The Boeing Company

Phillip John Crothers

Martin Alexander Szarski

David Michael Bain

Philip Lawrence Freeman

Kurtis Shuldberg Willden

Luke Fletcher

Mark Stewart Wilenski

Shane Edward Arthur

Alexander Rubin

Amol Ogale

Bennett M Moriarty

Ashleigh Raoul Nesbit

Gregg Robert Bogucki

Samuel J Tucker

Joshua David Kalin

Peter N Steele

Brian W Smith

Christopher L Brooks, Jr

Carla E Reynolds

Robert Coulter Fraser

Leo Christodoulou

Justin G Young

Geoffrey King Shun Lam

Robert C Fraser

A manufacturing system includes a stator base, a plurality of movers, one or more end effectors, and a controller. The stator base has a planar stator surface covering an array of electrical coils configured to generate an electromagnetic field. The movers each contain multiple permanent magnets configured to cause the movers to levitate and move relative to the stator surface in response to the electromagnetic field. The end effectors are coupled to the movers, and each end effector perform one or more functions in relation to a material sheet. The controller activates the electrical coils in a manner causing independent, coordinated movement of the movers over the stator surface, and causing the end effectors to engage with and operate on the material sheet.

Pick-and-place manufacturing system and method

Disclosed herein is a method of repairing a component. The method includes scanning a damaged area of the component, and preparing a repair plan in response to the scanning. The method may also include providing the repair plan to a guided tool having a position correcting controller, and removing damaged material from the component in preparation for a repair operation. An apparatus is also disclosed that includes a computing device configured for performing actions. The computing device includes a processor and a local memory. The actions include detecting damage to the component, recording position information of the detected damage, and incorporating the position information in the repair plan.

Apparatus and method for contoured-surface component repair

Methods and systems according to one or more examples are provided for testing an automated platform, such as a robot. In one example, a system comprises a first robot configured to perform one or more processing operations on a workpiece. The system further comprises a second robot configured to simulate one or more parameters of the workpiece and an associated processing operation to provide one or more test conditions corresponding to each of the one or more processing operations the first robot would perform on the workpiece to test the first robot.

Simulating process forces during robot testing

A method () of additively manufacturing an object () from a powder material () comprises discharging the powder material () from a powder-deposition opening () in a hollow body () of a powder-supply arm () while rotating the powder-supply arm () and an energy-supply arm () about a vertical axis A. Method () also comprises, while rotating the powder-supply arm () and the energy-supply arm () about the vertical axis A, distributing the powder material () within a powder-bed volume () using a powder-distribution blade () that is coupled to the hollow body () and extends along the powder-deposition opening (). The method () further comprises, while rotating the powder-supply arm () and the energy-supply arm () about vertical axis A, consolidating at least a portion of the powder material () in the powder-bed volume () using the energy emitters (), coupled to the energy-supply arm ().

Methods for additively manufacturing an object from a powder material

An additive-manufacturing apparatus () comprises a support () and a powder-material source (). The additive-manufacturing apparatus () further comprises a powder-supply arm (), which comprises a hollow body (), having an interior volume () that is in communication with the powder-material source (), a powder-deposition opening () in the hollow body (), and a powder-distribution blade (), coupled to the hollow body () and extending along the powder-deposition opening (). The additive-manufacturing apparatus () also comprises an energy source (), an energy-supply arm (), and energy emitters (), coupled to the energy-supply arm (). The additive-manufacturing apparatus () further comprises a rotary drive (), configured to rotate the powder-supply arm () and the energy-supply arm () about a vertical axis A, passing through the support (), and intersecting a powder-supply-arm central axis Aand an energy-supply-arm central axis A

Apparatuses for additively manufacturing an object from a powder material

A system to aid in design for manufacturing an object includes a processor and a memory configured to store instructions. The processor is configured to receive first data representing a design of the object to be manufactured and second data representing a machine-learning model. The processor is configured to execute the instructions to generate third data using the first data and the second data. The third data indicates at least one of a modification to the design of the object or process conditions for production of the object. The processor is configured to send the design of the object, the process conditions, or both, to a manufacturing tool to enable production of the object. The machine-learning model is representative of production data and based at least partially on one or more of: object features, process parameters, environmental factors, and quality data.

Object design using machine-learning model

Systems, methods, and apparatus are disclosed for machining a part. Methods include generating a first spatial representation identifying a first orientation of a machining tool, and mechanically coupling an end effector to the part at a first position, the end effector including the machining tool and a coupling tool. Methods include generating a second spatial representation identifying a second orientation of the machining tool relative to the part, the first and second spatial representations being generated based on images captured by at least one imaging device and measurements from a plurality of sensors. Methods include identifying a plurality of differences that result from the coupling and that include a rotational distance and translational distance, the identifying being based on a comparison of a first image and a second image. Methods include adjusting the machining tool to return the machining tool to the first orientation at the first position.

