Abstract: A method and apparatus for manufacturing. A fiber layer and a porous bonding layer are formed to form a unidirectional lay-up of fibers. The lay-up of fibers is heated under pressure to form a unidirectional composite tape of desired thickness to substantially maintain the fibers in a desired configuration. The unidirectional composite tape is slit to a desired width, and the slit unidirectional composite tape is loaded into a multiaxial fabric machine. A first layer is built from the composite tape in the multiaxial machine, and a second layer is built from the composite tape on the first layer at a predetermined angle from the first layer in the multiaxial machine. The first and second layers are consolidated to form a composite fabric in a continuous process.

Abstract: One embodiment of a fastening apparatus may include at least one of a fastener and a collar having a code with information regarding the fastener and/or collar. The code may be communicated to one or more databases of a computer. The fastener and/or collar may be tightened, located, maintained, and/or inspected according to the code and/or database information.

Abstract: A morphing aircraft includes a lifting body and a telescopic lifting or control surface, such as a wing, coupled to the lifting body. The lifting surface is deployable between extended and retracted positions relative to the lifting body and configured such that, when disposed in the extended position, the flight characteristics of the aircraft correspond to those of a low-speed, high-lift aircraft, and when disposed in the retracted position, the flight characteristics of the air-craft correspond to those of a high-speed, low-lift aircraft, the lifting surface is disposed entirely within the lifting body, and an outboard end surface of the lifting surface blends continuously into an outer mold line surface of the lifting body.

Abstract: An instrumented fastener (e.g., a “tack” fastener) includes one or more light sources (e.g., light-emitting diodes) configured to produce a light beacon that includes encoded information regarding the instrumented fastener (e.g., part number), wherein the direction of the light beacon can be used to align external and/or internal assembly systems to the instrumented fasteners. The light beacon may be activated automatically, or via an instruction received from an external system. Once aligned, the assembly system may, for example, proceed with installing permanent fasteners between neighboring tack fasteners.

Abstract: Apparatus for installing fasteners in a workpiece is mounted for computer controlled movement over the workpiece surface. The apparatus includes all of the tools, fasteners, drives and controls on-board that are needed to operate autonomously, without external connections. The apparatus may also include an on-board power supply for powering the tools, drives and controls. A supply of fasteners is held in an on-board replaceable cassette. An on-board fastener transferring device transfers individual fasteners from the cassette to the tools.

Abstract: An aircraft fuselage barrel (10) includes a skin (12) and a shear tie (18). The shear tie (18) resides within and is integrally formed with the skin (12). The shear tie (18) is separate from and configured for frame attachment thereon. A multi-ring system (79) for fuselage barrel formation includes a mold (68) with a ring (50). The ring (50) has width (W2) approximately equal to a separation distance (D) between two adjacent fuselage frames (22) and includes a module (52) that has a circumferential length (L1) that is greater than a circumferential distance between two fuselage longerons (14). A support structure (80) is coupled to and supports the mold (68). A method of forming the aircraft fuselage barrel (10) includes constructing the support structure (80). Rings (86) of the mold (68) are attached to and over the support structure (80). The mold (68) is constructed. Material is laid-up onto the mold (68) to integrally form the one-piece fuselage barrel (10) including a Hat-configured longeron (14).

Abstract: An aircraft fuselage barrel (10) includes a skin (12) and a shear tie (18). The shear tie (18) resides within and is integrally formed with the skin (12). The shear tie (18) is separate from and configured for frame attachment thereon. A multi-ring system (79) for fuselage barrel formation includes a mold (68) with a ring (50). The ring (50) has width (W2) approximately equal to a separation distance (D) between two adjacent fuselage frames (22) and includes a module (52) that has a circumferential length (L1) that is greater than a circumferential distance between two fuselage longerons (14). A support structure (80) is coupled to and supports the mold (68). A method of forming the aircraft fuselage barrel (10) includes constructing the support structure (80). Rings (86) of the mold (68) are attached to and over the support structure (80). The mold (68) is constructed. Material is laid-up onto the mold (68) to integrally form the one-piece fuselage barrel (10) including a Hat-configured longeron (14).

Abstract: An assembly system and method for assembling an aircraft wing box or other structure that may define an interior area accessible through at least one access opening are provided. The method includes inserting a robot having an assembly tool mounted thereto into the interior area through the at least one access opening. The assembly tool may be positioned at a fastener location, and may be clamped to the structure. A hole may be made through the structure, and a fastener may be installed in the hole.

Abstract: An aircraft fuselage barrel (10) includes a skin (12) and a shear tie (18). The shear tie (18) resides within and is integrally formed with the skin (12). The shear tie (18) is separate from and configured for frame attachment thereon. A multi-ring system (79) for fuselage barrel formation includes a mold (68) with a ring (50). The ring (50) has width (W2) approximately equal to a separation distance (D) between two adjacent fuselage frames (22) and includes a module (52) that has a circumferential length (L1) that is greater than a circumferential distance between two fuselage longerons (14). A support structure (80) is coupled to and supports the mold (68). A method of forming the aircraft fuselage barrel (10) includes constructing the support structure (80). Rings (86) of the mold (68) are attached to and over the support structure (80). The mold (68) is constructed. Material is laid-up onto the mold (68) to integrally form the one-piece fuselage barrel (10) including a Hat-configured longeron (14).

Abstract: A system for removing debris generated by a cutting tool draws the debris into a mixing chamber formed in a workpiece clamp where the debris is combined with a high velocity airflow. A vacuum source draws the debris-air mixture into a cyclonic airflow extraction chamber where the mixture is accelerated before being extracted from the clamp through an exhaust channel. A clamping ring seals the area surrounding the cutting site so that air velocity in the mixing chamber is increased and debris is accelerated into the extraction chamber.

