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: The disclosure is generally directed to a modified blade stiffener having enhanced mechanical properties. An illustrative embodiment of the modified blade stiffener includes a stiffener-forming material shaped into a pair of coupled blades having first and second ends, a filler cavity provided at the first end of the blades, a blade filler provided in the filler cavity and a pair of blade flanges provided at the second end of the blades.

Abstract: A one-piece barrel assembly cart includes a right assembly cart base connected with a left assembly cart base and at least three stabilizer rings that are attached to the assembly cart base. The one-piece barrel assembly cart may be used to stabilize a tapered cured composite barrel, for example the large fuselage barrel of the aft section of a large new generation aircraft, such as a 7E7 Boeing airplane. A modular assembly cart includes at least two identical modules. Each of these modules includes a cart base and a stabilizer ring. The diameter of the inner surface of the stabilizer ring may vary as needed. Other modules including a fuselage support may be added. By providing modular assembly carts any shape and size of a one-piece composite barrel may be stabilized after curing of the composite material.

Abstract: A production system for manufacturing a workpiece comprises an index system including a plurality of index devices removably mounted on the workpiece at known longitudinally spaced locations therealong, and a longitudinally extending index member releasably engaged with at least two of the index devices such that a position and orientation of the index member are fixed relative to the workpiece by the index devices, the index member having position-indicating features distributed therealong. The production system further comprises a machine module mounted for longitudinal movement along the index member and operable to perform an operation, the machine module being operable to detect the position-indicating features on the index member and thereby determine a position of the machine module relative to the workpiece.

Abstract: A modular composite manufacturing method. An illustrative embodiment of the method includes providing a plurality of composite modules; inspecting the composite modules; providing a curing tool; and placing the composite modules on the curing tool.

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 production system for manufacturing a workpiece comprises an index system including a plurality of index devices removably mounted on the workpiece at known longitudinally spaced locations therealong, and a longitudinally extending index member releasably engaged with at least two of the index devices such that a position and orientation of the index member are fixed relative to the workpiece by the index devices, the index member having position-indicating features distributed therealong. The production system further comprises a machine module mounted for longitudinal movement along the index member and operable to perform an operation, the machine module being operable to detect the position-indicating features on the index member and thereby determine a position of the machine module relative to the workpiece.

Abstract: During the manufacture an aircraft, a tool-carrying rail is removably attached to a rail-side surface of the aircraft with a vacuum cup. The tool-carrying rail includes a longitudinal axis to mount a tool. The vacuum cup is stiffened along a first axis transverse to the longitudinal axis of the tool-carrying rail and the vacuum cup is stiffened along a second axis parallel to the rail-side surface of the aircraft. To removably attach the tool-carrying rail, a perimeter of the vacuum cup is removably sealed to the rail-side surface of the aircraft against vacuum loss and a point on the rail is rigidly positioned with respect to a point on the rail-side surface of the aircraft. In addition, a vacuum source is coupled to a spatial volume occupying all of a space between the vacuum cup and the rail-side surface of the aircraft and the tool is slidably positioned along the longitudinal axis of the tool-carrying rail.

Abstract: A method and associated apparatus for forming a composite structural member from a charge are provided. The charge can be disposed on a first die of the apparatus and formed to a desired configuration defined by a recess of the die by inserting a second die or a tool into the recess. In some cases, the first die can include two portions that are adjustable in a transverse direction so that the recess can be opened by the insertion of the second die or tool. The second die or tool can be a substantially rigid member or an inflatable bladder. In either case, the charge can be disposed on the first die, formed, and then further processed on the first die, thereby facilitating indexing of the charge for each operation.

Abstract: A method and associated apparatus for forming a composite structural member from a charge are provided. The charge can be disposed on a first die of the apparatus and formed to a desired configuration defined by a recess of the die by inserting a second die or a tool into the recess. In some cases, the first die can include two portions that are adjustable in a transverse direction so that the recess can be opened by the insertion of the second die or tool. The second die or tool can be a substantially rigid member or an inflatable bladder. In either case, the charge can be disposed on the first die, formed, and then further processed on the first die, thereby facilitating indexing of the charge for each operation.

Abstract: During the manufacture an aircraft, a tool-carrying rail is removably attached to a rail-side surface of the aircraft with a vacuum cup. The tool-carrying rail includes a longitudinal axis to mount a tool. The vacuum cup is stiffened along a first axis transverse to the longitudinal axis of the tool-carrying rail and the vacuum cup is stiffened along a second axis parallel to the rail-side surface of the aircraft. To removably attach the tool-carrying rail, a perimeter of the vacuum cup is removably sealed to the rail-side surface of the aircraft against vacuum loss and a point on the rail is rigidly positioned with respect to a point on the rail-side surface of the aircraft. In addition, a vacuum source is coupled to a spatial volume occupying all of a space between the vacuum cup and the rail-side surface of the aircraft and the tool is slidably positioned along the longitudinal axis of the tool-carrying rail.

