Autonomous Carrier System for Moving Aircraft Structures

• US 20130158697A1
• Filed: 12/15/2011
• Published: 06/20/2013
• Est. Priority Date: 12/15/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Stone, Paul Reed, Munk, Clayton Lynn, Reid, Eric M.
• Granted Patent: US 9,014,836 B2
• Time in Patent Office: Days
• US Class Current: 700/114
• CPC Class Codes: B25J 9/1682 Dual arm manipulator; Coordination of several manipulators
• CPC Class Codes: B64F 5/10 Manufacturing or assembling aircraft, e.g. jigs therefor
• CPC Class Codes: B64F 5/50 Handling or transporting aircraft components
• CPC Class Codes: G05B 19/41895 using automatic guided vehicles [AGV] control of position or course of AGV's G05D1/00
• CPC Class Codes: G05B 2219/31008 Cooperation mobile robots, carrying common pallet, object or pushing together
• CPC Class Codes: G05B 2219/45071 Aircraft, airplane, ship cleaning manipulator, paint stripping
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/60 Electric or hybrid propulsion means for production processes
• CPC Class Codes: Y10T 29/49616 Structural member making
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/534 Multiple station assembly or disassembly apparatus

Abstract

A method and apparatus for manufacturing a structure. A part for the structure may be supported on a plurality of mobile fixtures configured to control an orientation of the part. The part for the structure may be moved using the plurality of mobile fixtures to a number of stations for performing a number of operations for manufacturing the structure using the part. The plurality of mobile fixtures may be configured to move in a coordinated manner and substantially maintain a desired orientation for the part while moving the part to a station in the number of stations. The number of operations for manufacturing the structure may be performed at the number of stations while the plurality of mobile fixtures supports the part.

Claims

1. A method for manufacturing a structure, the method comprising:

supporting a part for the structure on a plurality of mobile fixtures configured to control an orientation of the part;

moving the part for the structure using the plurality of mobile fixtures to a number of stations for performing a number of operations for manufacturing the structure using the part in which the plurality of mobile fixtures is configured to move in a coordinated manner and substantially maintain a desired orientation for the part while moving the part to a station in the number of stations; and

performing the number of operations for manufacturing the structure at the number of stations while the plurality of mobile fixtures supports the part.

2. The method of claim 1, wherein the step of moving the part for the structure using the plurality of mobile fixtures comprises:

moving the part for the structure using the plurality of mobile fixtures to the station in the number of stations, wherein the station is part of an assembly line and wherein a group of tools is configured to perform at least one of the number of operations for manufacturing the structure at the station.

3. The method of claim 2, wherein the step of performing the number of operations for manufacturing the structure at the number of stations comprises:

performing the at least one of the number of operations for manufacturing the structure at the station in the assembly line using the group of tools while the plurality of mobile fixtures supports the part.

4. The method of claim 1 further comprising:

moving a group of tools to the station in the number of stations to perform at least one of the number of operations for manufacturing the structure while the plurality of mobile fixtures supports the part.

5. The method of claim 1 further comprising:

changing the orientation of the part at the station in the number of stations using at least one of the plurality of mobile fixtures.

6. The method of claim 5, wherein the step of changing the orientation of the part at the station in the number of stations using the at least one of the plurality of mobile fixtures comprises:

rotating the part about at least one of an x-axis, a y-axis, and a z-axis using the at least one of the plurality of mobile fixtures to change the orientation of the part.

7. The method of claim 1 further comprising:

moving a portion of the plurality of mobile fixtures to move a portion of the part in a direction along at least one of an x-axis, a y-axis, and a z-axis.

8. The method of claim 1 further comprising:

receiving information at controllers in the plurality of mobile fixtures from a carrier controller in communication with the controllers in which the carrier controller is configured to control movement of the plurality of mobile fixtures in the coordinated manner.

9. The method of claim 1, wherein the step of moving the part for the structure using the plurality of mobile fixtures to the number of stations for performing the number of operations for manufacturing the structure using the part comprises:

moving the part for the structure using the plurality of mobile fixtures to a first station in the number of stations while the plurality of mobile fixtures substantially maintains a first desired orientation for the part, wherein a group of tools is configured to perform at least one of the number of operations for manufacturing the structure at the first station.

10. The method of claim 9, wherein the part is a first part and the step of performing the number of operations for manufacturing the structure at the number of stations while the plurality of mobile fixtures supports the part comprises:

attaching a second part to the first part at the first station to form a partially assembled structure using the group of tools.

11. The method of claim 10, wherein the step of moving the part for the structure using the plurality of mobile fixtures to the number of stations for performing the number of operations for manufacturing the structure using the part further comprises:

changing the first desired orientation of the first part with the partially assembled structure to a second desired orientation using the plurality of mobile fixtures; and

moving the first part with the partially assembled structure using the plurality of mobile fixtures to a second station in the number of stations while the plurality of mobile fixtures substantially maintains the second desired orientation for the first part with the partially assembled structure.

12. The method of claim 1, wherein the step of performing the number of operations for manufacturing the structure at the number of stations while the plurality of mobile fixtures supports the part comprises:

performing at least one of the number of operations for manufacturing the structure using a number of operators at the station in the number of stations while the plurality of mobile fixtures supports the part, wherein the number of operators includes at least one of a human operator and a robotic operator.

13. The method of claim 1, wherein the part is a wing box, the structure is a wing, and at least one of the number of operations includes attaching a skin panel to the wing box.

14. The method of claim 1, wherein the part is selected from one of a frame for the structure, a housing for the structure, a number of components previously assembled for the structure, a wing box, and the structure.

