Metrology system for positioning assemblies

• US 10,000,298 B2
• Filed: 12/03/2014
• Issued: 06/19/2018
• Est. Priority Date: 04/30/2014
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Cobb, James M., Munk, Clayton Lynn, Day, Dan Dresskell, Reid, Eric M., DesJardien, Matthew Ray, Best, Steven A.
• Primary Examiner(s): Bahta, Kidest
• Application Number:
  US14/559,034
• Publication Number:
  US 20150314891A1
• Time in Patent Office: 1,294 Days
• Field of Search: 700 97
• CPC Class Codes: B23Q 1/035 with an array of longitudinally movable rods defining a reconfigurable support surface
• CPC Class Codes: B23Q 1/621 a single sliding pair followed perpendicularly by a single sliding pair
• CPC Class Codes: B64F 5/10 Manufacturing or assembling aircraft, e.g. jigs therefor
• CPC Class Codes: G05B 19/19 characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
• CPC Class Codes: G05B 19/402 characterised by control arrangements for positioning, e.g. centring a tool relative to a hole in the workpiece, additional detection means to correct position G05B19/19 takes precedence
• CPC Class Codes: G05B 2219/45055 Assembly
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

A method and apparatus for maintaining a selected configuration for a structure during a manufacturing process for forming a product using the structure. Metrology data for a support system is received. The support system holds the structure during the manufacturing process. A determination is made as to whether a current configuration of the structure is within selected tolerances of the selected configuration for the structure based on the metrology data. The support system is reconfigured to move the structure into the selected configuration in response to a determination that the current configuration of the structure is not within the selected tolerances of the selected configuration for the structure.

Claims

1. A method for maintaining a selected configuration for a structure during a manufacturing process for forming a product using the structure, wherein the selected configuration for the structure comprises at least one of a selected shape of the structure or a selected position of the structure, the method comprising:

receiving, by a controller, metrology data for a support system, while the support system holds the structure during the manufacturing process, wherein the support system comprises a plurality of supports and wherein each of the plurality of supports comprises a supporting member connected to the structure;

determining, by the controller, whether a current configuration of the structure is within selected tolerances of the selected configuration for the structure based on the metrology data wherein the current configuration of the structure comprises at least one of a current shape of the structure or a current position of the structure, by;

identifying a plurality of local coordinate systems for the plurality of supports of the support system using the metrology data,

identifying a structure coordinate system for the structure using at least one of the metrology data or at least two of the plurality of local coordinate systems, and

determining whether the current configuration of the structure is within the selected tolerances of the selected configuration for the structure based on whether an X-Y plane of the structure coordinate system is parallel to a reference X-Y plane of a global coordinate system; and

reconfiguring the support system, by the controller, by moving the supporting member of one or more of the plurality of supports connected to the structure to move the structure into the selected configuration in response to a determination that the current configuration of the structure is not within the selected tolerances of the selected configuration for the structure.

2. The method of claim 1, wherein determining whether the current configuration of the structure is within the selected tolerances of the selected configuration for the structure based on the metrology data comprises:

identifying a plurality of positions for a plurality of control points using the metrology data, wherein each of the plurality of control points is selected from one of a point on a support in the support system, a point on the structure, and a connection point between the structure and the support; and

determining whether the current configuration of the structure is within the selected tolerances of the selected configuration for the structure based on whether a difference between the plurality of positions and a plurality of desired positions for the plurality of control points defined by the selected configuration for the structure is within the selected tolerances.

3. The method of claim 2, wherein reconfiguring the support system comprises:

identifying the each of the plurality of control points in an undesired position based on the selected configuration for the structure to form a selected number of control points;

generating commands for reconfiguring a selected portion of the plurality of supports of the support system to move the selected number of control points to a corresponding number of desired positions for the selected number of control points; and

sending the commands to the selected portion of the plurality of supports.

4. The method of claim 3 further comprising:

steering a support in the plurality of supports across a manufacturing environment.

5. The method of claim 4 further comprising:

providing steering direction for the support.

6. The method of claim 5, wherein the steering direction is provided by at least one of a human operator, a controller associated with the support, or a system controller.

7. The method of claim 2, wherein identifying the plurality of positions for the plurality of control points using the metrology data comprises:

identifying a plurality of origins of the plurality of local coordinate systems as the plurality of positions for the plurality of control points.

8. The method of claim 7, wherein identifying the plurality of local coordinate systems for the plurality of supports of the support system using the metrology data comprises:

identifying a local coordinate system in the plurality of local coordinate systems for a corresponding support in the plurality of supports using position information generated by a target system associated with the corresponding support.

