Abstract: A pressure clamp assembly for clamping a plurality of overlapping members together. The pressure clamp includes a pair of compression members attached to a clamp body and driven together by a power source. The power source includes a fluid pressure cylinder that repeatably produces high clamping forces so as to inhibit the production of inter-laminate burrs during drilling. The compression members each include an elongated compression foot that distributes the clamping pressure over a wide area to allow drilling in a relatively wide range of locations. In addition, each compression foot defines a drill bit assembly guide that facilitates accurate hole drilling through multiple overlapping parts.

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 pressure clamp assembly for clamping a plurality of overlapping members together. The pressure clamp includes a pair of compression members attached to a clamp body and driven together by a power source. The power source includes a fluid pressure cylinder that repeatably produces high clamping forces so as to inhibit the production of inter-laminate burrs during drilling. The compression members each include an elongated compression foot that distributes the clamping pressure over a wide area to allow drilling in a relatively wide range of locations. In addition, each compression foot defines a drill bit assembly guide that facilitates accurate hole drilling through multiple overlapping parts.

Abstract: An apparatus for installing rivets or other fasteners through a workpiece includes an automated machine disposed on one side of the workpiece and a hand-held tool that is manipulated by a single worker located on the opposite side of the workpiece. The automated machine includes an end effector supporting tools such as a drill and a riveter. The automated machine also includes a guide structure adapted to be releasably affixed to the workpiece, and a carriage that travels along the guide structure and supports the end effector so that the end effector can be positioned in various locations along the surface of the workpiece where fasteners are to be installed. The end effector includes an electromagnetic clamping device, and the hand-held tool includes a magnetic clamping block that is attracted by the clamping device to clamp the workpiece therebetween. The end effector generates a positioning signal and the hand-held tool includes a detector for detecting the positioning signal.

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: An apparatus for securing a first structure to a second structure and performing an operation on the first and second structures. The apparatus includes a frame structure, a plurality of suction cups, a clamp assembly, a conveyance mechanism and a tool. The plurality of suction cups are coupled to the frame structure and are operable in an energized mode for securing the apparatus to the first structure. The clamp assembly is coupled to the frame structure and exerts a clamping force onto the 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. The tool is configured to perform the operation. The conveyance mechanism is coupled to both the frame structure and the tool and enables the tool to be selectively positioned relative to the frame structure. A method for coupling a first structure to a second structure is also provided.

Abstract: An apparatus for installing rivets or other fasteners through a workpiece includes an automated machine disposed on one side of the workpiece and a hand-held tool that is manipulated by a single worker located on the opposite side of the workpiece. The automated machine includes an end effector supporting tools such as a drill and a riveter. The automated machine also includes a guide structure adapted to be releasably affixed to the workpiece, and a carriage that travels along the guide structure and supports the end effector so that the end effector can be positioned in various locations along the surface of the workpiece where fasteners are to be installed. The end effector includes an electromagnetic clamping device, and the hand-held tool includes a magnetic clamping block that is attracted by the clamping device to clamp the workpiece therebetween. The end effector generates a positioning signal and the hand-held tool includes a detector for detecting the positioning signal.

Abstract: An apparatus for installing rivets or other fasteners through a workpiece includes an automated machine disposed on one side of the workpiece and a hand-held tool that is manipulated by a single worker located on the opposite side of the workpiece. The automated machine includes an end effector supporting tools such as a drill and a riveter. The automated machine also includes a guide structure adapted to be releasably affixed to the workpiece, and a carriage that travels along the guide structure and supports the end effector so that the end effector can be positioned in various locations along the surface of the workpiece where fasteners are to be installed. The end effector includes an electromagnetic clamping device, and the hand-held tool includes a magnetic clamping block that is attracted by the clamping device to clamp the workpiece therebetween. The end effector generates a positioning signal and the hand-held tool includes a detector for detecting the positioning signal.

