Patents by Inventor Darrell D. Jones

Darrell D. Jones has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20220152947
    Abstract: Systems and methods are provided for fabricating composite parts. The method includes subdividing a laminate into zones, laying up tows of fiber reinforced material for the laminate over a layup mandrel via multiple laminations such that each lamination head applies tows in a different zone, and splicing the zones together to form the laminate during the laying up of the tows while moving the layup mandrel in a process direction during fabrication of the composite parts.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones, Michael Kenneth-Que Louie, Richard Allen Miller, II, Jordan Seth Erickson
  • Publication number: 20220153432
    Abstract: Systems and methods are provided for applying fasteners to a structure. One embodiment is a method that includes disposing a first set of end effectors along a fixed inner track that follows an Inner Mold Line (IML) of a structure, disposing a second set of end effectors along a fixed outer track that follows an Outer Mold Line (OML) of the structure, aligning a first end effector at the fixed inner track with a second end effector at the fixed outer track, clamping the structure between the first end effector and the second end effector, by pressing the first end effector and the second end effector into the structure, and applying a fastener to the structure.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Kwok Tung Chan, Farahnaz Sisco, Daniel R. Smith, Darrell D. Jones, Eric M. Reid, Riley HansonSmith
  • Publication number: 20220153453
    Abstract: Systems and methods are provided for inspecting a wing panel. Some methods include advancing a wing panel through a Non-Destructive Inspection (NDI) station, and inspecting the wing panel with inspection heads at the NDI station. The wing panel may be suspended beneath a strongback during inspection and/or advancement, such as by using vacuum couplers and/or adjustable-length pogos of the strongback, and suspending may include enforcing a contour to the wing panel using the vacuum couplers and/or pogos. Other methods include receiving a wing panel at an NDI station and inspecting a portion thereof during movement through the NDI station. Some systems include a track, a strongback to suspend a wing panel beneath it and to advance along the track, and an NDI station disposed at the track to inspect the wing panel while suspended.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones, James C. Kennedy, Jeremy Evan Justice
  • Publication number: 20220152860
    Abstract: Apparatus and methods are provided for fabrication of a structure, for example, a half barrel section of a fuselage. The apparatus includes an indexing unit dimensioned for coupling to an indexing feature disposed on the structure. The structure proceeds along a process direction during fabrication. A cutting station cuts out manufacturing excess from the structure to form, for example, openings for windows and doors. A method for fabrication of a structure includes indexing a structure to a cutting station based on an indexing feature associated or located on the structure. The method includes operating the cutting station to cut manufacturing excess from the structure. A method includes removing cut sections of the manufacturing excess and routing these sections away from the cutting station.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones, Monte D. Wright
  • Publication number: 20220152949
    Abstract: A method includes dispensing a first set of lanes, that each comprise a tow of fiber-reinforced material, at a first angle such that the lanes are placed side-by-side with respect to each other, forming a first layer of a multi-lane tow. The method further includes applying a film directly in contact with multi-lane tow that resists shear forces applied to the multi-lane tow, transporting the multi-lane tow to a mandrel, and compacting the multi-lane tow via a Ply-By-Ply (PBP) machine disposed at the mandrel. The method further comprises removing the film from the multi-lane tow.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Lisa Christina Carlson, Garrett Charles Hanson, Darrell D. Jones, Silas Lawton Studley, Daniel R. Smith, Paul Chace Wilcoxson, Scott Krajca
  • Publication number: 20220153400
    Abstract: Systems and methods are provided for fabricating multiple segment spars for an aircraft. In one example the method includes fabricating preforms of fiber reinforced material for spar segments, hardening the preforms to form the spar segments, and bonding the spar segments together to form a completed spar detail. In addition to bonding, other examples include co-curing and fastening the spar segments. In additional examples, the spar segments include kinks or sub-kinks as described.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Darrell D. Jones, Daniel R. Smith, Carlos Walker, Kurtis Shuldberg Willden, Hiteshkumar M. Patel, Jacob E. Koopmans, Scott Krajca, James P. Dobberfuhl, Marcus C. Hart, Gregory R. Klempel, Steven Kuan-chi Wu, Justin K. Alfred
  • Publication number: 20220153442
