Patent ID: 12194651

DESCRIPTION

The figures and the following description provide specific illustrative embodiments of the disclosure. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the disclosure and are included within the scope of the disclosure. Furthermore, any examples described herein are intended to aid in understanding the principles of the disclosure, and are to be construed as being without limitation to such specifically recited examples and conditions. As a result, the disclosure is not limited to the specific embodiments or examples described below, but by the claims and their equivalents.

The structures described herein may comprise composite parts or metal parts. Composite parts, such as Carbon Fiber Reinforced Polymer (CFRP) parts, are initially laid-up in multiple layers that together are referred to as a preform. Individual fibers within each layer of the preform are aligned parallel with each other, but different layers exhibit different fiber orientations in order to increase the strength of the resulting composite part along different dimensions. The preform includes a viscous resin that solidifies in order to harden the preform into a composite part (e.g., for use in an aircraft). Carbon fiber that has been impregnated with an uncured thermoset resin or a thermoplastic resin is referred to as “prepreg.” Other types of carbon fiber include “dry fiber” which has not been impregnated with thermoset resin but may include a tackifier or binder. Dry fiber is infused with resin prior to curing. For thermoset resins, the hardening is a one-way process referred to as curing, while for thermoplastic resins, the resin reaches a viscous form if it is re-heated.

Turning now toFIG.1, an illustration of an aircraft in which an illustrative embodiment may be implemented. Aircraft10is an example of an aircraft which can be formed in half barrel sections ofFIG.1A, respectively. Aircraft10is an example of an aircraft10which is formed of half barrel section24of fuselage12.

In this illustrative example, aircraft10has wing15and wing16attached to body28. Aircraft10includes engine14attached to wing15and engine14attached to wing16.

Body28has tail section18and a nose section38. Horizontal stabilizer20, horizontal stabilizer21, and vertical stabilizer22are attached to tail section18of body28.

Fuselage12is fabricated from half barrel sections24with an upper half barrel section126joined to a lower half barrel section to form a full barrel section29-1,29-2,29-3,29-4,29-5. The full barrel section29-1,29-2corresponds toFIG.1A-Aand full barrel section29-5corresponds toFIG.1B-Band are serially fastened into fuselage12.

Wing15and wing16are formed of wing panels comprising an upper wing panel and a lower wing panel joined together.

FIG.1Ais a block diagram of an assembly line100in an illustrative embodiment. Assembly line100comprises any system, device, or component operable to pulse118or to iteratively micro pulse149a half barrel section120a distance less than its length109along a track110at frame pitch147(FIG.1C-C) and to perform work on the half barrel section120while the half barrel section120is paused between pulses118or micro pulses149. In further embodiments, assembly line100continuously moves the half barrel section120at a desired takt while work is performed upon half barrel section120. The half barrel section120comprises a portion of fuselage12when assembled into half barrel sections24. An embodiment has half barrel section120of approximately forty feet long while some other half barrel sections24are about twenty-five feet long. In such embodiments, the sections of fuselage may comprise any suitable arcuate portion of fuselage, such as a one-third, one-quarter, one-sixth barrel section of fuselage as desired. In some embodiments, the half barrel section120comprises a hardened composite part or a metal part, such as a section of the skin of an aircraft in which stringers and/or frames have been installed in order to enhance rigidity.

In this embodiment, assembly line100includes the track110, which supports the half barrel section120as the half barrel section120proceeds in the process direction199. The track110comprises one or more rails111, stanchions112(also referred to as pogos) having rollers114or grooves, other elements that facilitate motion (e.g., rolling or sliding) of the half barrel section120along the track110while also enforcing a desired position and/or orientation upon the half barrel section120. In further embodiments, the track110includes a chain drive, motorized cart, or other powered system that is capable of moving the half barrel section120in the process direction199.

Assembly line100further comprises indexing units130. In this embodiment, each indexing unit130is designed to physically couple with a feature124in a surface of the half barrel section120. In further embodiments, coupling comprises aligning the indexing unit with a feature124at the half barrel section120. In further embodiments, the feature124comprises a Radio Frequency Identifier (RFID) chip at the half barrel section120, and coupling comprises reading the RFID chip associated with the half barrel section120. In one embodiment, the indexing unit130indexes to a section of window manufacturing excess prior to the cutter cutting the material. In further embodiments, the indexing units130are dimensioned for interacting with RFID chips associated with the half barrel section120, such as on a half barrel section120that proceeds along a process direction199during assembly. In further embodiments, it is also possible to index and/or align trim tooling to installed window or door surrounds (e.g., surrounds397ofFIG.3). The surrounds can also be used as trimming templates.

The features124are placed at known locations along the half barrel section120, and in one embodiment each of the features124is separated by the same distance along the half barrel section120, although in further embodiments the features124are separated by varying distances that are predefined. In further embodiments, the features124are disposed in a manufacturing excess of the half barrel section120, which is trimmed away prior to the half barrel section120being attached to additional components and entering service (i.e., trimmed away with the excess when no longer needed for manufacturing indexing). In such embodiments, a station is indexed to an indexing feature in a section of window manufacturing excess prior to the section of window manufacturing excess being trimmed off. In such an embodiment, the features124(i.e., indexing features) are disposed on a manufacturing excess selected from the group consisting of: a window manufacturing excess and a lower edge manufacturing excess of a fuselage.

In still further embodiments, indexing units do not physically couple with the half barrel section120, because they include components (e.g., lasers, acoustic sensors, cameras, rollers, etc.) that precisely detect a position of the half barrel section120. That is, the half barrel section120is scanned/characterized as needed for the stations which are working on the half barrel section120during the current pulse without performing any physical coupling as the half barrel section120proceeds in the process direction199during assembly. In one embodiment, information provided via indexing (e.g., a shape or identifier associated with an indexing feature) indicates that a station shall stand down or remain idle for a period of time, instead of operating upon the half barrel section120.

Assembly line100further comprises indexing units130. Each indexing unit130is designed to physically couple with a feature124, such as a machined feature such as a hole or slot and/or an added feature such as a pin in the half barrel section120. The features124are placed at locations along the half barrel section120. In one embodiment, each of the features124is separated by a distance such as micro pulse149or a fraction or multiple thereof along the half barrel section120. In an embodiment, each of the features124is separated by the different distances along the half barrel section120. In another embodiment, each of the features124are not linearly aligned in lengthwise direction198along the half barrel section120. In further embodiments, the features124are disposed in a manufacturing excess129,135(i.e. section of material) of the half barrel section120, which is trimmed away prior to the half barrel section120entering service.