15. An apparatus comprising:

a number of stations for performing a number of operations for manufacturing a structure; and

a plurality of mobile fixtures configured to support a part for the structure, control an orientation of the part, and move the part to a station in the number of stations while substantially maintaining a desired orientation for the part in which the plurality of mobile fixtures is configured to move in a coordinated manner.

16. The apparatus of claim 15, wherein the number of stations is part of an assembly line for manufacturing the structure.

17. The apparatus of claim 15 further comprising:

a group of tools configured to perform at least one of the number of operations for manufacturing the structure at the station in the number of stations while the plurality of mobile fixtures supports the part.

18. The apparatus of claim 15 further comprising:

a surface, wherein the plurality of mobile fixtures is configured to move on the surface to move the part to the station in the number of stations.

19. The apparatus of claim 15 further comprising:

a number of operators configured to perform at least one of the number of operations for manufacturing the structure using the part, wherein the number of operators includes at least one of a human operator and a robotic operator.

20. The apparatus of claim 17, wherein the group of tools is moved to the station in the number of stations to perform the at least one of the number of operations for manufacturing the structure while the plurality of mobile fixtures supports the part.

21. The apparatus of claim 15, wherein the plurality of mobile fixtures is configured to move in the coordinated manner to change the orientation of the part at the station in the number of stations.

22. The apparatus of claim 21, wherein the plurality of mobile fixtures is configured to rotate the part about at least one of an x-axis, a y-axis, and a z-axis to change the orientation of the part.

23. The apparatus of claim 15, wherein a portion of the plurality of mobile fixtures is configured to move a portion of the part in a direction along at least one of an x-axis, a y-axis, and a z-axis.

24. The apparatus of claim 15 further comprising:

a carrier controller configured to communicate with controllers in the plurality of mobile fixtures and control movement of the plurality of mobile fixtures.

25. The apparatus of claim 24, wherein the carrier controller is configured to control support systems in the plurality of mobile fixtures to substantially maintain the desired orientation for the part.

26. The apparatus of claim 15, wherein a mobile fixture in the plurality of mobile fixtures comprises:

a motorized base configured to move on a surface;

a support system associated with the motorized base in which the support system is configured to be positioned to support a portion of the part; and

a controller associated with the motorized base in which the controller is configured to control movement of the motorized base.

27. The apparatus of claim 15, wherein the part is selected from one of a frame for the structure, a housing for the structure, a number of components previously assembled for the structure, a wing box, and the structure and wherein the structure is selected from one of an aerospace structure, a wing, a fuselage, a horizontal stabilizer, a vertical stabilizer, a flight control surface, and an engine.

28. A mobile fixture comprising:

a motorized base configured to move on a surface;

a support system associated with the motorized base in which the support system is configured to be positioned to support a portion of a structure; and

a controller associated with the motorized base in which the controller is configured to control movement of the motorized base.

29. The mobile fixture of claim 28, wherein the support system comprises:

a post extending from the motorized base;

a connector system configured to be connected to the structure; and

a member moveably connected to the post and connected to the connector system, wherein movement of the member moves the connector system relative to the motorized base and changes a height of the connector system relative to the motorized base.

30. The mobile fixture of claim 29, wherein the mobile fixture further comprises:

a movement system configured to move the member relative to the connector system.

31. The mobile fixture of claim 29, wherein the connector system in the support system comprises:

a connector configured to be connected to the portion of the structure; and

a positioning system configured to position the connector about a number of axes.

32. The mobile fixture of claim 28, wherein the motorized base comprises:

a housing; and

a movement system.

33. The mobile fixture of claim 32, wherein the movement system comprises:

magnetic tracks; and

a motor configured to move the magnetic tracks.

34. A method for manufacturing a structure for an aerospace vehicle, the method comprising:

supporting a part for the structure on a plurality of mobile fixtures configured to control an orientation of the part with respect to an x-axis, a y-axis, and a z-axis;

receiving information at controllers in the plurality of mobile fixtures from a carrier controller in communication with the controllers in which the carrier controller is configured to control movement of the plurality of mobile fixtures in a coordinated manner;

moving the part for the structure using the plurality of mobile fixtures to a number of stations for performing a number of operations for manufacturing the structure using the part in which the plurality of mobile fixtures is configured to move and substantially maintain a desired orientation for the part while moving the part to a station in the number of stations and in which the number of stations is part of an assembly line for manufacturing the structure; and

performing at least one of the number of operations for manufacturing the structure at the station in the number of stations using a group of tools while the plurality of mobile fixtures supports the part.

35. A carrier system for an aircraft structure, the carrier system comprising:

a plurality of mobile fixtures configured to hold and move the aircraft structure, in which a mobile fixture in the plurality of mobile fixtures comprises;

(a) a motorized base configured to move on a surface;

(b) a support system associated with the motorized base and configured to be positioned to support a portion of a structure in which the support system comprises a post extending from the motorized base;

a connector system configured to be connected to the structure;

a member movably connected to the post and connected to the connector system and configured to move the connector system relative to the motorized base and change a height of the connector system relative to the motorized base;

(c) a controller associated with the motorized base and configured to control movement of the motorized base and the plurality of mobile fixtures on the surface; and

(d) a movement system configured to move the member relative to the connector system in which the connector system comprises a connector configured to be connected to the portion of the structure and a positioning system configured to position the connector about a number of axes, in which the motorized base has a housing and the movement system in which the movement system comprises magnetic tracks and a motor configured to move the magnetic tracks; and

a carrier controller configured to communicate with controllers in the plurality of mobile fixtures and control movement of the plurality of mobile fixtures in which the carrier controller is configured to control the plurality of mobile fixtures to maintain the structure in a desired orientation.