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: 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 pre-patterned layup kit with layup patterned to accommodate an airframe topological feature, trimmed to fit a preselected target region of a layup structure, and conformed to the target region contour. The kit can be fabricated in advance of airframe manufacture and stored until use. The kit includes a flexible carrier upon which the layup is laid, and a release layer between the layup and the carrier. The layup has multiple laminae oriented to an carrier indexing element, and indexed to the target region thereby. A kit manufacturing method includes preparing the laminae constituent of the layup, preparing the carrier, and laying down the laminae on the carrier to make the kit. The kit can be compacted, inspected, and prepared for storage. The layup can be fabricated of a pre-patterned lamina or multiple laminae that are shaped and trimmed to accommodate an airframe topological feature.

Abstract: A system and method for machining an elongate workpiece in a plurality of work cells are provided. The work cells are positioned along a substantially linear process flow path so that the work operations can be performed on different lengthwise portions of the workpiece simultaneously. A transport system advances the workpiece from an infeed system along the process flow path, thereby moving the lengthwise portions of the workpiece successively through the work cells. The transport system includes a plurality of pallets that can be engaged to the workpiece so that the workpiece is supported by the pallets throughout at least part of the machining system.

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 pre-patterned layup kit with layup patterned to accommodate an airframe topological feature, trimmed to fit a preselected target region of a layup structure, and conformed to the target region contour. The kit can be fabricated in advance of airframe manufacture and stored until use. The kit includes a flexible carrier upon which the layup is laid, and a release layer between the layup and the carrier. The layup has multiple laminae oriented to an carrier indexing element, and indexed to the target region thereby. A kit manufacturing method includes preparing the laminae constituent of the layup, preparing the carrier, and laying down the laminae on the carrier to make the kit. The kit can be compacted, inspected, and prepared for storage. The layup can be fabricated of a pre-patterned lamina or multiple laminae that are shaped and trimmed to accommodate an airframe topological feature.

Abstract: A system and method for machining an elongate workpiece in a plurality of work cells are provided. The work cells are positioned along a substantially linear process flow path so that the work operations can be performed on different lengthwise portions of the workpiece simultaneously. A transport system advances the workpiece from an infeed system along the process flow path, thereby moving the lengthwise portions of the workpiece successively through the work cells. The transport system includes a plurality of pallets that can be engaged to the workpiece so that the workpiece is supported by the pallets throughout at least part of the machining system.

Abstract: An assembly cell for accurate placement of stringer clips in a channel of a stringer for a compound contour section of an airplane fuselage, and for holding the clips at a predetermined orientation while drilling holes for fastening the clips in the stringers includes a fixture having locating surfaces for holding the stringer in a configuration that is the same as the configuration it will have when installed at its designated position in the airplane. The fixture has headers adjustable to conform to the shape of the airplane in which the stringers will be installed, The headers have clamps for securing the stringers against accurately machined reference surfaces on the headers. An end effector is held by a machine tool in the assembly cell for gripping a stringer clip and inserting it into the stringer channel.

Abstract: A machine for positioning clips in channel-shaped airplane fuselage stringers, and drilling holes in the stringers and clips, includes an elongated beam support having a box beam supported on five floor engaging legs and supporting a carriage assembly positioned on said beam and supported on bearings traveling along rails on the beam for longitudinal movement therealong. A motive mechanism, including a servomotor in the carriage and driving a pinion engaged with a rack fastened to the beam moves carriage longitudinally along the beam. An index mechanism including a fixed end stop at a known position indexes a stringer on the beam at a fixed reference position thereon. The stringer is centered under a drill by a centering mechanism mounted on the carriage, and a drill system drills a series of vertical holes along the channel floor of the stringer at locations specified in a digital product definition of said part.

Abstract: A reconfigurable fixture for holding a plurality of workpieces in proper position for manufacturing. The fixture includes an array of interleaved uniformly spaced contoured headers, with a predetermined set of headers corresponding to a predetermined workpiece contour. Each set of contoured headers may be simultaneously laterally displaced from an inactive stored position to a locked, active forward position, wherein the selection and movement of the set of headers is controlled by a computer controller. Each contoured header has a set of vacuum cups, that, when activated, pulls the predetermined workpiece against the contoured edges of the predetermined set of headers.

Abstract: A stringer clip end effector (21) suitable for use with a computer-controlled (CC) machine tool is disclosed. The stringer clip end effector (21) includes a pair of jaws (45,47) for picking up a clip (23) at a presentation location. After being moved by the CC machine tool to an insertion location adjacent to a hat-shaped stringer (31), a pair of cams (60a, 60b) located on opposite sides of the clip (23) are extended into the stringer cavity (25) and rotated to spread the stringer walls (27,29). Thereafter, the clip (23) is positioned in the stringer cavity (25). Then, the cams (60a, 60b) are rotated to a nonspread position, and clamp elements (49a, 49b, 51a, 51b) are actuated to press the walls (27, 29) of the stringer (31) against the clip (23). Next, drill bits (57a, 57b, 59a, 59b) that face the outer surface of the stringer walls (27, 29) are energized and moved toward the stringer walls. After holes are drilled through the stringer walls and the clip, the drill bits are withdrawn.

Abstract: A contact which is attached to a wire is fitted in a hole of a connector by first identifying the wire to which the contact is attached. The location of the hole that is to receive the contact is determined automatically from an electronic data lookup table, and a signal is provided which positions an end portion of a fiber optic rod in line with the correct hole of the connector. The opposite end of the fiber optic rod is optically coupled to a source of light. The fiber optic rod is advanced so that it enters the hole and projects from the opposite side of the connector identifying the correct hole. Light emitted from the fiber optic rod facilitates visual identification of the hole from which the rod is projecting. Therafter, the fiber optic rod is retracted, and the contact is inserted into the hole.

Abstract: Improvements in securing a blanket in place in vacuum bagging and like operations. Known systems for securing the blanket are cumbersome and time consuming and do not allow sufficient adjustment of the tension on the blanket. The system of the invention allows quick and easy attaching and detaching of the blanket, allows a wide range of adjustment of the tension, and does not require accurate alignment of the blanket. A strip (32) of net material is attached to a blanket (30) around the periphery of the blanket (30). A plurality of horizontally spaced pins (20) are secured to a lay-up structure (2) and positioned to extend downwardly and outwardly. The blanket (30) is placed over the structure (2) with the net (32) hanging down around pins (20). Net (32) is pulled over the free ends (22) of pins (20) to extend free ends (22) through holes (38) formed by the net structure. Tension may be adjusted by extending pins (20) through different holes (38).