Patent Publication Number: US-2023138523-A1

Title: Methods and systems for manufacturing a structure

Description:
PRIORITY 
     This application claims priority from U.S. Ser. No. 63/274,973 filed on Nov. 3, 2021. 
    
    
     FIELD 
     This application relates to the manufacturing of structures and, more specifically, to methods and systems for manufacturing composite aerospace structures. 
     BACKGROUND 
     Manufacturing of large structures in the aerospace industry typically requires manual processing, manually placing the structure into a workstation, and manually moving it out of the workstation. Additionally, movement of personnel into and out of the workstation is a manual process. 
     Safety hazards arise when personnel need to work directly on the structures, especially when high off the ground. Existing guard rails, gates, and doors are manually operated and, thus, pose safety hazards, including falls, for workers. 
     Further concerns arise regarding movement of structures within a workstation requiring manual processing as typical structures to keep structures in place do not close all gaps located along the length of the large structures. 
     Accordingly, those skilled in the art continue with research and development efforts in the field of manufacturing large structures. 
     SUMMARY 
     Disclosed are methods for manufacturing a structure. 
     In one example, the disclosed method for manufacturing a structure includes sensing activity in a workstation with at least one sensor. The method further includes transporting the structure to the workstation, engaging a telescoping platform with the structure, and releasing an access barrier after the engaging. 
     In another example, the disclosed method for manufacturing a structure includes sensing activity in a workstation with at least one sensor, moving the structure into the workstation with an overhead gantry system, sensing the structure with at least one sensor after the moving, engaging a telescoping platform with the structure at a contact force range of approximately 2 pounds (lbs) to approximately 4 pounds (lbs), releasing an access barrier after engaging, and releasing at least one additional access barrier after engaging, wherein the moving, the engaging, and the releasing are automated. 
     Also disclosed are systems for manufacturing a structure. 
     In one example, the disclosed system for manufacturing a structure includes a control system configured to automate movement of the structure, a transportation apparatus configured to move the structure based upon a command from the control system, at least one sensor in communication with the control system, a workstation in communication with the control system, the workstation configured to receive the structure, a telescoping platform located in the workstation, and an access barrier adjoining the workstation. 
     In another example, the disclosed system for manufacturing a structure includes a control system configured to automate movement of the structure, a transportation apparatus configured to move the structure based upon a command from the control system, at least one sensor in communication with the control system, at least one guard rail defining a work zone, and a plurality of telescoping doors located behind the at least one guard rail, the plurality of telescoping doors defining a work zone platform. 
     Other examples of the disclosed methods and systems for manufacturing a structure will become apparent from the following detailed description, the accompanying drawings, and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a flowchart depicting one example of the disclosed method for manufacturing a structure; 
         FIG.  2    is a perspective view of one example of the disclosed system for manufacturing a structure; 
         FIG.  3    is a perspective view of a portion of the system of  FIG.  2   ; 
         FIG.  4    is a perspective view of a portion of the system of  FIG.  2   ; 
         FIG.  5    is a perspective view of a portion of the system of  FIG.  2   ; 
         FIG.  6    is a perspective view of a portion of the system of  FIG.  2   ; 
         FIG.  7    is a perspective view of a portion of an example system for manufacturing a structure; 
         FIG.  8    is a perspective view of a portion of an example system for manufacturing a structure; 
         FIG.  9    is a perspective view of a portion of an example system for manufacturing a structure; 
         FIG.  10    is a perspective view of a portion of an example system for manufacturing a structure; 
         FIG.  11    is a perspective view of a portion of an example system for manufacturing a structure; 
         FIG.  12    is a block diagram depicting an example of the disclosed system for manufacturing a structure; 
         FIG.  13    is a flow diagram of an aircraft manufacturing and service methodology; and 
         FIG.  14    is a schematic illustration of an aircraft. 
     
    
    
     DETAILED DESCRIPTION 
     The following detailed description refers to the accompanying drawings, which illustrate specific examples described by the present disclosure. Other examples having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same feature, element, or component in the different drawings. 
     Illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed, of the subject matter according to the present disclosure are provided below. Reference herein to “example” means that one or more feature, structure, element, component, characteristic, and/or operational step described in connection with the example is included in at least one aspect, embodiment, and/or implementation of the subject matter according to the present disclosure. Thus, the phrases “an example,” “another example,” “one or more examples,” and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may be, but is not necessarily, combined with the subject matter characterizing any other example. 
     As used herein, a system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, device, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware that enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, device, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function. 
     For the purpose of this disclosure, the terms “coupled,” “coupling,” and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, put in communication, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with one another. In various examples, the elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. It will be understood that not all associations among the various disclosed elements are necessarily represented. Accordingly, couplings other than those depicted in the figures may also exist. 
     References throughout the present specification to features, advantages, or similar language used herein do not imply that all of the features and advantages that may be realized with the examples disclosed herein should be, or are in, any single example. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussion of features, advantages, and similar language used throughout the present disclosure may, but do not necessarily, refer to the same example. 
     The disclosed method  400  and system  100  for manufacturing a structure address needs related to manufacturing large structures. Specifically, the disclosed method  400  and system  100  for manufacturing a structure address needs related to manually placing a workpiece into and out of a workstation  500 , manually choreographing the movement of operators into and out of the workstation  500 , reducing gaps between the workpiece and workstation  500 , and deploying automated teledoors and other portions of a jig that need to be deployed to work upon the workpiece when in the workstation  500 . The disclosed method  400  and system  100  for manufacturing a structure utilize a supervisory control and data acquisition (SCADA) based controller. 
     The supervisory control and data acquisition (SCADA) based controller for the disclosed system  100  and method  400  for manufacturing a structure utilizes feedback control to ensure that the workstation  500  properly engages with the structure  150  and the operators. Much of the safety of the access barriers and the telescoping platforms is directed toward operator safety. The operators also need to be corralled and pushed out of the workstation  500  when the structure  150  is ready to move out and until the next structure is seated in the workstation  500 . Sensing the structure  150 , location of operators, and status of access barriers is critical during processing. The operators within the workstation  500  are sensed and tracked through motion detection, lasers, optical sensors, worn or carried RFID chips, or mobile devices including cell phones and tablets. 
     Referring to  FIG.  1   , disclosed is a method  400  for manufacturing a structure  150 . The method  400  is automated such that each step is performed automatically based upon data analysis and commands received from a control system  600 . The method  400  includes sensing  405  activity in a workstation  500  with a least one sensor  115 . The activity sensed may include presence and/or movement of operators, robots, access barrier  120 , and structure  150 . The sensing  405  may include sensing  405  movement of a structure  150 , position of an access barrier  120 , position of a telescoping platform  300 , and presence of operators within the workstation  500 . The sensing  405  may be performed with at least one sensor  115 . 
     Still referring to  FIG.  1   , the method  400  for manufacturing a structure includes transporting  410  the structure  150  to a workstation  500 , such as a sanding station. The transporting  410  may be automated, manual, or a combination thereof. The transporting  410  includes moving the structure  150  with a transportation apparatus  200 . In one example, the transportation apparatus  200  includes an overhead gantry system  210 , see  FIG.  2   . The transporting  410  is initiated upon instruction via a command  927  from the control system  600 . 
     Referring  FIG.  12   , the transportation system  200  and workstation  500  are in communication with a computer  900  of the control system  600 . The computer  900  may utilize one or more numerical control program  910  to direct transporting  410 . The computer  900  further utilizes a supervisory control and data acquisition (SCADA) based controller  920  to direct transporting and facilitate data analytics. In one example, the transporting  140  is initiated when 1) a first workstation  510  sends a ready to send signal  915  to the supervisory control and data acquisition (SCADA) based controller  920  based upon completion of work in the first workstation  510  and 2) a second workstation  520  sends a ready to receive signal  925  to the supervisory control and data acquisition (SCADA) based controller  920 . The ready to receive signal  925  is sent when the second workstation  520  is cleared of personnel and it is safe for transportation  410  to commence. 
