Patent ID: 12252271

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 airframe components discussed herein may be fabricated from metal or may be fabricated as composite parts. Composite parts, such as Carbon Fiber Reinforced Polymer (CFRP) parts, are initially laid-up in multiple layers that together are referred to as preforms. Individual fibers within each layer of a 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 aircraft10is depicted in which an illustrative embodiment may be implemented. In this illustrative example, aircraft10has a right wing15and left wing16attached to fuselage12. One each of engines14are attached to right wing15and left wing16. Embodiments of aircraft10are known with additional engines and different engine placements. Fuselage12includes a tail section18and a nose section38. Horizontal stabilizer20, horizontal stabilizer21, and vertical stabilizer23are attached to tail section18of fuselage12. Aircraft10is an example of an aircraft where the majority of the fuselage12is formed from multiple half barrel sections24, the fabrication of which is partially illustrated inFIG.2. The multiple half barrel sections24, when attached together, form the majority of fuselage12.

As mentioned, fuselage12is fabricated from multiple half barrel sections24. Half barrel sections24are configured to be either an upper half barrel section40or a lower half barrel section42which are ultimately joined together to form a full barrel section44.FIG.1depicts several full barrel sections including:44-1,44-2,44-3,44-4, and44-5. For completeness, full barrel section44-1is fabricated using upper half barrel section40-1and lower half barrel section42-1, full barrel section44-2is fabricated using upper half barrel section40-2and lower half barrel section42-2, full barrel section44-3is fabricated using upper half barrel section40-3and lower half barrel section42-3, full barrel section44-4is fabricated using upper half barrel section40-4and lower half barrel section42-4, and full barrel section44-5is fabricated using upper half barrel section40-5and lower half barrel section42-5. The full barrel sections44-1,44-2correspond to view A-A and illustrate that the full barrel sections44are serially fastened into fuselage12. Lower half barrel section42-3is sometimes referred to as a wing box as the right wing15and left wing16attach to this section.

All of the above described half barrel sections (e.g., upper half barrel section40and lower half barrel section42), unless specifically otherwise described, will be referred to generically as half barrel section24. As shown inFIG.1, each half barrel section24includes one or more frames146, separated at a frame pitch147, which helps define an inner mold line (EVIL) loft60and an outer mold line (OML) loft62for the half barrel section24. In some embodiments, the half barrel section24comprises a hardened composite skin part or a metal skin part, such as those awaiting installation of window surrounds145and door surrounds145-1(view A-A) and frames146to enhance rigidity.

FIG.2depicts an assembly environment100in an illustrative embodiment. Assembly environment100comprises an arrangement of machinery and tools that facilitates efficient and repeatable fabrication of aircraft, such as aircraft10. Assembly environment100has been enhanced to enable large airframe components, such as those for wing panels or sections of fuselage, to be fabricated and assembled on continuous, micro pulsed and/or pulsed assembly lines. This enables the portion of the structure needing work to be brought to workers, tools, and equipment, instead of requiring workers, tools, and equipment be brought to or into the structure. Assembly environment100provides a substantial benefit by reducing the amount of non-value added time expended during the assembly of an airframe, while also reducing the amount of factory space occupied by increasing work density. An embodiment has one half barrel section24as a composite skin part of one aircraft model and another half barrel section24as a metal skin part progressing serially down the assembly environment100.

A process tracking server102tracks and/or manages the operations of assembly environment100via memory104and controller106, which in the illustrated embodiment includes assembly lines110,120. Assembly line110operates to perform assembly operations on an upper half barrel section116and a lower half barrel section118. Assembly line120operates to perform assembly operations on an upper half barrel section126and a lower half barrel section128. One difference between assembly lines110and120is that assembly line110is configured for the assembly of non-cylindrical half barrel sections while assembly line120is configured for the assembly of cylindrical half barrel sections. Generally, operations of assembly lines110and120are the same, and reference numbers referring to components found in both assembly lines110,120will be used, for example, work stations114,124where work stations114are within assembly line110and work stations124are within assembly line120. A similar methodology is used when referring to the components that are assembled in the assembly lines110,120. For example, upper half barrel section116is assembled in assembly line110, while upper half barrel section126is assembled within assembly line120. Similarly, lower half barrel section118is assembled in assembly line110, while lower half barrel section128is assembled within assembly line120. When a difference between the two assembly lines110,120is relevant, an explanation will be provided herein.

As further discussed herein the process tracking server102directs the operations of one or more work stations114,124in the assembly environment100. In this embodiment, the process tracking server102includes a memory104that stores one or more Numerical Control (NC) programs for operating the assembly lines110,120. Controller106of the process tracking server102may further process feedback from the work stations114,124and/or assembly lines110,120, and provide instructions to the work stations114,124or reports to an operator based on such feedback.

In one embodiment, RFID readers or other indexing components115,125associated with a work station114,124, enable the act of indexing to directly provide instructions to a work station114,124. The instructions are for the portion of the upper half barrel section116,126and lower half barrel section118,128within the purview114-1,124-1of the work stations114,124. In such an embodiment, the instructions can be passed between controller106and the particular work station. Controller106may be implemented, for example, as custom circuitry, as a hardware processor executing programmed instructions, or some combination thereof. Memory104stores instructions for operating controller106and stores digital data.

In this embodiment, assembly environment100includes assembly line110for fabricating sections of fuselage12that exhibit non-uniform cross sections across their length, and further includes assembly line120for fabricating sections of fuselage12that exhibit largely uniform cross sections across their length. The assembly line110processes the upper half barrel section116and a complementary lower half barrel section, lower half barrel section118, respectively. The assembly line120processes the upper half barrel section126and a complementary lower half barrel section, lower half barrel section128, respectively. When upper or lower is not relevant, upper half barrel section116and lower half barrel section118are sometimes referred to together herein as a half barrel section117, while upper half barrel section126and lower half barrel section128are sometimes referred to together herein as half barrel section127. Arcuate sections119refer to any type of barrel section including half barrel sections117,127, quarter barrel sections, and one third barrel sections, with or without a uniform cross-section.

Half barrel sections117,127correspond to half barrel sections24after processing through assembly environment100. The assembly lines110,120discussed herein may further be operated to fabricate multiple sets of half barrel sections117,127or other arcuate sections119.

The assembly line110is configured with work stations114that are capable of accommodating the upper half barrel sections116and lower half barrel sections118with more exotic shapes such as tapered, as well as other arcuate sections119near the nose section38or tail section18. Work stations114associated with assembly line110exhibit a broader range of motion in order to accommodate the tapered nature of these half barrel sections117and non-uniform cross section arcuate sections119.

The assembly line110further includes a track112, along which upper half barrel sections116and lower half barrel sections118proceed in a process direction199. Track112includes a drive system113to advance the half barrel sections117along the track112. The track112brings the half barrel sections117in a process direction199to tools and equipment (not shown) disposed at work stations114,124which are serially arranged in a process direction199.

