Patent Description:
What is needed are new methods and systems for transferring flexible composite parts.

<CIT> discloses, according to a machine translation of its abstract, "a device (<NUM>) for transporting and depositing flat fiber semi-finished product cuts, which has a robot (<NUM>) and a gripping device (<NUM>) connected to its robot arm (<NUM>) with a plurality of grippers (<NUM>) for receiving at least one fiber semi-finished product cut, with at least some the gripper (<NUM>) is movably arranged on the gripping device (<NUM>) and can be actively moved by means of a drive, so that the received semi-finished fiber product blank can be deformed in a targeted manner during transport by moving these grippers (<NUM>) in a defined manner. The invention also relates to a gripping device (<NUM>) for use on such a device (<NUM>)".

In a first aspect there is provided a flexible truss mechanism as defined in claim <NUM> of the appended claims. In a second aspect there is provided a method of transferring a flexible composite part using a flexible truss system comprising a flexible truss mechanism and pick-and-place mechanisms, the method as defined by appended claim <NUM>.

Described herein are flexible truss systems and methods of transferring flexible composite parts using these systems. A flexible truss system comprises a flexible truss mechanism and composite pick-and-place mechanisms, supported on the flexible truss mechanism and designed to attach to various composite parts. The flexible truss mechanism comprises flexible elongated members and slidable ribs, coupled to each flexible elongated member. Specifically, each rib is slidably coupled to at least one flexible elongated member. In some examples, each rib is also fixedly coupled to another flexible elongated member. The slidable coupling allows the flexible truss mechanism to bend and follow the shape of a supported part, such that the composite pick-and-place mechanisms are able to contact and support different areas of the composite part. As such, the same flexible truss mechanism is able to support flexible composite parts having different shapes.

In some examples, a flexible truss mechanism comprising flexible elongated members, extending along a principal axis of the flexible truss mechanism, slidable ribs, coupled to each of the flexible elongated members and supporting the flexible elongated members with respect to each other. The slidable ribs are spaced apart from each other along the principal axis of the flexible truss mechanism. The slidable ribs are configured to receive and support one or more composite pick-and-place mechanisms. Each of the slidable ribs is slidably coupled to at least one of the flexible elongated members, thereby allowing each of the slidable ribs to slide relative to the at least one of the flexible elongated members along the principal axis and allowing the flexible elongated members to bend about at least one axis, perpendicular to the principal axis.

In some examples, a flexible truss system comprises a flexible truss mechanism, comprising flexible elongated members, extending along a principal axis of the flexible truss mechanism, and slidable ribs, coupled to each of the flexible elongated members and pick-and-place mechanisms. Each of the pick-and-place mechanisms is supported by a corresponding one of the slidable ribs. Each of the slidable ribs is slidably coupled to at least one of the flexible elongated members, thereby allowing each of the slidable ribs to slide relative to the at least one of the flexible elongated members along the principal axis and allowing the flexible elongated members to bend about at least one axis, perpendicular to the principal axis.

In some examples, a method of transferring a flexible composite part using a flexible truss system comprising a flexible truss mechanism and pick-and-place mechanisms is provided. The method comprises contacting the flexible composite part with each of the pick-and-place mechanisms, supported on the flexible truss mechanism. The flexible truss mechanism comprises flexible elongated members and slidable ribs, coupled to each of the flexible elongated members and supporting the flexible elongated members with respect to each other. The method also comprises contacting the flexible composite part comprises sliding at least one of the slidable ribs relative to at least one of the flexible elongated members, thereby allowing the flexible elongated members to bend and allowing each of the pick-and-place mechanisms to form contact with the flexible composite part. The method also comprises locking the slidable ribs relative to the at least one of the flexible elongated members in set positions, thereby preserving shape of the flexible elongated members and maintaining the contact between each of the pick-and-place mechanisms and the flexible composite part. The method also comprises transferring the flexible composite part using the flexible truss system while maintaining the contact between each of the pick-and-place mechanisms and the flexible composite part.

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the presented concepts. In some examples, the presented concepts are practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail so as to not unnecessarily obscure the described concepts. While some concepts will be described in conjunction with the specific examples, it will be understood that these examples are not intended to be limiting.

