Note: Descriptions are shown in the official language in which they were submitted.
¨ õ
APPARATUS FOR TWO-STAGE RIVETING
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 performing a two-stage riveting process to
install
rivets for building a 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 may need to be assembled in a manner that meets outer mold line
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(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, in some cases, rivets that are manually
installed to
join parts together may have less than the desired uniform interference fit
across the
interface between the parts.
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. 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 fastening two parts together may
be provided. An initial interference fit may be created between a fastener and
at least
a portion of a hole extending through the two parts while maintaining a force
equilibrium. A final interference fit may be created between the fastener and
the hole,
while maintaining a new force equilibrium.
In another illustrative embodiment, a method for installing a rivet may be
provided. A reactive structural force may be generated in a first direction
during
installation of the rivet and a new reactive structural force may be generated
in a
second direction opposite to the first direction during the installation of
the rivet.
In another illustrative embodiment, a method for performing a two-stage
riveting
process may be provided. An initial interference fit may be created between a
fastener and at least a portion of a hole extending through two parts, using a
hammer
associated with a first robotic device and a bucking bar associated with a
second
robotic device, while maintaining a force equilibrium. A final interference
fit may be
created between the fastener and the hole using the bucking bar and the
hammer,
while maintaining a new force equilibrium, such that the final interference
fit is
substantially uniform across an interface between the two parts.
In yet another illustrative embodiment, an apparatus may comprise a first
robotic device having a first tool, a second robotic device having a second
tool, and a
number of controllers that control the first robotic device and the second
robotic device
to perform a two-stage riveting process.
In still another illustrative embodiment, an apparatus may comprise a
plurality
of parts, a hole extending through the plurality of parts, and a partially
formed rivet
having an interference fit with at least a portion of the hole.
In another embodiment, there is provided an apparatus including a first
robotic
device having a first tool, a second robotic device having a second tool, and
a number
of controllers that control the first robotic device and the second robotic
device to
perform a two-stage riveting process. At least one controller of the number of
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controllers generates a first number of commands that cause the first robotic
device to
use the first tool to apply a first force to a first end of a rivet during a
first stage of said
two-stage process and to apply a new first force to the first end of the rivet
during a
second stage of the two-stage process. At least one controller of the number
of
controllers generates a second number of commands that cause the second
robotic
device to cause the second tool to apply a second force to a second, opposite
end of
the rivet during the first stage of the two-stage process and to apply a new
second
force to the second, opposite end of the rivet during the second stage of the
two-stage
process. The first and second forces are sufficient to cause the rivet to have
an initial
interference fit in a hole formed by aligned openings in two or more parts.
The new
first and second forces are sufficient to cause the rivet to have a final
interference fit
different from the initial interference fit in the hole.
The first tool may be a first riveting tool associated with the first robotic
device
and the second tool may be a second riveting tool associated with the second
robotic
device.
The first riveting tool may be a hammer and the second riveting tool may be a
bucking bar.
The number of controllers may include a first controller that controls the
first
robotic device and a second controller that controls the second robotic
device.
The number of controllers may be associated with at least one of the first
robotic device and the second robotic device.
The number of controllers may control the first robotic device and the second
robotic device to maintain a force equilibrium during a first stage of the two-
stage
riveting process and a new force equilibrium during a second stage of the two-
stage
riveting process.
The apparatus may further include an external mobile platform. The first
robotic
device may be an external robotic device associated with the external mobile
platform.
The apparatus may further include an internal mobile platform. The second
robotic device may be an internal robotic device associated with the internal
mobile
platform.
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The apparatus may further include a first clamping device associated with the
first robotic device and a second clamping device associated with the second
robotic
device.
The first clamping device and the second clamping device may be used to
clamp the two or more parts together prior to the first force being applied to
the first
end of a rivet . The first part and the second part may be unclamped prior to
the
second force being applied to the second opposite end of the rivet.
The features, functions, and advantages can be achieved independently in
various embodiments of the present disclosure or may be combined in yet other
embodiments in which further details can be seen with reference to the
following
description and drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
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;
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 riveting environment in the form of a block
diagram in accordance with an illustrative embodiment;
Figure 7 is an illustration of a riveting environment in accordance with an
illustrative embodiment;
Figure 8 is an illustration of an enlarged view of a section in accordance
with
an illustrative embodiment;
Figure 9 is an illustration of a fully installed rivet and a chart of the
final
interference fit created between the rivet and a hole in accordance with an
illustrative
embodiment;
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Figure 10 is an illustration of an isometric cutaway view of a plurality of
mobile
platforms performing fastening processes within an interior of a fuselage
assembly in
a manufacturing environment in accordance with an illustrative embodiment;
Figure 11 is an illustration of a cross-sectional view of a flexible
manufacturing
system and a fuselage assembly in accordance with an illustrative embodiment;
Figure 12 is an illustration of a process for fastening two parts together in
the
form of a flowchart in accordance with an illustrative embodiment;
Figure 13 is an illustration of a process for performing a two-stage riveting
process in the form of a flowchart in accordance with an illustrative
embodiment;
Figure 14 is an illustration of a process for performing a two-stage riveting
process in the form of a flowchart in accordance with an illustrative
embodiment;
Figure 15 is an illustration of a process for installing a rivet in the form
of a
flowchart in accordance with an illustrative embodiment;
Figure 16 is an illustration of a data processing system in the form of a
block
.. diagram in accordance with an illustrative embodiment;
Figure 17 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 18 is an illustration of an aircraft in the form of a block diagram in
which
an illustrative embodiment may be implemented.
DETAILED DESCRIPTION
The illustrative embodiments recognize and take into account different
considerations. For example, the illustrative embodiments recognize and take
into
.. account that it may be desirable to automate the process of building a
fuselage
assembly for an aircraft. Automating the process of building a fuselage
assembly for
an aircraft may improve build efficiency, improve build quality, and reduce
costs
associated with building the fuselage assembly. The illustrative embodiments
also
recognize and take into account that automating the process of building a
fuselage
assembly may improve the accuracy and precision with which assembly operations
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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
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
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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 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
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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.
Referring now to the figures and, in particular, with reference to Figures 1-
6,
illustrations of a manufacturing environment are depicted in the form of block
diagrams in accordance with an illustrative embodiment. In particular, in
Figures 1-6,
a fuselage assembly, a flexible manufacturing system, the various systems
within the
flexible manufacturing system that may be used to build the fuselage assembly,
and a
distributed utility network are described.
Turning now to Figure 1, an illustration of a manufacturing environment is
depicted in the form of a block diagram in accordance with an illustrative
embodiment.
In this illustrative example, manufacturing environment 100 may be an example
of one
environment in which at least a portion of fuselage 102 may be manufactured
for
aircraft 104.
Manufacturing environment 100 may take a number of different forms. For
example, without limitation, manufacturing environment 100 may take the form
of a
factory, a manufacturing facility, an outdoor factory area, an enclosed
manufacturing
area, an offshore platform, or some other type of manufacturing environment
100
suitable for building at least a portion of fuselage 102.
Fuselage 102 may be built using manufacturing process 108. Flexible
manufacturing system 106 may be used to implement at least a portion of
manufacturing process 108. In one illustrative example, manufacturing process
108
may be substantially automated using flexible manufacturing system 106. In
other
illustrative examples, only one or more stages of manufacturing process 108
may be
substantially automated.
Flexible manufacturing system 106 may be configured to perform at least a
portion of manufacturing process 108 autonomously.
In this manner, flexible
manufacturing system 106 may be referred to as autonomous flexible
manufacturing
system 112. In other illustrative examples, flexible manufacturing system 106
may be
referred to as an automated flexible manufacturing system.
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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
the fully
assembled fuselage 102. Flexible manufacturing system 106 may build fuselage
assembly 114 up to the point needed to move fuselage assembly 114 to a next
stage
in the manufacturing process for building aircraft 104. In some cases, at
least a
portion of flexible manufacturing system 106 may be used at one or more later
stages
in the manufacturing process for building aircraft 104.
In one illustrative example, fuselage assembly 114 may be an assembly for
forming a particular section of fuselage 102. As one example, fuselage
assembly 114
may take the form of aft fuselage assembly 116 for forming an aft section of
fuselage
102. In another example, fuselage assembly 114 may take the form of forward
fuselage assembly 117 for forming a forward section of fuselage 102. In yet
another
example, fuselage assembly 114 may take the form of middle fuselage assembly
118
for forming a center section of fuselage 102 or some other middle section of
fuselage
102 between the aft and forward sections of fuselage 102.
As depicted, fuselage assembly 114 may include plurality of panels 120 and
support structure 121. Support structure 121 may be comprised of plurality of
members 122. Plurality of members 122 may be used to both support plurality of
panels 120 and connect plurality of panels 120 to each other. Support
structure 121
may help provide strength, stiffness, and load support for fuselage assembly
114.
Plurality of members 122 may be associated with plurality of panels 120. As
used herein, when one component or structure is "associated" with another
component or structure, the association is a physical association in the
depicted
examples.
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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
component using a third component. Further, the first component may be
considered
to be associated with the second component by being formed as part of the
second
component, an extension of the second component, or both. In another example,
the
first component may be considered part of the second component by being co-
cured
with the second component.
As used herein, the phrase "at least one of," when used with a list of items,
means different combinations of one or more of the listed items may be used
and only
one of the items in the list may be needed. The item may be a particular
object, thing,
action, process, or category. In other words, "at least one of" means any
combination
of items or number of items may be used from the list, but not all of the
items in the list
may be required.
For example, "at least one of item A, item B, and item C" or "at least one of
item
A, item B, or item C" may mean item A; item A and item B; item B; item A, item
B, and
item C; or item B and item C. In some cases, "at least one of item A, item B,
and item
C" may mean, for example, without limitation, two of item A, one of item B,
and ten of
item C; four of item B and seven of item C; or some other suitable
combination.
In these illustrative examples, a member of plurality of members 122 may be
associated with at least one of plurality of panels 120 in a number of
different ways.