Abstract: An apparatus and method for securing a plurality of stringers to a mandrel during lay-up is provided, the plurality of stringers and mandrel forming a lay-up surface. The apparatus includes a vacuum source and a first vacuum attachment assembly in communication with said vacuum source to tightly secure the first vacuum attachment assembly down against the lay-up surface. A second vacuum attachment assembly is provided in communication with the vacuum source to force it tightly down against the lay-up. A flexible spacer is in rigid communication with the second vacuum attachment assembly and includes an extended end in communication with the first vacuum attachment assembly such that the flexible spacer presses one of the stringers against the mandrel.

Abstract: Methods and apparatus for track members having a neutral axis rack are disclosed. In one embodiment, an apparatus for supporting a manufacturing tool relative to a workpiece includes a track assembly adapted to be attached to the workpiece and including at least one rail, the rail having a longitudinally-extending neutral axis and a rack extending along a pitch line that at least approximately coincides with the longitudinally-extending neutral axis. In alternate embodiments, the rack includes a plurality of wedge-shaped apertures or a plurality of conically-shaped apertures.

Abstract: To fabricate a composite item, a device places a composite ply on a curved form at about 0° relative to a longitudinal axis of the form. The form includes a web surface and a cap surface. The device includes a web compaction roller and a set of guides. The web compaction roller compacts a composite material upon the web surface and generate a web ply. The set of guide rollers urges against the cap surface. The compaction roller is directed along the form by the guide rollers.

Abstract: Techniques of performing a manufacturing operation on a workpiece are disclosed. In one embodiment, a method includes forming an indexing hole in the workpiece. A coordinating pin may be installed into the indexing hole, the coordinating pin including a quantum of indexing information. A sensor may be positioned proximate the coordinating pin. The quantum of indexing information may be sensed with a sensor. A manufacturing operation may be performed on the workpiece based at least partially on the quantum of indexing information.

Abstract: In accordance with the present invention an apparatus for securing a plurality of stringers to a mandrel during lay-up is provided, the plurality of stringers and mandrel forming a lay-up surface. The apparatus includes a vacuum source and a first vacuum attachment assembly comprising a first vacuum cup assembly and a first flexible tube assembly in communication with said vacuum source to tightly secure down against the lay-up surface. A second vacuum attachment assembly comprises a second vacuum cup assembly and a second flexible tube assembly in communication with the vacuum source to force it tightly down against the lay-up. A flexible spacer is in rigid communication with the second vacuum cup assembly and includes an extended end in communication with the first vacuum cup assembly such that the flexible spacer presses one of the stringers against the mandrel.

Abstract: Apparatus and methods for manufacturing operations are disclosed. In one embodiment, a vacuum cup assembly includes a housing having a vacuum generator formed therein, and a compliant sealing member coupled to the housing. The vacuum generator is coupleable to a source of pressurized fluid and is adapted to generate a reduced pressure region. The sealing member forms an enclosable region in fluid communication with the reduced pressure region. In another embodiment, a method of performing a manufacturing operation includes installing a coordinating pin into an indexing hole, the coordinating pin including a quantum of indexing information. The quantum of indexing information is sensed, and a manufacturing operation is performed based at least partially on the quantum of indexing information.

Abstract: A conformal vacuum cup provides a machine tool attachment fitting usable in a flexible-track drill system. Using multiple, independently articulated stiffeners, the conformal vacuum cup conforms to the contour of complex aerostructure surface shapes. The individual stiffeners are decoupled from each other to some extent by grooves and slots molded into resilient overmolding material to support long-axis curving. Spacing pins employ a domed shape consonant with the elastic deformation of the workpiece surface under load. The pins employ a hard material to prevent particle embedment in use and to control position tolerance for drill heads and other tools traveling on the flexible track. Partial holes in each vacuum cup are blocked by diaphragms. Interconnection from a vacuum system manifold to the vacuum cups can be realized by penetrating the diaphragms and inserting barbed fittings connected by vacuum tubing.

Abstract: A flexible rail machine tool couples temporarily to a structure by vacuum cups and positions a tool head at any desired point over an area. The toolhead can perform operations such as drilling, bolt insertion, and acquisition of dimension data. The flexible rail can conform to surface curvature in one or more axes. Tool head perpendicularity to the structure can be sensed and adjusted as needed. The as-attached position of the rail may be compensated for through coordinate transformation, allowing holes, for example, to be placed with substantial precision.

Abstract: A rail system for positioning a toolhead above a workpiece uses a rack cut into one edge of the rail and driven by a pinion gear whose shaft is approximately perpendicular to a workpiece to couple the rail to the toolhead. Multiple rollers placed on the toolhead allow contact between the toolhead and the rail to be effectively continuous despite the cutting away of as much as or more than two-thirds of the rail edge to provide rack teeth. Separating thickness axis containment from transverse with a square rail edge and separate thickness axis and transverse rollers allows the toolhead to follow a rail as the rail flexes over a curved surface with minimal position error. Several variations in rail, bearing, and rack implementation can realize comparable results.