As noted above, handling large and flexible parts can be challenging. Conventional approaches involve manual handling (e.g., using multiple operators) or custom tools (e.g., designed to conform to specific shapes). However, manual handling is time consuming and can damage parts (e.g., if operators' movements are not synchronized). Custom supporting tools are expensive and need to be specific to each type of part. At the same time, modern aircraft use many unique parts, which would require many individual supporting tools, resulting in complex logistic problems (e.g., retrieval, storage, and costs).

Flexible truss systems, described herein, are configured to change shapes to provide sufficient support to flexible composite parts, while these parts are being transferred or otherwise handled using these flexible truss systems. In particular, a flexible truss system comprises a flexible truss mechanism and composite pick-and-place mechanism, supported on the flexible truss mechanism. The composite pick-and-place mechanisms are configured to engage a flexible composite part during the part transfer. The flexible truss mechanism is configured to change the shape, e.g., to follow the shape of the flexible composite part. In some examples, the flexible composite part is an uncured composite part. One having ordinary skill in the art would recognize that uncured composite parts tend to be more flexible than cured counterparts. In some examples, a flexible composite part is at least <NUM> meter long or even at least <NUM> meters long or even <NUM> meters long. One having ordinary skill in the art would recognize that longer composite parts tend to have higher flexibility than corresponding shorter ones.

This shape change is used to ensure that the composite pick-and-place mechanisms come in contact and provide sufficient support to the flexible composite part at multiple different locations. This multi-location support is important during the transfer of flexible composite parts. In some examples, the flexible truss mechanism is configured to fix the new shape (e.g., maintain the shape during the transfer) to ensure the continuous support of the flexible composite part.

This ability to change the shape is provided by particular design and structural features of the flexible truss mechanism. Specifically, the flexible truss mechanism comprises flexible elongated members and slidable ribs. The slidable ribs are coupled to each flexible elongated member. More specifically, each rib is slidably coupled to at least one flexible elongated member. The flexibility of the elongated members and the ribs' ability to slide allow the flexible truss mechanism to bend and change the shape. In other words, the same flexible truss mechanism can be configured to support multiple different composite parts, which have different shapes.

Therefore, when the flexible truss mechanism is reconfigured to support a new composite part with a new shape, the ribs are able to slide relative to at least one flexible elongated member. This sliding action allows all flexible elongated members to bend and reshape. However, when the ribs are locked in place, relative to the flexible elongated members, the truss mechanism is able maintain the shape, e.g., during the transfer of flexible composite parts. The process of reconfiguring the flexible truss mechanism is repeatable. Hence, the same flexible truss mechanism can be used on a variety of different composite parts.

<FIG> is a schematic perspective view of flexible truss system <NUM>, comprising flexible truss mechanism <NUM> and pick-and-place mechanisms <NUM>, in accordance with some examples. <FIG> is a schematic perspective view of a portion of flexible truss system <NUM> in <FIG>, illustrating additional features of flexible truss mechanism <NUM>. Finally, <FIG> is a block diagram of flexible truss system <NUM>, showing various other components of flexible truss system <NUM> as well as connections and relationship between these components, in accordance with some examples.

Pick-and-place mechanisms <NUM> are configured to support different flexible composite parts, various examples of which are listed above. Pick-and-place mechanisms <NUM> are attached and supported by flexible truss mechanism <NUM>, as further described below. Referring to <FIG>, in some examples, composite pick-and-place mechanisms <NUM> comprise suction cups <NUM>, which are controllably connected to vacuum source <NUM>. The operation of vacuum source <NUM> and other components (e.g., pressure source <NUM> for actuating position locks <NUM>) of flexible truss system <NUM> are controlled, in some examples, by system controller <NUM>. In some examples, system controller <NUM> is communicatively coupled to pressure source <NUM> and configured to selectively connect and disconnect linear actuator <NUM> of position lock <NUM> of each of slidable ribs <NUM> from pressure source <NUM>.

In some examples, flexible truss system <NUM> comprises lifting mechanism <NUM> for supporting flexible truss mechanism <NUM>. Specifically, lifting mechanism <NUM> is used for particularly large and heavy flexible composite parts. In an example, lifting mechanism <NUM> is a robotic system including one or more robotic arms configured to support and move the flexible truss mechanism.