Abstract: An airfoil box and associated method are provided. The airfoil box includes two or more half-shell structures. Each half-shell structure is an integral or unitary member that includes at least a portion of the outer skin of the airfoil as well as stiffener members and connection members. For example, the half-shell structures can be integrally formed of composite materials. The half-shell structures can be assembled by connecting the connection members with fasteners such as rivets to form the airfoil box.

Abstract: Methods are disclosed for producing a hole in a work-piece having first and second layers of material. The first layer of material contains a full-sized hole through the first layer of material. The first layer of material is positioned adjacent the second layer of material. An orbital drill is secured to the first layer of material to position a cutting tool of the drill within the through-hole. During operation, when the cutting tool is used to cut a hole in the second layer of material, the alignment keeps the orbital drill stationary.

Abstract: An aircraft fuselage barrel (10) includes a skin (12) and a shear tie (18). The shear tie (18) resides within and is integrally formed with the skin (12). The shear tie (18) is separate from and configured for frame attachment thereon. A multi-ring system (79) for fuselage barrel formation includes a mold (68) with a ring (50). The ring (50) has width (W2) approximately equal to a separation distance (D) between two adjacent fuselage frames (22) and includes a module (52) that has a circumferential length (L1) that is greater than a circumferential distance between two fuselage longerons (14). A support structure (80) is coupled to and supports the mold (68). A method of forming the aircraft fuselage barrel (10) includes constructing the support structure (80). Rings (86) of the mold (68) are attached to and over the support structure (80). The mold (68) is constructed. Material is laid-up onto the mold (68) to integrally form the one-piece fuselage barrel (10) including a Hat-configured longeron (14).

Abstract: An apparatus and associated method for joining structural members are provided. The apparatus includes a support structure of extendable members, each with an adjustable support surface for engaging the structural members so that structural members of different sizes and shapes can be accommodated. Gantries, which are longitudinally adjustable, support a joining device having co-operable heads that engage the structural members. The heads are adjustable in a transverse direction along the gantries so that the heads can be configured in an opposing configuration and used to join the structural members therebetween.

Abstract: A fastener delivery and installation method is provided that comprises an end effector mounted on an automated machine and operable to drill a hole through a workpiece and insert a fastener through the hole, and a fastener feed unit and method operable with the automated machine to deliver the fasteners through the end effector and into the workpiece. Further, a hand-held tool is positioned against a second surface of the workpiece and is aligned with the end effector. Once the hand-held tool is positioned properly, a magnetic field is generated and the workpiece is clamped to enable the end effector to drill a hole through the workpiece and insert a fastener therethrough. Additionally, a detector is located on the hand-held tool for generating guidance information to inform an operator where to move the hand-held tool so as to align the hand-held tool with the end effector.

Abstract: An airfoil box and associated method are provided. The airfoil box includes two or more half-shell structures. Each half-shell structure is an integral or unitary member that includes at least a portion of the outer skin of the airfoil as well as stiffener members and connection members. For example, the half-shell structures can be integrally formed of composite materials. The half-shell structures can be assembled by connecting the connection members with fasteners such as rivets to form the airfoil box.

Abstract: An apparatus that includes a frame structure, a plurality of suction cups and a clamp assembly. The plurality of suction cups are coupled to the frame structure and are operable in an energized mode for securing the apparatus to a first structure. The clamp assembly is coupled to the frame structure and exerts a clamping force onto a second structure when the suction cups have secured the apparatus to the first structure. The clamping force is of sufficient magnitude to retain the second structure in a predetermined position relative to the first structure. An optional tool may be included to perform a desired operation and an optional conveyance mechanism may be employed to selectively position the tool relative the frame structure. A method for coupling a first structure to a second structure is also provided.

Abstract: A fastener delivery and installation system is provided that comprises an end effector mounted on an automated machine and operable to drill a hole through a workpiece and insert a fastener through the hole, and a fastener feed unit operable with the automated machine to deliver the fasteners through the end effector and into the workpiece. Further, a hand-held tool is operable against a second surface of the workpiece and is aligned with the end effector. Once the hand-held tool is positioned properly, a magnetic field is generated and the workpiece is clamped to enable the end effector to drill a hole through the workpiece and insert a fastener therethrough. Additionally, a detector is located on the hand-held tool for generating guidance information to inform an operator where to move the hand-held tool so as to align the hand-held tool with the end effector.

Abstract: A fastener delivery and installation system is provided that comprises an end effector mounted on an automated machine and operable to drill a hole through a workpiece and insert a fastener through the hole, and a fastener feed unit operable with the automated machine to deliver the fasteners through the end effector and into the workpiece. Further, a hand-held tool is operable against a second surface of the workpiece and is aligned with the end effector. Once the hand-held tool is positioned properly, a magnetic field is generated and the workpiece is clamped to enable the end effector to drill a hole through the workpiece and insert a fastener therethrough. Additionally, a detector is located on the hand-held tool for generating guidance information to inform an operator where to move the hand-held tool so as to align the hand-held tool with the end effector.

Abstract: An apparatus and associated method for joining structural members are provided. The apparatus includes a support structure of extendable members, each with an adjustable support surface for engaging the structural members so that structural members of different sizes and shapes can be accommodated. Gantries, which are longitudinally adjustable, support a joining device having co-operable heads that engage the structural members. The heads are adjustable in a transverse direction along the gantries so that the heads can be configured in an opposing configuration and used to join the structural members therebetween.