9. The method of claim 1, wherein reconfiguring the support system comprises:

reconfiguring a selected portion of the plurality of supports of the support system to align the structure coordinate system with the global coordinate system such that the X-Y plane of the structure coordinate system is parallel to the reference X-Y plane of the global coordinate system.

10. The method of claim 1 further comprising:

identifying the global coordinate system using a plurality of transmitters positioned relative to the plurality of supports of the support system.

11. The method of claim 1 further comprising:

generating the metrology data using a group of transmitters positioned relative to a plurality of supports of the support system and a plurality of target systems associated with the plurality of supports.

12. The method of claim 11, wherein generating the metrology data comprises:

emitting signals from the group of transmitters;

receiving the signals at each of the plurality of target systems, wherein each target system in the plurality of target systems comprises at least three targets configured to receive the signals, wherein the at least three targets have a known arrangement, and wherein a distance between each of the at least three targets and a control point corresponding to a corresponding support with which the each target system is associated is known; and

generating position information by the each of the plurality of target systems to form the metrology data.

13. The method of claim 1, wherein reconfiguring the support system comprises:

reconfiguring a selected portion of the plurality of supports of the support system to move a selected number of control points towards a corresponding number of desired positions for the selected number of control points based on the selected configuration for the structure.

14. The method of claim 13, wherein reconfiguring the selected portion of the plurality of supports of the support system comprises:

moving a control point of the selected number of control points with at least one degree of freedom to move the control point from an undesired position to a desired position using a corresponding support in the selected portion of the plurality of supports.

15. The method of claim 13, wherein reconfiguring the selected portion of the plurality of supports of the support system comprises:

moving at least one of the supporting member of a support in the plurality of supports relative to a base structure of the support, an element of the supporting member relative to the base structure, the base structure relative to a platform structure, or the base structure relative to a floor of a manufacturing environment in which the manufacturing process is being performed.

16. The method of claim 13, wherein reconfiguring the support system further comprises:

repeating the steps of receiving the metrology data for the support system, while the support system holds the structure during the manufacturing process;

determining whether the current configuration of the structure is within the selected tolerances of the selected configuration for the structure based on the metrology data; and

reconfiguring the selected portion of the plurality of supports of the support system to move the selected number of control points towards the corresponding number of desired positions for the selected number of control points based on the selected configuration for the structure until the structure is moved into the selected configuration for the structure within the selected tolerances.

17. An apparatus comprising:

a support system to hold a structure during a manufacturing process for forming a product using the structure, wherein the support system comprises a plurality of supports and wherein each of the plurality of supports comprises a supporting member to connect to the structure;

a metrology system to generate metrology data while the support system holds the structure during the manufacturing process; and

a controller that receives the metrology data, determines whether a current configuration of the structure is within selected tolerances of a selected configuration for the structure based on the metrology data by identifying a plurality of local coordinate systems for the plurality of supports of the support system using the metrology data, identifying a structure coordinate system for the structure using at least one of the metrology data or at least two of the plurality of local coordinate systems, and determining whether the current configuration of the structure is within the selected tolerances of the selected configuration for the structure based on whether an X-Y plane of the structure coordinate system is parallel to a reference X-Y plane of a global coordinate system, and generates commands for reconfiguring the support system by moving the supporting member of one or more of the plurality of supports connected to the structure to move the structure into the selected configuration in response to a determination that the current configuration of the structure is not within the selected tolerances of the selected configuration for the structure, wherein the selected configuration for the structure comprises at least one of a selected shape of the structure or a selected position of the structure and the current configuration of the structure comprises at least one of a current shape of the structure or a current position of the structure.

18. The apparatus of claim 17, wherein steering direction to steer a support in the plurality of supports across a manufacturing environment is provided by at least one of a human operator, a controller associated with the support, or a system controller.

19. The apparatus of claim 18, wherein the support is configured to steer itself.

20. The apparatus of claim 17, wherein the metrology system comprises:

a group of transmitters configured to emit signals; and

a plurality of target systems associated with the plurality of supports and configured to receive the signals emitted by the group of transmitters.

21. The apparatus of claim 20, wherein each of the plurality of target systems comprises:

a frame associated with a corresponding support in the plurality of supports; and

a plurality of targets including at least three targets having a known arrangement in which a distance between each of the plurality of targets and a control point corresponding to the corresponding support is known, wherein the each of the plurality of targets generates position information in response to receiving the signals emitted by the group of transmitters.

22. The apparatus of claim 21, wherein the controller uses the position information generated by the each of the plurality of targets to identify a local coordinate system for the corresponding support.

23. The apparatus of claim 17, wherein the metrology system comprises at least one of an indoor global positioning system, an optical positioning system, a radio frequency positioning system, an acoustic positioning system, a laser tracker, a vision system, a motion capture system, a laser radar system, or a photogrammetry system.

