ROBOT-DEPLOYED ASSEMBLY TOOL AND METHOD FOR INSTALLING FASTENERS IN AIRCRAFT STRUCTURES

• US 20080155807A1
• Filed: 12/29/2006
• Published: 07/03/2008
• Est. Priority Date: 12/29/2006
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Sarh, Branko, Toh, Chin H., Harman, Edward Bruce
• Granted Patent: US 8,051,547 B2
• Time in Patent Office: Days
• US Class Current: 29/525.01
• CPC Class Codes: B21J 15/14 specially adapted for riveting specific articles, e.g. brake lining machines
• CPC Class Codes: B21J 15/142 Aerospace structures
• CPC Class Codes: B23P 19/04 for assembling or disassembling parts
• CPC Class Codes: B23P 2700/01 Aircraft parts
• CPC Class Codes: Y10T 29/49616 Structural member making
• CPC Class Codes: Y10T 29/49895 Associating parts by use of aligning means [e.g., use of a drift pin or a "fixture"]
• CPC Class Codes: Y10T 29/49947 by applying separate fastener
• CPC Class Codes: Y10T 29/4995 Nonthreaded
• CPC Class Codes: Y10T 29/53 Means to assemble or disassemble
• CPC Class Codes: Y10T 29/53039 with control means energized in response to activator stimulated by condition sensor
• CPC Class Codes: Y10T 29/53087 with signal, scale, illuminator, or optical viewer
• CPC Class Codes: Y10T 29/5343 Means to drive self-piercing work part

Abstract

An assembly system and method for assembling an aircraft wing box or other structure that may define an interior area accessible through at least one access opening are provided. The method includes inserting a robot having an assembly tool mounted thereto into the interior area through the at least one access opening. The assembly tool may be positioned at a fastener location, and may be clamped to the structure. A hole may be made through the structure, and a fastener may be installed in the hole.

Claims

1. A method for assembling a structure, the structure defining an interior area accessible through at least one access opening, the method comprising:

inserting a robot having an assembly tool mounted thereto into the interior area through the at least one access opening;

positioning the assembly tool at a fastener location;

clamping the assembly tool to the structure;

making a hole through the structure; and

installing a fastener in the hole.

2. The method according to claim 1, wherein inserting a robot having an assembly tool mounted thereto into the interior area through the at least one access opening, comprises:

inserting a robot arm having the assembly tool mounted thereto into the interior area through the at least one access opening.

3. The method according to claim 2, wherein positioning the assembly tool at a fastener location, comprises:

positioning the assembly tool at a fastener location adjacent an interior surface of the structure.

4. The method according to claim 3, wherein positioning the assembly tool at a fastener location adjacent an interior surface of the structure, comprises:

extending the inserted robot arm; and

adjusting the position of the assembly tool with respect to the fastener location.

5. The method according to claim 4, wherein adjusting the position of the assembly tool with respect to the fastener location, comprises:

adjusting the position of the assembly tool with respect to the fastener location with the aid of a vision module on the assembly tool.

6. The method according to claim 3, wherein clamping the assembly tool to the structure comprises:

clamping the assembly tool to the interior surface of the structure.

7. The method according to claim 6, wherein clamping the assembly tool to the interior surface of the structure comprises:

clamping the assembly tool to the interior surface of the structure to substantially eliminate any gap between components of the structure to be assembled.

8. The method according to claim 1, wherein making a hole through the structure, comprises:

drilling a hole through the structure.

9. The method according to claim 8, wherein drilling a hole through the structure comprises:

drilling a hole through the structure from exterior of the structure.

10. The method according to claim 9, wherein clamping the assembly tool to the structure, comprises:

clamping the assembly tool to an interior surface of the structure to substantially eliminate any gap between components of the structure to be assembled during drilling of the hole through the structure.

11. The method according to claim 1, wherein clamping the assembly tool to the structure, comprises:

clamping the assembly tool to an interior surface of the structure using an electromagnet external of the structure.

12. The method according to claim 1, wherein installing a fastener in the hole, comprises:

inserting a fastener through the hole wherein an end portion of the fastener extends into the interior area; and

operating the assembly tool to attach a fastener securing element to the end portion of the fastener.

13. The method according to claim 12, wherein installing a fastener in the hole further comprises;

operating the assembly tool to dispense the fastener securing element to the fastener prior to operating the assembly tool to attach the fastener securing element to the end portion of the fastener.

14. The method according to claim 13, wherein operating the assembly tool to attach the fastener securing element to the end portion of the fastener comprises:

operating the assembly tool to crimp the fastener securing element to the end portion of the fastener.

15. The method according to claim 1, wherein the fastener location comprises one of a plurality of fastener locations accessible through the at least one access opening, and wherein the method further comprises:

positioning the assembly tool at each of the plurality of fastener locations; and

repeating the positioning, clamping, making and installing steps at each of the plurality of fastener locations.