For example, without limitation, a member of plurality of members 122 may be
attached directly to a single panel, attached to two or more panels, attached
to
another member that is directly attached to at least one panel, attached to at
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CA 3004012 2018-05-02
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.
In another illustrative example, only a first portion of plurality of members
122
may be associated with plurality of panels 120 prior to the beginning of
assembly
process 110. Assembly process 110 may include attaching a remaining portion of
plurality of members 122 to plurality of panels 120 for at least one of
providing support
to plurality of panels 120 or connecting plurality of panels 120 together. The
first
portion of plurality of members 122 attached to plurality of panels 120 prior
to
assembly process 110 and the remaining portion of plurality of members 122
attached
to plurality of panels 120 during assembly process 110 may together form
support
structure 121.
In yet another illustrative example, all of plurality of members 122 may be
associated with plurality of panels 120 during assembly process 110. For
example,
each of plurality of panels 120 may be "naked" without any members attached to
or
otherwise associated with the panel prior to assembly process 110. During
assembly
process 110, plurality of members 122 may then be associated with plurality of
panels
120.
In this manner, support structure 121 for fuselage assembly 114 may be built
up in a number of different ways. Fuselage assembly 114 comprising plurality
of
panels 120 and support structure 121 is described in greater detail in Figure
2 below.
Building fuselage assembly 114 may include joining plurality of panels 120
together. Joining plurality of panels 120 may be performed in a number of
different
ways. Depending on the implementation, joining plurality of panels 120
together may
include joining one or more of plurality of members 122 to one or more of
plurality of
panels 120 or to other members of plurality of members 122.
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In particular, joining plurality of panels 120 may include joining at least
one
panel to at least one other panel, joining at least one member to at least one
other
member, or joining at least one member to at least one panel, or some
combination
thereof. As one illustrative example, joining a first panel and a second panel
together
may include at least one of the following: fastening the first panel directly
to the
second panel, joining a first member associated with the first panel to a
second
member associated with the second panel, joining a member associated with the
first
panel directly to the second panel, joining one member associated with both
the first
panel and the second panel to another member, joining a selected member to
both
the first panel and the second panel, or some other type of joining operation.
Assembly process 110 may include operations 124 that may be performed to
join plurality of panels 120 together to build fuselage assembly 114. In this
illustrative
example, flexible manufacturing system 106 may be used to perform at least a
portion
of operations 124 autonomously.
Operations 124 may include, for example, but are not limited to, temporary
connection operations 125, drilling operations 126, fastener insertion
operations 128,
fastener installation operations 130, inspection operations 132, other types
of
assembly operations, or some combination thereof. Temporary connection
operations
125 may be performed to temporarily connect plurality of panels 120 together.
For
example, without limitation, temporary connection operations 125 may include
temporarily tacking plurality of panels 120 together using tack fasteners.
Drilling operations 126 may include drilling holes through one or more of
plurality of panels 120 and, in some cases, through one or more of plurality
of
members 122. Fastener insertion operations 128 may include inserting fasteners
into
the holes drilled by drilling operations 126.
Fastener installation operations 130 may include fully installing each of the
fasteners that have been inserted into the holes. Fastener installation
operations 130
may include, for example, without limitation, riveting operations,
interference-fit bolting
operations, other types of fastener installation operations, or some
combination
thereof. Inspection operations 132 may include inspecting the fully installed
fasteners.
Depending on the implementation, flexible manufacturing system 106 may be used
to
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perform any number of these different types of operations 124 substantially
autonomously.
As depicted, flexible manufacturing system 106 may include plurality of mobile
systems 134, control system 136, and utility system 138. Each of plurality of
mobile
systems 134 may be a drivable mobile system. In some cases, each of plurality
of
mobile systems 134 may be an autonomously drivable mobile system. For example,
without limitation, each of plurality of mobile systems 134 may include one or
more
components that may be autonomously driven within manufacturing environment
100
from one location to another location. Plurality of mobile systems 134 are
described in
greater detail in Figure 3 below.
In this illustrative example, control system 136 may be used to control the
operation of flexible manufacturing system 106. For example, without
limitation,
control system 136 may be used to control plurality of mobile systems 134. In
particular, control system 136 may be used to direct the movement of each of
plurality
of mobile systems 134 within manufacturing environment 100. Control system 136
may be at least partially associated with plurality of mobile systems 134.
In one illustrative example, control system 136 may include set of controllers
140. As used herein, a "set of" items may include one or more items. In this
manner,
set of controllers 140 may include one or more controllers.
Each of set of controllers 140 may be implemented using hardware, firmware,
software, or some combination thereof. In one illustrative example, set of
controllers
140 may be associated with plurality of mobile systems 134. For example,
without
limitation, one or more of set of controllers 140 may be implemented as part
of
plurality of mobile systems 134. In other examples, one or more of set of
controllers
140 may be implemented independently of plurality of mobile systems 134.
Set of controllers 140 may generate commands 142 to control the operation of
plurality of mobile systems 134 of flexible manufacturing system 106. Set of
controllers 140 may communicate with plurality of mobile systems 134 using at
least
one of a wireless communications link, a wired communications link, an optical
communications link, or other type of communications link. In this manner, any
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number of different types of communications links may be used for
communication
with and between set of controllers 140.
In these illustrative examples, control system 136 may control the operation
of
plurality of mobile systems 134 using data 141 received from sensor system
133.
Sensor system 133 may be comprised of any number of Individual sensor systems,
sensor devices, controllers, other types of components, or combination
thereof. In
one illustrative example, sensor system 133 may include laser tracking system
135
and radar system 137. Laser tracking system 135 may be comprised of any number
of laser tracking devices, laser targets, or combination thereof. Radar system
137
may be comprised of any number of radar sensors, radar targets, or combination
thereof.
Sensor system 133 may be used to coordinate the movement and operation of
the various mobile systems in plurality of mobile systems 134 within
manufacturing
environment 100. As one illustrative example, radar system 137 may be used for
macro-positioning mobile systems, systems within mobile systems, components
within
mobile systems, or some combination thereof. Further, laser tracking system
135 may
be used for micro-positioning mobile systems, systems within mobile systems,
components within mobile systems, or some combination thereof.
Plurality of mobile systems 134 may be used to form distributed utility
network
144. Depending on the implementation, one or more of plurality of mobile
systems
134 may form distributed utility network 144. Number of utilities 146 may flow
from
number of utility sources 148 to the various mobile systems of plurality of
mobile
systems 134 that make up distributed utility network 144.
In this illustrative example, each of number of utility sources 148 may be
located with manufacturing environment 100. In other illustrative examples,
one or
more of number of utility sources 148 may be located outside of manufacturing
environment 100. The corresponding utility provided by these one or more
utility
sources may then be carried into manufacturing environment 100 using, for
example,
without limitation, one or more utility cables.
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
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plurality of mobile systems 134 over some number of utility cables. This one
mobile
system may then distribute number of utilities 146 to other mobile systems of
plurality
of mobile systems 134 such that these other mobile systems do not need to
directly
receive number of utilities 146 from number of utility sources 148.
As depicted, distributed utility network 144 may be formed using utility
system
138. Utility system 138 may include utility fixture 150. Utility system 138
may be
configured to connect to number of utility sources 148 such that number of
utilities 146
may flow from number of utility sources 148 to utility fixture 150. Utility
fixture 150
may be above-ground or in-ground, depending on the implementation. For
example,
without limitation, utility fixture 150 may be embedded in a floor within
manufacturing
environment 100.
Utility fixture 150 may then distribute number of utilities 146 to one or more
of
plurality of mobile systems 134. In particular, one autonomous coupling of one
of
plurality of mobile systems 134 to utility fixture 150 may be followed by any
number of
autonomous couplings of mobile systems to each other in series to form
distributed
utility network 144. Utility fixture 150 may distribute number of utilities
146 to each of
plurality of mobile systems 134 downstream of utility fixture 150 in the
series of
autonomous couplings of the mobile systems.
Depending on the implementation, distributed utility network 144 may have a
chain-like configuration or a tree-like configuration. In one illustrative
example,
plurality of mobile systems 134 may include mobile systems A, B, C, and D (not
shown in figure) with mobile system A autonomously coupled to utility fixture
150 and
mobile systems B, C, and D autonomously coupled to mobile system A and each
other in series. An example of a chain-like configuration for distributed
utility network
144 may include number of utilities 146 flowing from number of utility sources
148
over some number of utility cables to utility fixture 150, from utility
fixture 150 to mobile
system A, from mobile system A to mobile system B, from mobile system B to
mobile
system C, and from mobile system C to mobile system D. An example of a tree-
like
configuration 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
CA 3004012 2018-05-02
mobile system B and mobile system C, and from mobile system C to mobile system
D.
An example of one manner in which distributed utility network 144 may be
implemented using plurality of mobile systems 134 is described in greater
detail in
Figure 5 below.
In some illustrative examples, multiple flexible manufacturing systems may be
used to build multiple fuselage assemblies concurrently.
For example, flexible
manufacturing system 106 may be a first flexible manufacturing system of many
flexible manufacturing systems.
In one illustrative example, flexible manufacturing system 106, second
flexible
manufacturing system 152, and third flexible manufacturing system 154 may be
used
to build aft fuselage assembly 116, middle fuselage assembly 118, and forward
fuselage assembly 117, respectively. Aft fuselage assembly 116, middle
fuselage
assembly 118, and forward fuselage assembly 117 may then be joined together to
form a fully assembled fuselage 102. In this manner, in this example, flexible
manufacturing system 106, second flexible manufacturing system 152, and third
flexible manufacturing system 154 may together form flexible fuselage
manufacturing
system 158.
Thus, any number of fuselage assemblies, such as fuselage assembly 114,
may be built within manufacturing environment 100 using any number of flexible
manufacturing systems implemented in a manner similar to flexible
manufacturing
system 106. Similarly, any number of full fuselages, such as fuselage 102, may
be
built within manufacturing environment 100 using any number of flexible
fuselage
manufacturing systems implemented in a manner similar to flexible fuselage
manufacturing system 158.
