Abstract: Provided are systems and apparatuses for manufacturing aircraft support structures. An example robotic end effector comprises a rotatable reel with a flat strip of material wound around the reel. The end effector further includes a forming shoe including a forming surface contacting the strip of material. A first end of the forming surface corresponds to a start shape and a second end of the forming surface corresponds to an end shape. As the strip of material passes from the first end of the forming surface to the second end of the forming surface, the strip of material transitions from the first shape to the end shape and is deposited as a formed stringer ply onto an application surface. The forming shoe may further include a vacuum system to suction air through a plurality of ports along the forming surface to urge the strip of material against the forming surface.

Abstract: A method implemented by a computing system that facilitates formation of an object from a material comprises receiving an object model that specifies a top surface and a side surface connected to an edge of the top surface via a fillet that extends along the edge. At a particular region along the edge, adjacent planar regions of the side surface define an obtuse angle therebetween. The fillet is adjusted along the edge to have a first radius at a particular distance from the particular region and to have a second radius, smaller than the first radius, proximate the particular region. Output data associated with an adjusted model is communicated to equipment configured to form a mandrel that facilitates formation of the object. Adjusting the fillet to have a smaller radius proximate the particular region facilitates elimination of wrinkles in the material when draped over the mandrel to form the object.

Abstract: A method performed by a computing system that facilitates formation of an object comprises receiving manufacturing process data associated with an object to be formed via a drape-forming operation. The computing system receives a parametric model of the object. The parametric model facilitates specification of a radius of a fillet within a region associated with the object. The computing system determines, based on the parametric model of the object, a unit vector field associated with a surface of the object and the manufacturing process data. The computing system adjusts the radius of the fillet of the parametric model within the region to reduce an average divergence of the vector field to a minimum amount, and communicates output data associated with an adjusted parametric model to equipment configured to form a mandrel that facilitates formation of the object.

Abstract: There is provided a mechanical avatar assembly for use in a confined space in a structure. The mechanical avatar assembly includes a rail assembly for attachment to an access opening to the confined space. The rail assembly includes two or more rail segments coupled together to form an elongated base having a rail and a gear rack extending along a length of the elongated base. The rail assembly further includes a carriage portion coupled to the rail, and movable relative to the rail, and a drive assembly coupled to the carriage portion and to the gear rack, to move the carriage portion along the rail. The mechanical avatar assembly further includes an articulating avatar arm coupled to, and movable via, the carriage portion. The mechanical avatar assembly further includes an image capturing device.

Abstract: An apparatus and its method of use provide a preload to the assembly of large structures, for example the assembly of an aircraft wing panel to an aircraft wing frame. The apparatus and its method of use preloads the aircraft wing panel of the aircraft wing structure and presses the aircraft wing panel against the aircraft wing frame of the aircraft wing structure, temporarily securing the aircraft wing panel against the aircraft wing frame and indexing the aircraft wing panel to the aircraft wing frame for the installation of permanent fasteners securing the aircraft wing panel to the aircraft wing frame.

Abstract: Provided are systems and apparatuses for manufacturing aircraft support structures. An example robotic end effector comprises a rotatable reel with a flat strip of material wound around the reel. The end effector further includes a forming shoe including a forming surface contacting the strip of material. A first end of the forming surface corresponds to a start shape and a second end of the forming surface corresponds to an end shape. As the strip of material passes from the first end of the forming surface to the second end of the forming surface, the strip of material transitions from the first shape to the end shape and is deposited as a formed stringer ply onto an application surface. The forming shoe may further include a vacuum system to suction air through a plurality of ports along the forming surface to urge the strip of material against the forming surface.

Abstract: Provided are systems and apparatuses for manufacturing aircraft support structures. An example robotic end effector comprises a rotatable reel with a flat strip of material wound around the reel. The end effector further includes a forming shoe including a forming surface contacting the strip of material. A first end of the forming surface corresponds to a start shape and a second end of the forming surface corresponds to an end shape. As the strip of material passes from the first end of the forming surface to the second end of the forming surface, the strip of material transitions from the first shape to the end shape and is deposited as a formed stringer ply onto an application surface. The forming shoe may further include a vacuum system to suction air through a plurality of ports along the forming surface to urge the strip of material against the forming surface.

