The Boeing Company

David Boonstra

Arnold J Lauder

Antonio M Ferreira

Mark Frederick Gabriel

Claudio Zubin

Mathew J Shewfelt

Geoffrey Gibbings

Damjan Simonovic

John E Yestrau

Roger J Ledet

Trevor M McDonald

Kevin C Barrett

Alan Wright

Garth Vincent Kummen

Demsey Drew Kirkwood

Mark F Gabriel

A drilling system includes a single robotic drilling unit having a drill end effector positioned inside a barrel section configured as a composite sandwich structure having an inner face sheet. The robotic drilling unit is operable to drill a plurality of perforations into the inner face sheet using the drill end effector. The robotic drilling unit is configured to index a hole pattern of the perforations to one or more cell walls of a honeycomb core of the composite sandwich structure. The robotic drilling unit is configured to form the hole pattern in the inner face sheet such that the perforations are located at a spaced distance from the cell walls of the honeycomb core.

Systems and methods for forming perforations in a barrel structure

Presently disclosed systems and methods provide for a quick-change clamp arm that may be coupled to and removed from a robot end effector via a quick-change feature coupled to the robot end effector. Systems may include a plurality of such quick-change clamp arms that each may be coupled to a given robot end effector such that when one is removed, a different respective quick-change clamp arm may be coupled to the robot end effector. The robot end effector may be configured to perform a task to one side of a workpiece, while the quick-change clamp arm applies a stabilizing normal force to the other side of the workpiece. Due to the interchangeable nature of presently disclosed quick-change clamp arms, systems may reduce the number of robot end effectors required for a given manufacturing process. Related methods of removing and coupling quick-change clamp arms to robot end effectors may be automated.

Quick-change clamp arms for robot end effectors, systems including the same, and related methods

A drilling system may include a plurality of robotic drilling units. Each one of the robotic drilling units may include a drill end effector positioned inside a barrel section. The barrel section may be configured as a composite sandwich structure having an inner face sheet. The robotic drilling units maybe operable in synchronized movement with one another to drill a plurality of perforations into the inner face sheet using the drill end effectors in a manner providing a predetermined percent-open-area of the inner face sheet.

System for forming perforations in a barrel section

System and method for forming perforations in a barrel section

A method of fabricating a composite part comprises generating a partial vacuum between a ply material and a form, advancing the partial vacuum and the ply material along the form, sensing an edge of a previously applied course of the ply material and cutting a profile on the ply material in response to the sensed edge.

Machine assisted laminator and method

A system to fabricate a composite item includes an end effector, robotic vehicle, sensor, and cutting system. The end effector applies a course to a layup form. The robotic vehicle positions the end effector. The sensor senses an edge of a previously applied course. The cutting system cuts a profile on the course in response to the sensed edge.

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Dugald, Canada

David Boonstra