In further embodiments, tracking with RFID is used for indexing. The RFID tag124-1is associated with and located in the manufacturing excess129,135as part of a feature124. The RFID scanner134-1is part of complementary feature134. The RFID tag124-1is mounted singularly or along with other feature124in locations optimal to conveying indexing information to a cutting station, referred to specifically herein as a window manufacturing excess trim out station140,140-n. The RFID scanner134-1is mounted singularly or along with other complementary features134in locations optimal for communicating with feature124including RFID tag124-1to conveying indexing information to window manufacturing excess trim out station140,140-n. The indexing conveys information to window manufacturing excess trim out station140,140-nabout half barrel section120within the purview113of window manufacturing excess trim out station140,140-n. In such an embodiment, the RFID tags124-1themselves are used as the features124, and are serially located, (e.g., linearly aligned or non-linearly aligned) upon the manufacturing excess129,135of the half barrel section120. The indexing feature124including RFID tags124-1align with the complementary features134located relative to window manufacturing excess trim out station140,140-nand work station99. The indexing feature124including RFID tags124-1communicate specifics of desired 3D characterization, representation and/or orientation of IML128and OML122(FIG.1) for the half barrel section120via indexing unit130to controller160. The operations of the track110, window manufacturing excess trim out station140,140-n, work station99and/or other components are managed by controller160. In some embodiments, these features124, including RFID tags124-1, also include instructions for work to be performed by the window manufacturing excess trim out station140,140-nand work station99. For example, in an embodiment where window manufacturing excess trim out station140,140-nand/or work station99perform work on different purviews of a half barrel section120at the same time. An embodiment has an upper half barrel section followed by a lower half barrel section progressing serially down assembly line100. Another embodiment has the half barrel section120one model followed the half barrel section120of a different model. The indexing feature124on each half barrel section120communicates to the window manufacturing excess trim out station140,140-nand/or work station99what, if any, work needs to be completed on the particular section within purview113,113-1as it pauses between micro pulses149or during micro pulses149through window manufacturing excess trim out station140,140-nand/or work station99. The indexing feature124also communicates the OML122and IML128information during indexing.

In one embodiment, controller160determines a progress of the half barrel section120along the track110based on indexing, input from a technician, or artificial intelligence in accordance with an automated process such as input from a camera or physical sensor, such as a linear or rotary actuator. Work is performed on half barrel section120purview113,113-1in window manufacturing excess trim out station140,140-nand/or work station99, respectively, based upon index information conveyed to window manufacturing excess trim out station140,140-nand/or work station99. Then controller160instructs the window manufacturing excess trim out station140,140-nand/or work station99. Work station99is an installation station such as installation, or door surround installation or frame146installation. Window surround137installation, door surround installation or frame146installation stiffen up the half barrel section120prior removing manufacturing excess135. The controller160uses this input to manage the operations on the half barrel section120within purview113,113-1in window manufacturing excess trim out station140,140-nand/or work station99in accordance with instructions stored in a Numerical Control (NC) program. Controller160may be implemented, for example, as custom circuitry, as a hardware processor executing programmed instructions, or some combination thereof.

In this embodiment, each of the indexing units130includes a complementary feature134for insertion into, grasping, or otherwise fitting with a feature124. Complementary feature134for insertion into, grasping, or otherwise fitting with a feature124provides a hard stop at the end of a micro pulse149. Indexing units130are placed at locations relative to the window manufacturing excess trim out station140,140-nand/or work stations99and track110. Indexing units130are fixed relative to window manufacturing excess trim out station140,140-nand/or work station99for embodiment hard stops at the ends of micro pulse149. Indexing units130are not fixed relative to window manufacturing excess trim out station140,140-nand/or work station99for indexing during micro pulse149or continuous assembly. An embodiment has half barrel section120micro pulse149a distance at least equal to the shortest distance between features124and indexed to the indexing units130, and worked upon by the window manufacturing excess trim out station140,140-n. That is, the half barrel section120is indexed as part of a micro pulse149, pulse118or continuous system. Whenever the features124in the half barrel section120and the complementary features134in the indexing units130are mated, the location of the half barrel section120is indexed to a known location and the 3D characterization, representation and/or orientation of the half barrel section120relative to the track110, the indexing units130, and the window manufacturing excess trim out station140,140-nand/or work station99is known. Specifically, an embodiment has each indexing unit130disposed at a known offset (O) (e.g., along three axes) from the window manufacturing excess trim out station140,140-nand/or work station99, meaning that the act of indexing a half barrel section120to the indexing units130causes the position of the half barrel section120OML122and/or IML128relative to the window manufacturing excess trim out station140,140-nto be known. This embodiment is illustrated with indexing unit130offset O from window manufacturing excess trim out station140-n. Another embodiment has each indexing unit130disposed without offset (O) from the window manufacturing excess trim out station140and/or work station99. This embodiment is illustrated with indexing unit130at window manufacturing excess trim out station140and/or work station99. With or without the offset relative to window manufacturing excess trim out station140,140-nand/or work station99, indexing a half barrel section120to the indexing units130causes the 3D characterization, representation and/or orientation of the half barrel section120, relative to the position of the half barrel section120OML122and/or IML128, the window manufacturing excess trim out station140,140-n, and/or work station99, to be known.

In one embodiment, indexing is performed at least according to the following description. A structure in the form of a half barrel section120is carried upon a track110comprising a rail111embedded within or attached to the floor108. The rails111are positioned in locations relative to the indexing unit130and window manufacturing excess trim out station140,140-nand/or work station99. The half barrel section120has been fabricated on a layup mandrel according to precise dimensions, and this precise layup enables features124to be precisely located in a manufacturing excess129of the half barrel section120. Rough trimming of the half barrel section120occurs upon the layup mandrel. The manufacturing excess129is partially trimmed off to establish a bearing edge119. Thus, once the bearing edge119of the half barrel section120is located on the precisely located rails111, the half barrel section micro pulses through window manufacturing excess trim out station140,140-nand/or work station99. The 3D characterization, representation and/or orientation of the half barrel section120is precisely known when the indexing feature124is engaged, without the need for a full scan via probes or optical technology at each micro pulse149through window manufacturing excess trim out station140,140-nand/or work station99. In further embodiments, Non-Destructive Inspection (NDI) is utilized as an initial station during the processing of the half barrel section120in order to perform an initial baseline scan during micro-pulsing or during pauses between micro pulses149or both, or during continuous motion. This baseline scan is used during later processing of the half barrel section and is conveyed during subsequent indexing to work stations99.

The relative stiffness of the de-molded or otherwise formed half barrel section120is relied upon to help the half barrel section120maintain a desired EVIL128and/or OML122along with the precisely located rails111and precisely located bearing edge119to micro pulse149the half barrel section120without the need for any substantial shape defining tooling during micro pulsed assembly. In this arrangement, the features124are located precisely into the half barrel section120relative to the EVIL128and/or OML122and the precisely located rails111help convey the half barrel section120beyond window manufacturing excess trim out station140,140-nin process direction199through work station99without distortion. Therefore, a 3D characterization, representation and/or orientation and orientation of the half barrel section120within purview113,113-1including OML122and/or IML128is known by window manufacturing excess trim out station140,140-nand/or work station99quickly and precisely. This information is conveyed via indexing through controller160after each micro pulse149without the need to re-scan the purview113,113-1of half barrel section120each time. In this manner, the 3D characterization, representation and/or orientation of the half barrel section120OML122and/or IML128of at a specific portion within the purview113,113-1of a window manufacturing excess trim out station140,140-nand/or work station99is quickly conveyed to that particular station.