Abstract: A structural assembly including a first structural member defining a first partial bore and including a first protrusion and a second protrusion, a second structural member defining a second partial bore and including a first protrusion and a second protrusion, wherein the second partial bore is aligned with the first partial bore to define a through-bore, a shaft extending through the through-bore, wherein the shaft includes a first end portion and a second end portion, a first engagement member proximate the first end portion, wherein the first engagement member engages both the first protrusion of the first structural member and the first protrusion of the second structural member, and a second engagement member proximate the second end portion, wherein the second engagement member engages both the second protrusion of the first structural member and the second protrusion of the second structural member.

Abstract: An apparatus and its method of use provide a preload to the assembly of large structures, for example the assembly of an aircraft wing panel to an aircraft wing frame. The apparatus and its method of use preloads the aircraft wing panel of the aircraft wing structure and presses the aircraft wing panel against the aircraft wing frame of the aircraft wing structure, temporarily securing the aircraft wing panel against the aircraft wing frame and indexing the aircraft wing panel to the aircraft wing frame for the installation of permanent fasteners securing the aircraft wing panel to the aircraft wing frame.

Abstract: Provided are stiffened stringer panels with integrated indexing stacks. An example composite panel comprises a skin member having an inner surface. An index for positioning a support tool comprises a first set and second set of layered laminate stacks coupled to the inner surface such that a channel is formed between the first and second set of layered laminate stacks. The first and second set of layered laminate stacks is configured to cradle a support tool in the channel to automatically align the support tool relative to the panel. A stringer may include a cap portion that extends from the first set to the second set of layered laminate stacks to form flange portions on the inner surface of the skin member. The index and the skin member may be co-cured or co-bonded.

Abstract: A structural assembly including a first structural member defining a first partial bore and including a first protrusion and a second protrusion, a second structural member defining a second partial bore and including a first protrusion and a second protrusion, wherein the second partial bore is aligned with the first partial bore to define a through-bore, a shaft extending through the through-bore, wherein the shaft includes a first end portion and a second end portion, a first engagement member proximate the first end portion, wherein the first engagement member engages both the first protrusion of the first structural member and the first protrusion of the second structural member, and a second engagement member proximate the second end portion, wherein the second engagement member engages both the second protrusion of the first structural member and the second protrusion of the second structural member.

Abstract: Provided are stiffened stringer panels with integrated indexing stacks. An example composite panel comprises a skin member having an inner surface. An index for positioning a support tool comprises a first set and second set of layered laminate stacks coupled to the inner surface such that a channel is formed between the first and second set of layered laminate stacks. The first and second set of layered laminate stacks is configured to cradle a support tool in the channel to automatically align the support tool relative to the panel. A stringer may include a cap portion that extends from the first set to the second set of layered laminate stacks to form flange portions on the inner surface of the skin member. The index and the skin member may be co-cured or co-bonded.

Abstract: A structural assembly including a first structural member defining a first partial bore and including a first protrusion extending from a periphery of the first partial bore on a first side and a second protrusion extending from the periphery of the first partial bore on a second side, a second structural member defining a second partial bore and including a first protrusion extending from a periphery of the second partial bore on a first side and a second protrusion extending from the periphery of the second partial bore on a second side, wherein the second partial bore is aligned with the first partial bore to define a through-bore, a first engagement member engaged with the first protrusions and a second engagement member engaged with the second protrusions, wherein the first and second structural members are clamped between the first and second engagement members.

Abstract: Provided are systems and apparatuses for manufacturing aircraft support structures. An example robotic end effector comprises a rotatable reel with a flat strip of material wound around the reel. The end effector further includes a forming shoe including a forming surface contacting the strip of material. A first end of the forming surface corresponds to a start shape and a second end of the forming surface corresponds to an end shape. As the strip of material passes from the first end of the forming surface to the second end of the forming surface, the strip of material transitions from the first shape to the end shape and is deposited as a formed stringer ply onto an application surface. The forming shoe may further include a vacuum system to suction air through a plurality of ports along the forming surface to urge the strip of material against the forming surface.

Abstract: A structural assembly including a first structural member defining a first partial bore and including a first protrusion extending from a periphery of the first partial bore on a first side and a second protrusion extending from the periphery of the first partial bore on a second side, a second structural member defining a second partial bore and including a first protrusion extending from a periphery of the second partial bore on a first side and a second protrusion extending from the periphery of the second partial bore on a second side, wherein the second partial bore is aligned with the first partial bore to define a through-bore, a first engagement member engaged with the first protrusions and a second engagement member engaged with the second protrusions, wherein the first and second structural members are clamped between the first and second engagement members.