Abstract:
A portable programmable machine enhances efficiency and ergonomics associated with conducting otherwise manual operations within confined spaces. A main body supports a programmable telescoping arm configured to extend through an access port to reach a confined space. The arm includes an articulating wrist for holding and manipulating tools for autonomously processing work parts. The machine can also act semi-autonomously to accommodate interventions of an operator for overriding and fine-tuning interaction of a tool with a work part for proper processing of the part. The arm communicates with a computer in the main body for processing numerical data, and the operator may use a reference camera to fine tune any particular process. The machine incorporates multiple processing functions, for example collar swaging, nut running, cleaning, and/or application of sealants, all through an aircraft wing access port. The main body has lockable wheels for securing the main body near the access port.

Description:
FIELD 
       [0001]    The present disclosure relates generally to portable autonomous and/or semi-autonomous machines that facilitate automation, and more specifically to using such machines for enhancing manufacturing efficiencies, while reducing ergonomic injury risks often associated with manual operations conducted within confined spaces. 
       BACKGROUND 
       [0002]    Although construction of modern aircraft has generally become more efficient and cost-effective, there are portions of aircraft structures for which manufacturing processes remain challenging. One of these involves completion of physical work within aircraft wing interiors by technicians. The latter is commonly associated with finalizing spar and rib securement via fasteners to wing panels and/or panels within interior portions of wings. Such access, required for swaging of collars and torquing of nuts to bolts, may also include cleaning of cutting oils from wing panel interiors, and application of sealants to interior portions of aircraft wings. This work has involved technicians having to climb into and maneuver within confined spaces, exerting themselves in ergonomically stressful ways, resulting in occasional sprains, strains, over-extension injuries. 
       SUMMARY 
       [0003]    In accordance with the present disclosure, a portable programmable machine is configured to replicate certain manual operations within confined spaces. The machine has a counterbalanced telescoping arm and a main body that supports functions of the counterbalanced telescoping arm. An unsupported free end of the arm has an articulating wrist configured to hold and manipulate a tool for processing at least a portion of a work part. 
         [0004]    In accordance with the present disclosure, the machine is semi-autonomously operable to accommodate intervention by an operator for overriding and fine-tuning interaction of the tool with the work part for processing. 
         [0005]    In accordance with the present disclosure, the main body includes an on-board rechargeable battery, a battery-operated power system, and a programmable computer configured to process numerical data and for communication with and control of movements of the arm and wrist, and a reference camera is employed in real-time by the operator to fine tune processing of the work part. 
         [0006]    In accordance with the present disclosure, a system defined by a plurality of programmable counterbalanced telescoping arms includes each arm independently configured to replicate a sequence of manual operations within a confined space defined by a cavity on one side of an access port. Each arm acts autonomously, and each is portably supported on a perimeter lip of an associated access port, each arm extending into the confined space. 
         [0007]    In accordance with the present disclosure, each arm has a portable main body situated outside of the cavity; i.e. on an opposite side of the access port, and each arm has a free end including an articulating wrist configured to hold and manipulate a tool for processing a work portion situated within the confined space. 
         [0008]    In accordance with the present disclosure, each arm is also semi-autonomously operable to accommodate intervention by an operator for overriding and for fine-tuning interaction of the tool with the work part for processing the work portion. 
         [0009]    In accordance with the present disclosure, each main body includes an on-board rechargeable battery, a battery-operated power system, and a programmable computer configured to process numerical data for communication with and control of movements of the arm and wrist, and a reference camera is employed in real-time by the operator to fine tune the processing of the work portion. 
         [0010]    In accordance with the present disclosure, a method of processing of an interior cavity of an aircraft wing, includes the steps of placing a first telescoping arm through a wing access port, and securing the arm to a perimeter lip of the access port; configuring a main body to support and counterbalance the telescoping arm; forming a wrist on an unsupported end of the arm; configuring the wrist to have an articulating motion, and adapting the wrist to hold and manipulate a set of preselected tools for processing at least a portion of a work part within the cavity. 
         [0011]    In accordance with the present disclosure, the method includes additional steps of installing an on-board rechargeable battery, a battery-operated power system, and a programmable computer configured to process numerical data for communication with and control of movements of the arm and wrist; operating the arm semi-autonomously to accommodate intervention by an operator for overriding and fine-tuning interaction of the tool with the work part for processing; and securing a reference camera to the wrist for use by the operator to fine tune the processing of the work part. 
         [0012]    The features, functions, and advantages disclosed herein can be achieved independently in various embodiments or may be combined in yet other embodiments, the details of which may be better appreciated with reference to the following description and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a partial perspective view of an aircraft wing, vertically supported on an assembly jig, depicting legs and feet of a technician (not shown) extending from an access port of the wing. 