Because of the precise indexing performed, the tools at window manufacturing excess trim out station140,140-nand each work station99can be located relative to the OML122and/or IML128of the half barrel section120as desired when the half barrel section120is micro pulsed into place. Quick positioning the tools and technicians within the window manufacturing excess trim out station140,140-nand work station99relative to the OML122and/or IML128during the pause between micro pulses149increases the throughput and efficiency. The 3D characterization, representation and/or orientation of the half barrel section120OML122and/or EVIL128of the half barrel section120within purview113,113-1is then established or indexed into any Numerical Control (NC) programming or automated system in use at the window manufacturing excess trim out station140,140-nand/or work station99. Therefore, no setup time in the form of scanning is needed after each micro pulse149that exposes a purview113,113-1of the half barrel section120within the window manufacturing excess trim out station140,140-nor work station99. Similarly, no setup time is needed to bring tooling and technicians to the purview113,113-1of the half barrel section120within the window manufacturing excess trim out station140,140-nor work station99during the micro pulse149or the pause between micro pulses149or both. In some embodiments, multiple serially arranged NDI stations and/or work stations99perform work upon the half barrel section120during the same pause between micro pulses149. Furthermore, structure added to or removed from the half barrel section120in the prior work station99may be added or augmented to the half barrel section120electronic model or representation within the system and conveyed via indexing, without the need to scan the half barrel section120for the changes after and/or during micro pulse149. These augmentations can be done automatically, wherein typical characteristics/structures are added virtually to the scanned model.

That is, the indexing of a half barrel section120may be performed by aligning the indexing feature124to the indexing unit130. The window manufacturing excess trim out station140,140-nhas a known positional relationship with the indexing unit130. Indexing a half barrel section120includes mating a feature124at the half barrel section120with a complementary feature134at an indexing unit130having a known physical offset from the window manufacturing excess trim out station140,140-n, such that the mating instantly results in the half barrel section120OML122and EVIL128having a known location relative to the window manufacturing excess trim out station140,140-n. This is because the complementary features134at the indexing unit130are pre-located and sized to fit while the half barrel section120is at a specific and precisely determined location. In further embodiments, the indexing units130comprise cameras, lasers, acoustic sensors, or other components that index the half barrel section120without physical coupling with the indexing feature124of half barrel section120.

In still further embodiments, tracking is performed by scanning the RFID tags124-1that are mounted upon the manufacturing excess129,135of half barrel section120and are read as part of indexing a purview113,113-1of the half barrel section120within the particular window manufacturing excess trim out station140,140-nand/or work station99. The RFID tag124-1are features124and are serially located, but need not be linearly aligned upon a manufacturing excess129of the half barrel section120. In one embodiment, each RFID tag124-1used as indexing feature124aligns with each of multiple serially located window manufacturing excess trim out station140,140-nand/or work station99and communicate specifics of the 3D characterization, representation and/or orientation of the half barrel section120OML122and/or IML128as well as instructions for work to be performed at the window manufacturing excess trim out station140,140-nand/or work station99. The window manufacturing excess trim out station140,140-nand/or work station99work on purviews113,113-1of half barrel section120followed by a different half barrel section followed by a different half barrel section and of the same model of aircraft or a different model of aircraft, or a different section of the same model as the first two sections, as desired. The RFID tag124-1explains to the station what, if any, work shall be completed on the particular section being pulsed through window manufacturing excess trim out station140,140-nand/or work station99.

Scanning may be performed up stream of the work station that uses scan information, and the scanning may occur once or may occur multiple times. For example, scanning may occur at an NDI station and can be augmented by additions or subtractions to the half barrel section120being scanned.

Returning to the embodiment ofFIG.1A, each of the indexing units130includes a complementary feature134for insertion into, grasping, or otherwise fitting/joining/coupling with a feature124. Indexing units130are placed at fixed, known locations relative to window manufacturing excess trim out station140,140-nand/or work station99and track110. Whenever the features124in the half barrel section120and the complementary features134in the indexing units130are mated, the location of the half barrel section120is indexed to a known location in a coordinate space shared by the track110, the indexing units130, and the window manufacturing excess trim out station140,140-nand/or work station99. Thus, indexing provides a technique for characterizing the half barrel section120at each of the window manufacturing excess trim out station140,140-nand/or work station99. When the part is indexed, the configuration and loft of the part are known at the station to within desired tolerances. In further embodiments, half barrel section120retains a desired IML128and/or OML122shape without the external application of force. In any case, the half barrel section120is in conformance with a desired IML128and/or OML122when it receives work from window manufacturing excess trim out station140,140-nand/or work station99. Specifically, each indexing unit130is disposed at a known offset (O) (e.g., along three axes) from a station140, meaning that the act of indexing the half barrel section120to the indexing units130causes the position of the half barrel section120relative to window manufacturing excess trim out station140,140-nand/or work station99to be known at window manufacturing excess trim out station140,140-nand/or work station99. The width of the track110along with the shape of the half barrel section120, and the delaying of performing window or door cut-outs until after installation of the frames146and window surround137and door surrounds, and possibly other means of maintaining the desired curvature, help to ensure that the section configuration is as desired when indexed at a particular station. Work station99installs the window surround137around manufacturing excess135prior to trimming it off.

The relative stiffness of the de-molded or otherwise formed half barrel section120is relied upon to help the half barrel section120maintain a desired IML128and OML122along with the precisely located rails111and without the need for adding any substantial shape defining tooling during pauses between pulse118or micro pulse149and/or during pulse118or micro pulse149assembly.

Because of the precise indexing performed, the tools at window manufacturing excess trim out station140,140-nand/or work station99are able to know exactly where they are relative to the half barrel section120when the half barrel section120is indexed with indexing unit130. Therefore, no setup time or scanning is needed after each pulse118or micro pulse149of the half barrel section120. Furthermore, structure added to or removed from the half barrel section120in the prior station may be added to a model or representation that within the system (e.g., at a controller60), without the need to scan the half barrel section120for the changes after each pulse118or micro pulse149.

Window manufacturing excess trim out station140,140-nand/or work station99perform work on the half barrel section120. Specifically, the window manufacturing excess trim out station140,140-noperate one or more cutters142,142-nand grippers144,144-nto perform cutting operations on the half barrel section120that remove manufacturing excess135from the half barrel section120. The one or more cutters142,142-nuse reciprocating blades, circular blades, milling or etc. The grippers144,144-nattach via vacuum coupling to manufacturing excess135or coupling to features124in a manufacturing excess135. An embodiment has the grippers144,144-nfacilitate both supporting a cutter while cutting off manufacturing excess135, and dropping manufacturing excess135into chutes150,150-n. The gripper144,144-ncommunicates its location to the window manufacturing excess trim out station140,140-nto help it find the cutting line of the manufacturing excess135. Another embodiment has the gripper144,144-ncommunicating its location relative to the window surround137to window manufacturing excess trim out station140,140-nhelping cutter474follow window surround137like a template. Vacuums148,148-napply suction that removes dust generated during the cutting or milling process and places into chutes150. In one embodiment, the grippers144,144-ngrip a manufacturing excess135of the half barrel section120during the cutting, and place the separated manufacturing excess135-1into chute150,150-nto become part of an outflow361ofFIG.3at the direction of a controller160. That is, the controller160coordinates control of the grippers144,144-nand cutters142,142-nsuch that a gripper144,144-nattaches to the manufacturing excess135prior to cutting, and the gripper144,144-nplaces the separated manufacturing excess135-1into an outflow361of the chute150,150-n.