In some examples, each one of slidable ribs <NUM> of flexible truss mechanism <NUM> supports a corresponding one of composite pick-and-place mechanisms <NUM>. In other examples, flexible truss mechanism <NUM> comprises a plurality of slidable ribs where some of the slidable ribs have pick-and-place mechanism <NUM> attached to the ribs, while other slidable ribs do not have composite pick-and-place mechanism <NUM> attached to the ribs, e.g., free from any pick-and-place mechanisms. For instance, <FIG> illustrates an example flexible truss mechanism <NUM> having slidable rib <NUM> without a composite pick-and-place mechanism <NUM>. In some examples, composite pick-and-place mechanisms <NUM> can be attached to every other slidable rib <NUM>. In other examples, composite pick-and-place mechanisms <NUM> are attached at other intervals, including for instance at every third slidable rib <NUM> or every fourth slidable rib <NUM>. As indicated above, in other examples, pick-and-place mechanisms <NUM> are attached to each slidable rib <NUM> of flexible truss mechanism <NUM> to form flexible truss system <NUM> as, e.g., shown in <FIG>. In yet other examples, flexible truss mechanism <NUM> is used without pick-and-place mechanisms <NUM>, e.g., to perform other operations not involving handling composite parts.

Referring to <FIG>, and <FIG>, flexible truss mechanism <NUM> comprises flexible elongated members <NUM>, extending along principal axis <NUM> of flexible truss mechanism <NUM>. The figures illustrate three flexible elongated members <NUM>, e.g., first flexible elongated member <NUM>, second flexible elongated member <NUM>, and third flexible elongated member <NUM>. However, other numbers of flexible elongated members <NUM> are also within the scope, e.g., four, five, six, and so on. The number of flexible elongated members <NUM> determines the flexibility of flexible truss mechanism <NUM> and the support (e.g., to flexible composite parts) provided by flexible truss system <NUM>. In some examples, each of flexible elongated members <NUM> is formed from carbon fiber. Carbon fiber has a low weight, is sufficiently flexible, and provides significant structural support, especially in the direction along principal axis <NUM>. The length of flexible elongated members <NUM> (along principal axis <NUM>) is determined by the length of the longest composite part that flexible truss system <NUM> is designed to support. In some examples, the length of flexible elongated members <NUM> is at least about <NUM> meter, at least about <NUM> meters, or even at least about <NUM> meters.

Referring to <FIG>, and <FIG>, flexible truss mechanism <NUM> also comprises slidable ribs <NUM>. Specifically, <FIG> illustrates eleven slidable ribs <NUM>, positioned and spaced apart from each other along principal axis <NUM> between opposite ends of flexible elongated members <NUM>. However, other numbers of ribs are also within the scope. Slidable ribs <NUM> are coupled to each of flexible elongated members <NUM> and support flexible elongated members <NUM> with respect to each other. Various examples of these couplings are described below.

Referring to <FIG>, in some examples, slidable ribs <NUM> are configured to receive and support composite pick-and-place mechanisms <NUM>. In more specific examples, each one of slidable ribs <NUM> supports a corresponding one of composite pick-and-place mechanisms <NUM> (e.g., composite pick-and-place mechanism <NUM> is attached to first supporting arm <NUM> of slidable rib <NUM>). Alternatively, in other examples, at least one of slidable ribs <NUM> does not support any one of composite pick-and-place mechanisms <NUM>, such as slidable rib <NUM> shown in <FIG>. Furthermore, in some examples, at least one of slidable ribs <NUM> supports multiple ones of composite pick-and-place mechanisms <NUM>. In some examples, one or more composite pick-and-place mechanisms <NUM> are attached to one or more of flexible elongated members <NUM>.

Referring to <FIG>, in some examples, each of slidable ribs <NUM> comprises a plurality of supporting arms <NUM>. Each of plurality of supporting arms <NUM> defines, at least in part, a distance between a corresponding pair of flexible elongated members <NUM>. For example, first supporting arm <NUM> extends between first flexible elongated member <NUM> and second flexible elongated member <NUM> or, more specifically, between sliding mechanisms <NUM>, slidably coupled to first flexible elongated member <NUM> and second flexible elongated member <NUM>. Second supporting arm <NUM> extends between first flexible elongated member <NUM> and third flexible elongated member <NUM>. In the illustrated example, second supporting arm <NUM> is fixedly coupled directly to third flexible elongated member <NUM>. Second supporting arm <NUM> is also connected to sliding mechanism <NUM>, which is slidably coupled to first flexible elongated member <NUM>. Finally, third supporting arm <NUM> extends between second flexible elongated member <NUM> and third flexible elongated member <NUM>. In the illustrated example, third supporting arm <NUM> is fixedly coupled directly to third flexible elongated member <NUM>. Third supporting arm <NUM> is also connected to sliding mechanism <NUM>, which is slidably coupled to second flexible elongated member <NUM>. Similarly, <FIG> illustrates slidable ribs <NUM>, where each slidable rib <NUM> comprises a plurality of supporting arms <NUM> (in particular, first supporting arm <NUM>, second supporting arm <NUM> , and third supporting arm <NUM>).