With reference now to Figure 2, an illustration of fuselage assembly 114 from
Figure 1 is depicted in the form of a block diagram in accordance with an
illustrative
embodiment. As described above, fuselage assembly 114 may include plurality of
panels 120 and support structure 121. Fuselage assembly 114 may be used to
refer
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
16
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ones of plurality of panels 120 that have been or are being joined together, a
partially
built fuselage assembly, or a fully built fuselage assembly.
As depicted, fuselage assembly 114 may be built such that fuselage assembly
114 has plurality of fuselage sections 205. Each of plurality of fuselage
sections 205
may include one or more of plurality of panels 120. In this illustrative
example, each
of plurality of fuselage sections 205 may take the form of a cylindrically-
shaped
fuselage section, a barrel-shaped fuselage section, a tapered cylindrical
fuselage
section, a cone-shaped fuselage section, a dome-shaped fuselage section, or a
section having some other type of shape. Depending on the implementation, a
fuselage section of plurality of fuselage sections 205 may have a shape that
has a
substantially circular cross-sectional shape, elliptical cross-sectional
shape, oval
cross-sectional shape, polygon with rounded corners cross-sectional shape, or
otherwise closed-curve cross-sectional shape.
As one specific illustrative example, each of plurality of fuselage sections
205
may be a portion of fuselage assembly 114 defined between two radial cross-
sections
of fuselage assembly 114 that are taken substantially perpendicular to a
center axis or
longitudinal axis through fuselage assembly 114. In this manner, plurality of
fuselage
sections 205 may be arranged along the longitudinal axis of fuselage assembly
114.
In other words, plurality of fuselage sections 205 may be arranged
longitudinally.
Fuselage section 207 may be an example of one of plurality of fuselage
sections 205. Fuselage section 207 may be comprised of one or more of
plurality of
panels 120. In one illustrative example, multiple panel sections may be
arranged
circumferentially around fuselage section 207 to form the skin of fuselage
section 207.
In some cases, multiple rows of two or more longitudinally adjacent panels may
be
arranged circumferentially around fuselage section 207 to form the skin of
fuselage
section 207.
In one illustrative example, fuselage assembly 114 may have crown 200, keel
202, and sides 204. Sides 204 may include first side 206 and second side 208.
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
17
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one illustrative example, each of crown 200, keel 202, first side 206, and
second side
208 of fuselage assembly 114 may be formed by at least a portion of at least
one of
plurality of panels 120. Further, a portion of each of plurality of fuselage
sections 205
may form each of crown 200, keel 202, first side 206, and second side 208.
Panel 216 may be an example of one of plurality of panels 120. Panel 216 may
also be referred to as a skin panel, a fuselage panel, or a fuselage skin
panel,
depending on the implementation. In some illustrative examples, panel 216 may
take
the form of a mega-panel comprised of multiple smaller panels, which may be
referred
to as sub-panels. A mega-panel may also be referred to as a super panel. In
these
illustrative examples, panel 216 may be comprised of at least one of a metal,
a metal
alloy, some other type of metallic material, a composite material, or some
other type of
material. As one illustrative example, panel 216 may be comprised of an
aluminum
alloy, steel, titanium, a ceramic material, a composite material, some other
type of
material, or some combination thereof.
When used to form keel 202 of fuselage assembly 114, panel 216 may be
referred to as a keel panel or a bottom panel. When used to form one of sides
204 of
fuselage assembly 114, panel 216 may be referred to as a side panel. When used
to
form crown 200 of fuselage assembly 114, panel 216 may be referred to as a
crown
panel or a top panel. As one illustrative example, plurality of panels 120 may
include
crown panels 218 for forming crown 200, side panels 220 for forming sides 204,
and
keel panels 222 for forming keel 202. Side panels 220 may include first side
panels
224 for forming first side 206 and second side panels 226 for forming second
side
208.
In one illustrative example, fuselage section 207 of plurality of fuselage
sections 205 of fuselage assembly 114 may include one of crown panels 218, two
of
side panels 220, and one of keel panels 222. In another illustrative example,
fuselage
section 207 may form an end of fuselage assembly 114.
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.
18
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End panel 228 may be used to form one end of fuselage assembly 114. For
example, when fuselage assembly 114 takes the form of aft fuselage assembly
116 in
Figure 1, end panel 228 may form the aftmost end of fuselage assembly 114.
When
fuselage assembly 114 takes the form of forward fuselage assembly 117 in
Figure 1,
end panel 228 may form the forwardmost end of fuselage assembly 114.
In one illustrative example, end panel 228 may take the form of a
cylindrically-
shaped panel, a cone-shaped panel, a barrel-shaped panel, or a tapered
cylindrical
panel. For example, end panel 228 may be a single cylindrically-shaped panel
having
a substantially circular cross-sectional shape that may change in diameter
with
respect to a center axis for fuselage assembly 114.
In this manner, as described above, fuselage section 207 may be comprised
solely of end panel 228. In some illustrative examples, fuselage section 207
may be
an end fuselage section that is comprised of only a single panel, which may be
end
panel 228. In some cases, bulkhead 272 may be associated with end panel 228
when
fuselage section 207 is an end fuselage section. Bulkhead 272, which may also
be
referred to as a pressure bulkhead, may be considered separate from or part of
end
panel 228, depending on the implementation. Bulkhead 272 may have a dome-type
shape in these illustrative examples.
When fuselage assembly 114 takes the form of aft fuselage assembly 116 in
Figure 1, bulkhead 272 may be part of fuselage section 207 located at the
aftmost
end of aft fuselage assembly 116. When fuselage assembly 114 takes the form of
forward fuselage assembly 117 in Figure 1, bulkhead 272 may be part of
fuselage
section 207 located at forwardmost end of aft fuselage assembly 116. Middle
fuselage assembly 118 in Figure 1 may not include a bulkhead, such as bulkhead
272, at either end of middle fuselage assembly 118. In this manner, plurality
of
fuselage sections 205 may be implemented in any number of different ways.
Panel 216 may have first surface 230 and second surface 232. First surface
230 may be configured for use as an exterior-facing surface. In other words,
first
surface 230 may be used to form exterior 234 of fuselage assembly 114. Second
surface 232 may be configured for use as an interior-facing surface. In other
words,
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CA 3004012 2018-05-02
second surface 232 may be used to form interior 236 of fuselage assembly 114.
Each
of plurality of panels 120 may be implemented in a manner similar to panel
216.
As described earlier, support structure 121 may be associated with a
corresponding one of plurality of panels 120. Support structure 121 may be
comprised of plurality of members 122 that are associated with panel 216. In
one
illustrative example, corresponding portion 240 may be the portion of
plurality of
members 122 that correspond to panel 216. Corresponding portion 240 may form
support section 238 corresponding to panel 216. Support section 238 may form a
part
of support structure 121.
Plurality of members 122 may include support members 242. Support
members 242 may include, for example, without limitation, at least one of
connecting
members 244, frames 246, stringers 248, stiffeners 250, stanchions 252,
intercostal
structural members 254, or other types of structural members.
Connecting members 244 may connect other types of support members 242
together. In some cases, connecting members 244 may also connect support
members 242 to plurality of panels 120. Connecting members 244 may include,
for
example, without limitation, shear clips 256, ties 258, splices 260,
intercostal
connecting members 262, other types of mechanical connecting members, or some
combination thereof.
In one illustrative example, when panel 216 is comprised of multiple sub-
panels, connecting members 244 may be used to, for example, without
limitation,
connect together complementary frames of frames 246 running in the hoop-wise
direction on adjacent sub-panels and complementary stringers of stringers 248
running in the longitudinal direction on adjacent sub-panels. In other
illustrative
examples, connecting members 244 may be used to connect together complementary
frames, stringers, or other types of support members on two or more adjacent
panels
in 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.
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Operations 124, as described in Figure 1, may be performed to join plurality
of
panels 120 together to build fuselage assembly 114. In one illustrative
example,
plurality of fasteners 264 may be used to join plurality of panels 120
together.
As described above, joining plurality of panels 120 together may be performed
in a number of different ways. Joining plurality of panels 120 together may
include at
least one of joining at least one panel in plurality of panels 120 to another
one of
plurality of panels 120, joining at least one panel in plurality of panels 120
to at least
one of plurality of members 122, joining at least one member in plurality of
members
122 to another one of plurality of members 122, or some other type of joining
operation. Plurality of panels 120 may be joined together such that plurality
of
members 122 ultimately form support structure 121 for fuselage assembly 114.
As depicted, number of floors 266 may be associated with fuselage assembly
114. In this illustrative example, number of floors 266 may be part of
fuselage
assembly 114. Number of floors 266 may include, for example, without
limitation, at
least one of a passenger floor, a cargo floor, or some other type of floor.
With reference now to Figure 3, an illustration of plurality of mobile systems
134 of flexible manufacturing system 106 within manufacturing environment 100
from
Figure 1 is depicted in the form of a block diagram in accordance with an
illustrative
embodiment. As depicted, flexible manufacturing system 106 may be used to
build
fuselage assembly 114 on floor 300 of manufacturing environment 100. When
manufacturing environment 100 takes the form of a factory, floor 300 may be
referred
to as factory floor 302.
In one illustrative example, floor 300 may be substantially smooth and
substantially planar. For example, floor 300 may be substantially level. In
other
illustrative examples, one or more portions of floor 300 may be sloped,
ramped, or
otherwise uneven.
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
21
CA 3004012 2018-05-02
304 may include a designated area on floor 300 as well as the area above this
designated area.
Any number of assembly areas may be present within
manufacturing environment 100 such that any number of fuselage assemblies may
be
built concurrently within manufacturing environment 100.
