Integrated aircraft manufacturing system

• US 4,945,488 A
• Filed: 03/06/1989
• Issued: 07/31/1990
• Est. Priority Date: 04/14/1987
• Status: Expired due to Fees

• Current Assignee: Northrop Corporation
• Original Assignee: Northrop Corporation
• Inventors: Zamzow, Charles E., Mladenoff, Donald D., Carver, Larry L., Lovrien, Glenn A.
• Primary Examiner(s): MACDONALD, ALLEN R
• Application Number:
  US07/319,599
• Time in Patent Office: 512 Days
• Field of Search: 364/188, 364/189, 364/191, 364/192, 364/474.22-474.24, 364/425, 364/521, 364/522, 364/552
• US Class Current: 700/182
• CPC Class Codes: B29C 64/141 using only solid materials
• CPC Class Codes: B64F 5/10 Manufacturing or assembling aircraft, e.g. jigs therefor
• CPC Class Codes: G05B 19/4097 characterised by using design data to control NC machines, e.g. CAD/CAM G05B19/4093 takes precedence
• CPC Class Codes: G05B 19/41805 characterised by assembly
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/31407 Machining, work, process finish time estimation, calculation
• CPC Class Codes: G05B 2219/31415 Cost calculation in real time for a product manufactured
• CPC Class Codes: G05B 2219/35043 Tool, fixture design
• CPC Class Codes: G05B 2219/35095 Features library
• CPC Class Codes: G05B 2219/35194 From workpiece data derive tool data
• CPC Class Codes: G05B 2219/35196 From workpiece data derive assembly tool data
• CPC Class Codes: G05B 2219/35317 Display tool shape, to select tool for program, or for interference
• CPC Class Codes: G05B 2219/36352 Select tool as function of part shape, number of grooves and groove width
• CPC Class Codes: G05B 2219/37205 Compare measured, vision data with computer model, cad data
• CPC Class Codes: G06F 30/15 Vehicle, aircraft or watercraft design
• CPC Class Codes: G06T 17/00 Three dimensional [3D] modelling, e.g. data description of 3D objects
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A method of manufacturing aircraft includes constructing a definition of the aircraft in a computer memory and then defining in the memory a first tool for forming a component part of the aircraft and a second tool for assembling a component part made with the first tool. The definitions of the first and second tools are downloaded to a tool forming device which is operated to form the first and second tools essentially independent from one another.

Claims

1. A method of manufacturing tooling for aircraft construction which comprises:

constructing a definition of said aircraft in a computer memory;

defining in said computer memory a first tool means for forming a component part of said aircraft;

defining in said computer memory a second tool means for assembling a component part of said aircraft wherein said component part of said aircraft is formed with said first tool means;

downloading said definitions of said first tool means and said second tool means to means for forming tools; and

operating said means for forming tools to form said first tool means and said second tool means essentially independent from one another.

2. The method of manufacture of claim 1 including:

selecting said first tool means as a forming tool for forming component aircraft parts.

3. The method of manufacture of claim 1 including:

selecting said second tool means as an assembly jig for performing an assembly operation.

4. The method of manufacture of claim 1 including:

forming said second tool means without spatial location reference to said first tool means.

5. The method of manufacture of claim 1 including:

selecting said first tool means to include a plurality of profile boards and at least one connector board;

selecting said profile boards to include at least one profile edge;

locating said profile edge of each of said profile boards in a mold line surface which defines said image of said part;

selecting each of said profile boards to further include locator means for fixedly locating said profile board with respect to said connector board;

selecting said connector board to further include locator means for fixedly locating said connector board with respect to each of said profile boards; and

selecting said respective locator means to each include a locator edge on said respective profile boards and said respective connector board.

6. A method of manufacture of claim 1 including:

associating an interface means with said computer memory, said interface means for inputting commands to said computer memory; and

inputting commands through said interface means to said computer memory to generate said definitions of said first tool means and said second tool means.

7. A method of manufacture of claim 1 including:

associating computer aided tool design software with said computer memory; and

operating said computer aided tool design software to defining at least in part said first tool means and said second tool means.

8. A method of manufacture of claim 7 wherein:

associating computer aided tool manufacture software with said computer system; and

operating said computer aided tool manufacture software in coordination with said computer aided tool design software to define said first and said second tool means and to further define a sequence of operations for forming said first and said second tool means, said sequence of operations for forming said first and said second tool means downloaded to said means for forming tools.

9. A method of producing a tool of claim 8 including:

defining a features library in said computer memory, said features library including a plurality of features each having a set of defined attributes describing each of said respective features; and

calling said features library from said computer aided tool design software to selected features from said features library and to incorporate said features in to said first and second tool means design.

10. A method of producing a tool of claim 9 including:

interfacing a time and costs standards software program in said computer memory, said time and costs standards software program including a standard for material costs and manufacturing time for each of said respective features in said features library;

calling said time and costs standards software program from said computer aided tool manufacture software to generate material costs and manufacturing times for said first and second tool means.

11. A method of producing a tool of claim 1 including:

operating said means for forming tools to form said first tools means and said second tool means essentially parallel in time with one another.