In some examples, the length of each of plurality of supporting arms <NUM> is the same. As such, first flexible elongated member <NUM>, second flexible elongated member <NUM>, and third flexible elongated member <NUM> are positioned at the same distance from each other. Furthermore, in some examples, each of plurality of supporting arms <NUM> is straight. In some examples, supporting arms <NUM> are formed from a rigid material, such as aluminum.

Each slidable rib <NUM> is slidably coupled to at least one of flexible elongated members <NUM>. For example, in this slidable coupling, the at least one of flexible elongated members <NUM> protrudes through each slidable rib <NUM>. In some examples, each slidable rib <NUM> is slidably coupled to only one of flexible elongated members <NUM> and fixedly coupled to all remaining elongated members. Alternatively, each slidable rib <NUM> is slidably coupled to all but one of flexible elongated members <NUM> and fixedly coupled to the remaining elongated member. In some examples, each slidable rib <NUM> is slidably coupled to two of flexible elongated members <NUM> and fixedly coupled to one remaining elongated member. For example, <FIG> illustrate an example where each slidable rib <NUM> is slidably coupled to each of first flexible elongated member <NUM> and second flexible elongated member <NUM>. In the same example, each slidable rib <NUM> is fixedly coupled to third flexible elongated member <NUM>. In some examples, each slidable rib <NUM> is slidably coupled all flexible elongated members <NUM>. As noted above, the slidably coupling to at least one of flexible elongated members <NUM> allows flexible elongated members <NUM> to bend about one or more axes (e.g., axis 102a and axis 102b shown in <FIG>) perpendicular to principal axis <NUM>. For instance, in some examples, principal axis <NUM> corresponds to the Y-axis, and the slidably coupling to at least one of flexible elongated members <NUM> allows flexible elongated members <NUM> to bend about one or more of axis 102b (corresponding to the X-axis) and axis 102a (corresponding to the Z-axis). This feature will now be described with reference to <FIG>.

<FIG> are schematic overhead views of flexible truss mechanism <NUM> comprising two slidable ribs <NUM>, which may be referred to as first slidable rib 120a and second slidable rib 120b. Slidable rib 120a and second slidable rib 120b are slidably coupled to each of first flexible elongated member <NUM> and second flexible elongated member <NUM> and fixedly coupled to third flexible elongated member <NUM>. <FIG> illustrates flexible truss mechanism <NUM> where each of first flexible elongated member <NUM>, second flexible elongated member <NUM>, and third flexible elongated member <NUM> is straight. Because third flexible elongated member <NUM> is fixedly coupled to each of first slidable rib 120a and second slidable rib 120b, the distance between connection points formed by these components (a first connection point between third flexible elongated member <NUM> and first slidable rib 120a and a second connection point between third flexible elongated member <NUM> and second slidable rib 120b) remain constant. These connection points, corresponding to fixed connections, are identified with circles in <FIG>. However, the distance between connection points formed by first flexible elongated member <NUM> or second flexible elongated member <NUM> is adjustable. <FIG> identifies the distance between connection points formed by first flexible elongated member <NUM> (with first slidable rib 120a and second slidable rib 120b) to be L<NUM>. <FIG> also identifies the distance between connection points formed by second flexible elongated member <NUM> (with first slidable rib 120a and second slidable rib 120b) to be L<NUM>. These connection points, corresponding to slidable connections, are identified with squares in <FIG>. In this example of <FIG>, these distances are the same since first flexible elongated member <NUM> and second flexible elongated member <NUM> are straight and since first slidable rib 120a and second slidable rib 120b are parallel to each other.

