Abstract:
An improved method and automated apparatus provides for the automated surface finishing of aircraft panels, which includes a central controller, a universal shuttle for transporting aircraft panels, scanning means and a panel surface processor moveable about a plurality of axes to present a plurality of surface finishing tools to act upon the panel is disclosed herein.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to an improved automated method and apparatus for finishing aircraft panel surfaces and more particularly to an improved automated method of aircraft surface finishing for aircraft wings and fuselage.  
         BACKGROUND OF THE INVENTION  
         [0002]    Conventional surface finishing of aircraft panels, such as fuselage and wing panels is typically accomplished through manual sanding, polishing and other related processes. Traditional machining and forming processes include creep forming, hot forming, break forming, stretch forming, shot peen forming and super elastic forming which typically require surface improvement techniques in order to remove burrs, parting lines, scratches, tool marks and the like in order to reduce surface roughness.  
         SUMMARY OF INVENTION  
         [0003]    In a first preferred embodiment according to the present invention, there is provided an apparatus for surface finishing of aircraft panels comprising a retaining means for retaining a panel to be processed, a surface panel processing means for acting on a panel retained by the retaining means, the surface processing means being movable about a plurality of axes relative to the panel to present the processing means to act on the surface contour of the panel, means for effecting relative movement between the retaining means and the surface processing means and control means for controlling said surface panel processing means in combination with said means for effecting relative movement.  
           [0004]    In another embodiment according to the above, wherein the device further includes scanning means.  
           [0005]    In another embodiment having the above structures, the scanning means includes panel scanning means to for scanning for surface anomalies, wherein the scanning means is adapted to generate an output control signal to actuate and control the surface finishing means whereby the finishing means is actuated to correct the surface anomalies.  
           [0006]    In another embodiment according to any of the above structures, there is provided means to generate a first control signal relative to different locations of anomalies on the panel, the output control signal being adapted to control relative movement between the finishing means and the mounted panel for positioning the finishing means at different locations about the panel.  
           [0007]    In a second embodiment according to the present invention, there is provided an improvement in a method of surface finishing of an aircraft panel comprising providing an aircraft panel to be surface finished, mounting the panel in a fixed position, providing finishing means for surface finishing the panel, effecting relative movement between the finishing means and the mounted panel, in which the improvement includes the steps of detecting surface anomalies in the panel, generating a data-input control signal based on the surface anomalies; and generating a data output control signal to actuate the finishing means to act on the anomalies.  
           [0008]    In another embodiment, there is provided a method according to the above wherein the improvement includes the steps of scanning a defined area of the panel with scanning means to generate the data input control signal relative to the surface anomalies, and generating an output control signal to actuate and control the finishing means whereby the finishing means is actuated to correct the surface anomalies.  
           [0009]    In another embodiment there is provided a method according to any of the above methods wherein the improvement includes the step of generating a first control signal relative to different locations of anomalies on the panel, the output control signal being adapted to control relative movement between the finishing means and the mounted panel for positioning the finishing means at different locations about the panel.  
           [0010]    In any ofthe above embodiments, suitable scanning means and control means are utilized as are known in the field. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 is a side perspective view of an automated surface finishing device according to one embodiment of the present invention.  
         [0012]    [0012]FIG. 2 is a perspective view from one end of an alternative arrangement of a preferred embodiment showing the device in use, and  
         [0013]    [0013]FIG. 3 is a flowchart illustrating the central controller processes. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0014]    With reference to the drawing figures, there is illustrated a preferred form of a device for the automated surface finishing of aircraft panels depicted generally by reference numeral  10 . The device includes a controller  20 , a universal shuttle  30 , a scanning device  40  and a robotic surface processor  50 .  
         [0015]    In a preferred embodiment, the device includes a controller or programmable control means  20  housed in a conventional housing. Desirably, the controller utilizes programmable logic controllers which are adapted to control all machine components such as motor speed, part position surface finish pre and post sanding, trolley speed or shuttle speed and the like.  
         [0016]    In a preferred embodiment, the device  10  includes a universal shuttle tool  30  adapted to position and retain in position an aircraft panel or parts  100  to present a surface of the panel  100  to be finished by the surface processor or robot  50 . Universal shuttle tool  30  preferably includes a trolley or the like including retaining means such as conventional grips  32  or locking members adapted to support an aircraft panel  100 . The retaining means such as a grip device  32  are adapted to hold various sized and shaped panels or parts  100  providing mechanical support and presenting the component to the surface processing robot or manipulator. The universal shuttle  30  typically moves laterally in front of the robot although the aircraft panel may be held by the shuttle  30  in a stationary position thus requiring the robot to move laterally.  
         [0017]    The scanning device or sensor means  40  as illustrated in FIG. 1, that may be a moveable or stationary sensor or scanner is adapted to allow for the passage of the part or panel  100  through the sensor or scanner  40  to verify the panel geometry. Such a sensor or scanner would typically include a laser or other suitable scanning device to scan the surface to detect surface anomalies and generate a data-input signal to the controller  20 , which can then generate a data output signal in order to guide the robot  50  and associated end effector tools to act on the anomalies.  
         [0018]    Surface finish sensors or scanning means  40  would, in a preferred embodiment, desirably include sensors or the like that are able to pole or measure panel or part  100  skin surfaces in a real time fashion over the cord width ofthe panels  100 . Desirably, such measurement is accomplished pre and post sanding as the part or panel  100  enters and or leaves the device  10 . Most desirably, the sensors or scanner mean  40  would generate output data via which the controller  20  would adjust the tools  80  associated with end effector  60  accordingly to the set recipe and limits for each part or panel  100 . Additionally, graphical reporting may be effected for pre and post panel surface roughness.  
