Abstract: A method and apparatus for forming a number of filler members. The apparatus comprises a surface model generator and an analyzer. The surface model generator generates a first surface model of a surface and a second surface model of a flexible surface. The surface and the flexible surface are to be mated to form a mated surface and a mated flexible surface. The analyzer performs a structural analysis using the first surface model and the second surface model to identify a predicted final shape of the mated flexible surface. The predicted final shape of the mated flexible surface is used to form the number of filler members to fill a number of spaces between the mated surface and the mated flexible surface.

Abstract: Systems and methods for robotic measurement of parts are provided. One system includes one or more omni-directional ground vehicles configured to move within a facility defined work zone to a setup calibration station and an engineering defined work space, wherein the engineering defined work space includes a part to be measured. The system also includes a multi-axis robot removably coupled to each of the omni-direction ground vehicles and configured to move a laser scanner, wherein the laser scanner of each of the multi-axis robots is configured to move in at least two linear directions and one rotational direction. The system further includes a processor configured to automatically generate a surface ready output file from measurement data received from the laser scanners, wherein the surface ready output file is configured to command a machine to manufacture a mating component to the part.

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: Method and apparatus for use in curing of a composite charge having an internal cavity. Apparatus includes a flexible bladder adapted to be placed in the cavity for applying pressure on the composite charge during curing. An end fitting is operatively coupled to the flexible bladder. The end fitting defining a bolt bore and a horizontal bore. When a vent bolt is operatively coupled to the bolt bore of the end fitting, the vent bolt and the horizontal bore define a pressure passageway that allows an interior of the bladder to become subjected to external pressure.

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: Method and apparatus for layup placement on a layup structure is provided. The method includes iteratively loading a layup for the layup structure on a support frame of a saddle module; aligning the saddle module with a pre-selected registration position corresponding to a predetermined application path on the layup structure; and impressing the layup into forced contact with the layup structure along the predetermined application path using a predetermined application force. The apparatus includes a plurality of saddle modules configured to operate in unison, wherein the plurality of saddle modules is configured to receive a pre-selected composite material layup.

Abstract: Method and apparatus for layup placement on a layup structure is provided. The method includes iteratively loading a layup for the layup structure on a support frame of a saddle module; aligning the saddle module with a pre-selected registration position corresponding to a predetermined application path on the layup structure; and impressing the layup into forced contact with the layup structure along the predetermined application path using a predetermined application force. The apparatus includes a plurality of saddle modules configured to operate in unison, wherein the plurality of saddle modules is configured to receive a pre-selected composite material layup.

Abstract: A large scale composite structure is fabricated by forming a plurality of composite laminate modules and joining the modules together along their edges using scarf joints.

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, methods, and devices are disclosed for predictive shimming of large structures. Systems may include a remote device configured to move along a first path relative to a first vehicle structure. The remote device may be configured to move a sensor device along a plurality of measurement points included in the first path. A base device may be configured to identify a position of the sensor device at each measurement point. The base device may be configured to generate measurement data including a first plurality of measurements identifying at least one structural dimension of a first surface of the first vehicle structure. A controller may be configured to control operation of the base device and the remote device based on engineering data associated with the first vehicle structure. The controller may be further configured to determine at least one shim dimension associated with the first surface.

Abstract: A method of forming a flat composite charge into a contoured composite part reduces wrinkles in the part as the charge is being formed. Dies are used to form a portion of charge to the steepest contour of the part, while tension is maintained on the charge as the remaining portions of the charge are formed.

Abstract: A method of forming a flat composite charge into a contoured composite part reduces wrinkles in the part as the charge is being formed. Dies are used to form a portion of charge to the steepest contour of the part, while tension is maintained on the charge as the remaining portions of the charge are formed.

Abstract: Methods of fabricating shims for joining parts are disclosed. An example method of fabricating shims for joining parts, wherein the parts having mating surfaces separated by a gap, includes: generating first digital data representing a first surface profile of a first part; generating second digital data representing a second surface profile of a second part to mate with the first part; determining distances between the first and second parts, as assembled, at multiple locations; generating a digital volume that closely matches a gap between the first and second parts based on the determined distances; generating a three dimensional digital representation of a shim to fill the gap using the first and second digital data; and automatically fabricating the shim matching the gap using a computer-controlled machine, the machine being controlled using the three dimensional digital representation of the shim.

Abstract: An apparatus for manufacturing composite parts. An expandable tool with a transfer system may be moved on a surface of the expandable tool into an outer mold line tool with a composite material laid up on the outer mold line tool. The expandable tool may be expanded in the outer mold line tool to change the surface from a retracted state to an expanded state. The transfer system may be transferred from the expandable tool with the surface in the expanded state to the outer mold line tool.

Abstract: Systems, methods, and devices are disclosed for predictive shimming of large structures. Systems may include a remote device configured to move along a first path relative to a first vehicle structure. The remote device may be configured to move a sensor device along a plurality of measurement points included in the first path. A base device may be configured to identify a position of the sensor device at each measurement point. The base device may be configured to generate measurement data including a first plurality of measurements identifying at least one structural dimension of a first surface of the first vehicle structure. A controller may be configured to control operation of the base device and the remote device based on engineering data associated with the first vehicle structure. The controller may be further configured to determine at least one shim dimension associated with the first surface.

Abstract: A hands-free method and related apparatus are used to shape, place and compact a composite stringer on a composite skin of an aircraft. A composite charge is placed on a tool assembly that used to shape the charge into a preformed stringer. With the stringer held on the tool assembly, the tool assembly is used to move the preformed stringer into proximity with the skin and both place and compact the stringer against the skin. Following compaction of the stringer, the tool assembly is removed and the skin and the stringer are co-cured.

Abstract: A large scale composite structure is fabricated by forming a plurality of composite laminate modules and joining the modules together along their edges using scarf joints.

Abstract: A method and apparatus for manufacturing composite parts. An expandable tool with a transfer system may be moved on a surface of the expandable tool into an outer mold line tool with a composite material laid up on the outer mold line tool. The expandable tool may be expanded in the outer mold line tool to change the surface from a retracted state to an expanded state. The transfer system may be transferred from the expandable tool with the surface in the expanded state to the outer mold line tool.

Abstract: Method and apparatus for use in curing of a composite charge having an internal cavity. Apparatus includes a flexible bladder adapted to be placed in the cavity for applying pressure on the composite charge during curing. An end fitting is operatively coupled to the flexible bladder. The end fitting defining a bolt bore and a horizontal bore. When a vent bolt is operatively coupled to the bolt bore of the end fitting, the vent bolt and the horizontal bore define a pressure passageway that allows an interior of the bladder to become subjected to external pressure.

Abstract: A method of forming a flat composite charge into a contoured composite part reduces wrinkles in the part as the charge is being formed. Dies are used to form a portion of charge to the steepest contour of the part, while tension is maintained on the charge as the remaining portions of the charge are formed.