<FIG> illustrates flexible truss mechanism <NUM> where each of first flexible elongated member <NUM>, second flexible elongated member <NUM>, and third flexible elongated member <NUM> are bent, e.g., around axis 102a, which is perpendicular to principal axis <NUM> of flexible truss mechanism <NUM>. The distance between connection points formed by third flexible elongated member <NUM> with each rib remains the same. However, the distance between connection points formed by first flexible elongated member <NUM> with each rib has reduced to L<NUM> such that L<NUM> < L<NUM>. On the other hand, the distance between connection points formed by second flexible elongated member <NUM> with each rib has increased to L<NUM> such that L<NUM> > L<NUM>. First flexible elongated member <NUM> and second flexible elongated member <NUM> are no longer straight. Furthermore, first slidable rib 120a and second slidable rib 120b are no longer parallel to each other. As such, flexible truss mechanism <NUM> is reconfigured to a new shape, e.g., corresponding to a particular flexible composite part. One having ordinary skill in the art would understand that this bending and non-parallel configuration of adjacent ribs may be achieved with one rib being fixedly attached to all flexible elongated members. Such a rib may be referred to as a fixed rib. In other words, flexible truss mechanism <NUM> is able to bend with one fixed rib and at least one slidable rib. However, multiple fixed ribs may interfere with bending of flexible truss mechanism <NUM>. Additional features of fixed ribs will now be described with reference to <FIG>.

<FIG> are schematic illustrations of another example of flexible truss mechanism <NUM> comprising first slidable rib 120a, second slidable rib 120b, and fixed rib <NUM>. Similar to the example shown in <FIG> and described above, first slidable rib 120a and second slidable rib 120b are slidably coupled to each of first flexible elongated member <NUM> and second flexible elongated member <NUM> and fixedly coupled to third flexible elongated member <NUM>. However, fixed rib <NUM> is fixedly coupled to each of first flexible elongated member <NUM>, second flexible elongated member <NUM>, and third flexible elongated member <NUM>. In <FIG>, all first flexible elongated member <NUM>, second flexible elongated member <NUM>, and third flexible elongated member <NUM> are straight. First slidable rib 120a, second slidable rib 120b, and fixed rib <NUM> are all parallel to each other.

<FIG> illustrates flexible truss mechanism <NUM> where each of first flexible elongated member <NUM>, second flexible elongated member <NUM>, and third flexible elongated member <NUM> are bent, e.g., around axis 102a, which is perpendicular to principal axis <NUM> of flexible truss mechanism <NUM>. The distance between connection points formed by third flexible elongated member <NUM> with each rib remains the same. However, the distance between connection points formed by first flexible elongated member <NUM> with fixed rib <NUM> and each slidable rib has reduced. On the other hand, the distance between connection points formed by second flexible elongated member <NUM> with fixed rib <NUM> and each slidable rib has increased. First flexible elongated member <NUM> and second flexible elongated member <NUM> are no longer straight. First slidable rib 120a, fixed rib <NUM>, and second slidable rib 120b are no longer parallel to each other. Other example locations of fixed rib <NUM> are possible as well. For instance, in an example, fixed rib <NUM> is disposed at one end of flexible truss system <NUM>.

Referring to <FIG> and <FIG>, in some examples, each of slidable ribs <NUM> comprises one or more sliding mechanisms <NUM>. The number of sliding mechanisms <NUM> depends on how many flexible elongated members <NUM> this particular slidable rib <NUM> is slidably coupled to. Briefly referring to an example of <FIG>, slidable rib <NUM> is slidably coupled to both first flexible elongated member <NUM> and second flexible elongated member <NUM>. In this example, slidable rib <NUM> comprises two sliding mechanisms <NUM>, with one slidably coupling the rib to first flexible elongated member <NUM> and another one slidably coupling the rib to second flexible elongated member <NUM>. In other words, each slidable rib <NUM> comprises one sliding mechanism <NUM> for each flexible elongated member <NUM>, slidable relative to slidable ribs <NUM>. Sliding mechanism <NUM> provides the slidable coupling between the rib and the corresponding flexible elongated member.

Referring to <FIG>, in some examples, sliding mechanism <NUM> comprises one or more rollers <NUM>, rollably engaging at least one of flexible elongated members <NUM> (e.g., first flexible elongated member <NUM> shown in <FIG>). For example, sliding mechanism <NUM> comprises two rollers <NUM> such that first flexible elongated member <NUM> is positioned between these two rollers <NUM>. The two rollers <NUM> are supported with roller support <NUM>, which is attached to supporting arms <NUM> of slidable rib <NUM>. <FIG> shows slidable rib <NUM> with roller support <NUM> removed to illustrate the relative position of rollers <NUM> and first flexible elongated member <NUM>.