The track112may comprise a series of discrete stanchions having rollers, a rail or set of rails (not shown), etc., and airframe components at the track112may be pulsed incrementally in the process direction199across the work stations114,124. Work stations114,124are serially aligned, and the half barrel sections117or arcuate sections119proceed through the work stations114,124serially. While only a few work stations are shown, many are contemplated, since work stations114,124can be configured to perform operations such as, but not limited to, demolding, installing window surrounds, installing door surrounds, trimming manufacturing excess, installing frames, cutting out window manufacturing excess or otherwise removing material, NDI inspection, edge sealing, cutting out door manufacturing excess, installing windows and installing doors. Some work stations114,124may perform multiple of the above listed tasks, while other work stations114,124are dedicated to a single task.

In one embodiment, the work stations114,124are spaced and operated such that work is performed by multiple work stations on an upper half barrel section116of fuselage12simultaneously. The same is true for lower half barrel sections118. In a further embodiment, the work stations114are arranged at a work density, at least in part, based on a takt time for the half barrel section117or the arcuate sections119being fabricated. The same is true for work stations124with respect to upper half barrel sections126and lower half barrel sections128. That is, the work stations124are arranged at a work density, at least in part, based on a takt time for the half barrel section127or the arcuate sections119being fabricated.

The assembly line110processes the upper half barrel section116and delivers it to assembly stage320, for example, configured as a crown module attach station, for attachment of a crown module364. The assembly line110processes the lower half barrel section118for delivery to assembly stage330, for example, configured as a floor grid attach station, for joining to a passenger floor grid324and/or a cargo floor grid326.

In much the same way, work stations124are spaced and operated in the assembly line120to process the upper half barrel sections126and the lower half barrel sections128, that is, half barrel sections127along a track122having a drive system113-1. The assembly line120processes the upper half barrel section126and delivers it to assembly stage321for joining to a crown module364as well as the lower half barrel section128which is delivered to an assembly stage331for joining to a passenger floor grid324and/or a cargo floor grid326. It is understood that a crown module for upper half barrel section116is different than a crown module for upper half barrel section126, since upper half barrel section126is represented as being cylindrical and longer than upper half barrel section116, but for ease of understanding, both crown modules will be referred to herein as crown module364. Similarly, no matter which lower half barrel section is being referred to, the passenger floor grid is referred to as passenger floor grid324and the cargo floor grid is referred to as cargo floor grid326, the floor grids in combination being referred to herein in subsequent figures as floor grid365(FIG.5).

The assembly line120includes track122, along which upper half barrel section126and lower half barrel section128proceed in the process direction199in a similar fashion to that described above for the assembly line110. The assembly line120further includes work stations124having indexing components125. The work stations124, indexing components125, and track122may be implemented in a similar fashion to similarly recited components of the assembly line110. However, the work stations124may differ in that they may be more tightly conformed to each of the upper half barrel section126and lower half barrel section128being worked upon. There is less cross sectional variation between the upper half barrel section126and the lower half barrel section128than upper half barrel section116and the lower half barrel section118. As mentioned above, upper half barrel section126and the lower half barrel section128of assembly line120are more uniform in shape and size than of the upper half barrel section116and the lower half barrel section118of the assembly line110.

In further embodiments, additional assembly lines fabricate right wing15and left wing16for assembly together with the fuselage12to form a complete airframe. The assembly lines110,120are either operated in a pulsed fashion where the upper half barrel sections116,126and lower half barrel sections118,128advance in a process direction199a distance equal to a pulse length123,123-1or a micro pulse129. A micro pulse129is less than pulse length123,123-1, and in an embodiment, is equal to a frame pitch147between frames146of the upper half barrel sections116,126and lower half barrel sections118,128or a fraction or multiple thereof. A pulse length123, or a length of a micro pulse129can be the same for assembly lines110and120, or they can be different. Frame pitch147in an embodiment is about 18 to about 36 inches. After the micro pulse129, the upper half barrel sections116,126and lower half barrel sections118,128pause, then micro pulse again129in a process direction199.

Another embodiment has the upper half barrel sections116,126and lower half barrel sections118,128continuously advancing in the process direction199without pause. Thus, the assembly lines110,120discussed herein enable half barrel sections117,127to proceed with a desired takt across multiple different work stations in a pulsed, micro pulsed, or continuous fashion.

During these processes, tooling such as layup mandrels may be placed onto or removed from the tracks112,122as needed. In one embodiment, the track112,122include a drive system113,113-1, such as a chain drive, that moves the half barrel sections117,127, although in further embodiments the sections are independently driven along the tracks112,122.

In one embodiment, and referring to assembly line110, the upper half barrel sections116and the lower half barrel sections118are pulsed synchronously at the same time by the same amount of distance in the process direction199. The work stations114then perform work upon the upper half barrel section116or the lower half barrel section118in pauses between the pulses and/or during pauses at a common takt time. Thus, during the fabrication process, multiple work stations114work upon the upper half barrel sections116and/or the lower half barrel sections118during the same pause between micro pulses129and/or during micro pulse129.

Similarly, and referring to assembly line120, the upper half barrel sections126and the lower half barrel sections128are pulsed synchronously at the same time by the same amount of distance in the process direction199. The work stations124then perform work upon the upper half barrel section126or the lower half barrel section128in pauses between the pulses and/or during pauses at a common takt time. Thus, during the fabrication process, multiple work stations124work upon the upper half barrel sections126and/or the lower half barrel sections128during the same pause between micro pulses129and/or during micro pulse129.

In one embodiment of assembly line110, one or more work stations114also perform their work independently or synchronously upon the same half barrel section, half barrel section117, or the arcuate sections119during a pulse. Similarly, and in regard to assembly line120, one or more work stations124also perform their work independently or synchronously upon the same half barrel section, half barrel section127, or the arcuate sections119during a pulse. Such work stations might be referred to as traveling work stations139,139-1as they are attached to the half barrel section and move with the half barrel section. This work may include Non-Destructive Inspection (NDI), trimming of a manufacturing excess, or application of a sealant or other processes. In further embodiments, the half barrel sections117,127proceed continuously along the track112,122, and the work stations114,124perform work on the half barrel sections117,127as the half barrel sections117,127and the traveling work stations139,139-1attached thereto continue to move.

In some embodiments of assembly line110or120, the half barrel sections117,127are spaced with predetermined gaps131such as equal to a micro pulse129distance such as a fraction or multiple of frame pitch147or any distance less than or equal to a length of the half barrel section117,127or the arcuate sections119. Gaps131help to account for production delays, such as re-work or out of position work of the half barrel section117,127or the arcuate sections119or work station114,124maintenance and/or technician break time.