Separated manufacturing excess135-1is removed from half barrel section120and dropped into chutes150,150-n, resulting in openings133. In this embodiment, a window manufacturing excess trim out station140placed upstream with respect to the process direction199of the half barrel section120cuts out every other manufacturing excess, resulting in openings133and leaving the remaining manufacturing excess135to the window manufacturing excess trim out station140-nthat is disposed downstream. While two window manufacturing excess trim out stations140,140-nare shown, depending upon desired takt, more or less stations could be employed in assembly line100. Window manufacturing excess trim out station140,140-nare disposed along the track110and are separated by less than the length of the half barrel section120. For example, stations140may be spaced apart by a frame pitch147or a fraction or multiple thereof.

The operations of the window manufacturing excess trim out station are managed by controller160. In one embodiment, controller160determines a progress of the half barrel section120along the track110based on input from indexing, a technician, or a Numerical Control (NC) program. For example, the controller160may alter instructions in an NC program for the window manufacturing excess trim out station140,140-nto accommodate any deviations in position of the half barrel section120from a nominal position and orientation. Controller160may be implemented, for example, as custom circuitry, as a hardware processor executing programmed instructions, or some combination thereof.

Illustrative details of the operation of assembly line100will be discussed with regard toFIG.2. Assume, for this embodiment, that a half barrel section120has been pulsed down track110within range of an indexing unit130.

FIG.2is a flowchart illustrating a method200for cutting out sections of material from a structure in an illustrative embodiment. The steps of method200are described with reference to assembly line100ofFIG.1A, but those skilled in the art will appreciate that method200may be performed in other systems. The steps of the flowcharts described herein are not all inclusive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

In step202, the structure (half barrel section120) advances in the process direction199. For example, the half barrel section120is advanced by micro pulse149or pulse118. The pulse118is at least equal to length109. The micro pulse149is equal to frame pitch147or a fraction or multiple thereof. In further embodiments, micro pulse149facilitates greater work density by permitting work stations99or window manufacturing excess trim out station140,140-nplacement at frame pitch147, thus increasing manufacturing work density. Work stations99or window manufacturing excess trim out station140,140-nmay operate together after each pulse118or micro pulse149resulting in an increase in manufacturing work density and reduce floor space requirements, particularly over prior systems.

In step203, the half barrel section120is indexed to window manufacturing excess trim out station140,140-n, based on features124, RFID tags124-1located on the half barrel section120. This may comprise coupling the complementary features134of an indexing unit130to the features124, RFID tags124-1, respectively. Upon indexing, a position of the window manufacturing excess trim out station140,140-nand/or work station99to the half barrel section120becomes precisely known. Controller160commands window manufacturing excess trim out station140,140-naccording to the conveyed indexing. Controller160may then alter instructions in an NC program for the window manufacturing excess trim out station140,140-nto accommodate any deviations in position of the half barrel section120from the expected indexed position.

In step204, the gripper144,144-ncouples to manufacturing excess135of half barrel section120. The gripper144,144-ncouples to feature124or features124. The grippers144,144-nattach via vacuum coupling to manufacturing excess135or coupling to features124in a manufacturing excess135. The grippers144,144-ncouple to the IML128or the half barrel section and in particular to the manufacturing excess135.

Step206comprises placing a cutter142,142-nagainst the half barrel section120opposite the grippers144,144-n. This may comprise placing the cutter142,142-ninto contact with the OML122of the half barrel section120. The grippers144,144-ncouple to the IML128or the half barrel section120and in particular to the manufacturing excess135. The combination of the grippers144,144-non the IML128and the cutter142,142-non the OML122sandwich the half barrel section120there between. The cutter142,142-nand grippers144,144-nclamp the half barrel section120to form a clamp-up. In this manner, a gripper144,144-nsupports a cutter142,142-nat the window manufacturing excess trim out station140,140-nor vice versa while the cutter142,142-ncuts out a manufacturing excess135with the cutter142,142-n. The gripper144,144-ncommunicates its location to the window manufacturing excess trim out station140,140-nto help it find the cutting line of the manufacturing excess135. Another embodiment has the gripper144,144-ncommunicating its location relative to the window surround137to window manufacturing excess trim out station140,140-nhelping cutter142,142-nfollow window surround137like a template.

In step207, cutting out the separated manufacturing excess135-1using the cutter142,142-nfrom the half barrel section120, resulting in an opening133at the half barrel section120. This may comprise following a predefined contour, index conveyed instructions or instruction in an NC program or some combination to separate the manufacturing excess from the half barrel section120in a desired manner. During this process, gripper144,144-nand cutter142,142-nmay operate in tandem to clamp-up the half barrel section120and hold the manufacturing excess135within the claim-up. In one embodiment, operating the window manufacturing excess trim out station140,140-nto cut out the separated manufacturing excess135-1from the half barrel section120. An embodiment includes a two stage trimming process comprising performing a first cut at a first tolerance resulting in a separated manufacturing excess135-1. Then the method further comprises operating the window manufacturing excess trim out station140to cut out additional material from the half barrel section120during a second cut at a second tolerance. The first tolerance is at a less precise tolerance than the second tolerance. In one embodiment, this step involves operating multiple window manufacturing excess trim out stations140,140-nthat perform work on the half barrel section120during a pause between pulses118or the pause between micro pulses149that advance the half barrel section120in the process direction199. These window manufacturing excess trim out stations140,140-nmay comprise multiple cutters142,142-nthat operate on the same manufacturing excess135or different manufacturing excess135. Other stations in the assembly line100comprise NDI stations, painting stations, sealing stations, window surround install stations, door surround install stations, and/or cleaning stations, all of which are not shown, that operate on the same or different half barrel section, often at the same time. In an embodiment, the grippers144,144-nand cutters142,142-naccommodate lateral motion of the half barrel section120during micro pulse149or continuous motion relative to the window manufacturing excess trim out stations140,140-n.

In step208, the separated manufacturing excess135-1is disposed, by dropping separated manufacturing excess135-1down a chute150,150-n. The gripper144removes the separated manufacturing excess135-1that was cut off the half barrel section120, guiding it prior to dropping the material down the chute150,150-n. The chute150,150-nemploys gravity or some other means of removal device down the chute150,150-n. In embodiments where the half barrel section120is continuously driven, the gripper144,144-nand cutter142,142-nmay proceed, at least partially, in the process direction199along with the half barrel section120as fabrication continues. The separated manufacturing excess135-1exiting the window manufacturing excess trim out station140,140-nmay also be tracked by RFID tag124-1upon separated manufacturing excess135-1by RFID scanner134-1. These RFID tags provide unique identifiers, and the material may exit the station through and under the floor108and/or under the track110between stanchions112. In one embodiment, the gripper144,144-ndisposing the separated manufacturing excess135-1comprises placing the separated manufacturing excess135-1into the chute150,150-nand releasing it into chute150,150-n. The separated manufacturing excess135-1becomes part of an outflow361that removes the separated manufacturing excess135-1from the window manufacturing excess trim out station140,140-n.