While sliding of ribs relative to flexible elongated members allows bending of flexible truss mechanism <NUM>, e.g., to follow the shape of a new composite part, fixing the ribs relative to the flexible elongated members allows preserving the new shape of flexible truss mechanism <NUM> while, e.g., transferring the new composite part. Position locks <NUM> are used for this purpose, which will now be described with reference to <FIG>.

Referring to <FIG>, <FIG> and <FIG>, in some examples, each of slidable ribs <NUM> comprises one or more position locks <NUM>. Similar to sliding mechanisms <NUM>, the number of position locks <NUM> depends on how many flexible elongated members <NUM> this particular slidable rib <NUM> is slidably coupled to. Briefly referring to an example of <FIG>, slidable rib <NUM> is slidably coupled to both first flexible elongated member <NUM> and second flexible elongated member <NUM>. In this example, slidable rib <NUM> comprises two position locks <NUM>, one for maintaining the position of slidable rib <NUM> relative to first flexible elongated member <NUM> and another for maintaining the position of slidable rib <NUM> relative to second flexible elongated member <NUM>. In other words, each slidable rib <NUM> comprises one position lock <NUM> for each flexible elongated member <NUM>, slidable relative to slidable ribs <NUM>.

Position lock <NUM> is configured to lock the corresponding slidable rib <NUM>, which position lock <NUM> is a part of, in a set position. The fixed position is relative to flexible elongated member <NUM>, which this slidable rib <NUM> is slidably coupled to. For example, position lock <NUM> is switchable between a locked position and an unlocked position. When position lock <NUM> is in the locked position, position lock <NUM> prevents slidable rib <NUM> from sliding relative to the corresponding flexible elongated member <NUM>. When position lock <NUM> is in the unlocked position, position lock <NUM> allows slidable rib <NUM> to slide relative to the corresponding flexible elongated member <NUM>.

Referring to <FIG>, in some examples, position lock <NUM> comprises linear actuator <NUM>, cutout nut <NUM>, and threaded position shaft <NUM>. Threaded position shaft <NUM> is fixedly connected to at least one of flexible elongated members <NUM>, e.g., first flexible elongated member <NUM> shown in <FIG>. This fixed connection is provided, e.g., using position limiters <NUM>, fixedly connecting the end of threaded position shaft <NUM> to first flexible elongated member <NUM>. Linear actuator <NUM> is coupled to cutout nut <NUM> and configured to move cutout nut <NUM> relative to threaded position shaft <NUM> between a shaft-engaging position and a shaft-disengaging position. In some examples, linear actuator <NUM> is a pneumatic cylinder.

<FIG> illustrates the shaft engaging position, which corresponds to the locked position of position lock <NUM>. In this position, cutout nut <NUM> engages threaded position shaft <NUM> (e.g., threads of cutout nut <NUM> interlock with threads of threaded position shaft <NUM> thereby preventing cutout nut <NUM> from sliding along threaded position shaft <NUM>). Due to the fixed connection between threaded position shaft <NUM> and flexible elongated members <NUM> as well as the connection between cutout nut <NUM> and other components of slidable rib <NUM> (shown in <FIG>), slidable rib <NUM> is not able to slide relative to first flexible elongated member <NUM>.

<FIG> illustrates the shaft disengaging position, which corresponds to the unlocked position of position lock <NUM>. In this position, cutout nut <NUM> is moved away from threaded position shaft <NUM>, thereby allowing cutout nut <NUM> to slide along threaded position shaft <NUM> (e.g., along the direction parallel to threaded position shaft <NUM>). As a result, slidable rib <NUM> is also able to slide relative to first flexible elongated member <NUM>.

<FIG> is a process flowchart corresponding to method <NUM> of transferring flexible composite part <NUM> using flexible truss system <NUM>, in accordance with some examples. Various features of flexible truss system <NUM>, which comprises flexible truss mechanism <NUM> and pick-and-place mechanisms <NUM>, are described above.