Abstract: A stitching apparatus and end effector system particularly suited for stitching composite preforms includes a six-degree-of-freedom manipulator arm and an end effector that is releasably coupled to the end of the manipulator arm by a quick-change coupler system. The end effector comprises a C-shaped bow having a pair of spaced-apart legs the free ends of which support a stitching head and a bobbin in opposing relation so that a workpiece to be stitched can be received between the stitching head and bobbin. In accordance with a preferred embodiment of the invention, a plurality of bows of different configurations are provided, each having a quick-change coupler on each leg for releasably coupling the stitching head and the bobbin to the bow.

Abstract: The present invention provides a fastening assembly system for applying fasteners along the seams of a cylindrical structure. The fastening apparatus includes a base unit which releasably attaches to a cylindrical structure, and a first fastening device coupled the base unit for applying fasteners along a seam of the cylindrical structure. The base unit may be embodied as either two crescent shaped members in parallel alignment for attaching to the upper half of the cylindrical structure. Alternatively, the base unit may include a base plate that is attachable to the floor beams on the interior of the cylindrical structure. In the preferred embodiment, the first fastening device cooperate with a second fastening device located on the opposite side of the cylindrical structure during the fastening process.

Abstract: Reinforcing members for securement of reinforced plastic composite components in restricted and confined space locations as a substitute for reinforcing stitching. The reinforcing members are highly effective for securing "T" stiffeners and the like to a skin structure in confined and restricted locations where a stitching machine cannot be used. The composite pieces which are reinforced and secured together by the reinforcing members provide excellent damage tolerance, are highly resistant to delamination and are resistant to tensile pulling and plane shear properties. The reinforcing members primarily comprise a plurality of pins or spikes which are effectively formed by sewing through a disposable and eliminatable core such that when the core is removed, all of the pins, which originally constituted threads passing through the core are secured together in an array by an open mesh physical cross-linking of the pins.

Abstract: An assembly tower method and apparatus for use with an assembly jig having a tower guidance apparatus. The assembly tower includes a base, a platform coupled to the base for movement relative thereto, a drive system for moving the base relative to the ground and for moving the platform to the base in response to selected control signals. A Control System is included in the assembly tower for selectively generating and communicating the respective control signals to the drive system. A tower guidance apparatus is engagable with a guidance element of the tower to limit movement of the base relative to the ground in accordance with a pre-defined path. The tower carries a tool for assisting in constructing large aircraft components such as fuselage panels which are supported on the assembly jig.

Abstract: A method of making ducts having outwardly extending ribs formed integrally with the duct structure. Two tubes are formed from fiber reinforced resin materials, a uniform inner tube and a ribbed outer tube, then the inner tube is bonded with in the outer tube to form a high strength ribbed duct. An outer tube is formed by placing resin impregnated fibers over a cylindrical mandrel having an inflatable bladder on its surface, placing a plurality of spaced rings tightly against the outer surface, pressurizing the bladder to expand the tube into the spaces between rings to form low ribs, then gradually moving the rings toward each other to press the ribs therebetween and form thin upstanding ribs. The inner tube is formed by placing resin impregnated fibers on a slightly thinner mandrel that also has a surface bladder. When both tubes are formed, the mandrel is removed from the outer tube and the inner tube and mandrel are inserted therein and the inner tube bladder is inflated.

Abstract: A fixed wing aircraft that can be converted to an automotive vehicle, comprising a generally rectangular planform fuselage having four wheels as in conventional automobile practice, and a telescopic wing which retracts into a housing in the roof of the fuselage. Telescopic horizontal and vertical stabilizers are provided at the rear end of the fuselage, as well as a retractable pusher propeller that is driven by an engine mounted on the front end of the fuselage. Both the propeller and the rear wheels are connected by a transmission box to the engine, so that either can be driven to operate the vehicle as an aircraft or as an automobile. On take-off, the rear wheels are partially retracted so as to place the aircraft at a proper angle of attack at the same time that the elevators are raised by pulling back on the control wheel. The control wheel is also connected to both the front wheels and the ailerons, and when turned 90.degree.