    Abstract: Systems and methods are provided for fabricating a fuselage of an aircraft. The method includes: disposing arcuate sections of fuselage at a track of a factory such that concavities of the arcuate sections of the fuselage face a floor of the factory, and bearing edges of the arcuate sections of fuselage directly contact the track; advancing the arcuate sections of fuselage synchronously along the track in a process direction; and performing work within concavities of the arcuate sections of fuselage during pauses between pulses of the arcuate section of fuselage via stations that are disposed beneath the concavities and that are directly mounted to the floor of the factory.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones
  • Publication number: 20220153448
    Abstract: Systems and methods are provided for fabrication of frames for aircraft.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones
  • Publication number: 20220153438
    Abstract: Systems and methods are provided for fabricating a wing panel. Methods include aligning a strongback over a wing panel, vacuum attaching a wing panel surface and pogos extending beneath the strongback, and adjusting the length of pogos to enforce a contour to the wing panel. Systems include a strongback to extend over a wing panel, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Other systems include a track, work stations along the track, a strongback to extend over the wing panel and move along the track, adjustable-length pogos extending beneath the strongback, and vacuum couplers to attach to a wing panel surface. Apparatus includes a shuttle having adapters that mate the shuttle with a track, adjustable-length carriers with vacuum couplers to couple with a wing panel surface, and indexing units that interact with indexing features in a manufacturing excess of the wing panel.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones, Frederick M. Swanstrom, Monte D. Wright
  • Publication number: 20220153443
    Abstract: Systems, methods, and apparatus are provided for assembling a wing. Methods include coupling a robot arm to a bracket on a rib held against a wing panel, and operating the coupled robot arm to install shims between the rib and wing panel. Some methods further include mounting (e.g. detachably) the bracket, such as by aligning it with indexing features at the rib. In some methods, the bracket enforces a contour to the rib. Systems include a carriage coupled to a rib, and a robot arm extending therefrom that is operable to perform work (e.g. inspection, installing shims and/or fasteners, etc.) at an interface between the rib and a wing panel. Apparatus includes a robot arm dimensioned for placement at an interface between a rib and a wing panel, with the robot arm including an end effector to perform work upon the interface (e.g. inspection, installing shims and/or fasteners, etc.).
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones
  • Publication number: 20220153445
    Abstract: Systems and methods are provided for assembling a wing. Methods include suspending an upper wing panel of an aircraft beneath a shuttle, translating a rib to a position it, and placing the rib into contact with, then affixing the rib to, the upper wing panel, while suspended. Some methods include installing ribs and spars to the upper wing panel, and joining a lower wing panel to the ribs and spars, while the upper wing panel is suspended. Some methods involve joining ribs to spars (e.g., all, or some) to produce a support structure that is then affixed to the upper wing panel. Systems include a shuttle that suspends an upper wing panel, and a cart that includes supports to hold a rib, a chassis to translate the rib to a position beneath the upper wing panel, and a lifting apparatus to lift the rib into contact with the upper wing panel.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones
  • Publication number: 20220153433
    Abstract: Systems and methods are provided for placing preforms onto a mandrel. One illustrative method includes moving a mandrel in a process direction relative to a station(s) that comprises multiple pick-and-place machine(s), identifying a tray that stores a preform comprising an unhardened fiber-reinforced material, placing the strong back at the preform via at least one of the pick-and-place machine(s), applying a vacuum to hold the preform in contact with the strong back, transporting the preform to a mandrel via the pick-and-place machine(s), and placing the preform onto the mandrel.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Darrell D. Jones, Daniel R. Smith, Robert William Whiting, Allen James Halbritter
  • Publication number: 20220152956
    Abstract: Methods and apparatus involved in the process of hardening a composite part are disclosed herein. The methods include applying a preform to a mandrel, covering the preform with a caul plate, sealing the caul plate to the mandrel, pushing the caul plate toward the preform and the mandrel and hardening the preform into a composite part while the caul plate is held against the preform. The apparatus include a mandrel, a caul plate which defines a surface of a preform and where the caul plate may include a rigid material and seals disposed between the mandrel and the caul plate. In an additional aspect, the apparatus may include a sealed chamber with a mandrel and a caul plate and a circumferential seal between the mandrel and the caul plate.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones, Byron James Autry, James R. Kendall, Raviendra Sidath Suriyaarachchi