     Referring to  FIG.  1   , the method  400  for manufacturing a structure includes sensing  420  the structure  150  with at least one sensor  115 . The sensing  420  is performed before the transporting  410 , after the transporting  410  or both before and after the transporting  410 . In one example, the sensing  420  comprises obtaining an image of the structure  150 . In another example, the sensing  420  comprises obtaining data with at least one laser  117 . The sensing  420  may further include sharing the data obtained with the at least one sensor  115  with the control system  600 . 
     Still referring to  FIG.  1   , the method  400  for manufacturing a structure includes engaging  430  a telescoping platform  300  with the structure  150 . The engaging  430  may be automated, manual, or a combination thereof. In one example, the engaging  430  is performed at a contact force  431  range of approximately 2 lbs to approximately 4 lbs. In another example, the engaging  430  is performed at a contact force  431  range of approximately 3 lbs. The engaging  430  may initiate based upon receipt of a command  927  from the control system  600  indicating that the structure  150  is located in the workstation  500  and ready for deployment of the telescoping platform  300 . 
     Referring to  FIG.  6   , the telescoping platform  300  includes a plurality of telescoping doors  300   a . The telescoping platform  300  may include two panels laterally opposed from each other and configured to contact the structure  150  on opposing surfaces. The plurality of telescoping doors  300   a  are configured to contact the structure  150  and create a no gap work zone platform  305 . The work zone platform  305  is configured to provide a working surface for operators, robots, or a combination thereof. The telescoping platform  300  further serves as a means for holding the structure  150  in place while operators and/or robots perform work on the structure  150 . 
     The method  400  for manufacturing a structure may further include locking  470  the telescoping platform  300  after the engaging. The locking  470  may be automated such that it occurs based upon receipt of a command  927  from the control system  600  that the telescoping platform  300  is fully deployed and in contact with the structure  150 . 
     Referring back to  FIG.  1   , the method  400  for manufacturing a structure includes releasing  450  an access barrier  120  after the engaging  430 . In one example, the releasing  450  is automated such that it occurs based upon receipt of a command  927  from the control system  600  that the engaging  430  is complete and a work zone platform  305  is ready to receive operators. 
     The access barrier  120  is designed to protect operators from entering the workstation  500  prior to engaging  430  the telescoping platform  300 . The workstation  500  includes at least one access barrier  120 . The workstation  500  may include more than one access barrier  120 , see  FIG.  10   . In one example, the access barrier  120  comprises a u-shaped guard rail  122 . In another example, the access barrier  120  comprises a gate  124 . Once the releasing  450  occurs, the access barrier  120  is open and operators may safely enter the work zone  515 . 
     Still referring to  FIG.  1   , the method  400  for manufacturing a structure includes releasing  450   a  at least one additional access barrier  120  after the engaging  430 . In one example, the releasing  450   a  the at least one additional access barrier  120   a  is performed simultaneously with the releasing  450  an access barrier  120  after the engaging  430 . In another example, the releasing  450   a  the at least one additional access barrier  120   a  is performed sequentially with the releasing  450  an access barrier  120  after the engaging  430 . The releasing  450   a  is automated such that it occurs based upon receipt of a command  927  from the control system  600  that the engaging  430  is complete and a work zone platform  305  is ready to receive operators. 
     The method  400  for manufacturing a structure may further include retracting  460  the telescoping platform  300  after the releasing  450 . The retracting  460  may be initiated upon receiving a signal  925  from the control system  600  indicating that no operators or robots are present in the work zone  515  and it is therefore safe to retract the telescoping platform  300 . 
     The method  400  for manufacturing a structure may further include locking  470  the access barrier  120  after the retracting  460 , just before the retracting  460 , or simultaneously with the retracting  460 . The locking  470  is automated such that it occurs based upon receipt of a command  927  from the control system  600  that the work zone  515  is free from operators and/or the retracting  460  has commenced, thus it is not safe for operators to be in the work zone  515 . 
     The method  400  for manufacturing a structure may further include sending  480  a signal  925  to a control system  600 . The sending  480  is based upon sensed data collected from the workstation  500  indicating the presence of operators, robots, the structure  150 , and any other activity relevant to triggering an event in the workstation  500 . The control system  600  may then analyze the signal  925  to determine next steps of the method  400  for manufacturing a structure. 