In step210, separating the cutter142,142-nfrom half barrel section120and returning it and gripper144,144-nto a starting point within the window manufacturing excess trim out station140,140-nto await the next trim deployment

Method200facilitates separating manufacturing excess135as part of a window manufacturing excess trim out station140,140-nthrough which a half barrel section120pulses118, micro pulses149or continuously progresses through while moving in process direction199. The window manufacturing excess trim out station140,140-nis serially arranged in an assembly line100with other work stations99covering NDI stations, rework station, frame installation station, window surround installation station, door surround installation station upstream and edge trim out station, painting station, sealing station, and/or cleaning station located downstream. Many of these stations, not shown, are working upon half barrel section120at the same time at a common takt time as window manufacturing excess trim out station140,140-n. The serial arrangement of window manufacturing excess trim out station140,140-nand work stations99greatly increases work density upon half barrel section120.

FIG.3is an illustration of a series of cutting stations in a fabrication environment in an illustrative embodiment.FIG.3illustrates a series of window manufacturing excess trim out station140,140-n(e.g., end effectors313, manual tools (not shown), etc.) in a fabrication environment. According toFIG.3, the window manufacturing excess trim out station140,140-nperform cutting operations at a surface312of a half barrel section120. The half barrel section120also includes features124and RFID tag124-1located in a manufacturing excess129,135. Features124and RFID tag124-1are utilized by indexing units130and/or window manufacturing excess trim out station140,140-nto facilitate alignment before work is performed. In this embodiment, window manufacturing excess trim out station140,140-nare depicted as robot arms, although in further embodiments the cutting stations may comprise robots mounted to fixed tracks (not shown) that are placed proximate to the half barrel section120and follow an IML128. In a further embodiment, each window manufacturing excess trim out station140,140-nincludes or is accompanied by an NDI station390that inspects an edge133-1of opening133made at the window manufacturing excess trim out station140,140-n.

The half barrel section120is transported along stanchions112, which are secured to floor108, and include rollers114and/or grooves (not shown) that enforce a desire alignment with the half barrel section120. The half barrel section120includes window surrounds137, which manufacturing excess135where window cut-outs will be placed. The window surrounds137therefore are located just beyond boundaries of the manufacturing excess135. In one embodiment, the window manufacturing excess trim out station140,140-nuses the window surround137as a guide to control the position of a cutter142,142-nduring separation of manufacturing excess135. In other words, the window surround137is utilized to steer the cutter142during a first cut at a first tolerance resulting in separated manufacturing excess135-1. In this embodiment, cutter142-nof window manufacturing excess trim out station140-n, disposed furthest upstream, cuts out a portion to perform a fine “clean up” trim to finish opening133leaving a desired final trim edge398at a second tolerance. Second tolerance being tighter than first tolerance. In one embodiment, the final trim edge398is achieved via a cutter or machining process such as using a router or a mill.

Iteratively cutting out portions354of manufacturing excess135from the half barrel section120reduces the bulk of individual pieces dropped into the chutes150, and removed via outflows361, which may be implemented as conveyors, tracks, vacuum systems, containers, etc. Dropping the individual portions into the chutes150,150-nensures easier more efficient handling of the separated portions354. Furthermore, this arrangement enables routing of separated manufacturing excess135-1away from window manufacturing excess trim out station140,140-nvia an outflow361.

Furthermore, by iteratively operating the window manufacturing excess trim out station140,140-nto cut out a manufacturing excess135from the half barrel section120and advancing the half barrel section120in the process direction199, cut-outs for windows or other repeating openings may be rapidly installed. While iterative trimming may reduce blade wear and/or blade deflection using window manufacturing excess trim out station140,140-n, one pass cutting is also envisioned, wherein cutting to final trim edge398is performed in one pass and one or more window manufacturing excess trim out stations140,140-nare disposed along the assembly line100.

FIG.3also depicts a door manufacturing excess trim out station380, which follows a door surround382to cut out a manufacturing excess135-2for a door. That is, the cutting station utilizes a door surround382or surround397for a window as a template for guiding cut-out operations for that door or window. In further embodiments, door manufacturing excess trim out station380is integrated into window manufacturing excess trim out station140,140-n, and performs work when a door location advances to the window manufacturing excess trim out station140,140-n, as the presence of manufacturing excess135-2for door means that no manufacturing excess135for window exists at this location. Furthermore, in additional implementations, window manufacturing excess trim out station140,140-nand door manufacturing excess trim out station380may perform each other's tasks. For example, it is possible that a leading half/side of a manufacturing excess135-2for door cut out is worked upon by a door manufacturing excess trim out station380that is upstream, while simultaneously a trailing half/side of the manufacturing excess135-2for door cut out is being worked upon by another door manufacturing excess trim out station380that is downstream. It is also possible for a leading half/side of manufacturing excess135-2for door cut out to be worked upon by door manufacturing excess trim out station380and a trailing half/side of the manufacturing excess135-2for door cut out to be worked by the same door manufacturing excess trim out station380(e.g., after or even at least partially during a pulse118or micro pulse149). The same approach may be used on the manufacturing excess135for windows by window manufacturing excess trim out station140,140-n. That is, each manufacturing excess135for window is cut out over the span of two pulses or micro pulses, and similarly doors may be cut out over the span of two or more pulses118or micro pulses149. Similar operations may be performed by additional window manufacturing excess trim out station140,140-nto cut out manufacturing excess135, perform antenna cut-outs, etc. In some embodiments, an air knife392for sweeping debris after cutting operations for removing dust during a pulse118or micro pulse149or during continuous motion after cutting has been performed. An NDI station390is placed downstream of the window manufacturing excess trim out station140,140-n. In one embodiment, after sweeping debris, the debris is routed away from window manufacturing excess trim out station140-nand via chute150-nto outflow361.

Cutter142is shown trimming in a counter clockwise direction139-1during trimming. Cutter142-nis shown trimming in a clockwise direction139during trimming.

The NDI station390inspects final trim edges398at the openings133in order to detect out of tolerance conditions such as delaminations, voids or other conditions that necessitate analysis or re-work. The NDI station390may be narrowly focused on scanning the trim edges398and window surround137, or may be used to broadly scan the half barrel section120, and in particular, frame146, window surround137and door surround382installation.FIG.3further depicts a sealing station391that seals final trim edges398for windows, doors, or lower half barrel edges, as well a painting station393that paints openings for windows, doors, or lower edges.

FIG.4Aillustrates a track-mounted cutting station in a fabrication environment in an illustrative embodiment.FIG.4Aillustrates a cutting station470that is temporarily/removably track mounted in a fabrication environment in an illustrative embodiment. In the embodiment, cutting station470takes the form of a flex track type device. According toFIG.4A, the cutting station470travels via wheels472along a track460that is removably mounted to half barrel section120, and operates a cutter474to perform cutting operations at a surface412of the half barrel section120within a window belt. Track460is removably mounted to half barrel section120via suction cups and/or vacuum coupling. Similar to window manufacturing excess trim out station140,140-n(FIG.3), indexing conveys cutting instructions to cutting station470and secondarily to cutter474covering in instances where a window is needed, cutting location and dimensions or where a window is not needed, to skip the location. The window surround137is also capable of being used as a template during the cutting in a manner similar to window manufacturing excess trim out station140,140-n. Again, similar to the method used on window manufacturing excess trim out station140,140-n, a gripper144,144-n(FIG.1A) is coupled on the IML128or the manufacturing excess135within the window surround137. The gripper144,144-nlocation relative to the window surround137. The gripper144,144-ncommunicates its location to the cutting station470to help it find the cutting line of the manufacturing excess135. Another embodiment has the gripper144,144-ncommunicating its location relative to the window surround137to cutting station470helping cutter474follow window surround137like a template. The gripper144,144-nplaces the separated manufacturing excess135-1into chute150,150-n(FIG.1A). The gripper144,144-nis located at a fixed point on floor108or travels along on an interior track on wheels in a fashion similar to track460and wheels472. The interior tracked system would be removably coupled to the EVIL128to facilitate a parallel working arrangement of gripper144,144-nwith cutting station470.

