The Boeing Company

Dario I Valenzuela

Darrell Darwin Jones

Theodore Martin Boyl-Davis

Christina Michelle Vasquez

Eric M Reid

James N Buttrick, Jr

Roger A Gage

Paul G Kostenick, Jr

Ronald J Collins

Jesus Sanchez

Aksel Bode

James Niemann Buttrick

Clifford D Borowicz

Steven Best

Michael M Stepan

Matthew R Desjardien

Arlen Ray Pumphrey

Paul Gregory Kostenick, Jr

Samuel Chew

Disclosed aircraft wing-to-body join methods include measuring a 3D surface contour of each wing root interface surface of a wing root to form a complete wing root 3D surface profile; measuring a 3D surface contour of each wing stub interface surface of a wing stub to form a complete wing stub 3D surface profile; calculating a virtual fit between the aircraft wing and the aircraft body assembly that defines one or more gaps between the wing root interface surface and the wing stub interface surface; and aligning the aircraft wing to the aircraft body assembly to achieve a real fit consistent with the virtual fit.

Advanced automated process for the wing-to-body join of an aircraft with predictive surface scanning

A scanning apparatus for predictive shimming includes a scanning platform. The scanning apparatus also include a first scanner, coupled to the scanning platform, and a second scanner, coupled to the scanning platform. The scanning platform is configured to move the first scanner and the second scanner together along an X-axis and a Z-axis. The scanning platform is also configured to move the first scanner and the second scanner independent of and relative to each other along a Y-axis and a Z-axis. A first field of view of the first scanner and a second field of view of the second scanner at least partially overlap when the first scanner and the second scanner move in opposite directions along the Y-axis.

Scanning apparatus and method of scanning

A first surface of a part is scanned with a laser scanner as a platform of a computer numerical controlled (CNC) gantry tool moves relative to the part to form scan data, in which the laser scanner is connected to the platform of the computer numerical controlled (CNC) gantry tool. Differences between the first surface and design for the first surface are determined using the scan data.

Laser scanner scanning using a computer numerical controlled (CNC) system for movement

A method includes projecting a first reference image onto a first surface region that includes a component target; capturing a first pair of images that both include (i) the first reference image, (ii) a first ring target located at a first position on an inner ring, (iii) a third ring target located at a third position on an outer ring, and (iv) the component target; projecting a second reference image onto a second surface region; capturing a second pair of images that both include (i) the second reference image, (ii) a second ring target located at a second position on the inner ring, and (iii) a fourth ring target located at a fourth position on the outer ring; and based on the first pair of images and the second pair of images, generating coordinate data that defines the first surface region and the second surface region within a coordinate space.

Methods and systems for characterizing a surface of a structural component

Disclosed aircraft wing-to-body join methods include (a) applying targets to a wing and a body assembly at the respective wing root and wing stub, (b) determining the 3D locations of the targets by photogrammetry, (c) generating 3D surface profiles for the interface surfaces of the wing root and wing stub by combining scans of the interface surfaces, (d) calculating a virtual fit between the wing and the body assembly that defines one or more gaps between the generated 3D surface profiles of the wing root and wing stub, (e) positioning at least three position sensors within the wing root and/or the wing stub, and (f) aligning the wing to the body assembly to achieve a real fit consistent with the calculated virtual fit using feedback from the position sensors. Methods of determining the target locations and/or the 3D surface profiles may utilize a mobile scanning platform.

Systems and methods for robotic measurement of parts are provided. One system includes one or more omni-directional ground vehicles configured to move within a facility defined work zone to a setup calibration station and an engineering defined work space, wherein the engineering defined work space includes a part to be measured. The system also includes a multi-axis robot removably coupled to each of the omni-direction ground vehicles and configured to move a laser scanner, wherein the laser scanner of each of the multi-axis robots is configured to move in at least two linear directions and one rotational direction. The system further includes a processor configured to automatically generate a surface ready output file from measurement data received from the laser scanners, wherein the surface ready output file is configured to command a machine to manufacture a mating component to the part.

Systems and methods for robotic measurement of parts

Systems, methods, and devices are disclosed for predictive shimming of large structures. Systems may include a remote device configured to move along a first path relative to a first vehicle structure. The remote device may be configured to move a sensor device along a plurality of measurement points included in the first path. A base device may be configured to identify a position of the sensor device at each measurement point. The base device may be configured to generate measurement data including a first plurality of measurements identifying at least one structural dimension of a first surface of the first vehicle structure. A controller may be configured to control operation of the base device and the remote device based on engineering data associated with the first vehicle structure. The controller may be further configured to determine at least one shim dimension associated with the first surface.

Systems, methods, and apparatus for automated predictive shimming for large structures

Systems and methods for movement of objects are provided. One system includes a plurality of vehicles configured to support the object, wherein each of the vehicles includes omni-directional wheels and a height adjusting device. The system also includes a control system in communication with the plurality of vehicles, wherein the control system is configured to transmit a signal to the plurality of vehicles instructing the plurality of vehicles to move the object in a predetermined direction along the floor. Each of the plurality of vehicles is configured to adjust at least one of a direction of movement using the omni-directional wheels or a height at which the object is supported while moving the part in the predetermined direction using the height adjusting device.

Systems and methods for movement of objects

A method and apparatus for measuring diameters of holes and countersinks. A tip of a countersink measurement system may be moved to engage a countersink for a hole. A diameter of the countersink may be measured in response to the tip of the countersink measurement system engaging the countersink. A probe may be moved through the tip of the countersink measurement system into a channel for the hole, while the tip is engaged with the countersink. A number of diameters for the channel may be measured as the probe moves in the hole.

Hole and countersink measurement system

A crawler assembly includes an attachment mechanism that is removably attachable to a stringer. The stringer has a vertical web and a longitudinal axis. The crawler assembly includes a longitudinal slider that is engageable to the attachment mechanism and having a normalizing mechanism disposable in bearing contact against the vertical web for maintaining an orientation of the longitudinal slider relative to the stringer. The longitudinal slider is movable along a direction parallel to the longitudinal axis. The crawler assembly includes a lateral slider that is mountable to the longitudinal slider and is movable along a direction perpendicular to the longitudinal axis. The lateral slider includes a drill bushing. The longitudinal and lateral sliders cooperate to move the drill bushing to at least one predetermined hole location.

Stringer crawler with attachment mechanism

A self-contained crawler assembly is engageable to a stringer and is adapted to position a drill bushing along the stringer for performing machining operations. The crawler assembly includes a longitudinal slider, a lateral slider and a controller for regulating operation of the longitudinal and lateral sliders for positioning the drill bushing at a hole location. In a further embodiment, the crawler assembly may include a longitudinal friction drive which is directly engageable to the stringer and which is operative to move in a direction parallel to the stringer.

Stringer crawler

A computer-based method for defining a surface of a part for placement adjacent a mating surface of a base part is described. The method includes receiving raw data which defines the mating surface of the base part, smoothing the raw data, generating a stable reference frame consisting of at least one of a substantially smooth curve and surface based on the smoothed raw data, calculating a dimensional offset curve or surface using the smoothed raw data and the stable reference frame curve or surface by referencing any peaks in the smoothed raw data within a predefined range of a corresponding point in the stable reference frame curve or surface, smoothing the dimensional offset curve or surface, and outputting the dimensional offset curve or surface for utilization in fabricating the part that is to be adjacent the base part.

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Snohomish, WA, United States of America

Dario I Valenzuela