The Boeing Company

Kinson D VanScotter

Bobby Joe Marsh

Bob Marsh

Karen Malen-Hogle

Gary E Georgeson

Michael P Thompson

Thomas J Vanderwiel

Leonard S Bodziony

Brian E Campbell

Michael W Thompson

Karen M Malen-Hogle

Methods provide for the controlled application of forces to a structure during leveling and securing procedures. According to embodiments described herein, a structure is supported at a number of support locations. An upward force is applied to the structure by the force application devices to counteract an equivalent downward force from the structure at each support location. The forces applied by the force application devices are monitored to detect whenever one or more of the upward forces deviates outside of a threshold range of force values, which includes a quantity of force sufficient to counteract internal forces within a material of the structure. Each force may be adjusted to ensure no deviation outside of the allowed threshold range.

Controlled application of external forces to a structure for precision leveling and securing

Systems and methods provide for the controlled application of forces to a structure during assembly, machining, manufacturing, and/or transportation operations. According to embodiments described herein, a contour control system includes a number of force control modules that are communicatively linked to a control system. The control system receives or retrieves data indicating the shape of the structure and a shape associated with a desired structure, and determines if the structure is consistent with the design specifications and any associated tolerances. The control system controls the force control modules to apply calculated forces to the structure to control the contours of the structure and/or to maintain the structure in a desired configuration. According to embodiments, the force control modules include support cradles, air cushion pads, vacuum cups, and/or other structures for selectively applying dynamic and/or static forces to the structure.

Systems and methods for structure contour control

Methods and systems provide for the controlled application of forces to a structure during leveling and securing procedures. According to embodiments described herein, a force distribution system includes a number of force application devices that are communicatively linked to a computing system. The computing system controls the force application devices to apply calculated forces to the structure, monitor the forces, and adjust the forces when deviations occur. According to one embodiment, the force application devices include jack assemblies and the system is operative to level a structure and maintain the level position when the structure shifts. According to another embodiment, the force application devices include clamp assemblies and the system is operative to apply and maintain a constant and uniform pressure on a structure to secure the structure during machining. Other embodiments include using force application devices to secure a structure during transport.

A method is provided to measure an aircraft under simulated flight-loads while the aircraft is not in flight. Simulated flight-loads may be applied to the aircraft, while the aircraft is not in flight, in order to substantially simulate flight pressure distribution loads the aircraft would experience during flight. A position of one or more portions of the aircraft may be measured, while the aircraft is under the simulated flight-loads, to determine an effect of the simulated flight-loads on the aircraft.

Flight in factory

Fuselage sections of an aircraft are joined using splice elements that compensate for gaps caused by mismatches between mating surfaces on the fuselage sections. The fuselage sections are virtually assembled using computer models that are based on non-contact measurements of as-built fuselage sections. The virtually assembled fuselage sections are used to map the gaps between the mating surfaces. The mapped gaps are used to produce tool inserts having profiles that reflect the dimensions of the gaps. The tool inserts are used to manufacture splice elements having profiles that fill the gaps when the fuselage sections are assembled and joined, thereby eliminating the need for shims and spaces to fill the gaps.

Splicing fuselage sections without shims

Shims used to join part assemblies are automatically designed and fabricated without the need for fitting part assemblies together in order to determine the exact dimensions of voids filled by the shims. The locations of key features on part assemblies are surveyed using a merged photogrammetry and laser tracking technique that generate the dimensions of a virtual shim. The dimensions of the virtual shim are contained in a digital file that can be used to automatically fabricate the shim using automated fabrication equipment such as a CNC machining center. The automated virtual shim design may be modified to reflect the effect of part assembly fit on performance characteristics of the aircraft.

Method for fitting part assemblies

Systems and methods can automatically inspect a workpiece. Non-destructive inspection sensors are mounted on a frame mounted on a transport device. Position of a first predetermined location of a workpiece is measured with a tracking system. The transport device is moved to position the non-destructive inspection sensors proximate the first predetermined location of a workpiece. A first portion of a workpiece proximate the first predetermined location is non-destructively inspected with the non-destructive inspection sensors. Position of a second predetermined location of a workpiece can be measured with the tracking system. The transport device can be moved to position the non-destructive inspection sensors proximate the second predetermined location of a workpiece, and a second portion of a workpiece proximate the second predetermined location can be non-destructively inspected with the non-destructive inspection sensors. Data can be provided from the sensors to a computing system and analyzed by the computing system.

System and method for automated inspection of large-scale part

The invention relates to methods of measuring an aircraft under simulated flight-loads while the aircraft is not in-flight. While the aircraft is under the simulated flight-loads, positions of one or more portions of the aircraft may be measured in order to determine how the aircraft is performing under such loads. The aircraft may be readjusted and/or redesigned based on the measurements in order to reduce drag on the aircraft.

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Stanwood, WA, United States of America

Kinson D VanScotter