Patent ID: 12187456

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG.2shows an embodiment of a robotic manufacturing system20having sympathetic mounts22positioned adjacent to a fuselage24of an airplane. Other portions of an airplane, such as wings26, are shown in other Figs., such asFIG.5. In this embodiment, there are four sympathetic tracks22positioned at relatively equidistant intervals about a longitudinal axis28of the fuselage24. These positions are referred to as upper right30, upper left32, lower right34, and lower left36, so as to divide the manufactured surfaces of the fuselage24into four quadrants. With these longitudinal track paths22in place, the contour of the track paths may be sympathetic to the contour or shape of the fuselage24. That is, each track path22is sympathetic to the underlying component of the manufactured item, in this case the fuselage24, in that there exists at least one deviation38from linear for each track path.

Each sympathetic track path22may have curvatures that are similar, but not perfectly matched to the underlying manufactured part24. In this respect, a generalized “bend”38near and end40of the fuselage24may be positioned sympathetic enough to still undertake manufacturing tasks on a specific airplane fuselage, but also may be able to do so on another similar, but different, airplane fuselage (e.g., different models of similarly sized airplanes). That is, the path of the track22is not necessarily equivalent or identical to the contour of the underlying manufactured item24, but rather just sympathetic to it, in that the shape of the track22generally follows the contour of the fuselage24or other component.

Each track22may have one or more mounts4that are movable along a length of the track, each mount carrying at least one jointed member46attached thereto. These jointed members46are designed to move in an arc around the fuselage24and are motivated by a central motivator (e.g., the mobile mount44). These mounts44may move forward and backward along the sympathetic tracks22. As such, actuating a jointed member46all the way to one side of the mount44and moving the mobile mount forward or backward along the track22, the entire assembly may avoid a wing, or other protrusion from the fuselage24during the manufacturing and assembly. Further, each jointed member46may have more than one end effector48, and even up to at least 16 end effectors, to cover a number of manufacturing tasks simultaneously.

FIG.3Aschematically shows an embodiment where a jointed member46having two end effectors48is extended entirely to one side by the mobile mount44. This may be a state where the mobile mount44can be actuated forward or backward on the track22to be clear of a wing (not shown here) that may be mounted just below the mobile mount44and attached to the fuselage24on the left side. Once clear of the wing, the jointed member46may be free to return to a central position on the mount44, or any position as needed, to accomplish an underlying manufacturing task. From this perspective, it is seen that the jointed member46is also formed sympathetic to the underlying manufactured item24. That is, the shape of the jointed member46is curved similar to the fuselage24.

FIG.3Bshows an embodiment where the jointed member46has two end effectors48and is extended entirely to another side by the mobile mount44. This may be a state where the mobile mount44can be actuated forward or backward on the track22to be clear of a tail fin (not shown here) that may be mounted on the top center of the fuselage24. Once clear of the tail fin, the jointed member46may be free to return to a central position on the mount44or any position as needed to accomplish an underlying manufacturing task. From this perspective, it can be seen that the jointed member46is also formed sympathetic to the underlying manufactured item24. That is, the shape of the jointed member46is curved similar to the shape of the fuselage24.

FIG.4shows a forward end50of an embodiment of a manufacturing system20having sympathetic rails22positioned adjacent to a fuselage24of an airplane52.

The tracks22are assembled around the fuselage24or airplane52, once positioned in a manufacturing bay. The tracks22are shaped along the contour of the underlaying manufactured item24. InFIG.4, the sympathetic tracks22culminate at a “front” end54at end effector interchange stations56. Thus, depending on what task is to be accomplished (sanding, cleaning, painting, welding, and the like, a specific task focused set of end effectors48may be deployed from dedicated stations56at the fore of the fuselage24. In this manner, the interchangeability of the system20can be accommodated by having stations56for dedicated tasks (e.g., refilling paint, changing sanding elements, and the like).

From this perspective, it can be seen that the four tracks22are formed sympathetic to the underlying manufactured item24around the cockpit area58. That is, the shape of the upper right30and upper left32tracks22is curved similar to the fuselage24. Such curvatures may also be present in systems dedicated to manufacturing wings, whether already attached to the fuselage, or as a stand-alone system.

End effectors48may be interchangeable and stored in stations56at the forward end54of this manufacturing environment. As one set of end effectors48are being serviced within a dedicated storage area56, other task-specific end effectors48can be deployed and functioning-even within the same task group. That is, one set of painters48can be in a station56getting cleaned or refilled while another set of painters48are painting portions of the airplane52.

FIG.5shows an embodiment of a manufacturing system20having sympathetic tracks22positioned adjacent to the wing of an airplane52. Other portions of an airplane, such as fuselages24are also discussed (seeFIG.2above). In this embodiment, there is one sympathetic track22positioned along a lateral axis60of the wing26. With this lateral track path22in place, it can be seen that the contour of the track paths22may match the contour of the wing26. That is, this track path22is sympathetic to the underlying manufactured item26in that there exists the ability to deviate from a linear path along the wing26. Additional deviations are possible because of the jointed member46attached to the mount44. Further, multiple end effectors48may be mounted to a single jointed member46to accomplish manufacturing tasks simultaneously. Further yet, multiple mounts44may be mounted to the sympathetic track22.