In some examples, method <NUM> comprises contacting (block <NUM>) flexible composite part <NUM> with each of pick-and-place mechanisms <NUM>. Pick-and-place mechanisms <NUM> are supported on flexible truss mechanism <NUM> and distributed along principal axis <NUM> of flexible truss mechanism <NUM>. As described above with references to <FIG>, flexible truss mechanism <NUM> comprises flexible elongated members <NUM> and slidable ribs <NUM>. Slidable ribs <NUM> are coupled to each of flexible elongated members <NUM> and support flexible elongated members <NUM> with respect to each other. Furthermore, in some examples, composite pick-and-place mechanisms <NUM> are attached to or otherwise supported by slidable ribs <NUM>.

In some examples, contacting (block <NUM>) flexible composite part <NUM> with each of pick-and-place mechanisms <NUM> comprises sliding (block <NUM>) at least one of slidable ribs <NUM> relative to at least one of flexible elongated members <NUM> as described above with referenced to <FIG>. This feature allows flexible elongated members <NUM> to bend, which in turn allows each of pick-and-place mechanisms <NUM> to contact flexible composite part <NUM>.

For example, <FIG> illustrates flexible truss system <NUM> with straight, flexible elongated members <NUM>. As a result, composite pick-and-place mechanisms <NUM> are aligned along a straight line (shown as a dashed line in <FIG>). However, in this example, flexible composite part <NUM> is not straight and many of composite pick-and-place mechanisms <NUM> are not able to contact flexible composite part <NUM>. Without being contacted by a sufficient number of composite pick-and-place mechanisms <NUM>, flexible composite part <NUM> is not sufficiently supported, e.g., due to being flexible. The number, spacing, and other characteristics of composite pick-and-place mechanisms <NUM> are determined based on the type of flexible composite part <NUM> (e.g., size, weight, curing state, and the like).

<FIG> illustrates flexible elongated members <NUM> after sliding at least one of slidable ribs <NUM> relative to at least one of flexible elongated members <NUM> and bending flexible elongated members <NUM> (relative to <FIG>). In this illustration, composite pick-and-place mechanisms <NUM> are all in contact with flexible composite part <NUM>, providing sufficient support to flexible composite part <NUM>.

In some examples, method <NUM> proceeds with locking (block <NUM>) the position of at least one of slidable ribs <NUM> relative to at least one of flexible elongated members <NUM>, e.g., using position locks <NUM>, described above with reference to <FIG>. In more specific examples, all slidable ribs <NUM> are locked relative to each flexible elongated member <NUM>. It should be noted that in some examples, one or more flexible elongated members <NUM> are fixedly attached to slidable ribs <NUM>. This locking/fixed attachment preserves the shape of flexible elongated members <NUM>. As a result, the contact between each of pick-and-place mechanisms <NUM> and flexible composite part <NUM> is maintained, e.g., as shown in <FIG>.

In some examples, method <NUM> proceeds with transferring (block <NUM>) flexible composite part <NUM> using flexible truss system <NUM> while maintaining contact between each of pick-and-place mechanisms <NUM> and flexible composite part <NUM>. For example, composite part <NUM> is transferred, using flexible truss system <NUM>, between various processing, e.g., between forming flexible composite part <NUM> and curing flexible composite part <NUM>. For example, an assembly of flexible composite part <NUM> using flexible truss system <NUM> is handled manually or using lifting mechanism <NUM>. It should be noted that flexible composite part <NUM> is supported by flexible truss system <NUM> during this operation.

In some examples, method <NUM> proceeds with disengaging (block <NUM>) flexible composite part <NUM> from each of pick-and-place mechanisms <NUM>. For example, the vacuum applied to suction cups <NUM>, used as pick-and-place mechanisms <NUM>, is released, thereby allowing separation of suction cups <NUM> from flexible composite part <NUM>.

In some examples, method <NUM> proceeds with unlocking (block <NUM>) the positions of slidable ribs <NUM> relative to the at least one of flexible elongated members <NUM>. It should be noted that while pick-and-place mechanisms <NUM> engage and support flexible composite part <NUM>, slidable ribs <NUM> are locked relative to the at least one of flexible elongated members <NUM> to preserve the shape of flexible truss system <NUM>. However, in order to reconfigure flexible truss system <NUM> (e.g., to support additional flexible composite part <NUM>, which has a different shape), the positions of slidable ribs <NUM> are unlocked.