  • Publication number: 20220153434
    Abstract: Systems and methods are provided for assembling a structure. The systems and method including micro pulsing a structure along a track in a process direction by less than a length of the structure. The structure is indexed to one or more work stations by mating indexing features in a manufacturing excess of the structure to complementary features at the work stations. The work stations would the perform work on the structure at the work stations while the structure is indexed to the work stations. Iteratively repeating the micro pulsing and indexing and working upon the structure until it is ready to advance to the next assembly process.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones, Frederick M. Swanstrom
  • Publication number: 20220152757
    Abstract: Systems and methods are provided for aircraft assembly. The method includes receiving a half barrel section of fuselage in an assembly line having a plurality of serially arranged work stations; advancing the half barrel section in a process direction through the assembly line such that the half barrel section extends across at least a portion of the work stations; and performing work on the half barrel section with the portion of the work stations simultaneously.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Darrell D. Jones, Daniel R. Smith, Jeremy Evan Justice, Riley HansonSmith, Eric M. Reid, Parisa Nazaran
  • Publication number: 20220153440
    Abstract: Systems and methods are provided for assembling a section of a fuselage of an aircraft. The method includes pulsing a half barrel section of the fuselage along a track in a process direction, utilizing an indexing feature associated with the half barrel section to determine a desired contour for a portion of the half barrel section, and enforcing the desired contour onto the half barrel section using components that enforce an inner mold line and components that enforce an outer mold line when the half barrel section is out of tolerance from the desired contour.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones
  • Publication number: 20220153437
    Abstract: Systems and methods are provided for assembling an aircraft. The method includes receiving an upper half barrel section of fuselage that is in a crown up orientation and installing a crown module into the upper half barrel section.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones, Jeremy Evan Justice
  • Publication number: 20220153441
    Abstract: Systems and methods are provided for installing ribs and/or spars to a wing panel while a contour is enforced. Methods include suspending a wing panel beneath a shuttle that enforces the contour, advancing the wing panel through work stations via the shuttle, and installing a rib or a spar (or another wing panel) at a work station, while the contour is enforced. Other methods include locating a wing panel beneath a shuttle, coupling adjustable-length pogos to the wing panel at locations distinct from those corresponding with an installation location, e.g. for a rib or a spar, and controlling the length of the pogos to enforce a contour to the wing panel. Some systems include a track, work stations disposed along the track, and a shuttle to advance along the track and convey a wing panel to each of the work stations while enforcing a contour onto the wing panel.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones
  • Publication number: 20220153436
    Abstract: Systems and methods are provided for assembling aircraft fuselages. One embodiment is a method for assembling a fuselage of an aircraft. The method includes indexing an arcuate section of a fuselage to a frame installation station, feeding a frame at the frame installation station into a concavity defined by the arcuate section, placing the frame against an Inner Mold Line (IML) of the arcuate section while the frame is within the concavity, and affixing the frame to the arcuate section.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Daniel R. Smith, Darrell D. Jones, Farahnaz Sisco, Kwok Tung Chan, Riley HansonSmith
  • Publication number: 20220152758
    Abstract: Systems and methods are provided for assembling an airframe of an aircraft, including receiving a half barrel section of fuselage, advancing the half barrel section in a process direction across multiple stations to separately and simultaneously perform work on the half barrel sections, and subsequently joining the half barrel segments to form a section of the airframe. Each pair of half barrel sections, such as upper and lower half barrels, are progressed through assembly line processes to be delivered to a joining station for joining the half barrels together to form a circumferential section of the fuselage. Multiple joined circumferential sections are joined together to form an elongated extent of the fuselage. Indexing features are provided in the assembly process to monitor and control the progression of the half barrel sections in the work stations of the assembly line process.
    Type: Application
    Filed: November 10, 2021
    Publication date: May 19, 2022
    Inventors: Darrell D. Jones, Daniel R. Smith, Jeremy Evan Justice