figure 9 with a utilities unit associated with cradle fixture
908 is
depicted in accordance with an illustrative embodiment. In this illustrative
example,
rail system 3000 has been coupled to bracket 2538.
In this illustrative example, cable management system 3002 may be associated
with base 914. In this illustrative example, cable management system 3002 may
include cable track 3003 and cable support arm 3006. Cable track 3003 and
cable
support arm 3006 may be used to manage a number of utility cables associated
with
cradle fixture 908.
As depicted, utilities unit 3004 may be associated with rail system 3000. In
this
illustrative example, utilities unit 3004 may be coupled to rail system 3000
such that
utilities unit 3004 may be moved along rail system 3000 in a direction along X-
axis
2520. Utilities unit 3004 may be used to provide a number of utilities from
cradle
fixture 908 to an external mobile platform (not shown) that couples to
utilities unit
.. 3004.
Cradle coupling unit 3010 is shown associated with base 914. In this
illustrative
example, cradle coupling unit 3010 may be used to couple cradle fixture 908 to
cradle
fixture 910 in Figure 9. Cradle coupling unit 3010 may allow a number of
utilities to
flow from cradle fixture 910 to cradle fixture 908.
With reference now to Figure 31, an illustration of an enlarged isometric view
of
cradle fixture 910 from Figure 9 is depicted in accordance with an
illustrative
embodiment. In this illustrative example, plurality of stabilizing members 928
may take
the form of plurality of hydraulic legs 3100.
As depicted, cradle fixture 910 may include retaining structure 3102 and
retaining structure 3104. Retaining structure 3102 and retaining structure
3104 may
be moved relative to base 916 relative to X-axis 3106, Y-axis 3108, and Z-axis
3110.
In particular, movement system 3112 and movement system 3114 may be used to
move retaining structure 3102 relative to base 916. Movement system 3116 and
movement system 3118 may be used to move retaining structure 3104 relative to
base
916.
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As depicted, plurality of units 3120 may be associated with base 916. Further,
bracket 3122 may be associated with base 916. In this illustrative example,
radar
target 3124 is shown associated with base 916. Radar target 3124 may be used
to
position an external mobile platform (not shown) relative to cradle fixture
908.
With reference now to Figure 32, an illustration of an isometric view of
cradle
fixture 910 from Figure 9 with a utilities unit associated with cradle fixture
910 is
depicted in accordance with an illustrative embodiment. In this illustrative
example,
utilities unit 3200 has been coupled to bracket 3122. Cable management system
3202
is shown comprising cable support arm 3203 associated with base 916. Tower
coupling unit 3204 may also be associated with base 916. Tower coupling unit
3204
may be used to couple cradle fixture 910 to a tower, such as first tower 1001
in Figure
11 or second tower 1500 in Figure 15.
The illustrations in Figures 7-32 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 7-32 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 1-6 may
be
combined with components in Figure 1, used with components in Figure 1, or a
combination of the two.
Turning now to Figure 33, an illustration of a process for configuring an
assembly fixture is depicted is depicted in the form of a flowchart in
accordance with
an illustrative embodiment. The process illustrated in Figure 33 may be
implemented
to configure assembly fixture 324 in Figure 3.
The process may begin by driving number of cradle fixtures 314 across floor
300 to assembly area 304 (operation 3300). In one illustrative example, in
operation
3300, number of cradle fixtures 314 may be autonomously driven across floor
300.
Next, number of cradle fixtures 314 may be configured to form assembly fixture
324 for
fuselage assembly 114 (operation 3302).
CA 02895737 2015-06-25
Thereafter, fuselage assembly 114 may be built on assembly fixture 324
(operation 3304). Assembly fixture 324 may support fuselage assembly 114 as
fuselage assembly 114 is being built to maintain compliance with outer mold
line
requirements and inner mold requirements for fuselage assembly 114 within
selected
tolerances (operation 3306), with the process terminating thereafter.
In some cases, assembly fixture 324 may be used to transport fully built
fuselage assembly 114 to one or more other locations at which other operations
may
be performed. In some illustrative examples, assembly fixture 324 may be used
to
support fuselage assembly 114 while fuselage assembly 114 is being joined to
another
fuselage assembly, another aircraft structure, or some other type of
component.
Turning now to Figure 34, an illustration of a process for configuring an
assembly fixture is depicted in the form of a flowchart in accordance with an
illustrative
embodiment. The process illustrated in Figure 34 may be implemented to
configure
assembly fixture 324 in Figure 1.
The process may begin by moving cradle fixture 600 for assembly fixture 324
across floor 300 into selected cradle position 631 relative to tower 332 in
assembly
area 304 (operation 3400). Next, cradle fixture 600 may be coupled to tower
332
using cradle coupling unit 612 associated with tower 332 and tower coupling
unit 613
associated with cradle fixture 600 such that number of utilities 146 are
distributed from
tower 332 to cradle fixture 600 (operation 3402).