In some examples and with reference to decision block <NUM> in <FIG>, method <NUM> proceeds with transferring another flexible composite part (e.g., shown in <FIG>) using the same flexible truss system <NUM>. In this case, various operations described above with reference to blocks <NUM>-<NUM> are repeated. For examples, method <NUM> proceeds with contacting (block <NUM>) additional flexible composite part <NUM> with each of pick-and-place mechanisms <NUM>, supported on flexible truss mechanism <NUM>. This contacting operation (of additional flexible composite part <NUM>) comprises sliding (block <NUM>) at least one of slidable ribs <NUM> relative to at least one of flexible elongated members <NUM>. This sliding allows flexible elongated members <NUM> to bend and allows each of pick-and-place mechanisms <NUM> to form contact with additional flexible composite part <NUM>. As shown in <FIG>, additional flexible composite part <NUM> and flexible composite part <NUM> have different shapes. As such, flexible truss system <NUM> is reconfigured during this operation to match the shape of additional flexible composite part <NUM>.

In some examples, method <NUM> further comprises locking (block <NUM>) slidable ribs <NUM> relative to at least one of flexible elongated members <NUM> in additional set positions. This locking preserves the shape of flexible elongated members <NUM> (now matching additional flexible composite part <NUM>) and maintains contact between each of pick-and-place mechanisms <NUM> and additional flexible composite part <NUM>. These additional set positions are different from the set positions, used before for flexible composite part <NUM>.

In some examples, methods and systems described above are used on aircraft and, more generally, by the aerospace industry. Specifically, these methods and systems can be used during fabrication of aircraft as well as during aircraft service and maintenance.

Accordingly, the apparatus and methods described above are applicable for aircraft manufacturing and service method <NUM> as shown in <FIG> and for aircraft <NUM> as shown in <FIG>. During pre-production, method <NUM> includes specification and design <NUM> of aircraft <NUM> and material procurement <NUM>. During production, component and subassembly manufacturing <NUM> and system integration <NUM> of aircraft <NUM> takes place. Thereafter, aircraft <NUM> goes through certification and delivery <NUM> in order to be placed in service <NUM>. While in service by a customer, aircraft <NUM> is scheduled for routine maintenance and service <NUM>, which also includes modification, reconfiguration, refurbishment, and so on.

In some examples, each of the processes of method <NUM> is 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 includes without limitation any number of aircraft manufacturers and major-system subcontractors; a third party includes without limitation any number of venders, subcontractors, and suppliers; and an operator can be an airline, leasing company, military entity, service organization, and so on.

As shown in <FIG>, aircraft <NUM> produced by method <NUM> includes airframe <NUM> with plurality of systems <NUM> and interior <NUM>. Examples of systems <NUM> include one or more of propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and environmental system <NUM>. Any number of other systems can be included. Although an aerospace example is shown, the principles of the examples described herein is applied to other industries, such as the automotive industry.

Apparatus and methods presented herein can be employed during any one or more of the stages of method <NUM>. For example, components or subassemblies corresponding to manufacturing <NUM> are fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft <NUM> is in service. Also, one or more apparatus examples, method examples, or a combination thereof is utilized during manufacturing <NUM> and system integration <NUM>, for example, by substantially expediting assembly of or reducing the cost of an aircraft <NUM>. Similarly, one or more of apparatus examples, method examples, or a combination thereof is utilized while aircraft <NUM> is in service, for example and without limitation, to maintenance and service <NUM>.

Claim 1:
A flexible truss mechanism (<NUM>) comprising:
flexible elongated members (<NUM>), extending along a principal axis (<NUM>) of the flexible truss mechanism (<NUM>);
slidable ribs (<NUM>), coupled to each of the flexible elongated members (<NUM>) and supporting the flexible elongated members (<NUM>) with respect to each other, wherein:
the slidable ribs (<NUM>) are spaced apart from each other along the principal axis (<NUM>) of the flexible truss mechanism (<NUM>);
the slidable ribs (<NUM>) are configured to receive and support one or more composite pick-and-place mechanisms (<NUM>); and
each of the slidable ribs (<NUM>) is slidably coupled to at least one of the flexible elongated members (<NUM>), thereby allowing each of the slidable ribs (<NUM>) to slide relative to the at least one of the flexible elongated members (<NUM>) along the principal axis (<NUM>) and allowing the flexible elongated members (<NUM>) to bend about at least one axis (102a), perpendicular to the principal axis (<NUM>).