Abstract: An airframe handling apparatus is operable to support and move a partially assembled aircraft fuselage. The aircraft fuselage is incomplete, lacking a wing and landing gear. The apparatus is attachable to the aircraft fuselage in place of the wing and landing gear, utilizing wing attachment structures on the aircraft fuselage that are designed for flight loads. With the aircraft fuselage attached to the apparatus, the entire fuselage is supported on the apparatus that can be operated to move and manipulate the aircraft fuselage as if the wing and landing gear were present. With the apparatus attached to the aircraft fuselage, movement of the fuselage by the apparatus imparts no handling-induced internal loads on the aircraft fuselage, and maximizes unobstructed access to the exterior surface of the fuselage for painting and other surface preparations.

Abstract: A method of manufacturing a wing assembly for joining to a fuselage of an aircraft includes the steps of loading a center wing section into a wing join station, loading a right wing section into the wing join station proximate to the center wing section, loading a left wing section into the wing join station proximate to the center wing section, joining the right and left wing sections to the center wing section to form a complete wing assembly, moving the complete wing assembly to a processing station, performing drilling operations on the complete wing assembly at the processing station, installing fasteners in the complete wing assembly at the processing station, and moving the complete wing assembly to a wing-body join station to join the complete wing assembly to the fuselage.

Abstract: A flay assembly for separating a workpiece from a manufacturing fixture has a horizontal beam assembly and a pair of vertical beam assemblies. The horizontal beam assembly includes a horizontal beam having a horizontal drive motor. Each vertical beam assembly includes a vertical beam operably engaged to the horizontal drive motor and has a workpiece attachment assembly operably engaged to a vertical drive motor. The workpiece attachment assembly has an attachment mechanism attachable to the workpiece. The horizontal drive motor and the vertical drive motors are operable in a manner to move the vertical beams away from each other along a horizontal drive axis while simultaneously moving each workpiece attachment assembly along a vertical drive axis to cause the attachment mechanisms to pull the workpiece side portions away from the manufacturing fixture while a center support of the horizontal beam maintains a workpiece crown in contact with the manufacturing fixture.

Abstract: An airframe handling apparatus is operable to support and move a partially assembled aircraft fuselage. The aircraft fuselage is incomplete, lacking a wing and landing gear. The apparatus is attachable to the aircraft fuselage in place of the wing and landing gear, utilizing wing attachment structures on the aircraft fuselage that are designed for flight loads. With the aircraft fuselage attached to the apparatus, the entire fuselage is supported on the apparatus that can be operated to move and manipulate the aircraft fuselage as if the wing and landing gear were present. With the apparatus attached to the aircraft fuselage, movement of the fuselage by the apparatus imparts no handling-induced internal loads on the aircraft fuselage, and maximizes unobstructed access to the exterior surface of the fuselage for painting and other surface preparations.

Abstract: An airframe handling apparatus is operable to support and move a partially assembled aircraft fuselage. The aircraft fuselage is incomplete, lacking a wing and landing gear. The apparatus is attachable to the aircraft fuselage in place of the wing and landing gear, utilizing wing attachment structures on the aircraft fuselage that are designed for flight loads. With the aircraft fuselage attached to the apparatus, the entire fuselage is supported on the apparatus that can be operated to move and manipulate the aircraft fuselage as if the wing and landing gear were present. With the apparatus attached to the aircraft fuselage, movement of the fuselage by the apparatus imparts no handling-induced internal loads on the aircraft fuselage, and maximizes unobstructed access to the exterior surface of the fuselage for painting and other surface preparations.

Abstract: A method and system for alleviating a load is provided. A support system is positioned at a nominal location with respect to an object. The support system comprises jacks and supports. Each of the supports is associated with one of the jacks. The object is positioned on the support system. The support system with the object is moved across a path. The height of each of the jacks is adjusted as the support system moves along the path to maintain a desired minimum load on each jack. Maintaining the desired minimum load prevents damage to the object.

Abstract: A flay assembly for separating a workpiece from a manufacturing fixture has a horizontal beam assembly and a pair of vertical beam assemblies. The horizontal beam assembly includes a horizontal beam having a horizontal drive motor. Each vertical beam assembly includes a vertical beam operably engaged to the horizontal drive motor and has a workpiece attachment assembly operably engaged to a vertical drive motor. The workpiece attachment assembly has an attachment mechanism attachable to the workpiece. The horizontal drive motor and the vertical drive motors are operable in a manner to move the vertical beams away from each other along a horizontal drive axis while simultaneously moving each workpiece attachment assembly along a vertical drive axis to cause the attachment mechanisms to pull the workpiece side portions away from the manufacturing fixture while a center support of the horizontal beam maintains a workpiece crown in contact with the manufacturing fixture.

Abstract: A fuselage cradle support assembly, which can be used as part of a jacking system during aircraft manufacture, is described. The fuselage cradle support assembly can include an array of fuselage cradles. The fuselage cradle support assembly can be configured to limit motion of each fuselage cradle in a cradle array to only vertical and horizontal movements. The vertical movements can be generated using actuators, such as hydraulic actuators, which are communicatively coupled to one another to distribute loads within the cradle array.

Abstract: A method is provided for establishing a physical reference inside an airplane representing the airplane's optimized line of flight based on the as-built orientation of aerodynamically significant features of the airplane. Values generated for aerodynamic pitch, roll and yaw representing the optimized line of flight are used to orient a tool reference surface outside the airplane. The orientation of the tool reference surface is recorded using an inertial reference unit placed on the tool reference surface. The tool reference surface and inertial reference unit are moved into the airplane where they are used to establish the physical reference on the airframe.

Abstract: A method is provided for establishing a physical reference inside an airplane representing the airplane's optimized line of flight based on the as-built orientation of aerodynamically significant features of the airplane. Values generated for aerodynamic pitch, roll and yaw representing the optimized line of flight are used to orient a tool reference surface outside the airplane. The orientation of the tool reference surface is recorded using an inertial reference unit placed on the tool reference surface. The tool reference surface and inertial reference unit are moved into the airplane where they are used to establish the physical reference on the airframe.

Abstract: A method is provided for establishing a physical reference inside an airplane representing the airplane's optimized line of flight based on the as-built orientation of aerodynamically significant features of the airplane. Values generated for aerodynamic pitch, roll and yaw representing the optimized line of flight are used to orient a tool reference surface outside the airplane. The orientation of the tool reference surface is recorded using an inertial reference unit placed on the tool reference surface. The tool reference surface and inertial reference unit are moved into the airplane where they are used to establish the physical reference on the airframe.

Abstract: A system for assembling aircraft is disclosed. An example system for moving components of an airplane into assembly alignment includes a jacking system including assembly jacks for supporting and moving components of the airplane into assembly alignment; a measurement system independent of the jacking system for determining locations of a plurality of features the components of the airplane while the components are supported on the assembly jacks; and a computer system for determining the relative positions of the components in a coordinate system of the airplane and for controlling the movement of the assembly jacks to bring the components into assembly alignment.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: A method is provided for establishing a physical reference inside an airplane representing the airplane's optimized line of flight based on the as-built orientation of aerodynamically significant features of the airplane. Values generated for aerodynamic pitch, roll and yaw representing the optimized line of flight are used to orient a tool reference surface outside the airplane. The orientation of the tool reference surface is recorded using an inertial reference unit placed on the tool reference surface. The tool reference surface and inertial reference unit are moved into the airplane where they are used to establish the physical reference on the airframe.

Abstract: A system automatically moves large scale components of a vehicle such as an airplane, into final assembly alignment. A noncontact measurement system determines the locations of aerodynamically significant features on each of the components. The measured locations of the components are used to control an automated jacking system that includes assembly jacks for individually moving the components into assembly alignment. A system is provided for calculating the cruise configuration of the vehicle “as-built” and for transferring the cruise configuration into the vehicle where it is recorded in the form of a physical monument.

Abstract: A device is disclosed for sensing information relating to the orientation of a selected direction or plane with respect to the horizontal. In one embodiment, the invention comprises a housing (40), a vial (70) mounting in the housing, a source of electromagnetic radiation (62, 64), sensors (66, 68) and associated electronic circuitry, and a rail (12) for positioning the housing. The vial is elongated along a central longitudinal axis and is partially filled with liquid (72) to form a bubble (74) in the vial. The source of radiation is positioned in a housing plane to one side of the vial such that radiation passes through the vial and forms a shadow of the bubble on the other side of the vial. The shadow is detected by the sensors, and the associated electronic circuitry produces an output signal having a characteristic related to the bubble position along the longitudinal axis.