Autonomous carrier system for moving aircraft structures

• US 9,014,836 B2
• Filed: 12/15/2011
• Issued: 04/21/2015
• 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.
• Primary Examiner(s): Ali, Mohammad
• Assistant Examiner(s): Pan, Yuhui R
• Application Number:
  US13/326,996
• Publication Number:
  US 20130158697A1
• Time in Patent Office: 1,223 Days
• Field of Search: 700/114, 414/222.01
• 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 first part for the structure on a plurality of mobile fixtures configured to control an orientation of the first part;

moving the first 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 first part in which the plurality of mobile fixtures is configured to move in a coordinated manner and substantially maintain a desired orientation for the first part for a next station of the number of stations while moving the first part to the next 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 first part;

wherein each mobile fixture comprises a motorized base, wherein the motorized base comprises a movement system, and wherein the movement system comprises magnetic tracks configured to move;

wherein the magnetic tracks are configured to attract a steel plate on a surface of a floor of a manufacturing environment to manufacture the structure;

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

wherein the step of changing the orientation of the first part at the next station in the number of stations using the at least one of the plurality of mobile fixtures comprises;

rotating the first 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 first part; and

coordinating the movement and height adjustment of the fixtures to maintain the first part in a preselected orientation during a manufacturing step and while moving the first part from one position to another along the floor to prevent changes to an orientation of the structure beyond a desired amount that would bring one or more features of the structure out of tolerance and that would affect one or more of performance and maintenance of the structure.

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

moving the first part for the structure using the plurality of mobile fixtures to the next station in the number of stations, wherein the next 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 next 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 next station in the assembly line using the group of tools while the plurality of mobile fixtures supports the first part.

4. The method of claim 1 further comprising:

moving a group of tools to the next 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 first part.

5. The method of claim 1 further comprising:

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

6. 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.

7. The method of claim 1, wherein the step of moving the first 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 first part comprises:

moving the first 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 first 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.

8. The method of claim 7, 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 first 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.

9. The method of claim 8, wherein the step of moving the first 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 first 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.

10. 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 first part comprises:

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

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

12. The method of claim 1, wherein the first 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.

28. The method of claim 1, further comprising:

controlling the orientation of the first part to have the desired orientation corresponding to the next station of the number of stations after performing the number of operations at a current station of the number of stations; and

moving the first part to the next station while maintaining the desired orientation corresponding to the next station;

wherein members of the mobile fixtures are adjusted to take into account variations that may occur in a floor of a manufacturing environment to manufacture the structure to maintain the desired orientation for the structure; and

wherein the structure is a wing.

33. The method of claim 1, further comprising:

using a cable system of a crane system to lower a second part onto the first part;

wherein the crane system is configured to be wide and tall enough to allow the plurality of mobile fixtures carrying the first part to pass through and under a frame of the crane system.

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

wherein each mobile fixture comprises a motorized base, wherein the motorized base comprises a movement system, and wherein the movement system comprises magnetic tracks configured to move;

wherein the magnetic tracks are configured to attract a steel plate on a surface of a floor of a manufacturing environment to manufacture the structure;

wherein the orientation of the first part is changed at the next station in the number of stations using at least one of the plurality of mobile fixtures;

wherein the step of changing the orientation of the first part at the next station in the number of stations using the at least one of the plurality of mobile fixtures comprises;

rotating the first 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 first part;

wherein the movement and height adjustment of the fixtures is coordinated to maintain the first part in a preselected orientation during a manufacturing step and while moving the first part from one position to another along the floor to prevent changes to an orientation of the structure beyond a desired amount that would bring one or more features of the structure out of tolerance and that would affect one or more of performance and maintenance of the structure.

14. The apparatus of claim 13, wherein the number of stations is part of an assembly line for manufacturing the structure.

15. The apparatus of claim 13 further comprising:

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

16. The apparatus of claim 13 further comprising:

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

17. The apparatus of claim 13 further comprising:

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

18. The apparatus of claim 15, wherein the group of tools is moved to the next 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 first part.

19. The apparatus of claim 13, wherein the plurality of mobile fixtures is configured to move in the coordinated manner to change the orientation of the first part at the next station in the number of stations.

20. The apparatus of claim 19, wherein the plurality of mobile fixtures is configured to rotate the first part about at least one of an x-axis, a y-axis, and a z-axis to change the orientation of the first part.

21. The apparatus of claim 13, wherein a portion of the plurality of mobile fixtures is configured to move a portion of the first part in a direction along at least one of an x-axis, a y-axis, and a z-axis.

