The Boeing Company

Theodore Martin Boyl-Davis

Darrell Darwin Jones

James N Buttrick, Jr

Ronald W Outous

James Niemann Buttrick

Roger A Gage

Dario I Valenzuela

Lyle M Wallace

Alan Ray Merkley

Paul Reuben Arntson

Tracy Edward Zimmerman

James M Buttrick

David Paul Banks

Laurance N Hazlehurst

James C Murphy

Christina Michelle Vasquez

Kostandinos D Papanikolaou

Paul R Arnston

Dario Valenzuela

Alan R Merkley

James M Buttrick Jr

Roger M Gage

Konstandinos D Papanikolaou

A method and apparatus for positioning a manufacturing tool. A wheel assembly comprises a wheel plate and rollers. The wheel plate has a perimeter and an axis of rotation that is tiltable about a tilt axis. The rollers are arranged near the perimeter of the wheel plate, each of the rollers having an axis of rotation parallel to the tilt axis. An apparatus comprises an upper frame, a lower frame associated with the upper frame, a wedge slideably located between the upper frame and the lower frame, and a force applicator associated with the wedge.

Positioning systems

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

Methods of fabricating shims for joining parts are disclosed. An example method of fabricating shims for joining parts, wherein the parts having mating surfaces separated by a gap, includes: generating first digital data representing a first surface profile of a first part; generating second digital data representing a second surface profile of a second part to mate with the first part; determining distances between the first and second parts, as assembled, at multiple locations; generating a digital volume that closely matches a gap between the first and second parts based on the determined distances; generating a three dimensional digital representation of a shim to fill the gap using the first and second digital data; and automatically fabricating the shim matching the gap using a computer-controlled machine, the machine being controlled using the three dimensional digital representation of the shim.

Methods of fabricating shims for joining parts

A method assembling parts uses a shim for filling a void between interfacing part surfaces. The surface profile of each of the part surfaces is determined and a digital volume is generated that substantially matches the void. A three dimensional digital representation of the shim is generated by mapping the part surface profiles onto the digital volume. The shim is fabricated using the three dimensional representation of the shim.

Digitally designed shims for joining parts of an assembly

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.

Methods and systems for processing surface data for the manufacturing of optimum fit mating parts

A motor assembly including a body that includes a plurality of cylinders and a plurality of air channels and a conical shaped piston slidably coupled within each of said plurality of cylinders. The motor assembly also includes a rotatable timing shaft positioned concentric to and at least partially housed within the body and in flow communication with an air source and the plurality of air channels and a cam plate coupled to the timing shaft and configured to engage the pistons and generate torque.

Axial cam air motor

An interlocking precision flexible rail system for carrying a positionable machine tool employs a first rail element having a first step on a lower surface extending from a first end to a termination at a predetermined length and a second rail element having a mating step on an upper surface extending from a second end to receive the first step. A pair of first clips is removably affixed to a top surface of the first rail element adjacent the first end with a first pin and to the second rail element with a second pin in each clip. A pair of second clips is removably affixed to a bottom surface of the second rail element adjacent the second end with a third pin and to the first rail element with a forth pin in each clip. Alignment holes to receive the pins have tolerances defined in conjunction with the predetermined length of the step, the length of the step allowing a reduced tolerance. The first and second pairs of clips and associated pins laterally secure the rail elements in mated engagement.

Interlocking precision flexible rail system

During the manufacture an aircraft, a tool-carrying rail is removably attached to a rail-side surface of the aircraft with a vacuum cup. The tool-carrying rail includes a longitudinal axis to mount a tool. The vacuum cup is stiffened along a first axis transverse to the longitudinal axis of the tool-carrying rail and the vacuum cup is stiffened along a second axis parallel to the rail-side surface of the aircraft. To removably attach the tool-carrying rail, a perimeter of the vacuum cup is removably sealed to the rail-side surface of the aircraft against vacuum loss and a point on the rail is rigidly positioned with respect to a point on the rail-side surface of the aircraft. In addition, a vacuum source is coupled to a spatial volume occupying all of a space between the vacuum cup and the rail-side surface of the aircraft and the tool is slidably positioned along the longitudinal axis of the tool-carrying rail.

Conformal vacuum cup apparatus and method

Methods and apparatus for track members having a neutral axis rack are disclosed. In one embodiment, an apparatus for supporting a manufacturing tool relative to a workpiece includes a track assembly adapted to be attached to the workpiece and including at least one rail, the rail having a longitudinally-extending neutral axis and a rack extending along a pitch line that at least approximately coincides with the longitudinally-extending neutral axis. In alternate embodiments, the rack includes a plurality of wedge-shaped apertures or a plurality of conically-shaped apertures.

Methods and apparatus for track members having a neutral-axis rack

Apparatus and methods for manufacturing operations are disclosed. In one embodiment, a vacuum cup assembly includes a housing having a vacuum generator formed therein, and a compliant sealing member coupled to the housing. The vacuum generator is coupleable to a source of pressurized fluid and is adapted to generate a reduced pressure region. The sealing member forms an enclosable region in fluid communication with the reduced pressure region. In another embodiment, a method of performing a manufacturing operation includes installing a coordinating pin into an indexing hole, the coordinating pin including a quantum of indexing information. The quantum of indexing information is sensed, and a manufacturing operation is performed based at least partially on the quantum of indexing information.

Apparatus and methods for manufacturing operations

A conformal vacuum cup provides a machine tool attachment fitting usable in a flexible-track drill system. Using multiple, independently articulated stiffeners, the conformal vacuum cup conforms to the contour of complex aerostructure surface shapes. The individual stiffeners are decoupled from each other to some extent by grooves and slots molded into resilient overmolding material to support long-axis curving. Spacing pins employ a domed shape consonant with the elastic deformation of the workpiece surface under load. The pins employ a hard material to prevent particle embedment in use and to control position tolerance for drill heads and other tools traveling on the flexible track. Partial holes in each vacuum cup are blocked by diaphragms. Interconnection from a vacuum system manifold to the vacuum cups can be realized by penetrating the diaphragms and inserting barbed fittings connected by vacuum tubing.

A flexible rail machine tool couples temporarily to a structure by vacuum cups and positions a tool head at any desired point over an area. The toolhead can perform operations such as drilling, bolt insertion, and acquisition of dimension data. The flexible rail can conform to surface curvature in one or more axes. Tool head perpendicularity to the structure can be sensed and adjusted as needed. The as-attached position of the rail may be compensated for through coordinate transformation, allowing holes, for example, to be placed with substantial precision.

Flexible rail multiaxis machine tool and method

A rail system for positioning a toolhead above a workpiece uses a rack cut into one edge of the rail and driven by a pinion gear whose shaft is approximately perpendicular to a workpiece to couple the rail to the toolhead. Multiple rollers placed on the toolhead allow contact between the toolhead and the rail to be effectively continuous despite the cutting away of as much as or more than two-thirds of the rail edge to provide rack teeth. Separating thickness axis containment from transverse with a square rail edge and separate thickness axis and transverse rollers allows the toolhead to follow a rail as the rail flexes over a curved surface with minimal position error. Several variations in rail, bearing, and rack implementation can realize comparable results.

Growing community of inventors

Snohomish, WA, United States of America

Theodore Martin Boyl-Davis