The Boeing Company

David E Strand

Paul Elfes Nelson

Clayton Lynn Munk

Antonio C Micale

Paul Reed Stone

Mark S Soderberg

Albert L Hametner

Herman F Leppink

A method and apparatus for manufacturing wings includes a fixture that holds wing panels for drilling and edge trimming by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination features machined into the parts and subassemblies, thereby making the parts and subassemblies intrinsically determinant of the dimensions and contour of the wing. Spars are attached to the wing panel using the coordination holes to locate the spars accurately on the panel in accordance with the original engineering design, and in-spar ribs are attached to rib posts on the spar using accurately drilled coordination holes in the ends of the rib and in the rib post. The wing contour is determined by the configuration of the spars and ribs rather than by any conventional hard tooling which determines the wing contour in conventional processes.

Determinant wing assembly

Method of manufacturing a wing

A method and apparatus for holding a part on a fixture in a precisely known predetermined position includes pressing a surface of the part against a vacuum head and sealing an annular elastomeric sealing ring against the part surface. A valve button of a valve is engaged by the part surface to open the valve and establish communication between a vacuum source. The part is pulled by the vacuum against a hard stop in the vacuum head having a fixed precisely known relationship to said vacuum head reference surface. The hard-stop can be mounted in the base of the vacuum head for pivoting about at least one axis to self-align the hard-stop face with the part face.

Vacuum cup with precision hard stop

A method and apparatus for manufacturing large, semi-flexible metal components includes a fixture that holds the component blank in a desired position for manufacturing operations by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination features machined into the parts and subassemblies, thereby making the parts and subassemblies intrinsically determinant of the dimensions and contour of the part.

Determinant passively-located pogo machine

A method and apparatus for manufacturing wing spars includes a fixture that holds spar webs for drilling and edge trimming by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination features machined into the parts and subassemblies, thereby making the parts and subassemblies intrinsically determinant of the dimensions and contour of the wing.

Determinant spar assembly

An airplane fuselage panel including a sheet having peripheral edges routed on routing surfaces, while the sheet is held immobile on a fixture, using a routing end effector carried by a precision computer controlled robot that is directed to the routing surfaces using a digital dataset taken directly from digital engineering part definition records. The sheet has coordination holes drilled while on the fixture using a drilling end effector carried by the precision computer controlled robot that is directed to drilling locations using the digital dataset taken directly from the digital engineering part definition records to accurately locate the hole locations relative to the peripheral edges. The airplane fuselage panel also includes parts, including stringers, stringer clips and shear ties, each having coordination holes drilled by computer controlled drills at locations that will match with corresponding coordination holes in the sheet, so that the parts will be accurately located in positions called for in the digital engineering part definition records when the coordination holes in the parts and the coordination holes in the sheet are aligned and the parts are riveted to the sheet in the accurately located positions.

Airplane fuselage panel

A system for assembling parts on a sheet to form a panel includes a fixture for holding the sheet and presenting the sheet broadside to a robot. A rack within the reach of the robot holds a plurality of end effectors, each having an interconnect which can be gripped and centered by the robot when it picks up by the end effector. The end effectors include, 1) a drilling end effector having a drill for drilling holes in the sheet on centers determined by movement of the robot; 2) a routing end effector having a router for routing peripheral edge portions of the sheet along lines determined by movement of the router; 3) a probe end effector having a probe for sensing contact with surfaces on an index device mounted on the fixture at a known location to serve as a reference monument. A part program constituting a data set having complete panel assembly detail design information obtained directly from original digital engineering part definition records, including locations on the sheet of all fastener holes for fastening the parts needed to make up the panel, and the position on the sheet of the peripheral edge portions thereof relative to the holes, the part program also including machine instructions for directing the movement of the robot to carry the end effectors to the locations on the sheet at which machining operations are needed to fasten the parts in the correct locations and to produce peripheral routed edge portions of the correct configuration. A control computer controls the motion of the robot in accordance with the instructions contained in the part program and automatically performs absolute coordination probing to verify the accuracy of the robot and fixture positioning.

System for making a panel

A method and apparatus for manufacturing panels and major airplane fuselage sections, including a reconfigurable fixture that holds panels for routing and drilling by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination holes drilled into the parts and subassemblies and making the parts and subassemblies intrinsically determinate of the dimensions and contour of the assembly.

Method of assembling parts on an aircraft skin to form a panel

Panel and fuselage assembly

Drills (35), vertically oriented in a row/column array in a drill block (31), are moved in the column direction across a slot (49) located at a loading station (41). As the drills in each partially or fully occupied row reach the slot and drop, drill block movement halts. Thereafter a vertically oriented turn-over tube (51) is moved in the row direction beneath the slot (49). When an occupied drill position is reached, the drill drops into the turn-over tube, tube row movement temporarily halts, and the tube is rotated. The drill slides out of the turn-over tube (51) and down the channel (59) of a measuring station (43) until it hits a movable stop (61). After drill diameter is measured by a pneumatically positioned LVDT (87) and overall drill length is measured by a pneumatically positioned linear potentiometer (69)/proximity detector (PX3) combination, the stop (61) is withdrawn and the drill enters a clamp (95), which grips the adapter shank of the drill. The clamp (95) and the drill are moved by an air-over-oil mechanism toward a prepositioned bushing (385) that deburrs the drill when the drill enters the bushing. Drill movement stops when the end of the flutes reach the bushing, at which time the clamp position is measured by a linear potentiometer (100). The overall drill length measurement and the clamp position measurement are combined to determine the length of the drill's flutes. After the clamp (95) returns to its pickup position the drill is dropped into a prepositioned rotatable tray (123) located at a sorting station (47). The tray and a fan-shaped diverter (125) direct the drill into the appropriate upper or lower bin (131, 133). Drills having diameters other than the diameters to be sorted are dropped into the prepositioned tray without being deburred and directed to a non-selected bin. Bent drills (determined by the drill ends impinging on the periphery of the bushing, rather than entering the bushing) and drills with unacceptably short flutes are directed to a reject drill bin. The various mechanisms are controlled by control signals produced by a CPU (501).

Growing community of inventors

Newcastle, WA, United States of America

David E Strand