An embodiment has cutting station470trim off manufacturing excess135at a location relative to chute150,150-nthat facilitates separated manufacturing excess135-1placement into chute150,150-n. One way this is accomplished is to make the separation of the manufacturing excess135occur at the same location relative to the floor108and chute150,150-n. Therefore, as half barrel section120pulses118or micro pulses149in process direction199, the cutting station470along with gripper144,144-nremains relatively stationary relative to chute150,150-nby advancing in opposite to process direction499by a pulse118or micro pulse149. The separated manufacturing excess135-1is then placed into chute150,150-n.

Another embodiment has a window surround installation station473traveling via wheels472along the track460and operates a fastener installer476to fasten window surround137to half barrel section120upstream of cutting station470within a window belt. Window surround installation station478installs fastener415through window surround137and half barrel section120. In this embodiment, cutting station470works in tandem with window surround installation station478.

The half barrel section120also includes features124and RFID tags124-1, in particular, manufacturing excess135which may be utilized by indexing units and/or cutting station470to facilitate alignment with manufacturing excess135before work is performed. The cutting station470provides an advantage by moving in an anti-pulse118-1or anti-micro pulse149-1relative to half barrel section120as it pulses118or micro pulses149through work stations99. The cutting station470moves within the coordinate system of the half barrel section120, and hence does not require substantial re-indexing after initially being indexed to the half barrel section120.

The half barrel section120is transported along stanchions112, which are secured to floor108, and include rollers114and/or grooves (not shown) that enforce a desired alignment onto the half barrel section120. The half barrel section120includes window surrounds137, which surround manufacturing excess135where window cut-outs will be placed. Cutting station470may direct the cutter474to follow the window surround137used as an inner or an outer boundary of a window surround137in order to facilitate cutting operations. Separated manufacturing excess135-1is then dropped into a gravity chute490. In further embodiments, additional features at the manufacturing excess135and/or manufacturing excess135-2for door cut-out regions may be utilized as guides to facilitate the direction of movement of the cutter474. Specifically, the features124and/or RFID tag124-1guide a location of the cutter474relative to a manufacturing excess135. After cut out operations have been completed, an opening133for a window remains.

FIG.4Aalso depicts a door surround382, and trim regions482-1through482-6which may be cut from a manufacturing excess135-2inside of the door surround382. Breaking the entire door into regions482, regions482-1through482-6, facilitates the handling of separated regions482-1through482-6, in a similar manner as discussed above for separated manufacturing excess135-1. That is, breaking/cutting into smaller sizes makes for easier disposal, and may even allow for multiple cutters to separate the manufacturing excess135-2for door from half barrel section120at the same time.

In a further embodiment, multiple cutting stations470travel along a track to perform iterative cutting. For example, a lead cutter may implement a rough cut, followed by one or more cutters cutting a window to a final trim edge for an opening. In further embodiments, NDI edge inspection devices, edge sealing devices, and/or painting devices follow the cutters on the track and work upon the trimmed edge.

FIG.4Billustrates a further track-mounted cutting station in a fabrication environment in an illustrative embodiment. In this embodiment, one or more cutting stations470-1are mounted to a track460-1removably coupled to door surround382and/or half barrel section120and proceed around the door surround382to cut out manufacturing excess135-2for door using cutters474. The cutting station470-1cuts through half barrel section from IML128side to create separated manufacturing excess135-2. The cutting station470-1, shown through a cut away481through half barrel section120, is shown progressing in a counter clockwise direction492-1. One or more cutting stations470-1are capable of mounting upon a track460-2removably coupled to window surround137and/or half barrel section120and proceed around the window surround137to create separated manufacturing excess135-1for window using cutters474. The cutting station470-1, shown through a cut away through half barrel section120, is shown progressing in a clockwise direction492.

Any of the cutting stations470discussed with regard toFIGS.4A-4Bmay be movably or fixedly mounted to the half barrel section120(e.g., via tracks460,460-1,460-2) affixed to the half barrel section120, or features of the half barrel section120itself such as door surround382and window surrounds137. These cutting stations470may travel with the half barrel section120as the half barrel section120is advanced by pulse118or micro pulse149or moved continuously in the process direction499. The cutting stations470may continue to move and/or otherwise operate regardless of whether the half barrel section120is paused or is moving. Furthermore, the cutting stations470-1may remain affixed to the half barrel section120for longer than work station99takt time if desired, and may continue to operate as the half barrel section120advances through multiple work stations99.

While systems for window and door cut-outs have been illustrated above, in further embodiments any suitable cut-out operations (e.g., for cargo doors, panels, antenna cut-outs, etc.) may be performed with the systems discussed above.

FIGS.5-7illustrate acquisition and removal of material cut by a cutting station in an illustrative embodiment. These FIGS. correspond with view arrows5ofFIG.3. InFIG.5, a half barrel section120, which travels along track110, receives a removable gripping force from a gripper144,144-n, such as a robot arm551disposed at an EVIL128of the half barrel section120. The removable gripping force is provided via vacuum coupling. The gripper144,144-nholds a separated manufacturing excess135-1that is being removed during the cutting, and disposes the separated manufacturing excess135-1at a chute150,150-nafter operating a window manufacturing excess trim out station140,140-nor cutting station470,470-1,470-2to cut out the manufacturing excess135,135-1. Specifically, the gripper144,144-napplies vacuum coupling, fastens into, tacks onto, clamps onto indexing feature124, or otherwise holds a region of the half barrel section120that is about to be cut via a window manufacturing excess trim out station140,140-nor cutting station470,470-1,470-2disposed at an OML122of the half barrel section120.FIG.5further depicts a floor108onto which the track110is mounted. Chute150,150-nare located in floor108. Window manufacturing excess trim out station140,140-nare shown on the right side ofFIG.5working on OML122while cutting stations470,470-1are shown on the left side at the same time. Either side are capable of being serviced by window manufacturing excess trim out station140,140-nor cutting stations470,470-1,470-2. Both sides are serviced by gripper144,144-nwhich feeds chutes150,150-n.