16. The method according to claim 15, wherein the at least one access opening comprises a plurality of access openings, and wherein the method further comprises:

inserting the robot having the assembly tool mounted thereto into the interior area through each of the plurality of access openings; and

repeating the positioning, clamping, making and installing steps at each of a plurality of fastener locations accessible through each of the plurality of access openings.

17. The method according to claim 1, wherein the interior area comprises a confined interior area accessible through the at least one access opening.

18. The method according to claim 1, wherein the structure comprises a wing box for an aircraft.

19. An assembly system for assembling a structure, the structure defining an interior area accessible through at least one access opening, the assembly system comprising:

a robot; and

an assembly tool mounted to the robot, the assembly tool comprising;

a positioning mechanism for positioning the assembly tool in the interior area;

a clamp for clamping the assembly tool in the interior area of the structure during making of a hole in the structure; and

a fastener installing mechanism for installing a fastener in the hole.

20. The assembly system according to claim 19, wherein the robot comprises a robot arm, and wherein the assembly tool is mounted to the robot arm.

21. The assembly system according to claim 20, wherein the robot arm comprises an extendable robot arm for being extended into the interior area of the structure through the at least one access opening.

22. The assembly system according to claim 19, wherein the positioning mechanism comprises:

a vision module for use in guiding the assembly tool to a fastener location in the interior area of the structure.

23. The assembly system according to claim 22, wherein the vision module comprises a camera for use in guiding the assembly tool to a fastener location in the interior area of the structure.

24. The assembly system according to claim 23, wherein the vision module further comprises at least one of a light source and a laser sensor.

25. The assembly system according to claim 19, wherein the fastener installing mechanism comprises:

a securing utility tool for securing a fastener securing element to the fastener.

26. The assembly system according to claim 25, wherein the fastener securing mechanism further comprises a dispensing utility tool for dispensing the fastener securing element to the fastener.

27. The assembly system according to claim 26, wherein the assembly tool further comprises actuators for moving the dispensing utility tool and the securing utility tool into dispensing and securing positions, respectively.

28. The assembly system according to claim 19, wherein the clamp comprises a clamping foot for being magnetically clamped to an interior surface of the structure.

29. The assembly system according to claim 28, and further comprising an electromagnet external of the structure for magnetically clamping the clamping foot to the interior surface of the structure.

30. The assembly system according to claim 28, wherein the clamping foot comprises a tapered clamping foot for clamping the assembly tool to the interior surface of the structure at corner fastener locations.

31. The assembly system according to claim 19, wherein the structure comprises a wing box for an aircraft.

32. A method for assembling a structure, the structure defining an interior area accessible through at least one access opening, the method comprising:

inserting a robot arm having an assembly tool mounted thereto into the interior area through the at least one access opening;

positioning the assembly tool at a fastener location;

clamping the assembly tool to an interior surface of the structure to substantially eliminate any gap between components of the structure to be assembled;

making a hole through the components to be assembled while the assembly tool is clamped to the interior surface of the structure; and

installing a fastener in the hole to secure the components to be assembled.

33. The method according to claim 32, wherein clamping the assembly tool to an interior surface of the structure, comprises:

clamping the assembly tool to an interior surface of the structure using an electromagnet external of the structure.

34. The method according to claim 32, wherein making a hole through the components to be assembled, comprises:

drilling a hole through the components to be assembled.

35. The method according to claim 34, wherein drilling a hole through the components to be assembled, comprises:

drilling a hole through the components to be assembled from external of the structure.

36. The method according to claim 32, wherein installing a fastener in the hole to secure the components to be assembled, comprises:

inserting a fastener through the hole wherein an end portion of the fastener extends into the interior area; and

operating the assembly tool to attach a fastener securing element to the end portion of the fastener.

37. The method according to claim 36, wherein installing a fastener in the hole to secure the components to be assembled further comprises:

operating the assembly tool to dispense the fastener securing element to the fastener prior to operating the assembly tool to attach the fastener securing element to the end portion of the fastener.

38. The method according to claim 32, wherein the fastener location comprises one of a plurality of fastener locations accessible through the at least one access opening, and wherein the method further comprises:

positioning the assembly tool at each of the plurality of fastener locations; and

repeating the positioning, clamping, making and installing steps at each of the plurality of fastener locations.

39. The method according to claim 38, wherein the at least one access opening comprises a plurality of access openings, and wherein the method further comprises:

inserting the robot having the assembly tool mounted thereto into the interior area through each of the plurality of access openings; and

repeating the positioning, clamping, making and installing steps at each of a plurality of fastener locations accessible through each of the plurality of access openings.

40. The method according to claim 32, wherein the structure comprises a wing box of an aircraft.