         [0019]    The robot or surface processor  50  according to the present invention may be, in one embodiment, a computer controlled robot able to sense, grip and move objects. The robot or surface processor  50  is controlled via the controller  20  which allows the surface processor to accomplish numerous functions. According to a preferred embodiment, the surface processor or robot  50  includes a first arm member  52 , pivot means  53 , a second arm  54  having at one end an end effector  60 , and tool means or end effector tool  80 .  
         [0020]    Tools  80  can include, but are not limited to, surface finishing tools, such as sanding heads and associated drives for sanding and buffing heads, i.e. electrical motors or the like. Control of the head or tool  80  pressure on the part or panel  100  will be dictated by sensor means  40  adapted to provide sufficient pressure.  
         [0021]    The robot or surface processor  50  is adapted to move about in a plurality of axes with respect to the panel  100  thereby allowing the end effector  60  and the tool means  80  to act upon the entire surface contour of the panel  100 . The robot or surface processor  50  is adapted to use and automatically exchange a plurality of tools  80  mounted to the end effector  60 , such as sanding and polishing tools, and apply the abrasive materials of the tools  80  to the panel surface for material removal as appropriate.  
         [0022]    In use, the robot end effector  60  follows the contour of the panel through programming derived from the controller  20  and initially from the scanner  40 . Desirably, this information is derived from a CAD panel or parts geometry data, on-line scanning data and or an operator teach mode of a specific panel geometry. Control of the end effector  60  may involve feedback and control of data and relevant information, including displacement, speed, force and other associated variables. These variables are derived from the scanner or sensor means  40  passed to the controller  20  through any suitable conventional means.  
         [0023]    In use, the panel or part  100  is connected to and supported by the universal shuttle  30  and associated gripping or locking means  32 . The operator or automated controller co-ordinates all surface processor or robot  50  movements and part or panel  100  movements ,and establishes feedback with scanning devices  40  for pre and post processing panel geometry, surface finish, temperature and the like information. The information is processed and the appropriate tool, for example a sanding head, is selected and placed onto the end effector  60  for use on the surface contour of the panel  100 . The robot or processor means then presents the end effector  60  and tool head  80  to the panel surface  100  for material removal. The robot  50  may select a pre-determined tool  80  to act on the surface contour of the part or panel  100 . Sensor or scanner means  40  measure surface roughness, temperature and the like of the panel or part  100  during material removal and establishes feedback of data which thus permits the robot  50  to present select tools  80  to improve surface finish.  
         [0024]    In an alternative embodiment as illustrated in FIG. 2, there is provided a device  200  according to this invention which includes a controller  220 , panel support members  230  and  232 , a scanning device  240 , and a surface processor or robot  250  including an end effector  260 .  
         [0025]    As illustrated in FIG. 2, the panel or part  200  is positioned on supports  230 . Supports  230  are adapted to maintain the panel  200  in a position suitable for the surface processor  250  to effectively present the end effector  260  and tools  280  onto the surface of the panel  200  for material removal. A controller  220  is adapted to control the movement of all panel or parts  200 , robot  250  and end effector tools  280  by establishing or conforming the programmed panel geometry and guiding robot  250 .  
         [0026]    The robot  250  may be mounted onto tracks  300  or the like in order to allow the robot to travel along the length of the part  200 . Supports  320  or the like are provided and controlled by the controller  220 . The robot or surface processor  250  includes an end effector  260  having an end effector tool  280  adapted for surface finishing of the panel surface.  
         [0027]    In an alternative embodiment, sensor means  240  may include the use of temperature sensors or scanners to monitor part or panel  200  temperature during material removal, and optical acoustic and laser sensors to measure surface roughness of the panel or part  200  before and or after processing. As shown in FIG. 2, the sensors  240  may be mounted on the robot arm  254 . A central controller  220  and operator interface is used to coordinate all part  100  and robot  250 , and end effector tool  280  movements.  
         [0028]    In a further alternative embodiment, the controller  220  allows for operator input for part identification and processing requirements, and establish feedback with scanning devices for geometry, temperature, surface finish and the like whereby the panel geometry is verified suitable scanning devices to establish or conform the programmed panel geometry and guide the robot  250  and effector tools  280 .  
         [0029]    In various alternatives embodiments, sensor means  40  may be adapted to include a range of scanners and sensors, such as for measuring temperature. In use, temperature sensing means would be able to interpret, report graphically and adjust itself in real time fashion so that temperatures of the part or panel  1000  where a contact with a sanding head  80  occurs does not surpass the critical temperature of the material and set points entered within a specific part recipe, such as set forth in CAAI-FAA requirements, having ranges are between 50 to 250 degrees Fahrenheit.  
         [0030]    In another alternative embodiment, additional robots or surface processors may be positioned within the device  10  to surface finish both sides of the panel  100  or  200  with specialized tools, and in tandem to speed part or panel  100  or  200  throughput.  
         [0031]    In a further alternative embodiment, head pressure may be controlled through air pressure or other like drive means.  
         [0032]    In various versions according to the present invention, the device  10  may include dust containment and removal means for integral dust generated through panel surface finishing operations in a manner as would be readily understood by a person skilled in the art.  
         [0033]    In various embodiments, the aircraft panel  100  or  200  to be finished includes conventional aircraft panels, wings, fuselage and the like.  
         [0034]    Although embodiments of the invention have been described above, it is not limited thereto and it will be apparent to those skilled in the art that numerous modifications form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention.