Abstract: Disclosed aircraft wing-to-body join methods include measuring a 3D surface contour of each wing root interface surface of a wing root to form a complete wing root 3D surface profile; measuring a 3D surface contour of each wing stub interface surface of a wing stub to form a complete wing stub 3D surface profile; calculating a virtual fit between the aircraft wing and the aircraft body assembly that defines one or more gaps between the wing root interface surface and the wing stub interface surface; and aligning the aircraft wing to the aircraft body assembly to achieve a real fit consistent with the virtual fit.

Abstract: Systems and methods are used to determine a defined fastener for fastening two parts together at an assembly fastener location. The defined fastener comprises fastener components selected from a plurality of different fastener components available for use in an assembled fastener. The fastener components of the defined fastener may be selected based on criteria defining characteristics of an assembly stackup including the two parts and the assembled defined fastener. Dimensions of the two parts at respective fastener locations forming the assembly fastener location may be used to determine a part stackup dimension for the assembled fastener at the assembly fastener location.

Abstract: Systems and methods are used to determine a defined fastener for fastening two parts together at an assembly fastener location. The defined fastener comprises fastener components selected from a plurality of different fastener components available for use in an assembled fastener. The fastener components of the defined fastener may be selected based on criteria defining characteristics of an assembly stackup including the two parts and the assembled defined fastener. Dimensions of the two parts at respective fastener locations forming the assembly fastener location may be used to determine a part stackup dimension for the assembled fastener at the assembly fastener location.

Abstract: Disclosed aircraft wing-to-body join methods include measuring a 3D surface contour of each wing root interface surface of a wing root to form a complete wing root 3D surface profile; measuring a 3D surface contour of each wing stub interface surface of a wing stub to form a complete wing stub 3D surface profile; calculating a virtual fit between the aircraft wing and the aircraft body assembly that defines one or more gaps between the wing root interface surface and the wing stub interface surface; and aligning the aircraft wing to the aircraft body assembly to achieve a real fit consistent with the virtual fit.

Abstract: Disclosed aircraft wing-to-body join methods include (a) applying targets to a wing and a body assembly at the respective wing root and wing stub, (b) determining the 3D locations of the targets by photogrammetry, (c) generating 3D surface profiles for the interface surfaces of the wing root and wing stub by combining scans of the interface surfaces, (d) calculating a virtual fit between the wing and the body assembly that defines one or more gaps between the generated 3D surface profiles of the wing root and wing stub, (e) positioning at least three position sensors within the wing root and/or the wing stub, and (f) aligning the wing to the body assembly to achieve a real fit consistent with the calculated virtual fit using feedback from the position sensors. Methods of determining the target locations and/or the 3D surface profiles may utilize a mobile scanning platform.

Abstract: A method and apparatus for machining a part for an assembly. First sensor data is acquired for a surface of a first part from a first sensor system. Second sensor data is acquired for a set of existing holes in a second part from a second sensor system. A surface model of the surface of the first part is generated using the first sensor data. First offset data is computed based on a nominal model of a third part that is nominally positioned relative to the surface model within a three-dimensional virtual environment. Second offset data is computed for the set of existing holes using the second sensor data. Overall offset data is generated using the first and second offset data, wherein the overall offset data is used to drill a set of holes in the third part for use in fastening the third part to the second part.

Abstract: A method and apparatus for machining a part for an assembly. First sensor data is acquired for a surface of a first part from a first sensor system. Second sensor data is acquired for a set of existing holes in a second part from a second sensor system. A surface model of the surface of the first part is generated using the first sensor data. First offset data is computed based on a nominal model of a third part that is nominally positioned relative to the surface model within a three-dimensional virtual environment. Second offset data is computed for the set of existing holes using the second sensor data. Overall offset data is generated using the first and second offset data, wherein the overall offset data is used to drill a set of holes in the third part for use in fastening the third part to the second part.

Abstract: Disclosed wing-to-body join methods include commanding a wing to a first command position and then iteratively repeating a first-phase movement and/or commanding a wing to a second command position and then iteratively repeating a second-phase movement. The first-phase movement includes determining a real position of the wing, calculating a first-phase difference between the real position and the first command position, and commanding the wing to reduce the magnitude of the first-phase difference. The second-phase movement includes determining a real position of the wing, determining a real position of the body, calculating a second-phase difference based on the second command position and the real positions of the wing and body, and commanding the wing to reduce the magnitude of the second-phase difference. Some embodiments include performing a port-side move for a port wing of the aircraft and performing a starboard-side move for a starboard wing of the aircraft.

Abstract: Disclosed aircraft wing-to-body join methods include (a) applying targets to a wing and a body assembly at the respective wing root and wing stub, (b) determining the 3D locations of the targets by photogrammetry, (c) generating 3D surface profiles for the interface surfaces of the wing root and wing stub by combining scans of the interface surfaces, (d) calculating a virtual fit between the wing and the body assembly that defines one or more gaps between the generated 3D surface profiles of the wing root and wing stub, (e) positioning at least three position sensors within the wing root and/or the wing stub, and (f) aligning the wing to the body assembly to achieve a real fit consistent with the calculated virtual fit using feedback from the position sensors. Methods of determining the target locations and/or the 3D surface profiles may utilize a mobile scanning platform.