Abstract: Apparatuses and methods for positioning an automated processing system, coupled with a track, are disclosed. The apparatus includes an automated chassis having drive, steering, elevation, and track-gripping components actuated by an onboard controller to permit the chassis to carry a processing system together with its track from one location to another about a work surface.

Abstract: A crawler assembly includes an attachment mechanism that is removably attachable to a stringer. The stringer has a vertical web and a longitudinal axis. The crawler assembly includes a longitudinal slider that is engageable to the attachment mechanism and having a normalizing mechanism disposable in bearing contact against the vertical web for maintaining an orientation of the longitudinal slider relative to the stringer. The longitudinal slider is movable along a direction parallel to the longitudinal axis. The crawler assembly includes a lateral slider that is mountable to the longitudinal slider and is movable along a direction perpendicular to the longitudinal axis. The lateral slider includes a drill bushing. The longitudinal and lateral sliders cooperate to move the drill bushing to at least one predetermined hole location.

Abstract: A self-contained crawler assembly is engageable to a stringer and is adapted to position a drill bushing along the stringer for performing machining operations. The crawler assembly includes a longitudinal slider, a lateral slider and a controller for regulating operation of the longitudinal and lateral sliders for positioning the drill bushing at a hole location. In a further embodiment, the crawler assembly may include a longitudinal friction drive which is directly engageable to the stringer and which is operative to move in a direction parallel to the stringer.

Abstract: A self-contained crawler assembly is engageable to a stringer and is adapted to position a drill bushing along the stringer for performing machining operations. The crawler assembly includes a longitudinal slider, a lateral slider and a controller for regulating operation of the longitudinal and lateral sliders for positioning the drill bushing at a hole location. In a further embodiment, the crawler assembly may include a longitudinal friction drive which is directly engageable to the stringer and which is operative to move in a direction parallel to the stringer.

Abstract: Methods and apparatus for counterbalanced manufacturing operations are disclosed. In one embodiment, an assembly includes a base, a tool support assembly, and a biasing device. The tool support assembly includes a first component coupled to the base and a second component moveable along a translation axis relative to the first component. The second component is configured to be coupled to a tool operable to perform the manufacturing operation on a workpiece. The biasing device includes a first portion coupled to the first component, a second portion coupled to the second component, and a control component. The first and second portions are moveably coupled and configured to apply a biasing force to the second component to at least partially counterbalance a force exerted on the second component along the translation axis by a weight of the tool support assembly and the tool during performance of the manufacturing 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: 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: 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: 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: Methods and apparatus for counterbalanced manufacturing operations are disclosed. In one embodiment, an apparatus for supporting a tool relative to a surface of a workpiece includes a base adapted to be attached to the workpiece, a tool support coupled to the base, and a biasing device coupled to both the base and the tool support. The tool support is moveable relative to the base along a translation axis, and the biasing device is biasable along a biasing axis that is at least partially along the translation axis. The biasing device is adapted to at least partially counterbalance a force (e.g. a gravitational force) exerted on the tool support along the translation axis.

Abstract: Apparatus and methods for servo-controlled manufacturing operations are disclosed. In one embodiment, an apparatus includes a base member, a drive platform spaced apart from the base member by a separation distance, and a plurality of guide members extending between the drive platform and the base member. At least one of the drive platform and the base member are moveable along the guide members to increase or decrease the separation distance. The apparatus also includes a drive member operatively coupled between the drive platform and the base member, and a servo motor operatively coupled to the drive member. As the servo motor drives the drive member, the separation distance is varied. In an alternate embodiment, a manufacturing tool may be coupled to at least one of the drive platform and the base member.

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.

Abstract: Apparatus and methods for manufacturing operations using non-contact position sensing are disclosed. In one embodiment, an apparatus includes a track assembly adapted to be attached to a workpiece, a carriage assembly moveably coupled to the track assembly and moveable relative to the workpiece, and a position sensor. The position sensor includes a sensor element adapted to detect at least one edge of an index feature on the workpiece from a distance away from the index feature. In an alternate embodiment, the position sensor may include a sensing circuit that receives an analog signal from the sensing element and provides both analog and digital output signals. In another embodiment, a controller that controls manufacturing operations may be mounted directly on the carriage assembly.

Abstract: Methods and apparatus for manufacturing operations using opposing-force support systems are disclosed. In one embodiment, an apparatus includes a track assembly adapted to be attached to a workpiece, and a carriage moveably coupled to the track assembly. The carriage includes a tool support adapted to receive and support a manufacturing tool. An opposing-force support assembly is operatively coupled to the carriage and is adapted to be secured to the workpiece. The opposing-force support assembly at least partially counterbalances a manufacturing force exerted on the workpiece by the manufacturing tool.

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: Apparatus and methods for manufacturing operations using non-contact position sensing are disclosed. In one embodiment, an apparatus includes a track assembly adapted to be attached to a workpiece, a carriage assembly moveably coupled to the track assembly and moveable relative to the workpiece, and a position sensor. The position sensor includes a sensor element adapted to detect at least one edge of an index feature on the workpiece from a distance away from the index feature. In an alternate embodiment, the position sensor may include a sensing circuit that receives an analog signal from the sensing element and provides both analog and digital output signals. In another embodiment, a controller that controls manufacturing operations may be mounted directly on the carriage assembly.

Abstract: A flexible track drilling machine employs a pair of rails that are flexible in one direction to conform to a non-flat workpiece surface and are substantially stiff in a direction parallel to the workpiece surface. The rails are attached to the workpiece by vacuum cups spaced along each rail. An X-axis carriage is slidably mounted on the rails by rollers mounted on flexible spring plates affixed to the carriage. A drill or other device to be positioned is mounted on a Y-axis carriage that is slidably connected to the X-axis carriage. The three-dimensional surface of the workpiece is mathematically transformed into a two-dimensional flat pattern, and the positioning of the carriages is controlled based on the flat pattern.

Abstract: A workpiece is assembled by removably mounting an alignment tool to a conventional wing structure so that the alignment tool holds multiple conventional strut fittings to the wing structure. A frame of a CNC manufacturing machine is moved to and removably mounted to the workpiece. The orientation of the workpiece with respect to the frame mounted thereto is quantified. A predetermined pattern of operations to be performed by the CNC manufacturing machine to form attachment holes for use in attaching the strut fittings to the wing structure is adjusted to compensate for the orientation of the workpiece relative to the frame. Thereafter, the CNC manufacturing machine automatically forms the attachment holes.