24. The apparatus of claim 17, wherein the product is selected from one of a wing, a fuselage, a control surface for an aircraft, an engine system, a hull of a ship, a housing, a frame, and a container.

25. An apparatus comprising:

a support system to hold a structure during a manufacturing process for forming a product using the structure, wherein the support system comprises a plurality of supports and wherein each of the plurality of supports comprises a supporting member to connect to the structure; and

a controller that receives metrology data generated for the support system while the support system holds the structure during the manufacturing process, determines whether a current configuration of the structure is within selected tolerances of a selected configuration for the structure based on the metrology data by identifying a plurality of local coordinate systems for the plurality of supports of the support system using the metrology data, identifying a structure coordinate system for the structure using at least one of the metrology data or at least two of the plurality of local coordinate systems, and determining whether the current configuration of the structure is within the selected tolerances of the selected configuration for the structure based on whether an X-Y plane of the structure coordinate system is parallel to a reference X-Y plane of a global coordinate system, and generates commands for reconfiguring the support system by moving the supporting member of one or more of the plurality of supports connected to the structure to move the structure into the selected configuration in response to a determination that the current configuration of the structure is not within the selected tolerances of the selected configuration for the structure, wherein the selected configuration for the structure comprises at least one of a selected shape of the structure or a selected position of the structure and the current configuration of the structure comprises at least one of a current shape of the structure or a current position of the structure.

26. The apparatus of claim 25 further comprising:

a metrology system to generate the metrology data and send the metrology data to the controller.

27. A method for maintaining a selected configuration for a structure, wherein the selected configuration for the structure comprises at least one of a selected shape of the structure or a selected position of the structure, the method comprising:

receiving metrology data for a support system while the support system holds the structure, wherein the support system comprises a plurality of supports and wherein each of the plurality of supports comprises a supporting member connected to the structure; and

determining whether a current configuration of the structure is within selected tolerances of the selected configuration based on the metrology data, wherein the current configuration of the structure comprises at least one of a current shape of the structure or a current position of the structure, by;

identifying a plurality of local coordinate systems for the plurality of supports of the support system using the metrology data,

identifying a structure coordinate system for the structure using at least one of the metrology data or at least two of the plurality of local coordinate systems, and

determining whether the current configuration of the structure is within the selected tolerances of the selected configuration for the structure based on whether an X-Y plane of the structure coordinate system is parallel to a reference X-Y plane of a global coordinate system.

28. The method of claim 27 further comprising:

reconfiguring the support system by moving the supporting member of one or more of the plurality of supports connected to the structure to move the structure into the selected configuration in response to a determination that the current configuration is not within the selected tolerances of the selected configuration.

29. The method of claim 27, wherein determining whether the current configuration of the structure is within the selected tolerances of the selected configuration comprises:

identifying a plurality of positions for a plurality of control points using the metrology data.

30. The method of claim 29, wherein determining whether the current configuration of the structure is within the selected tolerances of the selected configuration further comprises:

determining whether a difference between the plurality of positions and a plurality of desired positions for the plurality of control points defined by the selected configuration for the structure is within the selected tolerances.

31. An apparatus comprising:

a support system to hold a structure, wherein the support system comprises a plurality of supports and wherein each of the plurality of supports comprises a supporting member to connect to the structure;

a metrology system to generate metrology data while the support system holds the structure, wherein the metrology system comprises a group of transmitters positioned relative to the plurality of supports of the support system and a plurality of target systems associated with the plurality of supports and wherein the metrology system is configured to generate the metrology data by;

emitting signals from the group of transmitters,

receiving the signals at each of the plurality of target systems, wherein each target system in the plurality of target systems comprises at least three targets configured to receive the signals, wherein the at least three targets have a known arrangement, and wherein a distance between each of the at least three targets and a control point corresponding to a corresponding support with which the each target system is associated is known, and

generating position information by the each of the plurality of target systems to form the metrology data; and

a controller that processes the metrology data for use in determining whether a current configuration of the structure is within selected tolerances of a selected configuration for the structure, wherein the selected configuration for the structure comprises at least one of a selected shape of the structure or a selected position of the structure and the current configuration of the structure comprises at least one of a current shape of the structure or a current position of the structure.

32. The apparatus of claim 31, wherein the controller generates commands for reconfiguring the support system by moving the supporting member of one or more of the plurality of supports connected to the structure to move the structure into the selected configuration in response to a determination that the current configuration of the structure is not within the selected tolerances of the selected configuration for the structure.

33. The apparatus of claim 32, wherein at least one control point corresponds to each of the plurality of supports.