Re-work or out of position work is rarely required, but can be performed in certain circumstances when a portion of the half barrel section117,127or the arcuate sections119needing re-work or out of position work is between work stations114,124or within work stations that do not need to perform work such as a window surround installation station opposite a lower half barrel section118. This enables unaccounted-for delays to be absorbed into the production process. The rework or out of position work discussed above can be performed within gaps131between the work stations114,124. Furthermore, in one embodiment, the half barrel section117,127or the arcuate sections119continues to progress through the work stations114,124while the rework or out-of-position work is being performed. Thus, the assembly environment100does not stop advancing in process direction199to work upon half barrel section117,127or the arcuate sections119to accommodate rework or out-of-position work. Such out of position work can include scheduled and unscheduled maintenance.

During the movement or in between micro pulses129of pulse length123,123-1, the half barrel sections117,127or the arcuate sections119encounter the indexing components115,125at the work stations114,124. The indexing components115,125physically interact with or nondestructively inspect indexing features133on or in the upper half barrel sections116,126and lower half barrel sections118,128and enable alignment to the work stations114,124before work is performed.

The indexing features133, such as physical features or Radio Frequency Identifier (RFID) chips, are engaged by an indexing components115,125associated with the work station114,124. Each indexing component115,125conveys to the work station114,124a 3D characterization of the upper half barrel sections116,126and lower half barrel sections118,128within a purview114-1,124-1of the work station114,124. The indexing also enables the determination of which tasks that a work station114,124is to accomplish on the particular half barrel section. The work/task are based on the information that the indexing features133convey to the indexing components115,125.

Referring back toFIG.1, an example of 3D characterization is of the inner mold line (EVIL) loft60and/or outer mold line (OML) loft62. The indexing described above results in instructions to the work station114,124about the work to be performed by the work station114,124upon the upper half barrel sections116,126and lower half barrel sections118,128. This indexing process can be performed multiple times, and at the same time, per pulse, or micro pulse129, for respective multiple work stations, work stations114,124. The work stations114,124may then perform the work during the pause between micro pulses129or during the micro pulses129themselves.

The indexing components115,125can comprise hard stops, pins, holes, or grooves that are complementary to the indexing features133for physical securement thereto. An embodiment has many indexing features arrayed upon the upper half barrel sections116,126and lower half barrel sections118,128, for example, in a manufacturing excess. In further embodiments, the indexing components115,125can comprise sensors, such as laser, ultrasonic, or visual inspection systems that track and then align with indexing features133.

Additional indexing features, indexing features133, also include RFID chips. RFID readers are another embodiment of indexing component115,125, that read the RFID chips. These non-contact techniques may be utilized, for example, within assembly lines110,120that continuously move upper half barrel sections116,126and lower half barrel sections118,128and may further be used to control movement of the half barrel sections117and/or arcuate sections119.

In further embodiments, indexing components115,125of hard stops, pins, holes, or grooves that are complementary to the indexing features133are utilized for continuous movement systems where traveling work stations139,139-1are utilized. In such embodiments, engagement of indexing features133to indexing components115,125occur during the advancement of the upper half barrel sections116,126and lower half barrel sections118,128within purview114-1,124-1of the next work station. The work station114,124can track the upper half barrel sections116,126and lower half barrel sections118,128as they advance in the process direction199. Continuing, traveling work stations139,139-1are attached in a work station114,124to the upper half barrel sections116,126or lower half barrel sections118,128and ride along with the half barrel sections117,127as it progresses in pulse, micro pulse, or continuously.

The traveling work station139,139-1performs its work upon the half barrel sections117,127and then separates and returns to the attachment point139-2for future use. An example of the traveling work station139,139-1is a flex track device or some similar device that follows a track removably installed onto the upper half barrel section116,126and/or lower half barrel section118,128.

Prior to entry into the assembly environment100, the upper half barrel sections116,126and lower half barrel sections118,128are laid up upon a layup mandrel (not shown) orientated with the crown135,135-1up and the keel137,137-1up, respectively. The orientation of the lower half barrel sections118,128is maintained from demold from the layup mandrel, through floor grid365installation, and up to where the lower half barrel sections118,128are inverted into a keel137,137-1down orientation. This inversion occurs in an inversion station (not shown) just prior to pulsing to join station194. This configuration enables different work stations to serially process the upper half barrel sections116,126and lower half barrel sections118,128in a pulsed manner through the same work stations during fabrication.

In one embodiment, the orientation of upper half barrel sections116,126and lower half barrel sections118,128on assembly line110,120, respectively, is set by a layup mandrel upon which the sections were laid up. The layup mandrel progresses from layup through cure with a preform laid-up onto it. After hardening, the upper half barrel sections116,126and lower half barrel sections118,128are then removed from the respective layup mandrels without changing the upper half barrel sections116,126and lower half barrel sections118,128orientation.

In an embodiment, multiple aircraft models are processed in serial on assembly lines110,120. Upper half barrel sections116,126and lower half barrel sections118,128for one model serially proceed down the assembly line110,120followed by the upper half barrel sections116,126and lower half barrel sections118,128of a different model. For example, a lower half barrel section118,128progresses down an assembly line110,120followed by a complementary upper half barrel section. Likewise, these lower half barrel sections118,128and upper half barrel sections116,126might be followed by another aircraft model's lower half barrel sections118,128and upper half barrel sections116,126, followed by the lower half barrel sections118,128and upper half barrel sections116,126of yet another model and so forth between aircraft models, if such a production methodology meets a need. Additionally, more than one assembly line110,120each are also envisioned in some embodiments to make sure that upper half barrel sections116,126and lower half barrel sections118,128are produced at a desired rate.

In some embodiments, work stations114,124discussed herein have the capability of performing work on different portions of upper half barrel sections116,126and lower half barrel sections118,128and are able to accommodate different diameters from model to model. Each indexing operation between indexing components115,125and indexing features133tells the work station114,124what lower half barrel sections118,128and upper half barrel sections116,126and which airplane model is within its purview114-1,124-1and what work needs to be performed, or if no work needs to be performed. For example, window manufacturing excess cut out stations may refrain from creating window cut outs when a lower half barrel section118,128is within their purview114-1,124-1since a window cut out is not needed.

A process tracking server102tracks and/or manages the operations of assembly lines110,120discussed herein, for example, by directing the operations of one or more work stations114,124in the assembly environment100. In this embodiment, the process tracking server102includes a memory104that stores one or more Numerical Control (NC) programs for operating the assembly lines110,120. A controller106of the process tracking server102may further process feedback from the work stations114,124and/or assembly lines110,120, and provide instructions to the work stations114,124or reports to an operator based on such feedback. In one embodiment, RFID readers or other indexing components125enable the act of indexing to directly provide instructions to a work station114,124for the portion of the upper half barrel section116,126and lower half barrel section118,128within the purview114-1,124-1of the work station114,124. In such an embodiment, the instructions can be passed between controller106and the particular work station. Controller106may be implemented, for example, as custom circuitry, as a hardware processor executing programmed instructions, or some combination thereof. Memory104stores instructions for operating controller106and may comprise a suitable receptacle for storing digital data.

