Abstract: Systems and methods are provided for structurally supporting an aircraft wing. The system comprises a section of aircraft wing that includes skin. The skin surrounds an internal volume of the wing and comprises layers of Carbon Fiber Reinforced Polymer (CFRP) having fiber orientations aligned to bear shear stresses applied to the wing. The section of aircraft wing also includes planked stringers that are laterally oriented within the wing, contact the skin within the internal volume, are attached to the skin, and comprise layers of CFRP having fiber orientations that are aligned to bear bending at the wing. Furthermore, the section includes spars that are positioned between planked stringers on an upper portion of the wing and planked stringers on a lower portion of the wing, wherein the spars are aligned with the planked stringers.

Abstract: A single piece pulsed flow wing assembly method providing for horizontal wing manufacture is accomplished using synchronized automated vehicles guided in a predetermined manner to move and, locate wing structure in a plurality of assembly positions. Multi-axis assembly positioning systems (MAPS) are used at each assembly position to support and index components in the wing structure and determinant assembly techniques are used for indexing of the components. Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.

Abstract: A system and method are provided to automate the assembly of a wing panel, such as utilized by commercial aircraft. In the context of a system, a tacking cell is provided that is configured to tack one or more stringers to a skin plank. The system also includes a riveting cell configured to receive a tacked plank from the tacking cell and to rivet the one or more stringers to the skin plank. The system also includes a splicing cell configured to receive a plurality of riveted planks from the riveting cell and to attach one or more splice stringers to the plurality of riveted planks. Further, the system includes a side of body cell configured to receive a spliced panel from the splicing cell and to attach a side of body chord thereto to produce a wing panel.

Abstract: Systems and methods are provided for integrating structural components of a wing box. One embodiment is a system that includes outboard planked stringers within an outboard section of a wing box and are co-cured with composite skin at the outboard section. Each outboard planked stringer of the outboard section includes planar layers of Carbon Fiber Reinforced Polymer (CFRP) that are parallel with the composite skin at the outboard section, have fiber orientations aligned to bear tension and compression applied to the wing box, and each extend a different distance along the composite skin at the outboard section. The system also includes center planked stringers within the center section and are co-cured with composite skin at the center section.

Abstract: A system and method are provided to automate the assembly of a wing panel, such as utilized by commercial aircraft. In the context of a system, a tacking cell is provided that is configured to tack one or more stringers to a skin plank. The system also includes a riveting cell configured to receive a tacked plank from the tacking cell and to rivet the one or more stringers to the skin plank. The system also includes a splicing cell configured to receive a plurality of riveted planks from the riveting cell and to attach one or more splice stringers to the plurality of riveted planks. Further, the system includes a side of body cell configured to receive a spliced panel from the splicing cell and to attach a side of body chord thereto to produce a wing panel.

Abstract: A system and method are provided to automate the assembly of a wing panel, such as utilized by commercial aircraft. In the context of a system, a tacking cell is provided that is configured to tack one or more stringers to a skin plank. The system also includes a riveting cell configured to receive a tacked plank from the tacking cell and to rivet the one or more stringers to the skin plank. The system also includes a splicing cell configured to receive a plurality of riveted planks from the riveting cell and to attach one or more splice stringers to the plurality of riveted planks. Further, the system includes a side of body cell configured to receive a spliced panel from the splicing cell and to attach a side of body chord thereto to produce a wing panel.

Abstract: Systems and methods are provided for integrating structural components of a wing box. One embodiment is a system that includes outboard planked stringers within an outboard section of a wing box and are co-cured with composite skin at the outboard section. Each outboard planked stringer of the outboard section includes planar layers of Carbon Fiber Reinforced Polymer (CFRP) that are parallel with the composite skin at the outboard section, have fiber orientations aligned to bear tension and compression applied to the wing box, and each extend a different distance along the composite skin at the outboard section. The system also includes center planked stringers within the center section and are co-cured with composite skin at the center section.

Abstract: Systems and methods are provided for structurally supporting an aircraft wing. The system comprises a section of aircraft wing that includes skin. The skin surrounds an internal volume of the wing and comprises layers of Carbon Fiber Reinforced Polymer (CFRP) having fiber orientations aligned to bear shear stresses applied to the wing. The section of aircraft wing also includes planked stringers that are laterally oriented within the wing, contact the skin within the internal volume, are attached to the skin, and comprise layers of CFRP having fiber orientations that are aligned to bear bending at the wing. Furthermore, the section includes spars that are positioned between planked stringers on an upper portion of the wing and planked stringers on a lower portion of the wing, wherein the spars are aligned with the planked stringers.

Abstract: A single piece pulsed flow wing assembly method providing for horizontal wing manufacture is accomplished using synchronized automated vehicles guided in a predetermined manner to move and, locate wing structure in a plurality of assembly positions. Multi-axis assembly positioning systems (MAPS) are used at each assembly position to support and index components in the wing structure and determinant assembly techniques are used for indexing of the components. Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.

Abstract: A single piece pulsed flow wing assembly method providing for horizontal wing manufacture is accomplished using synchronized automated vehicles guided in a predetermined manner to move and, locate wing structure in a plurality of assembly positions. Multi-axis assembly positioning systems (MAPS) are used at each assembly position to support and index components in the wing structure and determinant assembly techniques are used for indexing of the components. Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.