           [0014]      FIG. 2  is a perspective view of a programmable work machine, supported on the assembly jig of  FIG. 1 , the work machine configured in accordance with the present disclosure. 
           [0015]      FIG. 3  is another perspective view of the programmable work machine, apart from the assembly jig. 
           [0016]      FIG. 4  is yet another perspective view of the programmable work machine. 
           [0017]      FIG. 5  is a perspective view of an elbow portion and extended telescoping arm of the programmable work machine of  FIGS. 2-4 , the free end of the arm including an articulable wrist. 
           [0018]      FIG. 5A  is a perspective view of the wrist of the telescoping arm, oriented to reveal a face of the wrist, configured for attachment of various tools. 
           [0019]      FIG. 6  is a view of the free end of the telescoping arm, depicting a swage gun tool secured to the wrist face. 
           [0020]      FIG. 7  is another view of the free end of the telescoping arm, depicting a nut driving gun secured to the wrist face. 
           [0021]      FIG. 8  is another view of the free end of the telescoping arm, depicting a cleaning tool secured to the wrist face. 
           [0022]      FIG. 9  is another view of the free end of the telescoping arm, depicting a sealant tool secured to the wrist face. 
           [0023]      FIG. 10  is a cross-sectional view of a horizontally oriented aircraft wing, depicting an interior wing cavity between a rear and forward spar, with the elbow and telescoping arm portions of the programmable work machine supported within a perimeter lip of an access port of the wing. 
       
    
    
       [0024]    It should be understood that referenced drawings are not necessarily to scale, and that disclosed embodiments are illustrated only schematically. Aspects of the disclosed embodiments may be combined with or substituted by one another, and within various systems and environments that are neither shown nor described herein. As such, it should be understood that the following detailed description is merely exemplary, and not intended to be limiting in either application or use. 
       DETAILED DESCRIPTION 
       [0025]    The following detailed description addresses both apparatus and methods for carrying out the disclosure. Actual scope of the disclosure is as defined by the appended claims. 
         [0026]    In  FIG. 1 , a lower panel  146  of an aircraft wing  10  is shown oriented vertically during final processing of its interior portions. The lower panel  146  has a plurality of access ports  12 , each incorporating a perimeter lip  13 , further described below. A vertical support  14  of an assembly jig (not shown) is configured to retain the aircraft wing  10  vertically, as shown. During final processing, a technician accesses the interior (not shown in  FIG. 1 ) of the wing for various finishing operations to be described. In  FIG. 1 , legs  16  and feet  18  of the technician are shown extending from an access port  12 , over a walkway  20  of the assembly jig, and to a foot rest table  22  positioned on the walkway, while head and torso (neither shown) of the technician are situated within the interior of the wing  10 . 
         [0027]    Referring now to  FIG. 2 , a programmable work machine  30  is situated on the walkway  20 , and is configured for accessing the interior  15  of the wing  10  through the access ports  12 , instead of requiring such access by the technician. Thus, instead of having to physically work within the interior  15  of the wing  10  as shown in  FIG. 1 , the technician, or operator, can remain physically outside of the wing, on the walkway  20 , to manage various work machine functions, described below. To facilitate its manipulation, the machine includes a movable arm support  32 , a main body, or cart-style base,  34  having a frame  36 , and supported by lockable wheels  38  to accommodate portable movement of the work machine  30  along the walkway  20 . 
         [0028]    For purposes of this disclosure, the interior  15  of the wing  10  ( FIG. 2 ) is defined as a “confined space”, to the extent that a technician cannot stand tall or fully erect within such space. As a result, the technician must bend or contort his or her body in order to be able to physically access a work part within the space. Indeed, the wing  10  includes a plurality of “confined spaces” in accordance with this definition. 
         [0029]    Stored within the main body  34  is a rechargeable battery  42  configured to render the programmable work machine  30  fully autonomous. Also included within the main body  34  are a computer  44  and a hydraulic pump  46 , both powered by the rechargeable battery  42 . A compressed air cartridge  48  may also be included for a solvent-based cleaning operation to be described. All of the latter components are shown in phantom, and will be variously further described below. 
         [0030]    Referring now also to  FIG. 3 , the work machine  30  also includes a fixed arm support  40  configured to support the movable arm support  32 . Although shown vertically oriented in the arrangement disclosed, the fixed arm support  40  may have alternative configurations, as those skilled in the art will appreciate. The movable arm support  32  is configured to provide a zero gravity-style motion to facilitate placement and support of a portable work module  50  of the work machine  30  in any one of the access ports  12  ( FIG. 2 ). Referring now also to  FIG. 4 , versatility of movement of the arm support  32  for accommodating placement of the portable work module  50  may be appreciated, as the portable work module  50  is shown in  FIG. 4  to be positioned vertically lower with respect to the base  34 , as well as laterally spaced from the base  34 , as compared to its position in  FIG. 3 . 