According toFIG.2, each work station114at an assembly line110may be fed/supplied materials and/or components by a feeder line149(e.g., based on a takt time for a section of fuselage, and as illustrated inFIG.3), and these materials and/or components are affixed to the upper half barrel section116,126and lower half barrel section118,128being worked upon by the work stations114,124. Feeder lines149provide additive materials/components to the work stations114,124. Each feeder line149is designed to generate materials at a takt time in order to provide the additive material/component to a work station114,124just in time (JIT) for assembly onto a larger structure (e.g., a section of fuselage), which is also pulsed at a takt time. That is, the feeder lines149deliver the components JIT to the work stations114,124in an order of usage by the work stations114,124. In one embodiment, the feeder lines149that have a takt time equal to a fraction of a fuselage takt time.

The takt times of the feeder lines149, and/or the assembly lines110,120need not be the same. For instance, an upper half barrel section116and a lower half barrel section118may be micro pulsed through several work stations114at the same time. The upper half barrel section116and lower half barrel section118are indexed to the work stations114and each dedicated feeder line performs, for example, NDI, window surround installation, door surround installation, window manufacturing excess trim/removal, door manufacturing excess trim/removal, installing windows and installing doors etc. Feeder lines149also include output from the work stations114, including NDI inspection data and any excess trimmed off of upper half barrel section116and lower half barrel section118. A similar scenario can occur for assembly line120and the various components therein and assembled therein.

In a further example, the feeder line149provide frames146JIT to a work station114that installs the frames146onto upper half barrel section116and lower half barrel section118. Likewise, feeder lines149provide window surrounds JIT to a work station114where window surrounds are installed and door surrounds JIT to a work station114where door surrounds are installed. For each feeder line149, production times are designed based on the takt of an associated work station114. The feeder lines149each serially pulse components during fabrication, and completed components arrive at each work station114at a common takt time. This takt time design proceeds through each of the feeder lines149from the smallest part to the largest final assembly.

If a takt time cannot be achieved, it is possible to adjust the work statement of a particular work station to reduce or increase the amount of work occurring at the particular work station. In a further embodiment, it is possible to add or remove a work station114from the process based upon a work statement and a desired takt time for the entirety of assembly line110. Takt time is considered to be a number of minutes per month, divided by a number of desired units (e.g., of aircraft, stringers, frames, etc.) per month. The sum of micro pulse takt times equals a pulse of takt time. That is, after a number of micro pulses equal to a full pulse, an entire unit has advanced by its length through an assembly line110. For examples, the assembly line110is comprised of an integer multiple of standard module work stations which enable it to be designed upfront to have blank, or unused, work stations at low rates and add work stations that are functional, if required for certain processes into those unused work stations, to accommodate higher product output in areas that are sensitive to product output.

According toFIG.2, and referring specifically to assembly line120, and similar to assembly line110, each work station124at an assembly line120may be fed/supplied materials and/or components by a feeder line149(e.g., based on a takt time for half barrel section127, and as illustrated in followingFIG.3), and these materials and/or components are affixed to the upper half barrel section126and lower half barrel section128being worked upon by the work stations124. Feeder lines149provide additive materials/components to the work stations124. Each feeder line149is designed to generate materials at a takt time in order to provide the additive material/component to a work station just in time (JIT) for assembly onto a larger structure (e.g., a section of fuselage), which is also pulsed at a takt time. The feeder line149takt time may be the same or different from the takt time of assembly line120. That is, the feeder lines149deliver the components JIT to the work stations124in an order of usage by the work stations124. In one embodiment, the feeder lines149that have a takt time equal to or at a fraction of a fuselage takt time.

The takt times of the feeder lines149, and/or the assembly lines120need not be the same. For instance, an upper half barrel section126and lower half barrel section128may be micro pulsed through several work stations124at the same time. The upper half barrel section126and lower half barrel section128is indexed to the work stations124and each feeder line149performs NDI, window surround installation, door surround installation, window manufacturing excess trim/removal, door manufacturing excess trim/removal, installing windows and installing doors etc. Feeder lines149also include output from the work stations124, including NDI inspection data and any excess trimmed off of upper half barrel section126and lower half barrel section128. The feeder lines149synchronize to a pulse time or velocity of a main assembly line, to supply what is needed, when it is needed.

In a further example, the feeder line149provides the frames146JIT to a work station124that installs the frames146onto upper half barrel section126and lower half barrel section128. Likewise, feeder lines149provide window surrounds JIT to work stations124where window surrounds are installed and door surrounds JIT to work stations124where door surrounds are installed. For each feeder line149, production times are designed based on the takt of an associated work station124. The feeder lines149each serially pulse components during fabrication, and completed components arrive at each work station124at a common takt time. This takt time design proceeds through each of the feeder lines149from the smallest part to the largest final assembly.

If a takt time cannot be achieved by the assembly line120or feeder line149, it is possible to adjust the work statement of a particular work station to reduce or increase the amount of work occurring at the particular work station. In a further embodiment, it is possible to add or remove a work station124from the assembly line120based upon a work statement and a desired takt time for the entire assembly line. Takt time is considered to be a number of minutes per month, divided by a number of desired units (e.g., of aircraft, stringers, frames146, etc.) per month. The sum of micro pulse takt times equals a full pulse of takt time. That is, after a number of micro pulses129equal to advancing by its length through an assembly line120.

FIG.2further depicts the airframe assembly region180and the airframe assembly region190, which receive the outputs of assembly lines110and120respectively. Upper half barrel sections116,126and lower half barrel sections118,128are joined into the various full barrel sections described with respect toFIG.1. It is important to note that upper half barrel sections116and lower half barrel sections118come in various shapes and lengths as is depicted inFIG.2.

Joining of upper half barrel section116and lower half barrel section118occurs within joining work station182and joining of upper half barrel section126and lower half barrel section128occurs within joining work station192. Join station184is part of work station182, and join station194is part of work station192. The full barrel sections44that result proceed along tracks186and196, to a work cell188. In further embodiments, the operations of the assembly lines110,120discussed herein are merged into a single assembly line.