As depicted, plurality of mobile systems 134 may include plurality of
autonomous vehicles 306, cradle system 308, tower system 310, and autonomous
tooling system 312. Each of plurality of mobile systems 134 may be drivable
across
floor 300. In other words, each of plurality of mobile systems 134 may be
capable of
being autonomously driven across floor 300 from one location 315 to another
location
317 on floor 300.
In one illustrative example, each of plurality of autonomous vehicles 306 may
take the form of an automated guided vehicle (AGV), which may be capable of
operating independently without human direction or guidance. In some cases,
plurality of autonomous vehicles 306 may be referred to as a plurality of
automated
guided vehicles (AGVs).
In this illustrative example, cradle system 308 may be used to support and
hold
fuselage assembly 114 during assembly process 110 in Figure 1. In some cases,
cradle system 308 may be referred to as a drivable cradle system. In still
other cases,
cradle system 308 may be referred to as an autonomously drivable cradle
system.
Cradle system 308 may include number of fixtures 313. As used herein, a
"number of' items may include one or more items. In this manner, number of
fixtures
313 may include one or more fixtures. In some illustrative examples, number of
fixtures 313 may be referred to as a number of drivable fixtures. In other
illustrative
examples, number of fixtures 313 may be referred to as a number of
autonomously
drivable fixtures.
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.
22
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Number of retaining structures 326 may be associated with each of number of
cradle fixtures 314. Number of retaining structures 326 associated with each
of
number of cradle fixtures 314 may be engaged with and used to support fuselage
assembly 114. For example, number of retaining structures 326 associated with
cradle fixture 322 may be engaged with and used to support one or more of
plurality of
panels 120.
Number of cradle fixtures 314 may be autonomously driven across floor 300 of
manufacturing environment 100 to assembly area 304. In one illustrative
example,
each of number of cradle fixtures 314 may be autonomously driven across floor
300
using a corresponding one of plurality of autonomous vehicles 306. In other
words,
without limitation, number of corresponding autonomous vehicles 316 in
plurality of
autonomous vehicles 306 may be used to drive number of cradle fixtures 314
across
floor 300 into assembly area 304.
In this illustrative example, number of corresponding autonomous vehicles 316
may drive from, for example, without limitation, holding area 318, across
floor 300, to
assembly area 304. Holding area 318 may be an area in which at least one of
plurality of autonomous vehicles 306, cradle system 308, tower system 310,
autonomous tooling system 312, or control system 136 from Figure 1 may be held
when flexible manufacturing system 106 is not in use or when that particular
device or
system is not in use.
Holding area 318 may be referred to as a home area, a storage area, or a base
area, depending on the implementation. Although holding area 318 is depicted
as
being located within manufacturing environment 100, holding area 318 may be
located
in some other area or environment outside of manufacturing environment 100 in
other
.. illustrative examples.
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
23
CA 3004012 2018-05-02
a reference coordinate system. This reference coordinate system may be, for
example, without limitation, a fuselage coordinate system, an aircraft
coordinate
system, a coordinate system for manufacturing environment 100, or some other
type
of coordinate system.
When number of cradle fixtures 314 includes more than one cradle fixture such
that number of selected cradle positions 320 includes more than one cradle
position,
these cradle positions may be positions selected relative to each other. In
this
manner, number of cradle fixtures 314 may be positioned such that number of
cradle
fixtures 314 are in number of selected cradle positions 320 relative to each
other.
In these illustrative examples, number of corresponding autonomous vehicles
316 may be used to drive number of cradle fixtures 314 into number of selected
cradle
positions 320 within assembly area 304. "Driving" a component or a system
across
floor 300 may mean, for example, but not limited to, moving substantially the
entirety
of that component or system from one location to another location. For
example,
without limitation, driving cradle fixture 322 across floor 300 may mean
moving the
entirety of cradle fixture 322 from one location to another location. In other
words, all
or substantially all components that comprise cradle fixture 322 may be
simultaneously moved together from one location to another location.
Once number of cradle fixtures 314 has been driven into number of selected
cradle positions 320 in assembly area 304, number of cradle fixtures 314 may
be
coupled to each other and to tower system 310. Number of corresponding
autonomous vehicles 316 may then drive away from number of cradle fixtures 314
to,
for example, without limitation, holding area 318, once number of cradle
fixtures 314 is
positioned in number of selected cradle positions 320 within selected
tolerances. In
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
24
CA 3004012 2018-05-02
cradle positions 320 relative to each other. In some cases, assembly fixture
324 may
be formed when number of cradle fixtures 314 have been coupled to each other
while
number of cradle fixtures 314 is in number of selected cradle positions 320
and when
number of retaining structures 326 associated with each of number of cradle
fixtures
314 has been adjusted to receive fuselage assembly 114.
In this manner, number of cradle fixtures 314 may form a single fixture
entity,
such as assembly fixture 324. Assembly fixture 324 may be used to support and
hold
fuselage assembly 114. In some cases, assembly fixture 324 may be referred to
as
an assembly fixture system or a fixture system. In some cases, assembly
fixture 324
may be referred to as a drivable assembly fixture. In other cases, assembly
fixture
324 may be referred to as an autonomously drivable assembly fixture.
Once assembly fixture 324 has been formed, number of cradle fixtures 314
may receive fuselage assembly 114. In other words, plurality of fuselage
sections 205
may be engaged with number of cradle fixtures 314. In particular, plurality of
fuselage
sections 205 may be engaged with number of retaining structures 326 associated
with
each of number of cradle fixtures 314. Plurality of fuselage sections 205 may
be
engaged with number of cradle fixtures 314 in any number of ways.
When number of cradle fixtures 314 includes a single cradle fixture, that
cradle
fixture may be used to support and hold substantially the entire fuselage
assembly
114. When number of cradle fixtures 314 includes multiple cradle fixtures,
each of
these cradle fixtures may be used to support and hold at least one
corresponding
fuselage section of plurality of fuselage sections 205.
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
CA 3004012 2018-05-02
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
314 and then a remaining portion of plurality of members 122 associated with
plurality
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CA 3004012 2018-05-02
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.
Adjacent panels may be connected together using any number of panel splices,
stringer splices, frame splices, or other types of splices.
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CA 3004012 2018-05-02
In ore 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.
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
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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
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.
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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.
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
CA 3004012 2018-05-02
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
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
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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
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
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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.
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,
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CA 3004012 2018-05-02
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
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
34
CA 3004012 2018-05-02
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
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
CA 3004012 2018-05-02
type of tool, such as a fastener insertion tool, to become the new first tool
411
associated with first end effector 410 to perform a different type of
operation.
In one illustrative example, first tool 411 may take the form of first
riveting tool
412. First riveting tool 412 may be used to perform riveting operations. In
some
illustrative examples, a number of different tools may be exchanged with first
riveting
tool 412 and associated with first end effector 410. For example, without
limitation,
first riveting tool 412 may be exchangeable with a drilling tool, a fastener
insertion tool,
a fastener installation tool, an inspection tool, or some other type of tool.
External mobile platform 404 may be autonomously driven across floor 300 and
positioned relative to assembly fixture 324 in Figure 3 supporting fuselage
assembly
114 to position first end effector 410 and first tool 411 associated with
first end effector
410 relative to one of plurality of panels 120. For example, external mobile
platform
404 may be autonomously driven across floor 300 to external position 414
relative to
assembly fixture 324. In this manner, first tool 411 carried by external
mobile platform
404 may be macro-positioned using external mobile platform 404.
Once in external position 414, first end effector 410 may be autonomously
controlled using at least external robotic device 408 to position first tool
411
associated with first end effector 410 relative to a particular location on an
exterior-
facing side of one of plurality of panels 120. In this manner, first tool 411
may be
micro-positioned relative to the particular location.
Internal mobile platform 406 may be located on second tower 336 in Figure 3
when internal mobile platform 406 is not in use. When interface 342 described
in
Figure 3 is formed between second tower 336 and assembly fixture 324, internal
mobile platform 406 may be driven from second tower 336 into interior 236 of
fuselage
assembly 114 and used to perform one or more of operations 124. In one
illustrative
example, internal mobile platform 406 may have a movement system that allows
internal mobile platform 406 to move from second tower 336 onto a floor inside
fuselage assembly 114.
At least one internal robotic device 416 may be associated with internal
mobile
platform 406. In this illustrative example, internal robotic device 416 may
be
considered part of internal mobile platform 406. In other illustrative
examples, internal
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CA 3004012 2018-05-02
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.
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
37
CA 3004012 2018-05-02
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.
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.
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CA 3004012 2018-05-02
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.
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
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CA 3004012 2018-05-02
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
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.
CA 3004012 2018-05-02
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 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 a riveting environment is
depicted in the form of a block diagram in accordance with an illustrative
embodiment.
Riveting environment 600 may be an example of an environment in which rivet
605
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CA 3004012 2018-05-02
may be installed to join plurality of parts 601. Rivet 605 may be installed
using, for
example, two-stage riveting process 444 from Figure 4.
In one illustrative example, plurality of parts 601 may include two parts 603.
Two parts 603 may include first part 606 and second part 608. First part 606
and
second part 608 may meet at interface 613. In particular, interface 613 may be
formed at first interface surface 615 of first part 606 and second interface
surface 617
of second part 608. In other illustrative examples, first interface surface
615 and
second interface surface 617 may be referred to as a first faying surface and
a second
faying surface, respectively.
As depicted, first part 606 may take the form of first panel 610 and second
part
608 may take the form of second panel 612. First panel 610 and second panel
612
may be examples of panels in plurality of panels 120 in Figure 1. In other
illustrative
examples, second part 608 may take the form of a member, such as one of
plurality of
members 122 in Figure 1. In particular, second part 608 may take the form of a
__ support member, such as one of plurality of support members 242 in Figure
2.
Rivet 605 may be installed to join first part 606 and second part 608. In
other
illustrative examples, rivet 605 may be installed to join first part 606,
second part 608,
and a third part (not shown) together. Two-stage riveting process 444 from
Figure 4
may be used to fully install rivet 605.
Rivet 605 may be installed using first robotic device 602 and second robotic
device 604. In one illustrative example, first robotic device 602 may take the
form of
external robotic device 408 in Figure 4. In this example, second robotic
device 604
may take the form of internal robotic device 416 in Figure 4.
As depicted, first end effector 614 may be associated with first robotic
device
602 and first riveting tool 616 may be associated with first end effector 614.
First
riveting tool 616 may take the form of, for example, without limitation,
hammer 618. In
one illustrative example, first end effector 614 and first riveting tool 616
may take the
form of first end effector 410 and first riveting tool 412, respectively, in
Figure 4.
Further, second end effector 620 may be associated with second robotic device
604 and second riveting tool 622 may be associated with second end effector
620.
Second riveting tool 622 may take the form of, for example, without
limitation, bucking
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CA 3004012 2018-05-02
bar 624. In one illustrative example, second end effector 620 and second
riveting tool
622 may take the form of second end effector 418 and second riveting tool 420,
respectively, in Figure 4.
Hole 628 may be drilled through first part 606 and second part 608. As
depicted, hole 628 may extend from first surface 623 of first part 606 to
second
surface 625 of second part 608. Fastener 626 may be inserted into hole 628. In
this
illustrative example, fastener 626 may have first end 636 and second end 638.
In this illustrative example, fastener 626 may be inserted through hole 628 in
a
direction from first part 606 to second part 608. Fastener 626 may be inserted
such
that a portion of fastener 626 at first end 636 of fastener 626 remains
outside of first
surface 623 of first part 606 and a portion of fastener 626 at second end 638
of
fastener 626 extends past second surface 625 of second part 608. In other
words,
fastener 626 may protrude outside of hole 628 past both first surface 623 and
second
surface 625.
Fastener 626 may have head 640 at first end 636. In some illustrative
examples, hole 628 may have elongated portion 630, countersink portion 632,
and
counterbore portion 634. Elongated portion 630 may be the portion having a
substantially same diameter with respect to a center axis through hole 628.
Elongated
portion 630 may also be referred to as a shaft of fastener 626 in some
illustrative
examples. In other illustrative examples, hole 628 may have only elongated
portion
630 and countersink portion 632. In still other illustrative examples, hole
628 may only
have elongated portion 630.
First stage 633 of two-stage riveting process 444 may be performed by
applying first force 644 to head 640 of fastener 626 and applying second force
646 to
second end 638 of fastener 626 in which first force 644 is greater than second
force
646. First riveting tool 616 may apply first force 644, while second riveting
tool 622
may apply second force 646.
In particular, performing first stage 633 of two-stage riveting process 444
may
create initial interference fit 648 between fastener 626 and at least a
portion of hole
628. More specifically, initial interference fit 648 may be created between
fastener
626 and a portion of hole 628 extending from first surface 623 in a direction
towards
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CA 3004012 2018-05-02
second part 608. Performing first stage 633 of two-stage riveting process 444
may
cause a shape of at least a portion of fastener 626 to change. For example,
without
limitation, the shape of at least one of head 640 at first end 636, second end
638, or at
least a portion of fastener 626 between head 640 and second end 638 may change
in
response to the application of first force 644 to head 640 and second force
646 to
second end 638.
Force equilibrium 641 may be created by first force 644, second force 646, and
reactive structural force 645. Reactive structural force 645 may be the force
of
deflection of first part 606 and second part 608 in response to first force
644. In this
illustrative example, force equilibrium 641 is created when first force 644
substantially
equals the sum of second force 646 and reactive structural force 645.
In particular, reactive structural force 645 may be generated by first part
606
and second part 608 structurally compensating for a force differential between
first
force 644 and second force 646. Reactive structural force 645 may be
substantially
equal to a difference between first force 644 being applied to head 640 of
fastener 626
in hole 628 extending through two parts 603 and second force 646 that is
applied to
second end 638 of fastener 626. In this manner, this structural compensation
by first
part 606 and second part 608 may ensure that force equilibrium 641 is
substantially
maintained.
After first stage 633 of two-stage riveting process 444, fastener 626 may be
considered a partially formed rivet. In particular, first stage 633 may
transform
fastener 626 into a partially formed rivet having an interference fit within
selected
tolerances. This interference fit may be initial interference fit 648.
Once initial interference fit 648 has been created, at least one of first
force 644
or second force 646 may be adjusted to form new first force 650 and new second
force 652. New second force 652 may be greater than new first force 650. At
least
one of new first force 650 or new second force 652 may be different from the
original
first force 644 or original second force 646, respectively.
In this illustrative example, second stage 635 may be performed by applying
new first force 650 to head 640 of fastener 626 using first riveting tool 616
and
applying new second force 652 to second end 638 of fastener 626 using second
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CA 3004012 2018-05-02
riveting tool 622. Applying new second force 652 to second end 638, while
first
riveting tool 616 applies new first force 650 to first end 636, may create
final
interference fit 653 between fastener 626 and hole 628.
In particular, final interference fit 653 may be created such that final
interference fit 653 at a first side of interface 613, which may be at first
interface
surface 615 of first part 606, may be equal to final interference fit 653 at a
second side
of interface 613, which may be at second interface surface 617 of second part
608. In
other words, final interference fit 653 may be substantially equal across
interface 613.
In particular, during second stage 635, second riveting tool 622 may change a
shape at second end 638 of fastener 626 to form tail 642 by applying new
second
force 652 to second end 638, while first riveting tool 616 applies new first
force 650 to
first end 636. Once tail 642 has been formed, fastener 626 may be referred to
as rivet
605 that has been fully installed. In some cases, some other portion of
fastener 626
may change shape during second stage 635. For example, in addition to second
end
638, head 640, at least a portion of fastener 626 between head 640 and second
end
638, or both may change shape in response to the application of new first
force 650 to
head 640 and new second force 652 to second end 638.
New force equilibrium 647 may be created by new first force 650, new second
force 652, and new reactive structural force 654. New reactive structural
force 654
may be the force of deflection of first part 606 and second part 608 in
response to the
application of new second force 652.
In one illustrative example, new force
equilibrium 647 is created when new second force 652 substantially equals the
sum of
new first force 650 and new reactive structural force 654.
In particular, new reactive structural force 654 may be generated by first
part
606 and second part 608 structurally compensating for a new force differential
between new first force 650 and new second force 652. New reactive structural
force
654 may be substantially equal to a difference between new first force 650
being
applied to head 640 of fastener 626 in hole 628 extending through two parts
603 and
new second force 652 being applied to second end 638 of fastener 626. In this
manner, this structural compensation by first part 606 and second part 608 may
ensure that new force equilibrium 647 is substantially maintained.
CA 3004012 2018-05-02
In some illustrative examples, final interference fit 653 may be substantially
uniform along an entire length of hole 628. In other illustrative examples,
final
interference fit 653 may be substantially uniform across interface 613 but may
be
different near at least one of first surface 623 of first part 606 or second
surface 625 of
second part 608. In one illustrative example, final interference fit 653 near
second
surface 625 may be tighter than final interference fit 653 near first surface
623.
Having final interference fit 653 be substantially uniform across interface
613
may improve the quality of the formed rivet 605.
In particular, with this final
interference fit 653, the joining strength between two parts 603 may be
improved.
This type of installation may improve the fatigue life of the joint between
two parts 603.
Further, installing rivet 605 having final interference fit 653 may enhance
the joining of
two parts 603 in a manner that improves the overall strength of the structure
comprising two parts 603.
First robotic device 602 and second robotic device 604 may be controlled using
number of controllers 655 to perform two-stage riveting process 444. Number of
controllers 655 may include one or more controllers, depending on the
implementation, which may belong to set of controllers 140 described in Figure
1. In
one illustrative example, number of controllers 655 may include first
controller 656 and
second controller 658, each of which may be an example of one implementation
for a
controller in set of controllers 140 in Figure 1.
First controller 656 may generate a first number of commands that cause first
robotic device 602, and thereby, first riveting tool 616, to apply first force
644 to head
640 of fastener 626 during first stage 633 and new first force 650 to head 640
of
fastener 626 during second stage 635. Second controller 658 may generate a
second
number of commands that cause second robotic device 604, and thereby, second
riveting tool 622, to apply second force 646 to second end 638 of fastener 626
during
first stage 633 and new second force 652 to second end 638 of fastener 626
during
second stage 635.
In this manner, set of controllers 655 may command first robotic device 602
and
second robotic device 604 to perform first stage 633 and second stage 635 of
two-
stage riveting process 444. This type of control may ensure that rivet 605 is
installed
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CA 3004012 2018-05-02
having final interference fit 653 that is within selected tolerances. In one
illustrative
example, final interference fit 653 may be substantially uniform across
interface 613.
In one illustrative example, first clamping device 660 may be associated with
first robotic device 602 and second clamping device 662 may be associated with
second robotic device 604. First clamping device 660 and second clamping
device
662 may be used to clamp first part 606 and second part 608 together prior to
first
force 644 being applied to first end 636 of fastener 626. First clamping
device 660
may apply a first clamping force to first surface 623 of first part 606 and
second
clamping device 662 may apply a second force substantially equal to the first
clamping force to second surface 625 of second part 608 to clamp these parts
together.
Once first part 606 and second part 608 are clamped together, hole 628 may
be drilled. Thereafter, fastener 626 may be inserted into hole 628 while first
part 606
and second part 608 are clamped together. Next two-stage riveting process 444
may
be performed using fastener 626 to install rivet 605.
Clamping first part 606 and second part 608 together using first clamping
device 660 and second clamping device 662 may ensure that first part 606 and
second part 608 are held substantially in place relative to each other and
substantially
in contact with each other during the creation of initial interference fit 648
during first
stage 633 of two-stage riveting process 444. In other words, first part 606
and second
part 608 may be clamped to ensure that first part 606 does not move relative
to
second part 608 before and while first force 644 is applied to head 640 to
form initial
interference fit 648.
In this illustrative example, first part 606 and second part 608 may be
unclamped prior to second force 646 being applied to second end 638 of
fastener 626.
First part 606 and second part 608 may no longer need to be clamped because
initial
interference fit 648 has been formed and first riveting tool 616 remains
abutted against
head 640 after initial interference fit 648 has been formed.
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.
47
CA 3004012 2018-05-02
Some components may be optional. Also, the blocks are presented to illustrate
some
functional components. One or more of these blocks may be combined, divided,
or
combined and divided into different blocks when implemented in an illustrative
embodiment.
For example, in some cases, more than one flexible manufacturing system may
be present within manufacturing environment 100.
These multiple flexible
manufacturing systems may be used to build multiple fuselage assemblies within
manufacturing environment 100. In other illustrative examples, flexible
manufacturing
system 106 may include multiple cradle systems, multiple tower systems,
multiple
utility systems, multiple autonomous tooling systems, and multiple pluralities
of
autonomous vehicles such that multiple fuselage assemblies may be built within
manufacturing environment 100.
In some illustrative examples, utility system 138 may include multiple utility
fixtures that are considered separate from flexible manufacturing system 106.
Each of
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 a riveting environment is
depicted in accordance with an illustrative embodiment. In this illustrative
example,
riveting environment 700 may be an example of one implementation for riveting
environment 600 in Figure 6. First robotic device 702 may have end effector
706 with
tool 708 and second robotic device 704 may have end effector 710 with tool
712.
48
CA 3004012 2018-05-02
First robotic device 702 and second robotic device 704 may be examples of
first robotic device 602 and second robotic device 604, respectively, in
Figure 6.
Further, end effector 706 and tool 708 may be examples of implementations for
first
end effector 614 and first riveting tool 616, respectively, in Figure 6. End
effector 710
and tool 712 may be examples of implementations for second end effector 620
and
second riveting tool 622, respectively, in Figure 6.
Tool 708 and tool 712 may take the form of hammer 711 and bucking bar 713,
respectively. Hammer 711 and bucking bar 713 may be examples of
implementations
for hammer 618 and bucking bar 624, respectively, in Figure 6.
Tool 708 and tool 712 may be used to form a rivet to join first part 714 and
second part 716. In this illustrative example, rivet 718 and rivet 720 have
already
been installed.
As depicted, fastener 722 has been inserted through hole 721 that extends
through first part 714 and second part 716. Fastener 722 may be an example of
one
implementation for fastener 626 in Figure 6. Fastener 722 may have head 724
and
end 726. Head 724 and end 726 may be examples of implementations for head 640
and second end 638, respectively, in Figure 6. Section 730 may be shown
enlarged
in Figure 8 below.
With reference now to Figure 8, an illustration of an enlarged view of section
730 from Figure 7 is depicted in accordance with an illustrative embodiment.
As
depicted, hole 721 may have counterbore portion 803, countersink portion 805,
and
elongated portion 807, which may be examples of implementations for
counterbore
portion 634, countersink portion 632, and elongated portion 630, respectively,
in
Figure 6.
In this illustrative example, hammer force 800 may be applied to head 724 to
create initial interference fit 801 between head 724 and countersink portion
805 of
hole 721. Initial interference fit 801 may be an example of one implementation
for
initial interference fit 648 in Figure 6.
Hammer force 800 may be applied to head 724 while bucking force 802 is
applied to end 726. This application of hammer force 800 and bucking force 802
may
constitute a first stage of riveting. Hammer force 800 and bucking force 802
may be
49
CA 3004012 2018-05-02
examples of implementations for first force 644 and second force 646,
respectively, in
Figure 6. Hammer force 800 may be greater than bucking force 802.
First part 714 and second part 716 may generate reactive structural force 804
in response to hammer force 800. Reactive structural force 804 may include
deflection force 811 and deflection force 812. Deflection force 811 may be the
force
with which the portion of first part 714 and second part 716 at side 814 of
fastener 722
deflects in response to hammer force 800. Deflection force 812 may be the
force by
which the portion of first part 714 and second part 716 at the other side 816
of
fastener 722 deflects in response to hammer force 800. In this illustrative
example,
deflection force 811 and deflection force 812 may be substantially equal. In
particular,
deflection force 811 and deflection force 812 may both be equal to FD. Of
course, in
other illustrative examples, deflection force 811 and deflection force 812 may
not be
equal.
A force equilibrium is created between hammer force 800, bucking force 802,
and reactive structural force 804. In particular, hammer force 800, FH, may be
substantially equal to the sum of bucking force 802, Fs, and reactive
structural force
804, FRS, such that a force equilibrium is created. More specifically, hammer
force
800 may be substantially equal to the sum of bucking force 802, deflection
force 811,
and deflection force 812 such that:
FH = Fs FRS = FS + 2F0= (1)
Next, at least one of hammer force 800 or bucking force 802 is adjusted such
that new hammer force 806 and new bucking force 808 may be applied to fastener
722 to form a tail at end 726, shown as tail 902 in Figure 9 below. This
application of
new hammer force 806 and new bucking force 808 may constitute a second stage
of
riveting. New hammer force 806 and new bucking force 808 may be examples of
implementations for new first force 650 and new second force 652,
respectively, in
Figure 6. New bucking force 808 may be greater than new hammer force 806.
New reactive structural force 810 may be generated by first part 714 and
second part 716 in response to new bucking force 808. New reactive structural
force
CA 3004012 2018-05-02
810 may include new deflection force 818 and new deflection force 820. New
deflection force 818 may be the force with which the portion of first part 714
and
second part 716 at side 814 of fastener 722 deflects in response to new
bucking force'
808. New deflection force 820 may be the force by which the portion of first
part 714
.. and second part 716 at the other side 816 of fastener 722 deflects in
response to new
bucking force 808. In this illustrative example, new deflection force 818 and
new
deflection force 820 may be substantially equal. In particular, new deflection
force
818 and new deflection force 820 may both be equal to FND. Of course, in other
illustrative examples, new deflection force 818 and new deflection force 820
may not
be equal.
In this illustrative example, a new force equilibrium is created between new
hammer force 806, new bucking force 808, and new reactive structural force
810. In
particular, new bucking force 808, FNB, may be substantially equal to the sum
of new
hammer force 806, FNH, and new reactive structural force 810, FNRs, such that
a new
force equilibrium is created. More specifically, new bucking force 808 may be
substantially equal to the sum of new hammer force 806, new deflection force
818,
and new deflection force 820 such that:
FNB= FNH + FNRS = FNH 4" 2FND= (2)
The application of new hammer force 806 and new bucking force 808 during
second stage of riveting may create a final interference fit (not shown).
With reference now to Figure 9, an illustration of a fully installed rivet and
a
chart of the final interference fit created between the rivet and hole 721
from Figure 7
is depicted in accordance with an illustrative embodiment. In this
illustrative example,
rivet 900 has been fully formed and installed to join first part 714 and
second part 716.
As depicted, rivet 900 now has tail 902. The two-stage riveting process
described in
Figure 8 for forming rivet 900 may produce rivet 900 having an improved
quality.
In particular, the two-stage riveting process may result in final interference
fit
.. 904 being created between rivet 900 and hole 721. Final interference fit
904 may be
an example of one implementation for final interference fit 653 in Figure 6.
Final
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CA 3004012 2018-05-02
interference fit 904 may be within selected tolerances. In this illustrative
example, final
interference fit 904 may be substantially uniform across interface 906.
Interface 906
may be formed between first surface 907 and second surface 908.
Chart 910 illustrates final interference fit 904 created at various positions
along
rivet 900. As shown in chart 910, final interference fit 904 at position 912
located on
one side of interface 906 near first surface 907 may be substantially equal to
final
interference fit 904 at position 914 located on the other side of interface
906 near
second surface 908. In particular, final interference fit 904 may be
substantially
uniform across interface 906 between about position 912 and position 914.
Further, in this illustrative example, final interference fit 904 may be
greater at
position 914 near tail 902 of rivet 900 as compared to position 916 near head
724 of
rivet 900. In this manner, rivet 900 may have final interference fit 904 of a
desired
quality that, while different along a length of rivet 900, may be
substantially uniform
across interface 906.
With reference now to Figure 10, an illustration of an isometric cutaway view
of
a plurality of mobile platforms performing fastening processes within an
interior of a
fuselage assembly in a manufacturing environment is depicted in accordance
with an
illustrative embodiment. In this illustrative example, manufacturing
environment 1001
may be an example of one implementation for manufacturing environment 100 in
Figure 1.
As depicted, flexible manufacturing system 1000 may be present within
manufacturing environment 1001. Flexible manufacturing system 1000 may be used
to build fuselage assembly 1002. Flexible manufacturing system 1000 may be an
example of one implementation for flexible manufacturing system 106 in Figure
1.
Fuselage assembly 1002 may be an example of one implementation for fuselage
assembly 114 in Figure 1.
In this illustrative example, fuselage assembly 1002 may be comprised of
plurality of panels 1003 and plurality of members 1004. Plurality of panels
1003 and
plurality of members 1004 may be examples of implementations for plurality of
panels
120 and plurality of members 122 in Figures 1 and 2. Flexible manufacturing
system
1000 may be used to join plurality of panels 1003 together, which may include
joining
52
CA 3004012 2018-05-02
members of plurality of members 1004 to each other, to panels of plurality of
panels
1003, or both.
As depicted, flexible manufacturing system 1000 may include plurality of
autonomous vehicles 1006, cradle system 1008, tower system 1010, autonomous
tooling system 1012, and utility system 1014. Plurality of autonomous vehicles
1006,
cradle system 1008, tower system 1010, autonomous tooling system 1012, and
utility
system 1014 may be examples of implementations for number of corresponding
autonomous vehicles 316 in Figure 3, cradle system 308 in Figure 3, tower
system
310 in Figure 3, autonomous tooling system 312 in Figure 3, and utility system
138 in
Figure 1, respectively.