         [0031]    Referring now particularly to both  FIGS. 3 and 4 , the portable work module  50  incorporates a telescoping arm  52 , shown in a fully retracted state. A collar  54  is provided as a “locator ring” on the portable work module  50 , and is thus configured for securing the work module  50  within an access port  12  for work to be performed within confined spaces of the aircraft wing  10 , as described below. Referring now also to  FIG. 5 , the portable work module  50  is shown with the telescoping arm  52  in a fully extended state, which may be selectively achieved once the work module has been secured within an access port  12 . As was noted earlier, the portable work module  50  is supported on a zero gravity arm to facilitate its secure placement within the perimeter lip  13  of any one of the access ports  12  ( FIG. 2 ). For such purpose, the portable work module  50  incorporates an elbow portion  56  having handles  58 , as shown, for “zero-gravity” placement by the operator. 
         [0032]    Once the collar  54  of the portable work module  50  has been “locked” onto the perimeter lip  13  of an access port  12 , the location of the work module  50  is registered in memory of the computer  44  as a reference for physical movements of the telescoping arm to be carried out with respect to that particular operation, as further explained below. 
         [0033]    For purposes of locking the collar  54  in place within any particular perimeter lip  13 , the collar includes a plurality of spaced locator locks  51  and locator stops  53  about its periphery, as shown in  FIG. 5 . The operator inserts the collar  54  axially into a perimeter lip  13  with the locator locks  51  retracted. Upon full insertion, any further movement of the collar  54  is arrested by the locator stops  53 . The locator locks  51  are then extended to engage the collar  54  securely between the locator locks and stops  51 ,  53 . Registration of the referenced location of the machine  50  is a process that is repeatable every time, and for every access port  12  utilized by the machine  50 . 
         [0034]    Continuing reference to  FIG. 5 , pump-powered hydraulic actuators  60  include hydraulic motors  61  for providing computer controlled movements of a telescoping actuator  62  for selectively extending the telescoping arm  52  over a distance of up to several feet. Thus, from its retracted position, shown in  FIGS. 3 and 4 , various sections,  52 A,  52 B,  52 C, and  52 D, of the telescoping arm  52  move along telescoping arm guide rails  64  to accommodate full extension thereof. At the free end,  52 D, of the telescoping arm  52  is a wrist  70  which is movable translationally, pivotally, and rotationally along horizontal axes X and Y, as well as vertical axis Z, all orthogonally depicted in  FIG. 5 . As also depicted in both  FIGS. 5 and 5A , a wrist face  72  is configured to receive various tool attachments to be described. 
         [0035]    Continuing reference to  FIG. 5 , selective movements of the wrist  70  are effected by a series of motors, including a yaw rotation motor  74 , a pitch rotation motor  76 , and a roll rotation motor  78 , as will be appreciated by those skilled in the art. Each of the referenced angular movements occurs along at least one of the X, Y, and Z axes of  FIG. 5 . 
         [0036]    Referring now to  FIGS. 6-9 , various tools may be utilized to conduct various finishing operations within the interior  15  of the aircraft wing  10 . For example, referring specifically to  FIG. 6 , a swage gun  80  is shown secured to the wrist  70 . The swage gun  80  may be used to force-fit a collar member to the shank of a pin member to form a permanent connection, for example in the securement of a spar and/or stringer to a wing panel, as those skilled in the art may appreciate. Since the process requires removal of pintails, a pintail extractor  82 , collar holding fingers  84 , a collar feeder mechanism  88  and a collar and pintail storage bay  90 , comprise distinct parts of the swage gun tool assembly. During a swaging operation, a technician may also utilize a vision reference camera  86 , shown secured to the swage gun  80 , for making minor positioning adjustments, or for overriding a particular computer-based program, for example. 
         [0037]    Referring now to  FIG. 7 , a nut driving gun  100  is shown secured to the wrist  70 , instead of the swage gun  80  (of  FIG. 6 ). The nut driving gun  100  contains nut holding fingers  102 , a nut feeder mechanism  104 , and a nut storage bay  108 , for securing nuts to pre-attached bolts, for example, in various portions of the interior work space. The nut driving gun  100  may also incorporate a vision reference camera  106  for accommodating manual intervention by a technician. Referring now to  FIG. 8 , a cleaning tool  120  may include a cleaning solvent storage tank  122 , a set of active wiping and/or scrubbing brushes  124 , and a set of clean/replacement brushes  126 . Each of the tools as described may be embodied in modular cartridges that can be interchangeably secured to the wrist face  72  by the technician or operator. Each tool may have multiple functions; for example, the previously noted compressed air cartridge  48  situated within the main body  34  may be used to remove or void cleaning solvent from the cleaning tool  120  upon completion of the cleaning operation, among other functions. 
         [0038]    Referring now to  FIG. 9 , after the cleaning tool  120  has removed cutting oils with cleaning solvents, etc., a sealant tool  130  may be used to apply sealant (not shown) over the entire interior surfaces of the aircraft wing  10  ( FIG. 2 ), such as the upper and lower wing panels  144 ,  146  ( FIG. 10 ). For this purpose, the sealant tool  130  incorporates a sealant nozzle  132  having a nozzle tip  134 . A sealant supply tube  136  may be attached to an extended portion of the arm  52 , as shown. 
         [0039]    All of the described tools are exemplary, only. As such, other tools may be utilized with the programmable work machine  30 . In addition, computer programs such as various CAD programs may be replaced by other programs suitable for mechanized operations. Any one of such programs may be utilized for programming the activity of any one of the tools described herein. As disclosed, the programmable work machine  30  can be operated fully autonomously because of its rechargeable battery and self-contained apparatus, including hydraulic pump and compressed air units. 
         [0040]    Within the context of this disclosure, the terms “semi-autonomous” and “autonomous” apply principally to the portable work module  50 , once locked into place within a perimeter lip  13  of an access port  12 . Generally, within the scope of this disclosure, none of the physical movements of the main body  34 , programming of various selective work functions, and removal and replacement of the locating collar  54  between access ports  12 , are not amenable to autonomous or even semi-autonomous operations. 
         [0041]    With respect to the work module  50 , if operator intervention is involved to override various aspects of any particular work functions, it can be said that the portable work module  50 , hence the machine  30 , is being operated “semi-autonomously”. However once the machine  30  has been fully installed with the locator collar  54  locked within an access port  12 , the machine  30  may then be programmed for at least certain work functions to be carried out fully autonomously. 
         [0042]    Finally, referring now to  FIG. 10 , an aircraft wing cavity  140  is shown in cross section across a single bay, as another example of a confined space, within the interior of an aircraft wing  10 , wherein an interior rib  142  extends between rear and forward spars  148 ,  150 , respectively, as shown. As displayed in  FIG. 10 , the portable work module  50  is shown secured within an access port  12  via the described collar  54 , and the telescoping arm  52  is shown partially extended between upper and lower wing panels  144 ,  146 , respectively, within the wing cavity  140 . 
         [0043]    It will be appreciated that between bays, depending on the particular work process being carried out, an operator may make appropriate changes; e.g. of collar and pintail cartridges, or of nut and/or torqued portions of nut cartridges, and/or removal and installation of new sealant tubes, etc. All of such changes may be made by quick-change cartridges to prepare the work module  50  for access to each successive bay. A nut driving gun  100  is shown positioned for securement of a spar cap  158  of the forward spar  150  to the lower wing panel  146 . Within the wing cavity  140  are shown pluralities of stringers utilized for stiffening of the upper and lower wing panels  144 ,  146 . 
         [0044]    Thus, Z-shaped stringers  152 , T-shaped stringers  154 , and U-shaped stringers  156  may be used in selectively and for distinct purposes within the wing cavity  140 . For example the U-shaped stringers of  156  provide passageways for protection of electrical and hydraulic lines from fuel contamination. For uninterrupted passage of the elongated stringers between ribs, those skilled in the art will appreciate that the rib  142  includes openings  160 , as shown. 
         [0045]    This disclosure also provides a method of processing of an interior cavity of an aircraft wing, including placing a telescoping arm having an elbow through a wing access port, and securing the arm via the elbow to a perimeter lip of the access port. A main body, such as a wheeled cart may be fitted with an on-board rechargeable battery, a battery-operated power system such as a hydraulic pump, and a programmable computer configured to process numerical data and for communication with and control of movements of the arm. A wrist may be formed on an unsupported end of the arm, and the wrist may be configured to provide articulating motion, including translation and rolling motion in reference to the X, Y, and Z axes of the arm. 
         [0046]    The wrist may be configured to hold and manipulate a set of tools as described above for processing at least a portion of a work part within the cavity. The arm may be operated semi-autonomously to accommodate intervention by an operator for overriding and fine-tuning interaction of the tool with the work part for processing. A reference camera may be secured to the wrist for use by the operator to fine tune the processing of the work part. 
         [0047]    The disclosed programmable work machine  30  may have other variations and alternative constructions neither described nor suggested herein. For example, although described in terms of specific structures and components, other configurations and/or other components may be utilized, and in potentially in other environments. Moreover, although the disclosure presents structures in only the shapes and sizes depicted, numerous variations of the disclosed structures may be envisioned for use in the manufacture of alternative embodiments, as may be appreciated by those skilled in the art.