Arrows101indicate where differently shaped upper half barrel sections116and lower half barrel section118are moved as they exit the assembly line110and enter airframe assembly region180. For example, arrows101depict lower half barrel section118and upper half barrel section116being moved to an assembly stage320and assembly stage330, respectively, and then to join station184for joining, and movement to different assembly lines, etc. Arrows101indicate where similarly shaped upper half barrel sections126and lower half barrel sections128are moved as they exit the assembly line120and enter airframe assembly region190. For example, arrows101depict lower half barrel section128and upper half barrel section126being moved to an assembly stage321and assembly stage331, respectively, and then to join station194for joining, and movement to different assembly lines, etc.

In an embodiment, upper half barrel section116is joined with crown module364and lower half barrel section118is joined with cargo floor grid326and/or passenger floor grid324in assembly stages320and330, respectively. Assembly stages320and330are part of the upper half barrel section116and lower half barrel section118assembly process much like assembly stages321and331are part of the upper half barrel section126and lower half barrel section128assembly process where crown modules364, cargo floor grids326, and passenger floor grids324are similarly installed. Likewise join station184is part of the assembly process for the upper half barrel section116and lower half barrel section118and similarly corresponds to join station194which is part of the assembly process for the upper half barrel section126and lower half barrel section128.

FIG.3depicts an assembly line150for a component170-1,170-2in a factory in an illustrative embodiment. The assembly line150may be utilized for any component170-1,170-2, such as for post-hardening or pre-hardening fabrication and/or assembly processes and may be utilized as a feeder line149(FIG.2) to provide components170-1,170-2that are used by downstream assembly lines150. The component170-1may be different and distinct from component170-2or components170-1and170-2may be exactly the same. For instance, and relevant to subsequent figures, components170-1,170-2are intercostals522, floor beams524, or might be crown modules364or floor grids365in various stages of completion.

Component170-1and component170-2progress through serially arranged work stations152-1through152-n, wherein these multiple work stations152perform work on component170-1while additional work stations perform work on component170-2during a micro pulse129-3or pause between micro pulses129-3. It is understood that as components move down assembly line150that only a single work station might be performing work on a single component, depending on the progress of the components through the assembly line150.

In this embodiment, the assembly line150includes work stations152-1through152-nthat perform work such as layup, inspection, hardening, trimming, pick and placement, joining, fastening, etc., as the components170-1,170-2proceed along track154. The work stations152perform work on the components170-1,170-2such as those mentioned in the preceding paragraph during a same pause between pulses (FIG.2) or micro pulses (FIG.2) of the components170-1,170-2in the process direction199.

In the illustrated embodiment, one of work stations152-nis disposed at a gap121between components170-1,170-2which move or pulse in the process direction199. While disposed at the gap121, work station152-nreceives maintenance and/or inspection, and/or technicians operating the work station152-nmay engage in a break while the work station152-nis not performing work on one of the components170.

In one example of the illustrated embodiment, exit line169-1carries inspection data167-1from work station152-1while exit line169-2carries removed material167-2from one of work stations152-n. An example of inspection data167-1is the inspection data for a component170from a work station152configured as an NDI station. Similarly, when component170is mechanically trimmed, the removed material167-2is taken away from two work stations152-non exit lines169-2, the work stations152-nbeing configured as trimming stations.

Feeder lines160-1through160-nprovide subcomponents162-1,162-nto work stations152-2,152-3and one of work station152-n. In one example, the subcomponent162-1is coupled to the component170present in work station152-2. The subcomponents162-1,162-narrive at work stations152-2,152-n, and these work stations152-2,152-nutilize the subcomponents162-1,162-nby consuming, placing, or otherwise utilizing the subcomponents162-1,162-nto facilitate fabrication of components170-1,170-2.

A path164is through an ingress165-2and egress165-3for each of the work stations152, an example of which is illustrated at work station152-2, for the components170. In this embodiment, each feeder line160-1,160-nprovides subcomponents162-1,162-nto a work station152-1,152-2,152-3,152-n, and may provide the subcomponents162-1,162-nvia an ingress/egress port165-1that is independent of the path164.

Removed material167-2may also be removed via ingress/egress ports165-1. In one embodiment, the actions of the feeder lines160-1,160-nand assembly line150are coordinated to facilitate just-in-time (JIT) delivery of components to subsequent assembly line150-1to which it feeds according to a takt-time for the component170-1,170-2, which the work stations152work to. In one embodiment, the assembly line150is utilized for fabricating crown modules364(FIGS.4&5), and feeder lines160provide crown module components such as support structure, stow bins, lighting, ceiling panels, and insulation that is provided just in time (JIT) for joining into a crown module.

In one embodiment, one or more of work stations152-1,152-2,152-3, and152-ncomprise NDI stations, rework stations downstream of the NDI stations that address any out of tolerance conditions identified by NDI inspection. Many of these work stations152-1,152-2,152-3,152-ninclude a feeder line160-1,160-ndevoted to the inputting of material intended for addition at that work station152-1,152-n. The assembly line150is representative of one or all of assembly line110, assembly line120, airframe assembly region180, and airframe assembly region190. As further described herein, the assembly line150can also be representative of assembly stages320,321,330, and331.

FIG.4is a block diagram of a crown module feeder line700for installing crown modules364into upper half barrel sections116,126of fuselage12in an illustrative embodiment. Specifically,FIG.4depicts a line of serially arranged work stations with pulse length123between each. As shown inFIG.4, the crown module feeder line700includes a process tracking server710, which utilizes a controller712and a memory714to track the progress of an upper half barrel section116,126to an assembly stage320,321(see alsoFIG.2). Assembly stages320and321are both used in the description ofFIG.4since it is understood that the description applies to both upper half barrel sections116and126as introduced inFIG.2and that both incorporate some embodiment of a crown module364.

The crown module364is advanced via track716, and indexed to work stations720,730,740,750,760and assembly stage320,321via an indexing feature704(similar to indexing feature133described with respect toFIG.2) coupled to crown module364. Each of the work stations720,730,740,750,760are coupled to an indexing component718(similar to indexing components115and125described with respect toFIG.2).

Crown modules364are indexed to work stations720,730,740,750,760, via an indexing feature704being interfaced to indexing component718. As shown, multiple of each of crown module364are shown on track716. An embodiment has a crown module364at each of work stations720,730,740,750,760and at assembly stage320,321and full pulsing from one work station to the next work station. Feeder lines722,732,742,752,762, and772for each of work stations720,730,740,750,760, and assembly stage320,321, as discussed herein may further be controlled according to micro pulse, full pulse, or continuous line fabrication techniques in order to ensure that materials are delivered just in time for installation. This may involve tracking and/or control to manage the progress of materials.