Abstract: A machine comprising a horizontally elongated base having pairs of pylons slidably mounted on opposite sides of the base for horizontal movement along the length thereof, forming in effect, a moveable C-frame. The workpiece is fixedly supported on the base in a substantially vertical position, and the pylons of each pair work together on opposite sides of the workpiece to process rivets/fasteners or perform other functions. Each of the pylons comprises a vertical first component and a horizontal second component. The second component is movable vertically on the first component, and is also movable horizontally toward and away from the workpiece. Carried on the end of each of the horizontal second components adjacent the workpiece is a tool assembly holder that is rotatable about horizontal and vertical axes.

Abstract: A fixed wing aircraft that can be converted to an automotive vehicle, comprising a generally rectangular planform fuselage having four wheels as in conventional automobile practice, and a telescopic wing which retracts into a housing in the roof of the fuselage. Telescopic horizontal and vertical stabilizers are provided at the rear end of the fuselage, as well as a retractable pusher propeller that is driven by an engine mounted on the front end of the fuselage. Both the propeller and the rear wheels are connected by a transmission box to the engine, so that either can be driven to operate the vehicle as an aircraft or as an automobile. On take-off, the rear wheels are partially retracted so as to place the aircraft at a proper angle of attack at the same time that the elevators are raised by pulling back on the control wheel. The control wheel is also connected to both the front wheels and the ailerons, and when turned 90.degree.

Abstract: A telescopic airfoil comprising a plurality of short wing sections, each consisting of skin and rib, with tubular spar sections attached to the rib. Each spar section is adapted to telescope with respect to the next adjoining spar section toward the root end of the airfoil. Alternate spar sections are rotatable, and intermediate spar sections are held stationary, with the end portions of adjacent spar sections overlapping, and low-friction threads connecting the overlapping spar portions. The threads at opposite ends of each spar section are of opposite hand so that rotation of the rotatable spar sections causes the entire group to be drawn together into a housing at the root end of the wing. In this way, the wing span can be reduced to less than 30% of the full span, while during extension and retraction, the spars retain their full load-carrying capability.

Abstract: A structural component having a curved wall, such as an aircraft fuselage pipe, has a grid structure formed of box frames produced by winding tapes of fiber reinforced synthetic material, so-called prepregs, onto mold bodies. These mold bodies are then assembled on a mandrel for covering with a planking and curing whereby the tapes are bonded together to form stringers intersecting with ribs in a grid structure and whereby the planking is bonded to the grid structure. The ribs are reinforced by fiber reinforced belt segments of synthetic material inserted into gaps between adjacent short ends of the mold bodies, whereby these belt segments are bonded to the ribs during curing. The belt segments ave a width corresponding to a multiple of the width of the stringers and hence protrude radially inwardly. Preferably, an edge reinforcing strip of fiber reinforced material is arranged alongside the radially inner edge of the belt segments.

Abstract: A structural component having a curved wall, such as an aircraft fuselage pipe, has a grid structure formed of box frames produced by winding tapes of fiber reinforced synthetic material, so-called prepregs, onto mold bodies. These mold bodies are then assembled on a mandrel for covering with a planking and curing whereby the tapes are bonded together to form stringers intersecting with ribs in a grid structure and whereby the planking is bonded to the grid structure. The ribs are reinforced by fiber reinforced belt segments of synthetic material inserted into gaps between adjacent short ends of the mold bodies, whereby these belt segments are bonded to the ribs during curing. The belt segments have a width corresponding to a multiple of the width of the stringers and hence protrude radially inwardly. Preferably, an edge reinforcing strip of fiber reinforced material is arranged alongside the radially inner edge of the belt segments.

Abstract: A surface type structural component particularly applicable for aircraft, mprises a reinforcing grid structure of longitudinal and cross ribs made of fiber reinforced material. The grid structure is assembled from a plurality of molded box frames or cells. The modular box frames are formed on mold bodies and assembled and bonded together to form the reinforcing grid structure while still on the mold bodies. A laminated sheathing is bonded to the grid structure. Methods and apparatus including an automated assembly plant are disclosed for manufacturing the surface type structural component. The manufacturing plant includes automated handling equipment for molding the box frames on mold bodies, assembling the mold bodies and box frames into grid structures, forming and applying a laminate sheathing, curing and hardening the two-dimensional grid structure and laminate sheathing combination under heat and pressure and removing the mold bodies.