Thereafter, a determination is made as to whether another cradle fixture is
needed for assembly fixture 324 (operation 3404). If another cradle fixture is
not
needed, assembly fixture 324 is complete and plurality of panels 120 for
building
fuselage assembly 114 are engaged with assembly fixture 324 (operation 3406),
with
the process terminating thereafter.
With reference again to operation 3404, if another cradle fixture is needed, a
next cradle fixture for assembly fixture 324 is moved across floor 300 in
assembly area
304 into a selected cradle position relative to cradle fixture 600 previously
added to
assembly fixture 324 (operation 3408). Thereafter, the next cradle fixture may
be
coupled to the previous cradle fixture using the cradle coupling unit
associated with the
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CA 02895737 2015-06-25
previous cradle fixture and the cradle coupling unit associated with the next
cradle
fixture such that number of utilities 146 are distributed from the previous
cradle fixture
to the next cradle fixture (operation 3410). The process may then proceed to
operation 3404 as described above.
Turning now to Figure 35, an illustration of a process for adjusting a
retaining
structure of a cradle fixture is depicted in the form of a flowchart in
accordance with an
illustrative embodiment. The process illustrated in Figure 35 may be
implemented to
adjust, for example, without limitation, retaining structure 615 of cradle
fixture 600 in
Figure 1.
The process may begin by engaging panel 119 with retaining structure 616 of
cradle fixture 600 (operation 3500). Panel 216 may be a fuselage panel. Next,
panel
216 may passively position retaining structure 616 with respect to base 602 of
cradle
fixture 600 in response to panel 216 engaging retaining structure 616
(operation
3502). Thereafter, connection member 652 with which retaining structure 616 is
rotatably associated through spherical interface 654 may be actively
translated along
at least one of X-axis 634, Y-axis 636, or Z-axis 638 to position retaining
structure 616
relative to base 602 of cradle fixture 600 (operation 3504), with the process
terminating thereafter.
With reference now to Figure 36, an illustration of a process for ,adjusting
an
adjustable retaining structure is depicted in the form of a flowchart in
accordance with
an illustrative embodiment. The process illustrated in Figure 36 may be used
to
adjust, for example, without limitation, adjustable retaining structure 655 in
Figure 6.
The process may begin by passively rotating adjustable retaining structure 655
about spherical interface 654 as a panel applies load to adjustable retaining
structure
655 (operation 3600). Adjustable retaining structure 655 may be rotated about
spherical interface 654 as the load applied to adjustable retaining structure
655 by the
panel changes (operation 3602), with the process terminating thereafter. In
other
words, in operation 3602, adjustable retaining structure 655 may passively
rotate
about spherical interface 654 as the load being applied to adjustable
retaining
structure 655 during the building of fuselage assembly 114 changes over time.
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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
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.
Turning now to Figure 37, an illustration of a data processing system is
depicted in the form of a block diagram in accordance with an illustrative
embodiment.
Data processing system 3700 may be used to implement any of the controllers
described above, including control system 136 in Figure 1. In some
illustrative
examples, data processing system 3700 may be used to implement at least one of
a
controller in set of controllers 140 in Figure 1 or controller 650 in Figure
6.
As depicted, data processing system 3700 includes communications framework
3702, which provides communications between processor unit 3704, storage
devices
3706, communications unit 3708, input/output unit 3710, and display 3712. In
some
cases, communications framework 3702 may be implemented as a bus system.
Processor unit 3704 is configured to execute instructions for software to
perform a number of operations. Processor unit 3704 may comprise at least one
of a
number of processors, a multi-processor core, or some other type of processor,
depending on the implementation. In some cases, processor unit 3704 may take
the
form of a hardware unit, such as a circuit system, an application specific
integrated
circuit (ASIC), a programmable logic device, or some other suitable type of
hardware
unit.
Instructions for the operating system, applications and programs run by
processor unit 3704 may be located in storage devices 3706. Storage devices
3706
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CA 02895737 2015-06-25
may be in communication with processor unit 3704 through communications
framework 3702. As used herein, a storage device, also referred to as a
computer
readable storage device, is any piece of hardware capable of storing
information on a
temporary basis, a permanent basis, or both. This information may include, but
is not
limited to, data, program code, other information, or some combination
thereof.
Memory 3714 and persistent storage 3716 are examples of storage devices
3706. Memory 3714 may take the form of, for example, a random access memory or
some type of volatile or non-volatile storage device. Persistent storage 3716
may
comprise any number of components or devices. For example, persistent storage
3716 may comprise a hard drive, a flash memory, a rewritable optical disk, a
rewritable
magnetic tape, or some combination of the above. The media used by persistent
storage 3716 may or may not be removable.