12. The method of manufacturing of claim 1 including:

constructing said definition of said aircraft as a graphics data set in a data base in a 3-dimensional graphics computer system;

generating said definition of said aircraft to include coordinate points precisely locating said definition of said aircraft in a three dimensional coordinate system;

selecting at least a portion of said definition of said aircraft;

defining one of said first tool means and said second tools means as a set of further data in said data base defining virtual images of component parts of a tool which interact with said selected portion of said definition of said aircraft;

generating said virtual image of said component parts of said tool to include coordinate points in said coordinate system;

associating a data transferring means with said computer system, said data transferring means for outputting, storing and transferring data between data devices;

downloading a memory copy of at least said further data from said data base to said transferring means to form a copy of at least said further data;

transferring said copy of said further data from said transferring means to a numerically controlled machining tool means;

operating said numerically controlled machining tool means with said copy of said further data to form said component parts of said tool and further to locate coordinating points on at least one said component parts of said tool wherein said located coordinating points on said component parts of said tool correspond to said coordinate points in said coordinate system;

assembling said component parts of said tool into said tool;

inputting at least said copy of said further data to a microprocessor controlled measuring means, said measuring means for measuring target points in three dimensional space;

operating said measuring means to measure said coordinating points on said component parts of said tool; and

comparing said measured coordinating points on at least one of said component parts of said tool to respective coordinate points in said further data.

13. A method of manufacturing an aircraft which comprises:

generating a definition of said aircraft as a graphics data set in a data base in a 3-dimensional graphics computer system;

generating said definition of said aircraft to include coordinate points precisely locating said definition of said aircraft in a three dimensional coordinate system;

selecting at least a portion of said definition of said aircraft;

generating further data in said data base defining virtual images of component parts of a tool which interact with said selected portion of said definition of said aircraft;

generating said virtual image of said component parts of said tool to include coordinate points in said coordinate system;

associating a data transferring means with said computer system, said data transferring means for outputting, storing and transferring data between data devices;

downloading a memory copy of at least said further data from said data base to said transferring means to form a copy of at least said further data;

transferring said copy of said further data from said transferring means to a numerically controlled machining tool means;

operating said numerically controlled machining tool means with said copy of said further data to form said component parts of said tool and further to locate coordinating points on at least one said component parts of said tool wherein said located coordinating points on said component parts of said tool correspond to said coordinate points in said coordinate system;

assembling said component parts of said tool into said tool;

inputting at least said copy of said further data to a microprocessor controlled measuring means, said measuring means for measuring target points in three dimensional space;

operating said measuring means to measure said coordinating points on said component parts of said tool; and

comparing said measured coordinating points on at least one of said component parts of said tool to respective coordinate points in said further data.

14. A method of manufacturing an aircraft which comprises:

generating a definition of said aircraft as a graphics data set in a data base in a 3-dimensional graphics computer system;

generating said definition of said aircraft to include coordinate points precisely locating said definition of said aircraft in a three dimensional coordinate system;

selecting at least a portion of said definition of said aircraft;

generating further data in said data base defining virtual images of component parts of a tool which interact with said selected portion of said definition of said aircraft;

generating said virtual image of said component parts of said tool to include coordinate points in said coordinate system;

associating computer aided tool design software with said computer system;

running said computer aided tool design software to generate at least in part said further data defining said virtual images of said component parts of said tool;

associating computer aided tool manufacture software with said computer system;

running said computer aided tool manufacture software in coordination with said computer aided tool design software to generate said further data defining said virtual images of said component parts of said tool;

defining a features library in said data base, said features library including a plurality of features each having a set of defined attributes describing each of said respective features;

calling said features library from said computer aided tool design software to selected features from said features library and to incorporate said features in to said virtual images of said component parts of said tool;

interfacing a time and costs standards software program with said computer system, said time and costs standards software program including a standard for material costs and manufacturing time for each of said respective features in said features library;

calling said time and costs standards software program from said computer aided tool design software and said computer aided tool manufacture software to generate material costs and manufacturing times for said component parts of said tool;

associating a data transferring means with said computer system, said data transferring means for outputting, storing and transferring data between data devices;

downloading a memory copy of at least said further data from said data base to said transferring means to form a copy of at least said further data;

transferring said copy of said further data from said transferring means to a numerically controlled machining tool means;

operating said numerically controlled machining tool means with said copy of said further data to form said component parts of said tool and further to locate coordinating points on at least one said component parts of said tool wherein said located coordinating points on said component parts of said tool correspond to said coordinate points in said coordinate system;

assembling said component parts of said tool into said tool;

inputting at least said copy of said further data to a microprocessor controlled measuring means, said measuring means for measuring target points in three dimensional space;

operating said measuring means to measure said coordinating points on said component parts of said tool; and

comparing said measured coordinating points on at least one of said component parts of said tool to respective coordinate points in said further data.

15. An aircraft manufacturing system which comprises:

a 3-dimensional graphics computer system having memory;

said computer system containing a graphics definition of an aircraft stored in a data base in said memory;

said computer system including means for defining a graphics virtual surface of said aircraft in said memory;

said computer system including means for defining a graphics virtual member in said memory, said virtual member including at least a portion of said graphics virtual surface;

emulating means for forming a tangible member which corresponds to said virtual member, said emulating means operatively interfaced with said computer system;

means connected with said computer system for downloading said definition of said virtual member to said emulating means whereby said emulating means forms a tangible member corresponding to said virtual member;

said emulating means includes at least one numerically controlled tool means for forming a part;

said tangible member comprises an image tool means for forming one of an image copy or a complimentary image copy of at least a portion of said aircraft;

said means for defining said graphics virtual member includes an interface means for inputting commands to said computer system, said interface means connected to said computer system.

said interface means includes a plurality of software macro means each for defining a discrete operation of said tool means;

said interface means further includes means for choosing a sequence of said software macros means;

said definition of said aircraft includes coordinate points means for precisely locating a design definition of said aircraft in a three dimensional coordinate system;

said means for downloading said definition of said virtual member includes means for including coordinate points on said virtual member precisely locating said virtual member in said three dimensional coordinate system; and

said emulating means including means for translating said coordinate points on said virtual member to coordinating points on said tangible member, said coordinating points on said tangible member precisely related to said design definition of said aircraft in said three dimensional coordinate system.