As depicted, plurality of autonomous vehicles 1006 may include autonomous
vehicle 1007, autonomous vehicle 1009, and autonomous vehicle 1011, as well as
other autonomous vehicles (not shown). Autonomous vehicles 1007, 1009, and
1011
may have omnidirectional wheels. Plurality of autonomous vehicles 1006 have
been
used to move cradle system 1008, tower system 1010, and autonomous tooling
system 1012 into selected positions relative to each other.
Cradle system 1008 may form assembly fixture 1013 for supporting fuselage
assembly 1002 during the building of fuselage assembly 1002. Assembly fixture
1013
may be an example of one implementation for assembly fixture 324 in Figure 3.
Tower system 1010 may include robotic tower 1016, which may be an example
of one implementation for second tower 336 in Figure 3. Autonomous vehicle
1007 is
shown positioned under robotic tower 1016. Autonomous vehicle 1007 may be used
to move robotic tower 1016 into a selected tower position relative to utility
fixture 1018
of utility system 1014.
In this illustrative example, robotic tower 1016 may be coupled to utility
fixture
1018 of utility system 1014. Cradle system 1008 may be coupled to robotic
tower
1016. Further, autonomous tooling system 1012 may be coupled to cradle system
1008 and robotic tower 1016. In this manner, a number of utilities may be
distributed
downstream from utility fixture 1018 to robotic tower 1016, to cradle system
1008, and
to autonomous tooling system 1012.
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CA 3004012 2018-05-02
In this illustrative example, autonomous tooling system 1012 may include
plurality of mobile platforms 1015. Plurality of mobile platforms 1015 may be
used to
perform fastening processes to join plurality of panels 1003 together.
Plurality of
panels 1003 may be joined to form at least one of lap joints, butt joints, or
other types
of joints. In this manner, plurality of panels 1003 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 1003.
As depicted, plurality of mobile platforms 1015 may include internal mobile
platform 1020, internal mobile platform 1022, external mobile platform 1024,
and
external mobile platform 1026. Internal mobile platform 1020 and internal
mobile
platform 1022 may be performing operations within interior 1028 of fuselage
assembly
1002, while external mobile platform 1024 and external mobile platform 1026
are
performing assembly operations along the exterior of fuselage assembly 1002.
Internal mobile platform 1020 and internal mobile platform 1022 may be an
example of one implementation for at least a portion of number of internal
mobile
platforms 402 in Figure 4. External mobile platform 1024 and external mobile
platform 1026 may be an example of one implementation for at least a portion
of
number of external mobile platforms 400 in Figure 4.
Internal mobile platform 1020 may be configured to move along passenger floor
1021 while internal mobile platform 1022 may be configured to move along cargo
floor
1023. Internal mobile platform 1020 and internal mobile platform 1022 may be
coupled to robotic tower 1016 to receive the number of utilities through
robotic tower
1016. External mobile platform 1024 and external mobile platform 1026 may be
coupled to cradle system 1008 to receive the number of utilities from cradle
system
1008.
As depicted, internal robotic device 1036 and internal robotic device 1038 may
be associated with internal mobile platform 1022. Each of internal robotic
device
1032, internal robotic device 1034, internal robotic device 1036, and internal
robotic
device 1038 may be an example of one implementation for internal robotic
device 416
in Figure 4.
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CA 3004012 2018-05-02
External robotic device 1040 may be associated with external mobile platform
1024. External robotic device 1042 may be associated with external mobile
platform
1026. Each of external robotic device 1040 and external robotic device 1042
may be
an example of one implementation for external robotic device 408 in Figure 4.
As depicted, external robotic device 1040 and internal robotic device 1034 may
work collaboratively to install fasteners, such as fastener 626 in Figure 6,
autonomously in fuselage assembly 1002. Similarly, external robotic device
1042 and
internal robotic device 1038 may work collaboratively to install fasteners,
such as
fastener 626 in Figure 6, autonomously in fuselage assembly 1002.
In this illustrative example, end effector 1044 of external robotic device
1040
and end effector 1046 of internal robotic device 1034 may be positioned
relative to a
same location on fuselage assembly 1002 to perform a fastening process, such
as
fastening process 424 in Figure 4, at this location. In this illustrative
example, the
fastening process may include a two-stage riveting process, such as two-stage
riveting process 444 described in Figures 4 and 6. Similarly, end effector
1048 of
external robotic device 1042 and end effector 1050 of internal robotic device
1038
may be positioned relative to a same location on fuselage assembly 1002 to
perform a
fastening process, which may include a two-stage riveting process, at the
location.
In this illustrative example, autonomous vehicle 1009 may be fixedly
associated
with external mobile platform 1024. Autonomous vehicle 1009 may be used to
drive
external mobile platform 1024 autonomously. For example, autonomous vehicle
1009
may be used to autonomously drive external mobile platform 1024 across floor
1052
of manufacturing environment 1001 relative to assembly fixture 1013.
Similarly, autonomous vehicle 1011 may be fixedly associated with external
mobile platform 1026. Autonomous vehicle 1011 may be used to drive external
mobile platform 1026 autonomously. For example, autonomous vehicle 1011 may be
used to autonomously drive external mobile platform 1026 across floor 1052 of
manufacturing environment 1001 relative to assembly fixture 1013.
By being fixedly associated with external mobile platform 1024 and external
mobile platform 1026, autonomous vehicle 1009 and autonomous vehicle 1011 may
be considered integral to external mobile platform 1024 and external mobile
platform
CA 3004012 2018-05-02
1026, respectively. However, in other illustrative examples, these
autonomous
vehicles may be independent of the external mobile platforms in other
illustrative
examples.
In these illustrative examples, a metrology system (not shown) may be used to
help position internal mobile platform 1020, internal mobile platform 1022,
external
mobile platform 1024, and external mobile platform 1026 relative to fuselage
assembly
1002. In particular, the metrology system (not shown) may be used to precisely
position internal robotic device 1032 of internal mobile platform 1020,
internal robotic
device 1034 of internal mobile platform 1020, internal robotic device 1036 of
internal
mobile platform 1022, internal robotic device 1038 of internal mobile platform
1022,
external robotic device 1040 of external mobile platform 1024, and external
robotic
device 1042 of external mobile platform 1026. In particular, these robotic
devices may
be precisely positioned relative to each other and to fuselage assembly 1002.
With reference now to Figure 11, an illustration of a cross-sectional view of
flexible manufacturing system 1000 and fuselage assembly 1002 from Figure 10
is
depicted in accordance with an illustrative embodiment. In this illustrative
example, a
cross-sectional view of flexible manufacturing system 1000 and fuselage
assembly
1002 from Figure 10 is depicted taken in the direction of lines 11-11 in
Figure 10. As
depicted, internal mobile platform 1020 may move along passenger floor 1021
within
.. interior 1028 of fuselage assembly 1002, while internal mobile platform
1022 may
move along cargo floor 1023 of fuselage assembly 1002.
A metrology system (not shown) may be used to precisely position the various
robotic devices associated with autonomous tooling system 1012 relative to
each
other and to fuselage assembly 1002 such that fasteners may be installed in
fuselage
.. assembly 1002. In one illustrative example, rivets may be installed using a
two-stage
riveting process, such as two-stage riveting process 444 in Figure 4. For
example,
without limitation, internal robotic device 1032 associated with internal
mobile platform
1020 and external robotic device 1040 associated with external mobile platform
1024
may be positioned relative to a same location on fuselage assembly 1002 to
perform
the two-stage riveting process.
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CA 3004012 2018-05-02
The illustrations in Figures 7-11 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 7-11 may be illustrative examples
of how components shown in block form in Figures 1-6 can be implemented as
physical structures. Additionally, some of the components in Figures 7-11 may
be
combined with components in Figure 1-6, used with components in Figure 1-6, or
a
combination of the two.
Turning now to Figure 12, an illustration of a process for fastening two parts
together is depicted in the form of a flowchart in accordance with an
illustrative
embodiment. The process illustrated in Figure 12 may be implemented using
flexible
manufacturing system 106 in Figure 1. In particular, the process illustrated
in Figure
12 may be used to fasten first part 606 and second part 608 in riveting
environment
.. 600 in Figure 6.
The process may begin by creating initial interference fit 648 between
fastener
626 and at least a portion of hole 628 extending through two parts 603 while
maintaining force equilibrium 641 (operation 1200).
In operation 1200, force
equilibrium 641 may be between first force 644 being applied to first end 636
of
fastener 626, second force 646 that is less than first force 644 being applied
to second
end 638 of fastener 626, and reactive structural force 645. First end 636 of
fastener
626 may take the form of head 640. Further, in operation 1200, two parts 603
may
include, for example, first part 606 and second part 608.
Next, final interference fit 653 may be created between fastener 626 and hole
628 while maintaining new force equilibrium 647 (operation 1202), with the
process
terminating thereafter. Operation 1202 may be performed by forming tail 642 at
second end 638 of fastener 626 while maintaining new force equilibrium 647 to
fully
install rivet 605. New force equilibrium 647 may be between new first force
650 being
applied to head 640, new second force 652 being applied to the end, and new
reactive
structural force 654. Forming tail 642 at second end 638 of fastener 626 in
operation
1202 may complete the fastener installation and thereby, complete the joining
of two
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parts 603 together at the particular location at which fastener 626 is
installed. The
process described in Figure 12 may be repeated any number of times at any
number
of locations to install any number of rivets.
Turning now to Figure 13, an illustration of a process for performing a two-
stage riveting process is depicted in the form of a flowchart in accordance
with an
illustrative embodiment. The process illustrated in Figure 13 may be
implemented
using flexible manufacturing system 106 in Figure 1. In particular, the
process
illustrated in Figure 13 may be used to perform two-stage riveting process 444
in
Figures 4 and 6 to fasten first part 606 and second part 608 in riveting
environment
600 in Figure 6.
