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 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: 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 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: 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: 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 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 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.

Abstract: An electromagnetic coil assembly particularly suited for use in high-acceleration impact devices includes an inner hub having a flat metal and dielectric strip wound thereabout to form a coil, and an outer body mounted about the inner hub against one side of the coil. Inner and outer coil leads are formed by flat 90° bends of the inner and outer ends of the coil strip, such that the coil leads extend axially away from the coil toward one end of the coil assembly. Recesses are formed in the end faces of the inner hub and outer body at this end of the assembly, and the coil leads are folded into these recesses and attached by lug connectors to a pair of electrical conductors that lead out the side of the coil assembly. The coil leads and conductors are secured in the recesses, preferably by potting them in place.

Abstract: One side of an access panel is trimmed while an opposite side of the panel is secured in an opening between skin sheets on the underside of an aircraft wing. The trimming apparatus includes a frame secured to one of the skin sheets with a rail extending along an edge of the opening and a trim saw assembly slideable along the rail. The frame can be secured in position by several vacuum cups, and can include index flanges engageable against an edge of the opening for precise positioning of the rail and the trim saw assembly carried thereby.

Abstract: An electromagnetic coil assembly particularly suited for use in high-acceleration impact devices includes an inner hub having a flat metal and dielectric strip wound thereabout to form a coil, and an outer body mounted about the inner hub against one side of the coil. Inner and outer coil leads are formed by flat 90° bends of the inner and outer ends of the coil strip, such that the coil leads extend axially away from the coil toward one end of the coil assembly. Recesses are formed in the end faces of the inner hub and outer body at this end of the assembly, and the coil leads are folded into these recesses and attached by lug connectors to a pair of electrical conductors that lead out the side of the coil assembly. The coil leads and conductors are secured in the recesses, preferably by potting them in place.

Abstract: An apparatus for assembling panel-shaped workpieces such as aircraft wing panels includes a traveling gantry that supports a tool-holding frame on which are supported a plurality of tools such as drills, riveters, rivet shavers, inspection tools, and the like. The frame is movable along a plurality of axes and is rotatable about at least one axis for positioning the tools in relation to the workpiece. The apparatus also includes a fixture for holding a workpiece, the fixture comprising a plurality of slidable holders that can be extended or retracted along a horizontal direction generally perpendicular to the surfaces of a wing panel or the like. The holders have clamps and/or vacuum cups for engaging the workpiece to hold the workpiece in a desired position. The holders are retractable to create a clearance between the workpiece and the holders to allow the frame to be passed through the clearance.

Abstract: A controller, for use with a fastener installation apparatus having a primary turret tooling head and an opposed reactionary tooling head, includes a data acquisition computer and several servomotors controlled by the computer for operatively connecting the computer to the primary tooling head turret for rotatably positioning the turret, and actuating the tools. The servo operated drive systems are computer operated and numerically controlled to position the turret relative to the work piece for accurate and repeatable positioning of the tools on the turret over the desired location of the hole without sacrificing desirable machine rigidity for some fastening operations. The system includes programming means operable to cause the computer to rotate the primary turret tooling head and actuate the tools using the computer numerically controlled servo motors for remotely controlling both the linear carriage position, the turret angular rotation, and actuation of the tools.

Abstract: The present invention relates to a pressure foot that applies a clamping pressure to an area undergoing drilling or fastening operations on a joint formed by a first panel and a second panel. The pressure foot includes a front clamp for pressing against a front side of the area undergoing the drilling or fastening operations, and a carriage for moving the front clamp along a length and width of the joint formed by the first panel and the second panel.

Abstract: The present invention relates to a tool position detection assembly that aligns a tool relative to a feature within a lap joint of a first panel and a second panel. The detection assembly includes an indexing device engageable to the feature. The indexing device includes a reflecting member having a width. The assembly also includes an end-effector movable along at least one axis parallel to the lap joint for positioning the tool. The end-effector has a dual laser device for detecting when the device is aligned with the reflecting member.

Abstract: The present invention relates to vacuum fastened guide that supports and facilitates movements of a machining device along at least one component to be operated upon. The guide includes a primary rail that is vacuum coupled to the component. The primary rail includes a primary tube portion for slideable engagement with the machining device, and a primary contact platform coupled to the primary tube portion for forming a vacuum between the primary rail and the component.

Abstract: The present invention relates to a bucking bar that upsets a shank of a rivet. The bucking bar includes an L-shaped bucking die having a wide section and a thin angular section capable of sliding between an obstacle and the shank. The L-shaped bucking bar consists of Tungsten Carbide. The bucking bar also includes a bucking bar arm coupled to the wide section of the L-shaped bucking die for positioning the thin angular section of the bucking die between the obstacle and the shank of the rivet.

Abstract: The present invention relates to a bucking bar assembly that positions a bucking bar for clamping a first panel and a second panel along a lap joint and upsets a rivet to fasten the first panel to the second panel at the lap joint. The assembly includes a lateral carriage system for moving the bucking bar along a length of the lap joint, and a rotational carriage system for rotating the bucking bar relative to the lateral carriage.