In this embodiment, the crown module feeder line700includes work station720, a crown module grid work station, which assembles ceiling grids for crown modules364. Feeder line722provides ceiling grid components to work station720for joining into the ceiling grid. The ceiling grid is then full pulsed to an insulation attach work station730, which installs insulation. Feeder line732provides insulation to insulation attach work station730JIT for installation into the ceiling grid. The ceiling grid with insulation full pulses to stow bin attach work station740. Stow bins, fasteners and other needed materials are delivered to stow bin attach work station740via feeder line742. Stow bins are attached to the ceiling grid and insulation assembly within stow bin attach work station740before full pulse to ceiling panel attach work station750. Ceiling panels and other needed materials are delivered to ceiling panel attach work station750JIT via feeder line752. The ceiling panels are attached to the ceiling grid, insulation and stow bin assembly within ceiling panel attach work station750before full pulse to lighting attach work station760. Lighting and other needed materials are delivered to lighting attach work station760JIT via feeder line762. The lighting is attached to the ceiling grid, insulation, stow bin and ceiling panel assembly within lighting attach work station760before full pulse to assembly stage320,321for installation of the completed crown module364into upper half barrel section116,126.

Feeder lines722,732,742,752,762provide various materials such as crown module components, fasteners, insulation, stow bins, ceiling panels, plumbing, electrical systems, lighting, etc., to the work stations720,730,740,750,760discussed herein.

In a further embodiment, a crown module364arrives just in time for install at assembly stage320,321with ceiling grid, insulation, stow bins, ceiling panels, lighting, electric components and any plumbing, which are all installed during a full pulse into upper half barrel section116,126. Thus, in such an embodiment, no micro pulsing takes place and all assembly operations are performed during a full pulse length, pulse length123.

FIG.5has the crown module364advanced by micro pulse129-4through work stations720-1,720-2,730,740,760-1,760-2, and750to arrive in a completed state at an assembly stage320,321for crown module364for installation into an upper half barrel section116,126, in a full pulse length123. The crown modules364are assembled in parallel to the upper half barrel section116,126so that the crown module364arrives completed for installation to reduce the upper half barrel section116,126time in assembly stage320,321to as low as possible. The crown module364shown at the beginning of the work stations is shown as dashed, as it is understood that the components that are added at each work station are what eventually forms the crown module364, which is shown in solid line leaving the work stations as the crown module364is completed, in certain implementations.

A feeder line773provides the crown module364to assembly stage320just-in-time and ready for installation into the upper half barrel section116,126. Again, it is mentioned that the crown module process is essentially the same for upper half barrel section116feeding into assembly stage320as it is for upper half barrel section126and assembly stage321, which is why116,126is used in the description, as well as320,321.

The crown module364has to be assembled in parallel to the upper half barrel section116,126to reduce the time for the crown module364attachment in the assembly stage320,321to as low as possible. The various crown modules are assembled inverted. The crown module364arrives at the assembly stage320ready for installation. The crown module364is assembled from ceiling grid components721-1,721-2, combined into a ceiling grid with, insulation731, stow bins741, and electrical and lighting systems761-1,761-2. Ceiling panels751are then added to the assembly.

It is noted that ceiling panel attach work station750and lighting attach work station760are shown in reversed positions inFIGS.4and5. This is meant to illustrate that the assembly order is predicated by the architecture of the aircraft being assembled, and not by the factory. Other orders of work station are contemplated to be within the scope of this disclosure.

The crown module364begins assembly by micro pulses129-4through serially arranged work stations720-1,720-2,730,740,760-1,760-2, and750on feeder line773each with feeder lines722-1,722-2,732,742,762-1,762-2,752, respectively, delivering crown module components Just in Time (JIT) of just the right part to the work stations720-1,720-2,730,740,760-1,760-2, and750for assembly into crown module364. The ceiling grid components721-1,721-2are delivered JIT to work stations720-1,720-2via feeder line722-1and feeder line722-2. Micro pulse129-4is illustrated as having a length equal to the space between two adjacent work stations or equal to the purview774or some multiple or fraction thereof.

The crown module364continues assembly on feeder line773by micro pulses129-4through serially arranged work stations730,740,760-1,760-2, and750each with feeder lines732,742,762-1,762-2,752delivering JIT the insulation731, stow bins741added, electrical and lighting systems761-1,761-2and then ceiling panels751, respectively, for assembly into crown module364. Optionally, ceiling panels751are placed into the crown module during installation into upper half barrel section116,126.

The work stations720-1,720-2,730,740,760-1,760-2, and750index to the crown module364as it advances through the floor grid feeder line, feeder line773, during pauses between micro pulses129-4and/or during micro pulses129-4of the crown module364. The crown module364is indexed to each of the serially arranged work stations720-1,720-2,730,740,760-1,760-2, and750singularly, or in multiples, to convey a 3D characterization of the crown module364within the purview774of each work station720-1,720-2,730,740,760-1,760-2, and750prior to work station720-1,720-2,730,740,760-1,760-2, and750work upon the crown module364. The one or more work stations720-1,720-2,730,740,760-1,760-2, and750perform work upon the crown module364during pauses between micro pulses129-4and/or during micro pulse129-4. Indexing features704may be on several portions of the crown module364or on several portions of a moveable jig conveying the crown module364.

The crown module364is assembled in parallel to the upper half barrel section116,126and arriving JIT at the assembly stage320,321for installation into the upper half barrel section116,126. Each of feeder lines722,732,742,752,762are shown as the ends of an assembly fabrication/delivery line for a particular subcomponent. Feeder lines722-1and722-2place the ceiling grid components721-1and721-2into work stations720-1and720-2, respectively and adding same to micro pulsing a ceiling grid (see crown module364depicted with dashed line). Feeder lines732and742respectively place the insulation731and the stow bins741into work stations730and740, respectively, and adding same to micro pulsing ceiling grid. Feeder lines762-1,762-2place electrical and lighting systems761-1,761-2into work stations760-1and760-2, respectively, and the micro pulsing crown module begins to take shape (as denoted by the solid lines). Feeder line752places the ceiling panels751into work station750which are added to complete the crown module364, as denoted inFIG.5.

While disposed at the gap121-4, work station740receives maintenance and/or inspection, and/or technicians operating the work station740go on break and/or perform maintenance while the work station740is not performing work on crown module364. While seven work stations and feeder lines are shown, any number of work stations or feeder lines are possible during crown module364fabrication.

The feeder lines for the various stow bins, other crown module features, floor grid elements, etc. discussed herein may be designed to fabricate integral singular components (e.g., entire crown modules or floor grids for placement into a section) for placement in their entirety into a fuselage section. In a further embodiment, the feeder lines provide multiple components at once. Thus, for example, stow bins741may be installed as a full length equal to that of the upper half barrel section116,126, or some fraction thereof. In a further example, installing the crown module364comprises installing an entirety of the crown module364for the upper half barrel section116,126, or a longitudinal fraction thereof. The feeder line773feeds the crown module364into assembly stage320,321, and along with feeder lines782,792provide sealant and fasteners, respectively, to assembly stage320,321just-in-time and ready for installation into the upper half barrel section116,126. After installation of crown module364into the upper half barrel section116,126, upper half barrel section116,126is placed into join station194. The feeder lines for the various stow bins, other crown module features, floor grid elements, etc. discussed herein may be designed to fabricate integral singular components (e.g., entire crown modules or passenger floor grids324or cargo floor grids326) for placement into a half barrel section117,127for placement in their entirety into a fuselage section.