22. The apparatus of claim 13 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.

23. The apparatus of claim 22, wherein the carrier controller is configured to control support systems in the plurality of mobile fixtures to substantially maintain the desired orientation for the first part.

24. The apparatus of claim 13, 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 first part; and

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

25. The apparatus of claim 13, wherein the first 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.

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

supporting a first part for the structure on a plurality of mobile fixtures configured to control an orientation of the first 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 first 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 first part in which the plurality of mobile fixtures is configured to move and substantially maintain a desired orientation for the first part for a next station of the number of stations while moving the first part to the next 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 first part;

wherein each mobile fixture comprises a motorized base, wherein the motorized base comprises a movement system, and wherein the movement system comprises magnetic tracks configured to move;

wherein the magnetic tracks are configured to attract a steel plate on a surface of a floor of a manufacturing environment to manufacture the structure;

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

wherein the step of changing the orientation of the first part at the next station in the number of stations using the at least one of the plurality of mobile fixtures comprises;

rotating the first 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 first part; and

coordinating the movement and height adjustment of the fixtures to maintain the first part in a preselected orientation during a manufacturing step and while moving the first part from one position to another along the floor to prevent changes to an orientation of the structure beyond a desired amount that would bring one or more features of the structure out of tolerance and that would affect one or more of performance and maintenance of the structure.

27. A system comprising:

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;

wherein the magnetic tracks are configured to attract a steel plate on a surface of a floor of a manufacturing environment to manufacture the structure; 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 for a next station of a number of stations while moving the structure to the next station in a number of stations;

wherein the orientation of the structure is changed at the next station in the number of stations using at least one of the plurality of mobile fixtures;

wherein the step of changing the orientation of the structure at the next station in the number of stations using the at least one of the plurality of mobile fixtures comprises;

rotating the structure 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 structure;

wherein the movement and height adjustment of the fixtures is coordinated to maintain the structure in a preselected orientation during a manufacturing step and while moving the structure from one position to another along the floor to prevent changes to an orientation of the structure beyond a desired amount that would bring one or more features of the structure out of tolerance and that would affect one or more of performance and maintenance of the structure.

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

supporting a first part for the structure in a preselected orientation with a plurality of mobile fixtures, each fixture being movable along a factory floor and adjustable in height;

coordinating the movement and height adjustment of the fixtures to maintain the first part in the preselected orientation during a manufacturing step and while moving the first part from one position to another along the factory floor to prevent changes to an orientation of the structure beyond a desired amount that would bring one or more features of the structure out of tolerance and that would affect one or more of performance and maintenance of the structure; and

changing the orientation of the first part at a next station in a number of stations using at least one of the plurality of mobile fixtures;

wherein the step of changing the orientation of the first part at the next station in the number of stations using the at least one of the plurality of mobile fixtures comprises;

rotating the first 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 first part;

wherein each mobile fixture comprises a motorized base, wherein the motorized base comprises a movement system, and wherein the movement system comprises magnetic tracks configured to move; and

wherein the magnetic tracks are configured to attract a steel plate on a surface of the factory floor.

30. The method of claim 29, wherein the coordinated movement and height adjustment of the plurality of fixtures is capable of rotating a portion of the first part about any combination of an x-axis, y-axis and z-axis.

31. The method of claim 30, further comprising coordinating the movement and height adjustment of the fixtures so as to reorient the first part to a second preselected orientation during its manufacture.

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

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

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

maintaining a desired orientation for the first part during manufacture of the structure to manufacture the structure within desired tolerances via the plurality of mobile fixtures that are configured to move in a coordinated manner and substantially maintain a desired orientation for the first part;

wherein each mobile fixture comprises a motorized base, wherein the motorized base comprises a movement system, and wherein the movement system comprises magnetic tracks configured to move;

wherein the magnetic tracks are configured to attract a steel plate on a surface of a floor of a manufacturing environment to manufacture the structure;

changing the orientation of the first part at a next station in the number of stations using at least one of the plurality of mobile fixtures;

wherein the step of changing the orientation of the first part at the next station in the number of stations using the at least one of the plurality of mobile fixtures comprises;

rotating the first 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 first part; and

coordinating the movement and height adjustment of the fixtures to maintain the first part in a preselected orientation during a manufacturing step and while moving the first part from one position to another along the floor to prevent changes to an orientation of the structure beyond a desired amount that would bring one or more features of the structure out of tolerance and that would affect one or more of performance and maintenance of the structure.