The process may begin by creating initial interference fit 648 between
fastener
626 and at least a portion of hole 628 extending through two parts 603 using
hammer
618 associated with first robotic device 602 and bucking bar 624 associated
with
second robotic device 604 while maintaining force equilibrium 641 (operation
1300).
Force equilibrium 641 may be between first force 644 being applied to head 640
at
first end 636 of fastener 626, second force 646 being applied to second end
638 of
fastener 626 that is less than first force 644, and reactive structural force
645.
Next, final interference fit 653 may be created between fastener 626 and hole
628 using bucking bar 624 and hammer 618, while maintaining new force
equilibrium
647, such that final interference fit 653 is substantially uniform across
interface 613
between two parts 603 (operation 1302), with the process terminating
thereafter. In
other words, final interference fit 653 at a first side of interface 613
between two parts
603 may be equal to final interference fit 653 at a second side of interface
613 within
selected tolerances. New force equilibrium 647 may be between new first force
650
being applied to head 640, new second force 652 being applied to second end
638,
and new reactive structural force 654. In operation 1302, tail 642 may be
formed at
second end 638 of fastener 626 to substantially complete installation of rivet
605.
Forming tail 642 at second end 638 of fastener 626 in operation 1302 may
complete the installation of rivet 605 that joins two parts 603 together at
the location of
rivet 605. With final interference fit 653 being substantially uniform across
interface
613, rivet 605 may be considered as being of a desired or sufficiently high
quality.
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Turning now to Figure 14, an illustration of a process for performing a two-
stage riveting process is depicted in the form of a flowchart in accordance
with an
illustrative embodiment. The process illustrated in Figure 14 may be
implemented
using flexible manufacturing system 106 in Figure 1. In particular, the
process
illustrated in Figure 14 may be used to perform two-stage riveting process 444
in
Figure 4 to fasten first part 606 and second part 608 in riveting environment
600 in
Figure 6.
The process begins by clamping first part 606 and second part 608 relative to
each other (operation 1400). In operation 1400, first part 606 and second part
608
may be clamped together using first clamping device 660 and second clamping
device
662. First clamping device 660 may apply a first clamping force to first
surface 623 of
first part 606 and second clamping device 662 may apply a second clamping
force
substantially equal to the first clamping force to second surface 625 of
second part
608 to clamp these parts together.
Next, first force 644 is applied to head 640 of fastener 626 positioned within
hole 628 through first part 606 and second part 608 using hammer 618
associated
with first robotic device 602 (operation 1402). Thereafter, first part 606 and
second
part 608 are unclamped (operation 1404). Second force 646 is then applied to
an end
of fastener 626 using bucking bar 624 associated with second robotic device
604 in
which second force 646 is less than first force 644 (operation 1406).
Head 640 of fastener 626 is then hammered a plurality of times over a time
interval using hammer 618 to create initial interference fit 648 between
fastener 626
and at least a portion of hole 628 through first part 606 and second part 608,
while
maintaining force equilibrium 641 between first force 644 being applied to
head 640,
second force 646 being applied to the end of fastener 626, and reactive
structural
force 645 (operation 1408). Next, at least one of first force 644 or second
force 646 is
adjusted to form new first force 650 and new second force 652 in which new
second
force 652 is greater than new first force 650 (operation 1410).
The end of fastener 626 is then hammered the plurality of times over the time
interval using bucking bar 624 to form tail 642 at the end of fastener 626 and
create
final interference fit 653 between fastener 626 and hole 628, while
maintaining new
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CA 3004012 2018-05-02
force equilibrium 647 between new first force 650 being applied to head 640,
new
second force 652 being applied to the end, and new reactive structural force
654
(operation 1412), with the process terminating thereafter. Once operation 1412
has
been performed, rivet 605 may be considered fully formed and installed and
first part
606 and second part 608 may be considered fastened. Rivet 605 may have a
desired
quality such that final interference fit 653 created between fastener 626 and
hole 628
may be within selected tolerances. In one illustrative example, final
interference fit
653 may be substantially uniform across interface 613 between first part 606
and
second part 608.
Turning now to Figure 15, an illustration of a process for installing a rivet
is
depicted in the form of a flowchart in accordance with an illustrative
embodiment. The
process illustrated in Figure 15 may be implemented to install a rivet, such
as rivet
605 in Figure 6.
The process may begin by generating reactive structural force 645 in a first
direction during installation of rivet 605 (operation 1500). New reactive
structural force
654 may then be generated in a second direction opposite to the first
direction during
the installation of rivet 605 (operation 1502), with the process terminating
thereafter.
The flowcharts and block diagrams in the different depicted embodiments
illustrate the architecture, functionality, and operation of some possible
implementations of apparatuses and methods in an illustrative embodiment. In
this
regard, each block in the flowcharts or block diagrams may represent a module,
a
segment, a function, a portion of an operation or step, some combination
thereof.
In some alternative implementations of an illustrative embodiment, the
function
or functions noted in the blocks may occur out of the order noted in the
figures. For
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 16, 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 1600 may be used to implement any of the controllers
CA 3004012 2018-05-02
described above, including control system 136 in Figure 1. For example, data
processing system 1600 may be used to implement one or more of set of
controllers
140 in Figure 1.
As depicted, data processing system 1600 includes communications framework
1602, which provides communications between processor unit 1604, storage
devices
1606, communications unit 1608, input/output unit 1610, and display 1612. In
some
cases, communications framework 1602 may be implemented as a bus system.
Processor unit 1604 is configured to execute instructions for software to
perform a number of operations. Processor unit 1604 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 1604 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 1604 may be located in storage devices 1606. Storage devices
1606
may be in communication with processor unit 1604 through communications
framework 1602. 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 1614 and persistent storage 1616 are examples of storage devices
1606. Memory 1614 may take the form of, for example, a random access memory or
some type of volatile or non-volatile storage device. Persistent storage 1616
may
comprise any number of components or devices. For example, persistent storage
1616 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 1616 may or may not be removable.
Communications unit 1608 allows data processing system 1600 to
communicate with other data processing systems, devices, or both.
Communications
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unit 1608 may provide communications using physical communications links,
wireless
communications links, or both.
Input/output unit 1610 allows input to be received from and output to be sent
to
other devices connected to data processing system 1600. For example,
input/output
unit 1610 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 1610 may allow output to be sent to a printer connected to data
processing
system 1600. Display 1612 is configured to display information to a user.
Display
1612 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 1604 using computer-implemented
instructions. These instructions may be referred to as program code, computer
usable
program code, or computer readable program code and may be read and executed
by
one or more processors in processor unit 1604.
In these examples, program code 1618 is located in a functional form on
computer readable media 1620, which is selectively removable, and may be
loaded
onto or transferred to data processing system 1600 for execution by processor
unit
1604. Program code 1618 and computer readable media 1620 together form
computer program product 1622. In this illustrative example, computer readable
media 1620 may be computer readable storage media 1624 or computer readable
signal media 1626.
Computer readable storage media 1624 is a physical or tangible storage device
used to store program code 1618 rather than a medium that propagates or
transmits
program code 1618. Computer readable storage media 1624 may be, for example,
without limitation, an optical or magnetic disk or a persistent storage device
that is
connected to data processing system 1600.
Alternatively, program code 1618 may be transferred to data processing system
1600 using computer readable signal media 1626. Computer readable signal media
1626 may be, for example, a propagated data signal containing program code
1618.
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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 1600 in Figure 16 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 1600. Further, components shown in
Figure 16
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 1700 as shown in Figure 17 and
aircraft
1800 as shown in Figure 18. Turning first to Figure 17, an illustration of an
aircraft
manufacturing and service method is depicted in the form of a block diagram in
accordance with an illustrative embodiment.
During pre-production, aircraft
manufacturing and service method 1700 may include specification and design
1702 of
aircraft 1800 in Figure 18 and material procurement 1704.
During production, component and subassembly manufacturing 1706 and
system integration 1708 of aircraft 1800 in Figure 18 takes place. Thereafter,
aircraft
1800 in Figure 18 may go through certification and delivery 1710 in order to
be placed
in service 1712. While in service 1712 by a customer, aircraft 1800 in Figure
18 is
scheduled for routine maintenance and service 1714, which may include
modification,
reconfiguration, refurbishment, and other maintenance or service.
Each of the processes of aircraft manufacturing and service method 1700 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.
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CA 3004012 2018-05-02
With reference now to Figure 18, 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 1800 is produced by aircraft manufacturing and service
method
1700 in Figure 17 and may include airframe 1802 with plurality of systems 1804
and
interior 1806. Examples of systems 1804 include one or more of propulsion
system
1808, electrical system 1810, hydraulic system 1812, and environmental system
1814.
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 1700 in Figure
17. In
particular, flexible manufacturing system 106 from Figure 1 may be used to
manufacture the fuselage of aircraft 1800 during any one of the stages of
aircraft
manufacturing and service method 1700. For example, without limitation,
flexible
manufacturing system 106 from Figure 1 may be used during at least one of
component and subassembly manufacturing 1706, system integration 1708, or some
other stage of aircraft manufacturing and service method 1700. In particular,
two-
stage riveting process 444 in Figure 4 may be used to install rivets in
fuselage panels,
such as plurality of panels 120 in Figure 1, to build, for example, without
limitation,
fuselage assembly 114 in Figure 1, for airframe 1802 of aircraft 1800.
In one illustrative example, components or subassemblies produced in
component and subassembly manufacturing 1706 in Figure 17 may be fabricated or
manufactured in a manner similar to components or subassemblies produced
while aircraft 1800 is in service 1712 in Figure 17. 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 1706 and system integration 1708 in Figure 17. One or more
apparatus embodiments, method embodiments, or a combination thereof may be
utilized while aircraft 1800 is in service 1712, during maintenance and
service 1714 in
Figure 17, or both. The use of a number of the different illustrative
embodiments may
substantially expedite the assembly of and reduce the cost of aircraft 1800.
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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.
CA 3004012 2018-05-02