In a further embodiment, the feeder lines provide multiple components at once. Thus, for example stow bins may be installed as a full length equal to that of the fuselage section, or some fraction thereof. The feeder line773feeds the crown module364into assembly stage320,321and along with feeder lines782,792provide sealant and fasteners, respectively, to assembly stage320,321just-in-time and ready for installation into the upper half barrel section116,126. After installation of crown module364into the upper half barrel section116,126upper half barrel section116,126is placed into join station194.

Not shown, vertical inversion station rotates the lower half barrel section118,128about a longitudinal center line to place it in a keel down orientation. More specifically, the lower half barrel section118,128is rotated about a longitudinal center line prior to joining to the upper half barrel section116,126(shown inFIG.7).

As described elsewhere herein, a join station194unites the lower half barrel section128to an upper half barrel section126. This joining process results in the upper half barrel section126and the lower half barrel section128being longitudinally spliced together, including splicing the skin and the frames590and any surrounds thereat. A splice plate (not shown) may be installed entirely in the join station194. InFIG.6, a cross-section of a full barrel section44in join station194is depicted, which includes a passenger floor grid596and a cargo floor grid594.FIG.6further illustrates that a crown module599and doubler597have been added to the full barrel section44of fuselage. As described herein, the crown module599includes stow bins and interior lighting, and these details are not shown inFIG.6for the sake of clarity. Insulation591and interior panels593are also shown as being installed.

FIG.7is a flowchart depicting a method800for utilizing the crown module assembly lines ofFIGS.4and5in an illustrative embodiment. Method800includes receiving802an upper half barrel section116,126in a crown up orientation. Next, a crown module364is installed804into the upper half barrel section116,126while a floor grid365is being installed into a lower half barrel section118,128. The upper half barrel section116,126is advanced806in a process direction199to join station194. The upper half barrel section116,126is then aligned808with a respective lower half barrel section, lower half barrel section118,128. The upper half barrel section116,126is then attached810to the lower half barrel section118,128. Micro pulsing and/or full pulsing as described herein are utilized in order to perform just in time assembly in a variety of techniques similar to those discussed herein.

The upper half barrel sections116,126and lower half barrel sections118,128, by definition, have to have the same takt-time. In other words, both an upper half barrel section126and a lower half barrel section128are needed within the time interval demanded by a customer. Continuing, the amount of work to fabricate and process the lower half barrel section128could be more or less than the amount of work to fabricate and process the upper half barrel section126, but the takt-time is same and is addressed in the upfront design of the assembly line120.

In a further embodiment, the method of joining the upper half barrel section116,126to the lower half barrel section118,128is similar to that described above, but the upper half barrel section116,126and the lower half barrel section118,128both advance to the join station194. The upper half barrel section116,126and the lower half barrel section118,128are aligned for joining in the join station194, and splice plates are installed onto the upper half barrel section116,126and/or the lower half barrel section118,128-2to form a butt splice either via bonding and/or via multiple rows of fasteners and fay surface sealing.

Method800provides a technical benefit over prior techniques because it enables crown modules364to be installed into upper half barrel sections116,126at the same time that cargo floor grid326and passenger floor grid324are being installed into a corresponding lower half barrel section, lower half barrel section118,128. This increases throughput and assembly efficiency as it requires a lot of coordination to install a cargo floor grid326and passenger floor grid324as well as the crown module364while using temporarily installed tooling within a full barrel section44.

FIG.8is a flowchart illustrating a method1400of takt time assembly in an illustrative embodiment. Method1400includes progressing1402a series of subcomponents162(162-1through162-n) through a series of work stations152at a common takt time. In one embodiment, the subcomponents162are delivered according to the common takt time. Thus, the deliveries are provided JIT from a feeder line160, and each feeder line160may have a common takt time or not. The feeder lines160may have their own takt time, and this takt time may be equal to a fraction of a fuselage takt time, or not.

The term takt-time needs further explanation. For example, and with reference toFIG.3, there is a Takt time of Product (TTP) for each assembly line150, as well as for each feeder line160. The description applies to the other figures described herein, for example, assembly lines110,120, and feeder lines149. Often the takt times are same but can be different, as feeder lines160always need to be synchronized with assembly lines150. For example, if there was only one assembly line150and there were eight half barrel sections going down assembly line150, combined with a product demand requiring eight half barrel sections every 32 available hours, the TTP for the assembly line150is 4 hours. The TTP is equal to pulse time only when pulse length is the full length of product produced. In case of a micropulsed line, where pulse length is a fraction of full product length, gaps121between products have to be accounted for, and the pulse time (PT) is much less. All feeder lines160need to support mainline TTP, PT, or velocity. As an additional example, if pulse length was equal to a frame pitch147(around 2 feet), then a frame feeder line would need to deliver a number of frames146(e.g., two) per frame station. On some half barrel sections117there may be no doors, so the feeder line160needs to supply two frames every pulse time. Some half barrel sections117include doors and, in those areas, frames146are not needed for at least a few micropulses. However, feeder lines160still have to synchronize to assembly line150pulse time. The feeder lines160can have greater TTP if the number of products per pulse is greater than one and with only one feeder line160. If number of products is greater than one and the number of feeder lines160for that product is same as the number of products in feeder line160, then PT of feeder line160is same as that of the assembly line150. When there is no need to supply feeder products to assembly line150, then PT is variable for the feeder line160.

At the feeder lines160, additional work stations perform work on subcomponents162during a pause between pulses of the subcomponents162in a process direction199. Some subcomponents162may be produced in a continuous non-pulsed, non-micro pulsed fashion. Method1400includes delivering1404a subcomponent162-1just in time to a work station152-2along with a subcomponent162-nproduced in parallel with the subcomponent162-1. The subcomponents162are delivered to the stations Just In Time (JIT) in an order of usage. Method1400includes joining1406the subcomponent162-nto the subcomponent162-1to form a component170-1. In one embodiment, the subcomponent162is a section (e.g., an upper half barrel section126or a lower half barrel section128) of a fuselage. In a further embodiment, the component170-1is a full barrel section44formed from an upper half barrel section126and a lower half barrel section128).

In further embodiments, the method1400further includes simultaneously performing work on the subcomponents162via more than one of the work stations152. Depending on the embodiments, progressing comprises iteratively pulsing the subcomponents162by less than their length, then pausing while work is performed on the subcomponents162. Alternatively, progressing comprises iteratively pulsing the subcomponents162at least their length, then pausing while work is performed on the subcomponents162. Alternatively, progressing comprises continuously moving the subcomponents162while work is performed on the subcomponents162. In pulsed embodiments, the first type of subcomponent162-1and the second type of subcomponent162-nare joined into the component170at a work station152after a pulse.

Attention is now directed toFIG.9, which broadly illustrates control components of a production system (e.g., assembly environment100) that performs continuous manufacturing. A controller1600coordinates and controls operation of work stations1620(corresponds to any and all of work stations and movement of one or more of the aircraft components described herein)) along a moving line1660having a powertrain1662. The controller1600may comprise a processor1610which is coupled with a memory1612that stores programs1614. In one example, the mobile platforms1670are driven along a moving line1660that is driven continuously by the powertrain1662, which is controlled by the controller1600. In this example, the mobile platform1670includes utility connections1672which may include electrical, pneumatic and/or hydraulic quick disconnects that couple the mobile platform1670with externally sourced utilities1640. In other examples, as previously mentioned, the mobile platforms1670comprise Automated Guided Vehicles (AGVs) that include on board utilities, as well as a GPS/autoguidance system1674. Mobile platforms1670also include some or all of the indexing systems, bar codes and RFID systems previously discussed. In still further examples, the movement of the mobile platforms1670is controlled using laser trackers1650. Laser trackers1650use indexing components, bar code readers or RFID readers. Position and/or motion sensors1630coupled with the controller1600are used to determine the position of the mobile platforms1670as well as the powertrain1662.

FIG.10is a flowchart of what is depicted inFIG.5. The crown module364is advanced by micro pulse129-4through work stations720-1through750to arrive at an assembly stage320,321for crown module364for installation into an upper half barrel section116,126, in a full pulse length123. The crown module364is assembled in parallel with the upper half barrel section116,126so that the crown module364arrives completed, or nearly complete, for installation to minimize the time the upper half barrel section116,126is in assembly stage320. Feeder line773for the crown module364provides it to assembly stage320,321just-in-time and ready for installation into the upper half barrel section116,126. The crown module364are assembled inverted. The crown module364arrives at the assembly stage320,321ready for installation complete, or nearly complete.

In the method ofFIG.10, feeder lines722-1,722-2feed2002ceiling grid material732-2JIT to work station720-1,720-2for joining into the ceiling grid. The ceiling grid and the provided ceiling grid material are joined2004while micro pulsing through work stations720-1,720-2.

Ceiling grid/crown module or components are indexed2006to each work station after or during micro pulse to convey a 3D characterization within the purview of the work station. InFIG.5micro pulse129-4is illustrated as having a length equal to the space between two adjacent work stations or equal to the purview774or some multiple or fraction thereof. The work stations720-1,720-2,730,740,760-1,760-2, and750index to the crown module364as it advances through the floor grid feeder line, feeder line773, during pauses between micro pulses129-4and/or during micro pulses129-4of the crown module364. The crown module364is indexed2006to each of the serially arranged work stations720-1,720-2,730,740,760-1,760-2, and750singularly or in multiples to convey a 3D characterization of the crown module364within the purview774of each work station720-1,720-2,730,740,760-1,760-2, and750prior to work stations720-1,720-2,730,740,760-1,760-2, and750working upon the crown module364.

One or more work stations720-1,720-2,730,740,760-1,760-2, and750perform work upon the crown module364during pauses between micro pulses129-4and/or during micro pulse129-4. Indexing features704(shown inFIG.4) may be on several of the components described herein that make up the crown module364or on several portions of a moveable jig conveying the crown module364. The crown module364is assembled in parallel to the upper half barrel section116,126and arriving JIT at the assembly stage320,321for installation into the upper half barrel section116,126.

The crown module364continues assembly on feeder line773by micro pulses129-4through serially arranged work stations720-1,720-2,730,740,760-1,760-2, and750the associated feeder lines722-1,722-2,732,742,762-1,762-2, and752delivering JIT, the insulation731, only the right stow bins, the electrical and lighting systems761-1,761-2and then the ceiling panels751, respectively, for assembly into crown module364.

Continuing with the flowchart, the ceiling grid is micro pulsed2008to an insulation attach work station730, which installs the insulation731fed by feeder line732into insulation attach work station730upon ceiling grid while upstream work station(s) continue joining ceiling grid material into ceiling grid.

The ceiling grid is micro pulsed2010to stow bin attach work station740and feeder line742feeds stow bins741to same work station where the stow bins741, fasteners and other needed materials are attached to the ceiling grid and insulation assembly within stow bin attach work station740while upstream work stations (e.g.,720-1,720-2,730) continue joining ceiling grid material and placing insulation into ceiling grid.

The ceiling grid with insulation and stow bin is micro pulsed2012to lighting attach work station760-1to attach feeder line762-1fed lighting and other needed materials to the ceiling grid, insulation and stow bin assembly within lighting attach work station760-1while upstream work stations (e.g.,720-1,720-2,730,740) continue joining ceiling grid material into ceiling grid along with insulation and stow bin. As the installation of electrical and lighting might take longer, work station760-2is also incorporated, with the micro pulsing2012occurring each time.

Next, the ceiling grid, insulation, stow bin and lighting assembly of the crown module are micro pulsed2014to ceiling panel attach work station750to attach feeder line752fed ceiling panels751to the ceiling grid, insulation and stow bin at ceiling panel attach work station750to attach feeder line fed ceiling panels and other needed materials to the ceiling grid, insulation, stow bin and ceiling panel assembly within ceiling panel attach station while upstream work stations (e.g.,720-1,720-2,730,740,760-1,760-2) continue joining ceiling grid material into ceiling grid along with insulation and stow bin and lighting, if needed.

Crown module364is full pulsed2018to assembly stage320,321for installation into upper half barrel section116,126-1. Optionally, the crown module364without ceiling panels does not go through ceiling panel installation and instead advances directly to assembly stage320.

Finally, the crown module364is full pulsed2020without ceiling panels to assembly stage320,321where ceiling panels are delivered JIT to assembly stage320,321and ceiling panels are added during crown module364installation into upper half barrel section116,126.

FIG.11is a flowchart2100illustrating methods of fabricating portions of an airframe (e.g., full barrel sections) in illustrative embodiments. The methods illustrated include continuously performing2122work on a lower half barrel section118,128in a process direction199at a plurality of work stations114,124spaced along an assembly line110,120at less than a length of the lower half barrel section118,128. The method further includes continuously performing2124work on an upper half barrel section116,126behind the lower half barrel section118,128in the process direction199. The lower half barrel section118,128is removed2126from the assembly line110,120. The upper half barrel section116,126is subsequently removed2128from the assembly line110,120. Finally, the lower half barrel section118,128is attached2130to the upper half barrel section116,126.

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