     Referring to  FIGS.  2 - 12   , disclosed is a system  100  for manufacturing a structure  150 . The system  100  is configured to automate movement of the structure  150  into and out of a workstation  500 . The system  100  includes a control system  600 . The control system  600  is configured to collect data  650 , analyze the data  650 , and initiate various functions in response to the data  650  collected and analyzed. 
     Referring to  FIG.  12   , the system  100  for manufacturing a structure includes at least one sensor  115 . In one example, the sensor  115  is a laser  117 . The sensor  115  may employ lidar technology, radar sensing, proximity sensing, and motion detection. In another example, the sensor  115  is an optical sensor  119 . The sensor  115  is in communication with the control system  600  such that it may capture data  650  and relay it to the control system  600  for analysis. 
     Referring to  FIG.  12   , the system  100  for manufacturing a structure includes a transportation apparatus  200 . The transportation apparatus  200  is configured to move the structure  150  based upon a command  927  from the control system  600 . In one example, the transportation apparatus  200  includes an overhead gantry system  210 . The overhead gantry system  210  may include at least one sensor  115  to collect data  650  in the workstation  500 . The transportation system  200  is automated such that transportation of the structure  150  is dictated via at least one numerical control program  910 , a supervisory control and data acquisition (SCADA) based controller  920 , or a combination thereof. The transportation apparatus  200  includes a j-frame via ball index. 
     Referring to  FIG.  3    and  FIG.  4   , the overhead gantry system  210  includes two self-aligning interconnects  215 . The supervisory control and data acquisition (SCADA) based controller  920  is in communication with the self-aligning interconnects  215  and is configured to send a signal based upon completion of interconnecting. 
     Referring to  FIG.  5   , the system  100  for manufacturing a structure may include at least one panel holder  220 . The panel holder  220  is configured to couple with the structure  150  and hold the structure  150  in a neutral attitude with no torque. In one example, the structure  150  includes at least one hole  152 . The panel holder  220  couples with the hole  152  to suspend the structure  150  from the overhead gantry system  210 . 
     Referring to  FIG.  12   , the system  100  for manufacturing a structure includes at least one workstation  500 . The system  100  may further include a second workstation  520 . The workstation  500  is in communication with the control system  600  such that functions occurring in the workstation  500  are automated based upon sending and receiving of a signal  925  and command  927 . The workstation  500  is configured to receive the structure  150 . In one example, the workstation  500  is a sanding station or an inspection station. In another example, the system  100  includes a first workstation  510  and a second workstation  520 . The first workstation may be a trim station and the second workstation  520  may be a sanding station. 
     Referring to  FIG.  12   , the system  100  for manufacturing a structure includes a telescoping platform  300 , see  FIG.  7   ,  FIG.  8   ,  FIG.  9   , and  FIG.  11   . The telescoping platform  300  includes a plurality of telescoping doors  300   a . The plurality of telescoping doors  300   a  are configured to contact the structure  150  and create a no gap work zone platform  305 . In another example, the system  100  includes more than one telescoping platform, see  FIG.  2   , such that an operator may access the structure  150  at one section and a different operator may access the structure  150  at a location above or below, see  FIG.  11   . 
     Referring to  FIG.  8   ,  FIG.  9   , and  FIG.  12   , the system  100  for manufacturing a structure includes an access barrier  120 . The system  100  may include more than one access barrier, see  FIG.  10   . The access barrier  120  is adjoining the workstation  500  such that it allows access to a work zone  515  in proximity to the structure  150 . In one example, the access barrier  120  comprises a gate  124 . In another example, the access barrier  120  comprises a u-shaped guard rail  122 . The system  100  may further include at least one additional access barrier  120   a . The access barrier  120  may include a sensor  115  for detection of operators and collection of data  650 . The access barrier may further be in communication with the control system  600  for analysis of data  650  collected as well as automated locking and unlocking functionality. 