Communications unit 3708 allows data processing system 3700 to
communicate with other data processing systems, devices, or both.
Communications
unit 3708 may provide communications using physical communications links,
wireless
communications links, or both.
Input/output unit 3710 allows input to be received from and output to be sent
to
other devices connected to data processing system 3700. For example,
input/output
unit 3710 may allow user input to be received through a keyboard, a mouse,
some
other type of input device, or a combination thereof. As another example,
input/output
unit 3710 may allow output to be sent to a printer connected to data
processing
system 3700.
Display 3712 is configured to display information to a user. Display 3712 may
comprise, for example, without limitation, a monitor, a touch screen, a laser
display, a
holographic display, a virtual display device, some other type of display
device, or a
combination thereof.
In this illustrative example, the processes of the different illustrative
embodiments may be performed by processor unit 3704 using computer-implemented
instructions. These instructions may be referred to as program code, computer
usable
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CA 02895737 2015-06-25
program code, or computer readable program code and may be read and executed
by
one or more processors in processor unit 3704.
In these examples, program code 3718 is located in a functional form on
computer readable media 3720, which is selectively removable, and may be
loaded
onto or transferred to data processing system 3700 for execution by processor
unit
3704. Program code 3718 and computer readable media 3720 together form
computer program product 3722. In this illustrative example, computer readable
media 3720 may be computer readable storage media 3724 or computer readable
signal media 3726.
1 0
Computer readable storage media 3724 is a physical or tangible storage device
used to store program code 3718 rather than a medium that propagates or
transmits
program code 3718. Computer readable storage media 3724 may be, for example,
without limitation, an optical or magnetic disk or a persistent storage device
that is
connected to data processing system 3700.
Alternatively, program code 3718 may be transferred to data processing system
3700 using computer readable signal media 3726. Computer readable signal media
3726 may be, for example, a propagated data signal containing program code
3718.
This data signal may be an electromagnetic signal, an optical signal, or some
other
type of signal that can be transmitted over physical communications links,
wireless
communications links, or both.
The illustration of data processing system 3700 in Figure 37 is not meant to
provide architectural limitations to the manner in which the illustrative
embodiments
may be implemented. The different illustrative embodiments may be implemented
in a
data processing system that includes components in addition to or in place of
those
illustrated for data processing system 3700. Further, components shown in
Figure 37
may be varied from the illustrative examples shown.
The illustrative embodiments of the disclosure may be described in the context
of aircraft manufacturing and service method 3800 as shown in Figure 38 and
aircraft
3900 as shown in Figure 39. Turning first to Figure 38, an illustration of an
aircraft
manufacturing and service method is depicted in the form of a block diagram in
CA 02895737 2015-06-25
accordance with an illustrative embodiment.
During pre-production, aircraft
manufacturing and service method 3800 may include specification and design
3802 of
aircraft 3900 in Figure 39 and material procurement 3804.
During production, component and subassembly manufacturing 3806 and
system integration 3808 of aircraft 3900 in Figure 39 takes place. Thereafter,
aircraft
3900 in Figure 39 may go through certification and delivery 3810 in order to
be placed
in service 3812. While in service 3812 by a customer, aircraft 3900 in Figure
39 is
scheduled for routine maintenance and service 3814, which may include
modification,
reconfiguration, refurbishment, and other maintenance or service.
Each of the processes of aircraft manufacturing and service method 3800 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 39, 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 3900 is produced by aircraft manufacturing and service
method
3800 in Figure 38 and may include airframe 3902 with plurality of systems 3904
and
interior 3906. Examples of systems 3904 include one or more of propulsion
system
3908, electrical system 3910, hydraulic system 3912, and environmental system
3914.
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 3800 in Figure
38. In
particular, flexible manufacturing system 106 from Figure 1 may be used to
build at
least a portion of airframe 3902 of aircraft 3900 during any one of the stages
of aircraft
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CA 02895737 2015-06-25
manufacturing and service method 3800. For example, without limitation,
flexible
manufacturing system 106 from Figure 1 may be used during at least one of
component and subassembly manufacturing 3806, system integration 3808, or some
other stage of aircraft manufacturing and service method 3800 to form a
fuselage for
aircraft 3900.
In one illustrative example, components or subassemblies produced in
component and subassembly manufacturing 3806 in Figure 38 may be fabricated or
manufactured in a manner similar to components or subassemblies produced
while aircraft 3900 is in service 3812 in Figure 38. 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
3806 and system integration 3808 in Figure 38.
One or more apparatus
embodiments, method embodiments, or a combination thereof may be utilized
while
aircraft 3900 is in service 3812, during maintenance and service 3814 in
Figure 38, or
both. The use of a number of the different illustrative embodiments may
substantially
expedite the assembly of and reduce the cost of aircraft 3900.
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
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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