The cutting station470travels via wheels472along a track460that is removably mounted to half barrel section120via suction cups and/or vacuum coupling, and operates a cutter474to perform cutting operations at a surface412of the half barrel section120within a window belt. Track460is removably mounted to half barrel section120via suction cups and/or vacuum coupling. Similar to window manufacturing excess trim out station140,140-n, indexing conveys cutting instructions to cutting station470and secondarily to cutter474covering in instances where a window is needed, cutting location and dimensions or where a window is not needed, to skip the location. The window surround137is also capable of being used as a template during the cutting in a manner similar to window manufacturing excess trim out station140,140-n. Again, similar to the method used on window manufacturing excess trim out station140,140-n, a gripper144,144-nis coupled on the IML128or the manufacturing excess135within the window surround137. The gripper144,144-nlocation relative to the window surround137. The gripper144,144-ncommunicates its location to the cutting station470to help it find the cutting line of the manufacturing excess135. Another embodiment has the gripper144,144-ncommunicating its location relative to the window surround137to cutting station470helping cutter474follow window surround137like a template. The gripper144,144-nplaces the separated manufacturing excess135-1into chute150,150-n. The gripper144,144-nis located at a fixed point on floor108or travels along on an interior track on wheels in a fashion similar to track460and wheels472. The interior tracked system would be removably coupled to the IML128to facilitate a parallel working arrangement of gripper144,144-nwith cutting station470.

InFIG.6, manufacturing excess135is separated, and the gripper tool550moves separated manufacturing excess135-1into position over the chute150,150-nas shown on the right side ofFIG.6. On the left side ofFIG.6, one or more cutting stations470-1are mounted to a track460-1removably coupled to window surround137and/or half barrel section120, and proceed around the window surround137to cut out manufacturing excess135for door using cutters474. Track460-1is removably coupled to window surround137either clamping and/or by vacuum coupling. The cutting station470-1cuts through half barrel section from IML128side to create separated manufacturing excess135-1. A gripper144-2couples to the manufacturing excess135during trimming and passes the separated manufacturing excess135-1past cutter474and is dropped by gripper144-2into chute150,150-n. Gripper144-2, in this embodiment, is moveably attached to cutting station470-1. The cutting station470-1is capable of progressing in a clockwise direction492or in counter clockwise direction492-1relative to manufacturing excess135. The creation of separated manufacturing excess135-1occurs over chute150,150-nafter half barrel section120micro pulses149cutting station470-1over chute150,150-n. The cutting station470-1is then released from half barrel section120and cycled back to a point of origin upstream of the chute150,150-nfor attachment to another portion of the half barrel section120.

InFIG.7, the piece of separated manufacturing excess135-1is dropped into the chute150,150-n, and the gripper tool550moves back into position to grip a new portion of the half barrel section120. After creation of separated manufacturing excess135-1occurs, the cutting station470-1is then released from track460-2and cycled back to a point of origin145upstream of the chute150,150-nfor attachment to another portion of the half barrel section120. The track460-2is separated from window surround137and also cycled back to a point of origin145upstream of the chute150,150-nfor attachment to another portion of the half barrel section120.

FIG.8illustrates a face of a cutting head in an illustrative embodiment. In particular,FIG.8illustrates a face of a cutting head542of window manufacturing excess trim out station140,140-n, and corresponds with view arrows8ofFIG.5. InFIG.8, a blade830, such as a reciprocating, twisting or circular blade, a mill or other type of cutter is positioned on cutting head542. The proximity of cutting head542relative to half barrel section120and/or manufacturing excess135is detected by sensors835to position the cutting heads542according to indexed conveyed information. The cutting head542is separated relative to the half barrel section by bumpers820which physically contact the half barrel section. The bumpers820may also serve as a vacuum coupling device using vacuum delivered to cutting head542through window manufacturing excess trim out station140,140-n. The bumpers820and the blade830both project out of the page beyond a body810of the cutting head542sufficiently to separate the manufacturing excess135from half barrel section120. When the cutting head542is moved to place blade within a window surround137, bumpers820contact the half barrel section120and the manufacturing excess135during cutting operations. The gripper144,144-nlocates the window surround137and communicates it to sensor835and then blade830is guided using window surround137location data. The window surround137is installed before the window manufacturing excess trim out station140,140-n. In further embodiments, an inner or outer perimeter, or another feature of the surround acts as a guide. Suction ports840remove/vacuum dust/debris, Foreign Object Debris (FOD), etc. from cutting operations performed by the cutting head542during cutting, and the debris may be routed away from a window manufacturing excess trim out station140,140-ninto chute150,150-nand beyond via outflow361.

The half barrel section120pulses118, micro pulses149or continuously advances into window manufacturing excess trim out station140,140-npurview113. The half barrel section is indexed to window manufacturing excess trim out station140,140-n. The window trim out instructions are conveyed from indexing feature124and/or RFID tag124-1to window manufacturing excess trim out station140,140-n. Cutting head542is then located relative to manufacturing excess135to facilitate creating separated manufacturing excess135-1. The cutting head542is then vacuum coupled to half barrel section120using bumpers820to lock it into place. The blade830creates separated manufacturing excess135-1without cutting head542movement relative to half barrel section120. An embodiment has blade830fixed relative to the cutting head542with movement of the cutter relative to half barrel section120facilitated by cutting head542movement.

FIG.9is a flowchart illustrating a further method900for fabricating a structure by cutting out sections from a composite part in an illustrative embodiment. Step902includes acquiring station specific instructions by indexing with an indexing feature of a half barrel section disposed at a manufacturing excess trim out station. The station specific instructions can be indicated by one or more of a position of the feature (e.g., an indexing feature as discussed above), a spacing of the feature relative to other features, a unique identifier associated with an RFID feature comprising an RFID chip, a shape of the feature, a size of the feature, etc. For example, an indexing feature of a certain shape or size, or located at a certain position, can indicate an instruction to cut, or not cut, an opening with a specific station. The station specific instructions result in different operations at different cutting stations. That is, different stations may respond differently to the same input, for example such that upstream cutting stations omit cutting operations in response to a feature, but a downstream cutting station performs cutting operations in response to the same feature. In this manner, the feature conveys station-specific instructions, because the feature itself is interpreted to result in different actions at different cutting stations.

The instructions are acquired by an indexing unit interacting with the feature. In one embodiment, this comprises attempting to physically couple with the feature or image the feature via the indexing unit, while in another embodiment this comprises reading a feature in the form of an RFID chip (an RFID feature) embedded in the structure, via the indexing unit.

In one embodiment, acquiring station specific instructions from the feature comprises acquiring instructions that describe a portion of the structure within the purview of the station. In a further embodiment, this comprises providing station specific instructions from the feature to multiple stations regarding the portion of the structure within the purview of each station.

Step904includes operating the cutting station to cut out a section of material (i.e., manufacturing excess) from the structure based on the station specific instructions, resulting in an opening. In one embodiment, the instruction is interpreted as a go or no-go flag indicating whether the cutting station should operate. In a further embodiment, a shape or position or size or identifier for a feature indicates specifics of operation such as locations to be cut, cutting speed, shapes to be cut, etc.

In one embodiment, this further comprises performing operations upon the structure by multiple stations during a pause between pulses that advance the structure in the process direction. The multiple stations could comprise cutting stations, and the operations could include stand down operations for a station during which no work is performed by a station.

Step906includes advancing the structure in a process direction (e.g., process direction199ofFIG.1A). This may be performed via any of the techniques discussed above for advancing a structure (e.g., along a track).