     Referring to  FIG.  2   , the system  100  for manufacturing a structure includes a telescoping platform  300 . The telescoping platform  300  is automated such that engagement and retraction of the telescoping platform  300  is based upon receipt of a command  927  from the control system  600 . In one example, telescoping platform  300  includes a plurality of telescoping doors  300   a . The plurality of telescoping doors  300   a  are located behind an access barrier  120 . The plurality of telescoping doors  300   a  may include two panels laterally opposed from each other configured to contact the structure  150  on opposing surfaces. The telescoping platform  300  defines a work zone platform  305  for operators, robots, or any other machinery needed to work on the structure. Further, the plurality of telescoping doors  300   a  may be configured to hold the structure  150  in a predefined position. The plurality of telescoping doors  300   a  may include elastomeric-rubber-contact surfaces (protect-the-part (PTP)) type of bumpers at the contact surfaces to protect impact damage on the structure  150 . 
     The structure  150  may be a structure of an airplane, such as a wing of an airplane. The structure  150  may include composite materials, metallic materials, or a combination thereof. The structure  150  may be a post-cure composite structure requiring further processing such as sanding, grinding, and finishing. 
     In one example, the system  100  for manufacturing a structure  150  includes a control system  600  configured to automate movement of the structure  150 , a transportation apparatus  200  configured to move the structure  150  based upon a command  927  from the control system  600 , at least one sensor  115  in communication with the control system  600 , at least one guard rail  122  defining a work zone  515 , and a plurality of telescoping doors  300   a  located behind the at least one guard rail  122 , the plurality of telescoping doors  300   a  defining a work zone platform  305 . In one example, the at least one sensor  115  is one of a laser  117 , proximity sensor, motion detector, and lidar. 
     Examples of the subject matter disclosed herein may be described in the context of aircraft manufacturing and service method  1100  as shown in  FIG.  13    and aircraft  1102  as shown in  FIG.  14   . During pre-production, illustrative method  1100  may include specification and design (block  1104 ) of aircraft  1102  and material procurement (block  1106 ). During production, component and subassembly manufacturing (block  1108 ) and system integration (block  1110 ) of aircraft  1102  may take place. Thereafter, aircraft  1102  may go through certification and delivery (block  1112 ) to be placed in service (block  1114 ). While in service, aircraft  1102  may be scheduled for routine maintenance and service (block  1116 ). Routine maintenance and service may include modification, reconfiguration, refurbishment, etc. of one or more systems of aircraft  1102 . 
     Each of the processes of illustrative method  1100  may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on. 
     As shown in  FIG.  14   , aircraft  1102  produced by illustrative method  1100  may include airframe  1118  with a plurality of high-level systems  1120  and interior  1122 . Examples of high-level systems  1120  include one or more of propulsion system  1124 , electrical system  1126 , hydraulic system  1128 , and environmental system  1130 . Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Accordingly, in addition to aircraft  1102 , the principles disclosed herein may apply to other vehicles, e.g., land vehicles, marine vehicles, space vehicles, etc. 
     The disclosed methods and systems for manufacturing a structure shown or described herein may be employed during any one or more of the stages of the manufacturing and service method  1100 . For example, components or subassemblies corresponding to component and subassembly manufacturing (block  1108 ) may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft  1102  is in service (block  1114 ). Also, one or more examples of the systems, methods, or combination thereof may be utilized during production stages (block  1108  and block  1110 ), for example, by substantially expediting assembly of or reducing the cost of aircraft  1102 . Similarly, one or more examples of the systems or method realizations, or a combination thereof, may be utilized, for example and without limitation, while aircraft  1102  is in service (block  1114 ) and/or during maintenance and service (block  1116 ). 
     The disclosed methods and systems for manufacturing a structure are described in the context of an aircraft. However, one of ordinary skill in the art will readily recognize that the disclosed methods and systems for manufacturing a structure may be utilized for a variety of applications. For example, the disclosed methods and systems for manufacturing a structure may be implemented in various types of vehicles including, e.g., helicopters, watercraft, passenger ships, automobiles, and the like. 
     Although various examples of the disclosed methods and systems for manufacturing a structure have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.