Abstract: A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structu

Abstract: A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structu

Abstract: A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structu

Abstract: A system for moving first and second fuselage structures into assembly alignment, the system including a first transmitter indexed to a first seat track of the first fuselage structure, a first reflector target indexed to a first seat track of the second fuselage structure, a second transmitter indexed to a second seat track of the first fuselage structure, a second reflector target indexed to a second seat track of the second fuselage structure, wherein the first and second transmitters and the first and second reflector targets cooperate to provide first and second measurements indicative of position of the first fuselage structure relative to the second fuselage structure, and a manipulator system including at least one assembly actuator coupled to the first fuselage structure to move the first fuselage structure into assembly alignment with the second fuselage structure based upon the first and second measurements.

Abstract: Ergonomic puncture-resistant pads are disclosed. An example disclosed herein includes a first layer configured to be adjacent a person and to conform to the person; a second layer coupled to the first layer, the second layer configured to resist puncture; and a third layer coupled to the second layer, the third layer including a flexible support structure extending away from the second layer, the third layer configured to support the person and to conform to a shape of a surface supporting the person, the flexible support structure configured to contact the surface, the flexible support structure including cavities to receive at least one object protruding from the surface to isolate the person from the at least one protruding object.

Abstract: A system for moving first and second fuselage structures into assembly alignment, the system including a first transmitter indexed to a first seat track of the first fuselage structure, a first reflector target indexed to a first seat track of the second fuselage structure, a second transmitter indexed to a second seat track of the first fuselage structure, a second reflector target indexed to a second seat track of the second fuselage structure, wherein the first and second transmitters and the first and second reflector targets cooperate to provide first and second measurements indicative of position of the first fuselage structure relative to the second fuselage structure, and a manipulator system including at least one assembly actuator coupled to the first fuselage structure to move the first fuselage structure into assembly alignment with the second fuselage structure based upon the first and second measurements.

Abstract: There is provided a tool assembly for transferring locations and dimensions of a pattern of holes from a first structure to a second structure. The tool assembly has a transfer plate with a transfer plate pattern of transfer plate holes that include a plurality of oversize holes and two transfer plate index holes. The transfer plate pattern is substantially identical to the pattern in the first structure. The tool assembly has one or more alignment elements installed in the plurality of oversize holes. Each alignment element has a through opening in a coaxial alignment with the oversize hole. The oversize hole allows formation of an alignment variation gap between an exterior of the alignment element and an inner wall of the oversize hole. The tool assembly has one or more holding elements coupled to the transfer plate, each with a central through opening in coaxial alignment with the oversize hole.

Abstract: A method includes making a first structure with a first plurality of pre-drilled holes at pre-defined locations, making a second structure with a second plurality of pre-drilled holes at pre-defined locations, making a third structure without pre-drilled full-size holes, measuring the location and orientation of the first and second plurality of pre-drilled holes in the first and second structures, determining the location of a third plurality of holes to be drilled in the third structure that correspond to first and second plurality of pre-drilled holes measured in the first and second structures, creating a program to drill the third plurality of holes in the third structure that align with the measured location and orientation of the first and second plurality of pre-drilled holes in the first and second structures based on the measure location and orientation of the first and second plurality of pre-drilled holes in the first and second structure, drilling the third plurality of holes in the third structu

Abstract: Drill plate assemblies are disclosed in the examples herein. An example method includes positioning an absorbent material between a drill plate and a surface to be drilled; performing a drilling operation on the surface including flowing coolant through the drill; and capturing at least some of coolant in the absorbent material.

Abstract: A method, automated workstation, and computer system for automatically adjusting a workpiece to suit a particular operator is provided. An operator can be identified by scanning an identification badge, using facial recognition, or voice recognition. A physiological profile for the identified operator is then retrieved. A work station holding a workpiece is then automatically adjusted to set the workpiece at a height and/or orientation that is ergonomically beneficial for the operator.

Abstract: Ergonomic puncture-resistant pads are disclosed. An example disclosed herein includes a first layer configured to be adjacent a person and to conform to the person; a second layer coupled to the first layer, the second layer configured to resist puncture; and a third layer coupled to the second layer, the third layer including a flexible support structure extending away from the second layer, the third layer configured to support the person and to conform to a shape of a surface supporting the person, the flexible support structure configured to contact the surface, the flexible support structure including cavities to receive at least one object protruding from the surface to isolate the person from the at least one protruding object.

Abstract: Method and apparatus for aligning fastener holes of two components. An alignment fixture includes two mating fixtures. Each mating fixture includes a reference plate that is aligned to the fastener holes of one of the components. Each mating fixture also includes an alignment device. The alignment devices can be aligned with the respective reference plates such that the alignment between the reference plates and the fastener holes are transferred to the alignment devices. Once aligned, the alignment devices can be temporarily attached to the respective components at locations away from the fastener holes. The reference plates can then be removed. Thereafter, the components can be brought together such that mating features on the alignment devices engage. Engagement of the mating features aligns the two components such that the fastener holes on the components are aligned.

Abstract: There is provided a tool assembly for transferring locations and dimensions of a pattern of holes from a first structure to a second structure. The tool assembly has a transfer plate with a transfer plate pattern of transfer plate holes that include a plurality of oversize holes and two transfer plate index holes. The transfer plate pattern is substantially identical to the pattern in the first structure. The tool assembly has one or more alignment elements installed in the plurality of oversize holes. Each alignment element has a through opening in a coaxial alignment with the oversize hole. The oversize hole allows formation of an alignment variation gap between an exterior of the alignment element and an inner wall of the oversize hole. The tool assembly has one or more holding elements coupled to the transfer plate, each with a central through opening in coaxial alignment with the oversize hole.

Abstract: Drill plate assemblies are disclosed in the examples herein. An example method includes positioning an absorbent material between a drill plate and a surface to be drilled; performing a drilling operation on the surface including flowing coolant through the drill; and capturing at least some of coolant in the absorbent material.

Abstract: A method, automated workstation, and computer system for automatically adjusting a workpiece to suit a particular operator is provided. An operator can be identified by scanning an identification badge, using facial recognition, or voice recognition. A physiological profile for the identified operator is then retrieved. A work station holding a workpiece is then automatically adjusted to set the workpiece at a height and/or orientation that is ergonomically beneficial for the operator.

Abstract: Method and apparatus for aligning fastener holes of two components. An alignment fixture includes two mating fixtures. Each mating fixture includes a reference plate that is aligned to the fastener holes of one of the components. Each mating fixture also includes an alignment device. The alignment devices can be aligned with the respective reference plates such that the alignment between the reference plates and the fastener holes are transferred to the alignment devices. Once aligned, the alignment devices can be temporarily attached to the respective components at locations away from the fastener holes. The reference plates can then be removed. Thereafter, the components can be brought together such that mating features on the alignment devices engage. Engagement of the mating features aligns the two components such that the fastener holes on the components are aligned.

Abstract: Cutting tools and machining methods using cutting tools are disclosed. An example cutting tool comprises a shank and a head on the shank, the head comprising a diamond abrasive-coated cutting surface, the cutting head having grooves interrupting the cutting surface and extending from the cutting surface toward an axis of rotation of the head, the cutting surface having a substantially constant radius.

Abstract: An automated filler production method includes obtaining gap measurement data by measuring a gap between component parts of a structure, delivering the gap measurement data to a data collector function, monitoring incoming filler requirements, updating solid model definitions of the filler, creating portable Machine Control Data (MCD) using the gap measurement data in the form of the updated solid model, delivering the MCD to a filler machining center and machining a filler from a filler substrate using the MCD, while providing status updates as the data progresses through the filler machining process.