FIG.10is an illustration of an array1000of feeder line outflows for in an illustrative embodiment. As used herein, an “outflow” refers to an active (e.g., motorized), vacuum propelled, pushed by airflow or passive (e.g., gravity-fed) outflow system that automatically removes debris placed in chutes150,150-nfrom assembly line100. Thus, outflows361may comprise chutes150,150-n, tracks110, vacuum system, Automated Guided Vehicles (AGVs), or other elements that facilitate automated removal of separated manufacturing excess129-1,135-1. Separated manufacturing excess129-1is derived from trimmed off manufacturing excess129from half barrel section120.

InFIG.10, an outflow1001advances debris1090for separated manufacturing excess135-1. The debris1090advances to outflow1005, which acquires additional debris, consisting primarily of vacuumed up debris and swept up debris from window trimming, from window trimming from outflow1007and outflow1008. Outflow1001,1007and1008are derived from the same trimming operation. Each of these outflows may receive the debris1090from one or more window manufacturing excess trim out station140,140-nat one or more assembly lines100. Meanwhile, outflow1002provides debris1090from separated manufacturing excess135-2to outflow1006. Outflow1006also includes additional debris, consisting primarily of vacuumed up debris from outflow1003and swept up debris from outflow1004is derived from trim off of manufacturing excess135-2from door trimming. Additionally, outflow1012provides debris1090from separated manufacturing excess129-1to outflow1010. Outflow1010also includes additional debris, consisting primarily of vacuumed up debris from outflow1009and swept up debris from outflow1011is derived from trim off of separated manufacturing excess129-1from bearing edge119trim off.

Integrating outflow1013receives debris1090from outflow1005, and also receives debris1090from outflow1010. Outflow1010itself receives debris1090from outflow1009, as well as outflow1011and outflow1012. Thus, the outflows1002,1003,1004,1006and outflows1001,1005,1007,1008and outflows1009,1010,1011,1012feed into each other until arriving at an integrating outflow1013. That is, the integrating outflow1013receives debris from the multiple outflows1001through1012. In this manner, as the outflows flow into each other, debris from the half barrel section120consisting of separated manufacturing excess129-1,135-1,135-2and associated dust from window, door and bearing edge trim off make up the debris1090. Separated manufacturing excess129-1,135-1,135-2, for the most part, still has RFID tag124-1. An RFID scanner134-1could track the RFID tag124-1as it progresses through outflows1001,1002,1003,1004,1005,1006,1007,1008,1009,1010,1011,1012and1013. In one embodiment, the outflows1001,1002,1003,1004,1005,1006,1007,1008,1009,1010,1011,1012and1013further comprise stations (not shown) which perform work on the debris1090such as sorting, breaking down, or advancing the debris1090along a corresponding outflow. Examples of such stations include grinders, shredders, vibrational engines, mills, stamps, sieves, baths, and other mechanical devices.

FIG.11is an illustration of a method1100of removing debris in an illustrative embodiment. Step1102comprises receiving debris1090at stations140,140-nwithin an assembly line100. The stations140,140-ngenerate debris1090at the assembly line100. This may be accomplished as the stations140,140-nperform work such as cutting, trimming, drilling, machining, etc. at the assembly line100. Step1104comprises routing the debris1090at the stations140via outflows (e.g., outflows1001through1013) away from the assembly line100. In further embodiments, the debris1090being removed may comprise a manufacturing excess, trim filings, dust, or other material. In a further embodiment, the debris1090is collected as cut-off chunks, is vacuumed as filings or chips, or is swept as filings or chips.

In further embodiments, multiple stations140feed trimmed off debris1090for windows, or trimmed off debris1090for doors, or trimmed off debris1090for a manufacturing excess disposed at an edge of a section of fuselage. In further embodiments, similar arrangements of outflows may be utilized to remove debris1090for a wing, such as excess trim and/or access hole material, or to remove any kind of debris1090for a fuselage.

EXAMPLES

Referring more particularly to the drawings, embodiments of the disclosure may be described in the context of aircraft manufacturing and service in method1200as shown inFIG.12and an aircraft1202as shown inFIG.13.FIG.12is a flow diagram of aircraft production and service methodology in an illustrative embodiment. During pre-production, method1200may include specification and design1204of the aircraft1202and material procurement1206. During production, component and subassembly manufacturing1208and system integration1210of the aircraft1202takes place. Thereafter, the aircraft1202may go through certification and delivery1212in order to be placed in service1214. While in service by a customer, the aircraft1202is scheduled for routine work in maintenance and service1216(which may also include modification, reconfiguration, refurbishment, and so on). Apparatus and methods embodied herein may be employed during any one or more suitable stages of the production and service described in method1200(e.g., specification and design1204, material procurement1206, component and subassembly manufacturing1208, system integration1210, certification and delivery1212, service1214, maintenance and service1216) and/or any suitable component of aircraft1202(e.g., airframe1218, systems1220, interior1222, propulsion system1224, electrical system1226, hydraulic system1228, environmental1230).

Each of the processes of method1200may 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.

FIG.13is a block diagram of an aircraft in an illustrative embodiment. As shown inFIG.13, the aircraft1202produced by method1200may include an airframe1218with a plurality of systems1220and an interior1222. Examples of systems1220include one or more of a propulsion system1224, an electrical system1226, a hydraulic system1228, and an environmental system1230. Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention may be applied to other industries, such as the automotive industry.

As already mentioned above, apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service described in method1200. For example, components or subassemblies corresponding to component and subassembly manufacturing1208may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft1202is in service1214. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the component and subassembly manufacturing1208and system integration1210, for example, by substantially expediting assembly of or reducing the cost of an aircraft1202. Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft1202is in service, for example and without limitation during the maintenance and service1216. Thus, the invention may be used in any stages discussed herein, or any combination thereof, such as specification and design1204, material procurement1206, component and subassembly manufacturing1208, system integration1210, certification and delivery1212, service1214, maintenance and service1216and/or any suitable component of aircraft1202(e.g., airframe1218, systems1220, interior1222, propulsion system1224, electrical system1226, hydraulic system1228, and/or environmental1230).

In one embodiment, a part comprises a portion of airframe1218, and is manufactured during component and subassembly manufacturing1208. The part may then be assembled into an aircraft in system integration1210, and then be utilized in service1214until wear renders the part unusable. Then, in maintenance and service1216, the part may be discarded and replaced with a newly manufactured part. Inventive components and methods may be utilized throughout component and subassembly manufacturing1208in order to manufacture new parts.

Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein may be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination of these. For example, an element may be implemented as dedicated hardware. Dedicated hardware elements may be referred to as “processors”, “controllers”, or some similar terminology. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” or “controller” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (DSP) hardware, a network processor, application specific integrated circuit (ASIC) or other circuitry, field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), non-volatile storage, logic, or some other physical hardware component or module.

Also, a control element may be implemented as instructions executable by a processor or a computer to perform the functions of the element. Some examples of instructions are software, program code, and firmware. The instructions are operational when executed by the processor to direct the processor to perform the functions of the element. The instructions may be stored on storage devices that are readable by the processor. Some examples of the storage devices are digital or solid-state memories, magnetic storage media such as a magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media.

Although specific embodiments are described herein, the scope of the disclosure is not limited to those specific embodiments. The scope of the disclosure is defined by the following claims and any equivalents thereof.