Path repeatable machining for full sized determinant assembly

An inspection apparatus for performing an automated inspection operation across a surface of a workpiece is disclosed. The inspection apparatus may include a positioning apparatus, a platen fabricated from a magnetic material and having a platen surface, with the platen being mounted on the positioning apparatus and the positioning apparatus being operational to move the platen relative to the surface of the workpiece, and an inspection module disposed on the platen surface and having an inspection end effector. The inspection module may generate a magnetic field that biases the inspection module toward the platen, and may be operable to generate a magnetic flux to control movement of the inspection module over the platen surface to perform the automated inspection operation across the surface of the workpiece.

System and method for performing an automated inspection operation

Thermoplastic assemblies, methods of defining thermoplastic assemblies, aircraft that include the thermoplastic assemblies, and aircraft that are formed utilizing the methods are disclosed herein. The methods include heating a joining structure and pressing a thermoplastic layer against a base of the joining structure. The pressing includes transferring thermal energy from the joining structure to the thermoplastic layer and penetrating the thermoplastic layer with a plurality of reinforcing projections of the joining structure. The pressing also includes adhering the thermoplastic layer to a surface of the base and to a surface of the plurality of reinforcing projections. The thermoplastic assemblies include the thermoplastic layer and the joining structure.

Thermoplastic assemblies, methods of defining thermoplastic assemblies, and aircraft including the thermoplastic assemblies and/or manufactured utilizing the methods

Systems and methods for retuning a surface to a nominal geometry using local reference points are disclosed. The system can include an imaging device for detecting the location of local features on an object. The system can use the location of local features, as opposed to an absolute reference frame, to determine one or more reference areas and one or more surface defects on an object. The system can then determine a nominal geometry for the surface (i.e., a surface that is substantially free of surface defects) and calculate the tool path necessary to create a nominal geometry. The system can machine the surface and, in some cases, rescan the surface to ensure the operation has machined the part to the nominal geometry.

Systems and methods for machining to nominal geometry using local features

Systems, methods, and apparatus are disclosed for machining a part. The methods may include generating a plurality of spatial representations associated with a plurality of positions identified by a machining pattern associated with the part. The plurality of spatial representations may include a first spatial representation identifying a first orientation of a machining tool relative to the part at a first position. The methods may include moving an end effector to the first position. The methods may include mechanically coupling, using a coupling tool, the end effector to the part at the first position. The methods may include generating a second spatial representation identifying a second orientation of the machining tool relative to the part at the first position. The methods may include adjusting the machining tool in response to determining that the second spatial representation is different than the first spatial representation.

Systems and methods are provided for designing flat composites that are formed into 3D shapes. One embodiment is a method that includes loading data defining a three dimensional (3D) shape for a composite part, identifying constraints based on dimensions of the 3D shape, simulating flattening of the 3D shape into a planar shape, and acquiring a mandrel having the planar shape. The method also includes placing features at the mandrel which permit a laminate laid-up onto the mandrel to compensate for the constraints during forming of the laminate into the 3D shape, and generating a Numerical Control (NC) program that directs an Automated Fiber Placement (AFP) machine laying up the laminate. The NC program includes instructions for laying up tows of constituent material onto the mandrel having the features, to form layers of the laminate.

Flat composites having layup features for forming into 3D shapes

A finishing apparatus for performing an automated finishing operation on a surface of a workpiece is disclosed. The finishing apparatus may include a platen fabricated from a magnetic material and having a platen surface, and a finishing module disposed on the platen surface and having a finishing operation end effector. The finishing module may generate a magnetic field that biases the finishing module toward the platen, and may be operable to generate a magnetic flux to control movement of the finishing module over the platen surface to perform the automated finishing operation on the surface of the workpiece.

Apparatus, system and method for performing automated finishing operations on a workpiece

A system includes a robotic device for moving an inspection tool, a scanner coupleable to the robotic device such that the robotic device is configured to automatically move the scanner to collect data associated with a surface of the object, and a computer system configured to determine a surface profile associated with the surface of the object based on the data, and generate a tool path for inspecting the object using the inspection tool based on the surface profile.

Methods and systems for automatically inspecting an object

An inspection apparatus for performing an automated inspection operation across a surface of a workpiece is disclosed. The inspection apparatus may include a platen fabricated from a magnetic material and having a platen surface, and an inspection module disposed on the platen surface and having an inspection end effector. The inspection module may generate a magnetic field that biases the inspection module toward the platen, and may be operable to generate a magnetic flux to control movement of the inspection module over the platen surface to perform the automated inspection operation across the surface of the workpiece.

Growing community of inventors

Hampton East, Australia

Phillip John Crothers