Abstract: A system and method are provided to automate the assembly of a wing panel, such as utilized by commercial aircraft. In the context of a system, a tacking cell is provided that is configured to tack one or more stringers to a skin plank. The system also includes a riveting cell configured to receive a tacked plank from the tacking cell and to rivet the one or more stringers to the skin plank. The system also includes a splicing cell configured to receive a plurality of riveted planks from the riveting cell and to attach one or more splice stringers to the plurality of riveted planks. Further, the system includes a side of body cell configured to receive a spliced panel from the splicing cell and to attach a side of body chord thereto to produce a wing panel.

Abstract: A single piece pulsed flow wing assembly method providing for horizontal wing manufacture is accomplished using synchronized automated vehicles guided in a predetermined manner to move and, locate wing structure in a plurality of assembly positions. Multi-axis assembly positioning systems (MAPS) are used at each assembly position to support and index components in the wing structure and determinant assembly techniques are used for indexing of the components. Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.

Abstract: A method and apparatus for manufacturing wings includes a fixture that holds wing panels for drilling and edge trimming by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination features machined into the parts and subassemblies, thereby making the parts and subassemblies intrinsically determinant of the dimensions and contour of the wing. Spars are attached to the wing panel using the coordination holes to locate the spars accurately on the panel in accordance with the original engineering design, and in-spar ribs are attached to rib posts on the spar using accurately drilled coordination holes in the ends of the rib and in the rib post. The wing contour is determined by the configuration of the spars and ribs rather than by any conventional hard tooling which determines the wing contour in conventional processes.

Abstract: A single piece pulsed flow wing assembly method providing for horizontal wing manufacture is accomplished using synchronized automated vehicles guided in a predetermined manner to move and, locate wing structure in a plurality of assembly positions. Multi-axis assembly positioning systems (MAPS) are used at each assembly position to support and index components in the wing structure and determinant assembly techniques are used for indexing of the components. Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.

Abstract: A method and apparatus for moving a structure. The structure is supported on a carrier. The carrier comprises a platform having a first side and a second side, a movement system associated with the first side and configured to move the platform on a surface, a support system associated with the second side of the platform and configured to support the structure on the platform, and a leveling system configured to substantially maintain the structure in a desired orientation during movement of the platform on the surface. The carrier is moved with the structure over the surface. At least one of the movement system and the support system is adjusted to substantially maintain the structure in the desired orientation.

Abstract: A method and apparatus for moving a structure. The structure is supported on a carrier. The carrier comprises a platform having a first side and a second side, a movement system associated with the first side and configured to move the platform on a surface, a support system associated with the second side of the platform and configured to support the structure on the platform, and a leveling system configured to substantially maintain the structure in a desired orientation during movement of the platform on the surface. The carrier is moved with the structure over the surface. At least one of the movement system and the support system is adjusted to substantially maintain the structure in the desired orientation.

Abstract: A method and apparatus for manufacturing wings includes a fixture that holds wing panels for drilling and edge trimming by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination features machined into the parts and subassemblies, thereby making the parts and subassemblies intrinsically determinant of the dimensions and contour of the wing. Spars are attached to the wing panel using the coordination holes to locate the spars accurately on the panel in accordance with the original engineering design, and in-spar ribs are attached to rib posts on the spar using accurately drilled coordination holes in the ends of the rib and in the rib post. The wing contour is determined by the configuration of the spars and ribs rather than by any conventional hard tooling which determines the wing contour in conventional processes.

Abstract: A method and apparatus for manufacturing wings includes a fixture that holds wing panels for drilling and edge trimming by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination features machined into the parts and subassemblies, thereby making the parts and subassemblies intrinsically determinant of the dimensions and contour of the wing. Spars are attached to the wing panel using the coordination holes to locate the spars accurately on the panel in accordance with the original engineering design, and in-spar ribs are attached to rib posts on the spar using accurately drilled coordination holes in the ends of the rib and in the rib post. The wing contour is determined by the configuration of the spars and ribs rather than by any conventional hard tooling which determines the wing contour in conventional processes.

Abstract: A method and apparatus for manufacturing wings includes a fixture that holds wing panels for drilling and edge trimming by accurate numerically controlled machine tools using original numerical part definition records, utilizing spatial relationships between key features of detail parts or subassemblies as represented by coordination features machined into the parts and subassemblies, thereby making the parts and subassemblies intrinsically determinant of the dimensions and contour of the wing. Spars are attached to the wing panel using the coordination holes to locate the spars accurately on the panel in accordance with the original engineering design, and in-spar ribs are attached to rib posts on the spar using accurately drilled coordination holes in the ends of the rib and in the rib post. The wing contour is determined by the configuration of the spars and ribs rather than by any conventional hard tooling which determines the wing contour in conventional processes.

Abstract: A method for assembling wings includes supporting a pair of wing spars, which include a plurality of coordination features, upon a pair of stanchions in a generally horizontal position. A plurality of ribs and wing panels are accurately fastened to the pair of wing spars at a first workstation using the coordination features to position accurately the parts. The combination is transferred to downstream workstations via a ground transport vehicle for further processing and assembly to define a pulsed flow wing assembly system.