Each sympathetic track path22may have curvatures that are similar but not perfectly matched to the underlying manufactured part24. In this respect, a generalized “bend” near an end of a wing (not shown inFIG.5) may be positioned sympathetic enough to still undertake manufacturing tasks on a specific airplane wing, but also be able to do so on another similar but different airplane wing (e.g., different models of similarly sized airplanes).

That is, the path of the track22is not necessarily equivalent or identical to the contour of the underlying manufactured item, but rather just sympathetic to it in that the shape of the track generally follows the contour of the wing.

Further, the jointed member46may be sympathetic to a curvature of the wing as shown.

While the track22may have a “step” or other change in shape along its length to move the entire mount44, and hence the jointed member46(vertically, for example), sympathetically, the mount44itself may have a separate portion44A, as shown inFIG.6, which may move sympathetically while another portion44B remains fixed in two perpendicular directions relative to the track22, which also remains in a fixed or constant position along its length relative to an underlying support, such as a floor. For example, an upper portion44A of a lower mount44may be movable up and down, while an upper portion44B of the same mount may be vertically (and laterally) fixed relative to the track22.

In an embodiment shown inFIGS.7A-7B, a single track22is provided for carrying the mount44and the jointed member46has an arcuate length of greater than 180 degrees such that more than one half of a circumference of the manufactured item component24may be reached by one or more end effectors48, without moving the circumferential position of the jointed member46. A movement of the jointed member46relative to the mount44will result in the one or more end effectors48being able to reach all other circumferential positions on the manufactured item component24.

The jointed member46may be moved via a gear and rack system64as shown inFIGS.8and9, with a rack66having an arcuate shape to match the shape of the jointed member46and a driven gear68moving the jointed member46. Another arrangement for moving the jointed member46might be a cable drive system70shown schematically inFIG.10and described in greater detail in our co-pending U.S. patent application having Ser. No. 18/194,023 filed simultaneously on Mar. 31, 2023 herewith.

In a situation, as shown inFIG.11, where the manufactured item component24is held in an elevated position by vertical supports72, and the end effectors48are required to be positioned both above the points of support74, as well as below the points of support, the jointed members46may be moved to one side or another in the mount44so as to avoid contact with the supports72as the mount44is moved along the longitudinal direction of the component24. Once the mount44has moved longitudinally past the support72, the jointed member46can be moved in the mount44to reach higher or lower positions, as needed.

Thus, it is seen that the present invention provides a robotic manufacturing system20comprising:a track22extending along a length of a component24of a partially manufactured item52, wherein the component has a non-constant longitudinal shape, the track being supported independently of the partially manufactured item,at least one jointed member46,a mount44longitudinally movable along the track22and configured to receive the jointed member46in an articulating manner,at least one end effector48movably mounted on the jointed member46,wherein the jointed member46is movable along at least a portion of the length of the component24in a generally radial position that is sympathetic to the non-constant longitudinal shape of the component.

A longitudinal shape of the track22may be sympathetic to the non-constant longitudinal shape of the component.

The mount44may be configured to change a horizontal position of the jointed member46as the mount longitudinally moves along the track22when the component24is arranged in a horizontal elongated position.

The jointed member46may have an elongated arcuate shape.

The jointed member46may be longitudinally movable relative to the mount44along an elongated arcuate shape of the jointed member such that the jointed member can move in an arc spaced from and around an outer surface of the component24.

Two jointed members46may be received in the mount44, each member46being independently longitudinally movable relative to the mount along the elongated arcuate shape of the jointed member, such that each jointed member will move in an arc spaced from and around an outer surface of the component.

The jointed member46may extend through of an arc of greater than 180 degrees along the elongated arcuate shape of the jointed member.

The jointed member46may extend through of an arc of less than 180 degrees along the elongated arcuate shape of the jointed member.

At least a portion of the end effector48may have at least 6 degrees of freedom of movement relative to the jointed member.

At least a portion of the end effector48may be movable along a length of the jointed member46.

At least a portion of the end effector48may be movable laterally relative to the jointed member46.

At least a portion of the end effector48may be movable radially relative to the elongated arcuate shape of the jointed member46.

At least a portion of the end effector48may be movable angularly relative to the jointed member46.

At least one jointed member46may be configured to carry a plurality of end effectors48.

Each end effector48of the plurality of end effectors may be independently movable on the jointed member46.

The track22may be positioned above a top of the component24when the component is arranged in a horizontal elongated position.

The track22may be positioned below a bottom of the component24when the component is arranged in a horizontal elongated position.

The end effector48may be interchangeably mounted on the jointed member46.

