Abstract: A system for assembling aircraft is disclosed. An example system for moving components of an airplane into assembly alignment includes a jacking system including assembly jacks for supporting and moving components of the airplane into assembly alignment; a measurement system independent of the jacking system for determining locations of a plurality of features the components of the airplane while the components are supported on the assembly jacks; and a computer system for determining the relative positions of the components in a coordinate system of the airplane and for controlling the movement of the assembly jacks to bring the components into assembly alignment.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: A method and apparatus for inspecting a surface of an object. Data from measuring the surface of the object is obtained to form surface data for the object. A range of frequencies for features on the object is selected based on a range of distances between adjacent peaks for the features. The features are formed by a tool moving along a number of paths. Desired surface data for the features is obtained from the surface data using the range of frequencies selected. A determination is made as to whether the desired surface data for the features meets a policy specifying a desired surface for the object. In response to an absence of a determination that the desired surface data for the features meets the policy, the object is reworked.

Abstract: A method and apparatus for inspecting a surface of an object. Data from measuring the surface of the object is obtained to form surface data for the object. A range of frequencies for features on the object is selected based on a range of distances between adjacent peaks for the features. The features are formed by a tool moving along a number of paths. Desired surface data for the features is obtained from the surface data using the range of frequencies selected. A determination is made as to whether the desired surface data for the features meets a policy specifying a desired surface for the object. In response to an absence of a determination that the desired surface data for the features meets the policy, the object is reworked.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: Illustrative computer-executable methods, systems, and computer software program products compute assembly jack locations to align parts for assembly. Initial locations of at least one component to be moved and a desired final location for the at least one component to be moved are determined from initial position measurement data for the at least one component to be moved and the final location. Motion to align the at least one component to be moved with the final location is automatically determined. Optimal displacements of assembly jacks to produce the determined motion are automatically determined. After movement, location of the at least one moved part at a final assembled position is automatically determined. If applicable, data regarding additional assembly jack displacement can be inputted, the determined optimal location for the at least one part to be moved can be adjusted, and additional motion due to additional assembly jack displacement can be determined.

Abstract: Illustrative computer-executable methods, systems, and computer software program products compute orientation alignment transfer tool location. Orientation of at least one aerodynamically significant feature of an as-built airplane is automatically determined. Orientation of an orientation monument for the as-built airplane is automatically determined from the determined orientation of the at least one aerodynamically significant feature of the as-built airplane, and motion to align an orientation alignment transfer tool with the determined orientation of the orientation monument is automatically determined.

Abstract: A method of defining a composite tape course to form at least a portion of a composite part ply comprises approximating a contoured surface with a reference plane. The method further includes selecting a three-dimensional reference surface to approximate the contoured surface and defining a first function to correlate a first point from the contoured surface to a first intermediate point on the reference surface. The method includes selecting the reference plane to approximate the reference surface, defining a second function to correlate the first intermediate point to a reference point in the reference plane, and mapping a ply boundary from the contoured surface to a reference ply boundary in the reference plane. A tape boundary may be mapped from the contoured surface to a reference tape boundary in the reference plane.

Abstract: To generate course head assignments for a multihead composite material application machine having a set of heads, a set of paths for a ply for a composite part is received and it is determined whether each path of the set of paths complies with a head characteristic for the set of heads. In addition, a special head of the set of heads is assigned to a non-standard path of the set of paths in response to determining the non-standard path does not comply with the head characteristic and ones of the set of heads are assigned to corresponding ones of the set of paths in response to the ones of the set of paths being in compliance with the head characteristics. Furthermore, a constellation of head locations is calculated in response to the set of paths being in compliance with the head characteristic and the set of heads are assigned to the constellation of head locations in response to calculating the constellation of head locations.

Abstract: A tape course generator produces tape course definitions for use in programming a CNC composite tape lamination machine. The tape course generator includes a reference surface parameterizer that maps a contoured surface onto a parametric reference surface, and a reference plane instantiator that maps the reference surface onto a reference plane. The tape course generator also includes a tape boundary plotter that plots a tape boundary, and a boundary mapper that maps the tape boundary and a ply boundary into the reference plane. In addition, the tape course generator includes an intersection locator that identifies intersections of the ply boundary and the tape boundary, and a tape course delimiter that defines tape cuts and determines which points in the reference plane are within a tape course. Moreover, the tape course generator includes a tape course transformer that maps the defined tape course back onto the contoured surface.

Abstract: A method of defining a composite tape course to form at least a portion of a composite part ply comprises approximating a contoured surface with a reference plane. The method further includes selecting a three-dimensional reference surface to approximate the contoured surface and defining a first function to correlate a first point from the contoured surface to a first intermediate point on the reference surface. The method includes selecting the reference plane to approximate the reference surface, defining a second function to correlate the first intermediate point to a reference point in the reference plane, and mapping a ply boundary from the contoured surface to a reference ply boundary in the reference plane. A tape boundary may be mapped from the contoured surface to a reference tape boundary in the reference plane.

Abstract: Illustrative computer-executable methods, systems, and computer software program products compute orientation alignment transfer tool location. Orientation of at least one aerodynamically significant feature of an as-built airplane is automatically determined. Orientation of an orientation monument for the as-built airplane is automatically determined from the determined orientation of the at least one aerodynamically significant feature of the as-built airplane, and motion to align an orientation alignment transfer tool with the determined orientation of the orientation monument is automatically determined.

Abstract: Illustrative computer-executable methods, systems, and computer software program products compute assembly jack locations to align parts for assembly. Initial locations of at least one component to be moved and a desired final location for the at least one component to be moved are determined from initial position measurement data for the at least one component to be moved and the final location. Motion to align the at least one component to be moved with the final location is automatically determined. Optimal displacements of assembly jacks to produce the determined motion are automatically determined. After movement, location of the at least one moved part at a final assembled position is automatically determined. If applicable, data regarding additional assembly jack displacement can be inputted, the determined optimal location for the at least one part to be moved can be adjusted, and additional motion due to additional assembly jack displacement can be determined.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: A composite part program generator includes a computer-aided design (CAD) system interface, a path generator, a course head manager, a post-processor and a machine simulator. The composite part program generator produces composite part programs for use on a multihead composite material application machine, such as a composite tape lamination machine or an automated fiber placement (AFP) machine, to manufacture a complex composite parts, including relatively flat, contoured, or generally cylindrical composite parts. This programming method can reduce the labor and time required to produce a composite part program for a multihead composite material application machine by an order of magnitude with respect to manual or existing automated programming methods.