The end effector48may be configured to perform a task consisting of at least one of: sanding, cleaning, preparing, painting, drilling, welding, fastening, inspecting, printing.

The track22may terminate in an interchange station56wherein the end effector48may be removed from the jointed member46and replaced with a different end effector.

The component may be a fuselage24of an aircraft52.

The component may be a wing26of an aircraft52.

The non-constant shape of the component24may comprise generally a cylinder having a non-constant diameter along a length thereof.

The non-constant shape of the component24may comprise a shape that tapers along a length thereof.

More than one track may22be provided adjacent to the component24.

More than one mount44may be movably mounted on the track22.

A method of manufacturing a component24of a partially manufactured item52, utilizing a robotic manufacturing system20is provided, where the robotic manufacturing system includes a track22extending along a length of the component24of the partially manufactured item52, wherein the track22has a non-constant longitudinal shape, and is supported independently of said component, there is at least one jointed member46, a mount44is longitudinally movable along the track22and is configured to receive the jointed member46in an articulating manner, at least one end effector48is mounted on the jointed member, wherein the jointed member46is movable along at least a portion of the length of the component24in a path that is sympathetic to the non-constant longitudinal shape of the component. The method comprises the steps:moving, in a first moving step, at least one of the mount44, the jointed member46, or the end effector48relative to the track22, to position at least a portion of the end effector48in an operating position relative to the component24,operating the end effector48to perform a manufacturing step on the component24,moving, in a second moving step, at least one of the mount44, the jointed member46, or the end effector48relative to the track22to distance the at least a portion of the end effector48from the operating position.

The first moving step may comprise moving the jointed member46in a path that is sympathetic to the non-constant longitudinal shape of the component.

The first moving step may comprise moving the mount44longitudinally along the track22.

The first moving step may comprise moving a portion of the mount44to change a vertical position of the jointed member46relative to the component24.

The jointed member46may have an elongated arcuate shape and the first moving step may comprise moving the jointed member46, along the elongated shape of the jointed member relative to the mount44, to move the jointed member in an arc spaced from and around an outer surface of the component24.

The first moving step may comprise moving at least a portion of the end effector48through at least one of 6 degrees of freedom of movement relative to the elongated arcuate shape of the jointed member46.

The first moving step may comprise moving at least a portion of the end effector48along a length of the jointed member46.

The first moving step may comprise moving at least a portion of the end effector48laterally relative to the jointed member46.

The jointed member46may have an elongated arcuate shape and the first moving step may comprise moving at least a portion of the end effector48radially relative to the elongated arcuate shape of the jointed member46.

The first moving step may comprise moving at least a portion of the end effector48angularly relative to the jointed member46.

At least one jointed member46may be configured to carry a plurality of end effectors48, and the first moving step may comprise moving each end effector48independently on the jointed member.

The end effector48may be interchangeably mounted on the jointed member46, and following the second moving step, the end effector may be moved to an interchange station56wherein the end effector48is removed from the jointed member46and replaced with a different end effector48.

More than one track22may be provided adjacent to the component24, and jointed members45, mounts44and end effectors48may be carried on each track22, such that the first moving step may be undertaken at more than one track simultaneously.

More than one mount44may be movably mounted on the track22, such that the first moving step may comprise moving more than one mount44simultaneously.

More than one end effector48may be movably mounted on the jointed member46, such that the first moving step may comprise moving more than one end effector simultaneously.

In another embodiment, a method of manufacturing a manufacturing a component of a partially manufactured item, utilizing a robotic manufacturing system20is provided wherein the robotic manufacturing system comprises a track22extending along a length of the component24of the partially manufactured item52, wherein the component24has a non-constant longitudinal shape and at least one horizontal or vertical projection or support72extends from a surface of the component24, the track22being supported at a distance from and independently of the component24, at least one jointed member46, a mount44longitudinally movable along the track22and configured to receive the jointed member46in an articulating manner, at least one end effector48mounted on the jointed member46, wherein the jointed member is movable along at least a portion of the length of the component24in a path that is sympathetic to the non-constant longitudinal shape of the component. The method comprises the steps:moving, in a first moving step, the jointed member46, to a position where an end of the jointed member46will avoid contact with the at least one horizontal or vertical projection72while the mount44, in a second moving step, is moving along the track22horizontally past the at least one horizontal or vertical projection72, moving, in a third moving step, the jointed member46, to a position in which the end of the jointed member would otherwise contact the at least one horizontal or vertical projection72if the mount44and jointed member46would be moved relative to the track22into a region vertically aligned with the at least one horizontal or vertical projection72,moving, in a fourth moving step, at least one of the mount44, the jointed member46, or the end effector48relative to the track22to position at least a portion of the end effector48in an operating position relative to the component24,operating the end effector48to perform a manufacturing step on the component24,moving, in a fifth moving step, at least one of the mount44, the jointed member46, or the end effector48relative to the track22to distance the at least a portion of the end effector48from the operating position.

While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise.