U.S. patent application number 12/192248 was filed with the patent office on 2010-02-18 for reconfigurable flexible rail apparatus and method.
Invention is credited to Alan R. Merkley, James C. Murphy, Eric M. Reid.
Application Number | 20100037444 12/192248 |
Document ID | / |
Family ID | 41095002 |
Filed Date | 2010-02-18 |
United States Patent
Application |
20100037444 |
Kind Code |
A1 |
Reid; Eric M. ; et
al. |
February 18, 2010 |
RECONFIGURABLE FLEXIBLE RAIL APPARATUS AND METHOD
Abstract
A method and apparatus for performing operations on a work piece
comprises a flexible rail system and a multi-axis carriage. The
flexible rail system may be capable of being attached to a work
surface. The multi-axis carriage may be coupled to the flexible
rail system. The multi-axis carriage may be capable of moving along
the flexible rail system and may be capable of moving a tool in
axes relative to the work surface. The tool may be single use or
multi use and may be removably coupled to the frame and or
carriage
Inventors: |
Reid; Eric M.; (Bothell,
WA) ; Merkley; Alan R.; (Greenbank, WA) ;
Murphy; James C.; (Kirkland, WA) |
Correspondence
Address: |
DUKE W. YEE
YEE & ASSOCIATES, P.C., P.O. BOX 802333
DALLAS
TX
75380
US
|
Family ID: |
41095002 |
Appl. No.: |
12/192248 |
Filed: |
August 15, 2008 |
Current U.S.
Class: |
29/33R |
Current CPC
Class: |
B23Q 2210/008 20130101;
B23Q 9/0007 20130101; B23Q 9/0042 20130101; Y10T 29/51 20150115;
B64F 5/10 20170101 |
Class at
Publication: |
29/33.R |
International
Class: |
B21D 39/03 20060101
B21D039/03 |
Claims
1. An apparatus comprising: a flexible rail system capable of being
attached to a work surface; and a multi-axis carriage coupled to
the flexible rail system, wherein the multi-axis carriage is
capable of moving along the flexible rail system and is capable of
moving a tool in axes relative to the work surface.
2. The apparatus of claim 1 further comprising: a tool module
capable of being removably coupled to the multi-axis carriage,
wherein the tool module comprises a frame and the tool, wherein the
tool is mounted on the frame.
3. The apparatus of claim 2, wherein the tool is located on a first
side of the tool module further comprising: a pressure foot located
on the first side and capable of applying pressure to the work
surface.
4. The apparatus of claim 3, wherein the flexible rail system
comprises a flexible rail, and wherein the tool module further
comprises: a reaction unit located on a second side of the tool
module and capable of stabilizing the multi-axis carriage during
operation of the tool.
5. The apparatus of claim 4, wherein the reaction unit is capable
of stabilizing the multi-axis carriage while the multi-axis
carriage moves along the flexible rail.
6. The apparatus of claim 4 further comprising: a set of rollers
associated with the pressure foot.
7. The apparatus of claim 5, wherein the reaction unit comprises at
least one of a set of feet and a set of rollers.
8. The apparatus of claim 4, wherein the multi-axis carriage
comprises: a first motor that is capable of moving the multi-axis
carriage on the flexible rail along an X-axis in the axes.
9. The apparatus of claim 8, wherein the multi-axis carriage
further comprises: a second motor capable of moving the tool in the
tool module along a Y-axis in the axes
10. The apparatus of claim 4, wherein the pressure foot is
rotatable about an A-axis that is parallel to the X-axis and is
movable to contact the work surface.
11. The apparatus of claim 10, wherein the pressure foot is capable
of providing a force that is normal to the work surface.
12. The apparatus of claim 1, wherein the flexible rail system is a
flexible vacuum rail system.
13. The apparatus of claim 1, wherein the flexible rail system
comprises: a plurality of rails.
14. The apparatus of claim 1, wherein the work surface is
curved.
15. The apparatus of claim 2, wherein the tool is removably
attached to the frame.
16. The apparatus of claim 2, wherein the tool is selected from one
of a drill, a measurement probe, a rivet hammer, a router, a
trimming saw, a grinding wheel, and a fastener.
17. The apparatus of claim 1, wherein the work surface is a surface
of a work piece selected from one of an aircraft fuselage, an
aircraft wing, an aircraft door, an aircraft empennage, an aircraft
control surface, a spacecraft, a ship, a tank, and a building.
18. An apparatus for performing operations on an aircraft work
piece. a flexible vacuum rail capable of being attached to a curved
work surface of the work piece; a multi-axis carriage coupled to
the flexible rail system, wherein the multi-axis carriage is
capable of moving along the flexible rail system and is capable of
moving a tool in axes relative to the curved work surface and
wherein the multi-axis carriage comprises: a first motor capable of
moving the multi-axis carriage on the flexible rail along an X-axis
in the axes; and a second motor capable of moving the tool in a
tool module along a Y-axis in the axes; a tool module capable of
being removably coupled to the multi-axis carriage and comprising:
a frame; the tool, wherein the tool is mounted on the frame,
wherein the tool is located on a first side of the tool module, and
wherein the tool is selected from one of a drill, a measurement
probe, a rivet hammer, a router, a trimming saw, a grinding wheel,
and a fastener; a pressure foot located on the first side of the
tool module, wherein the pressure foot is capable of applying
pressure to the curved work surface, is rotatable about an A-axis
that is parallel to the X-axis, and is capable of providing a force
that is normal to the curved work surface; and a reaction unit
located on a second side of the tool module and capable of
stabilizing the multi-axis carriage during operation of the tool
and capable of stabilizing the multi-axis carriage while the
multi-axis carriage moves along the flexible rail, wherein the
reaction unit comprises at least one of a set of fixed feet and a
set of rollers.
19. A method for performing an operation on a work piece, the
method comprising: attaching a vacuum rail with a multi-axis
carriage coupled to the vacuum rail to a surface of a work piece;
coupling a tool module to the multi-axis carriage, wherein the tool
module has a tool capable of performing the operation; moving the
multi-axis carriage along the flexible vacuum rail to a location on
the work piece; and performing the operation at the location.
20. The method of claim 19, wherein the performing step comprises:
applying a force against the surface with a pressure unit located
on a first side of the tool module, wherein the pressure unit is
rotatable around an axis parallel to an axis of movement of the
multi-axis carriage and wherein force is normal to the surface;
providing a reactive force to the force with a reactive unit
located on a second side of the tool module; and performing the
operation after the force and the reactive force are applied.
21. The method of claim 20, wherein the operation is selected from
at least one of a drilling operation, a sealing operation, a
measuring operation, and a fastening operation.
22. A method for performing an operation on an aircraft work piece
comprising: attaching a flexible vacuum rail with a multi-axis
carriage coupled to the flexible vacuum rail to a surface of the
aircraft work piece; coupling a tool module to the multi-axis
carriage, wherein the tool module has a tool capable of performing
the operation; moving the multi-axis carriage along the flexible
vacuum rail to a location on the aircraft work piece; and applying
a force against the surface with a pressure unit located on a first
side of the tool module, wherein the pressure unit is rotatable
around an axis parallel to an axis of movement of the multi-axis
carriage and wherein force is normal to the surface; providing a
reactive force to the force with a reactive unit located on a
second side of the tool module; and performing the operation after
the force and the reactive force are applied, wherein the operation
is selected from at least one of a drilling operation and a
fastening operation.
Description
BACKGROUND INFORMATION
[0001] 1. Field
[0002] The present disclosure relates generally to manufacturing
and in particular to manufacturing tools and automation. Still more
particularly, the present disclosure relates to rail mounted tools
used for manufacturing.
[0003] 2. Background
[0004] Manufacturing aircraft may involve aligning different
components on structures and/or other components. Holes may be
drilled through these aligned parts to prepare for attaching the
parts to each other. The parts may be attached using fasteners such
as, for example, without limitation, rivets, screws, bolts, and
other suitable fasteners. The creation of these holes may be
performed manually or through machine tools.
[0005] These machine tools may comprise a robotic apparatus that
may move with respect to the aligned parts and drill the desired
holes. These types of tools often may require substantial floor
space and large investment costs, and may have limits on efficiency
because these types of tools may only drill one hole at a time.
Further, the amount and/or types of work that may be performed
using these types of tools may be reduced based on required safety
zones.
[0006] Other types of machine tools include smaller flexible tools,
such as, for example, without limitation, tools on flexible rails.
These types of tools may include rails attached to the parts. For
example, with the fuselage, a rail system may be attached to the
fuselage with a drilling tool moving along the rail to drill the
desired holes. These types of flexible rail systems may provide
lower equipment and implementation costs. Further, these types of
systems also may provide for quicker setup time and the capability
to drill holes with many types of surface contours.
[0007] Currently available rail systems may take the form of a dual
rail system. With the dual rail system, attaching and maintaining
the rails using a parallel configuration with desired offset
dimensions between the rails may be difficult depending on the
curvature of the surface of the object on which drilling operations
may be performed.
[0008] Further, after a drilling operation has been performed, a
sealant and/or fasteners may be applied to the holes used to fasten
components to each other. This type of operation may require
removing the rails and the unit and placing a new set of rails and
unit onto the fuselage. In some systems, the old unit may be moved
off the rail and a new unit with the appropriate tool may be
coupled to the rail. This type of process may be time consuming, as
well as more costly by duplicating rail systems and/or units for
different operations.
[0009] Accordingly, a need is present for a method and apparatus
for minimizing the limitations discussed above.
SUMMARY
[0010] The advantageous embodiments of the present invention may
provide a method and apparatus for performing operations on a work
piece. In one embodiment, an apparatus may comprise a flexible rail
system and a multi-axis carriage. The flexible rail system may be
capable of being attached to a work surface. The multi-axis
carriage may be coupled to the flexible rail system. The multi-axis
carriage may be capable of moving along the flexible rail system
and may be capable of moving a tool in axes relative to the work
surface.
[0011] In another advantageous embodiment, an apparatus may be
present for performing operations on a work piece. A flexible
vacuum rail may be capable of being attached to a curved work
surface of the work piece. A multi-axis carriage may be removably
coupled to the flexible rail system. The multi-axis carriage may be
capable of moving along the flexible rail system and may be capable
of moving a tool in axes relative to the curved work surface. The
multi-axis carriage may comprise a first motor capable of moving
the multi-axis carriage on the flexible rail along an X-axis in the
axes. A second motor may be capable of moving the tool in the tool
module along a Y-axis in the axes. A tool module may be capable of
being removably coupled to the multi-axis carriage and may comprise
a frame. The tool may be mounted on the frame. The tool may be
located on a first side of the tool module. The tool may be
selected from at least one of a drill, a measurement probe, a rivet
hammer, a router, a trimming saw, a grinding wheel, and a fastener.
A pressure foot may be located on the first side and may be capable
of applying pressure to the curved work surface. The pressure foot
may be rotatable about an A-axis parallel to the X-axis, and may be
capable of providing a force that is normal to the curved work
surface. A reaction unit may be located on a second side of the
tool module, and may be capable of stabilizing the multi-axis
carriage during operation of the tool and while the multi-axis
carriage moves along the flexible rail. The reaction unit may
comprise at least one of a set of fixed feet and a set of
rollers.
[0012] In yet another advantageous embodiment of the present
invention, a method is present for performing an operation on a
work piece. A vacuum rail may be attached with a multi-axis
carriage removably coupled to the vacuum rail to a surface of a
work piece. A tool module may be coupled to the multi-axis
carriage. The tool module may have a tool capable of performing the
operation. The multi-axis carriage may move along the flexible
vacuum rail to a location on the work piece. The operation may be
performed at the location.
[0013] In still yet another advantageous embodiment, a method for
performing an operation on an aircraft work piece may comprise a
flexible vacuum rail, and a tool module. The flexible vacuum rail
with a multi-axis carriage removably coupled to the flexible vacuum
rail may be attached to a surface of the aircraft work piece. The
tool module may be coupled to the multi-axis carriage and may have
a tool capable of performing the operation. The multi-axis carriage
may move along the flexible vacuum rail to a location on the
aircraft work piece. A force may be applied against the surface
with a pressure foot located on a first side of the tool module.
The pressure foot may be rotatable around an axis parallel to an
axis of movement of the multi-axis carriage. The force may be
normal to the surface. A reactive force may be provided to the
force with a reactive unit located on a second side of the tool
module. The operation may be performed after the force and the
reactive force are applied. The operation may be selected from at
least one of a drilling operation and a fastening operation.
[0014] The features, functions, and advantages can be achieved
independently in various embodiments of the present disclosure or
may be combined in yet other embodiments in which further details
can be seen with reference to the following description and
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The novel features believed characteristic of the
advantageous embodiments are set forth in the appended claims. The
advantageous embodiments, however, as well as a preferred mode of
use, further objectives and advantages thereof, will best be
understood by reference to the following detailed description of an
advantageous embodiment of the present disclosure when read in
conjunction with the accompanying drawings, wherein:
[0016] FIG. 1 is a flow diagram of an aircraft production and
service methodology in which an advantageous embodiment may be
implemented;
[0017] FIG. 2 is a block diagram of an aircraft in accordance with
an advantageous embodiment;
[0018] FIG. 3, a block diagram of a flexible rail apparatus in
accordance with an advantageous embodiment;
[0019] FIG. 4 is a diagram of a perspective view of a flexible rail
apparatus in accordance with an advantageous embodiment;
[0020] FIG. 5 is a diagram of a top view of a flexible rail
apparatus in accordance with an advantageous embodiment;
[0021] FIG. 6 is a diagram of a front view of a flexible rail
apparatus in accordance with an advantageous embodiment;
[0022] FIG. 7 is a diagram of a side view of a flexible rail
apparatus in accordance with an advantageous embodiment;
[0023] FIG. 8 is a diagram of a perspective view of a flexible
apparatus in which the tool module is disengaged from the
multi-axis carriage;
[0024] FIG. 9 is a diagram of another perspective view of a tool
module detached from a multi-axis carriage in accordance with an
advantageous embodiment;
[0025] FIG. 10 is a diagram of a flexible rail apparatus in
accordance with an advantageous embodiment;
[0026] FIG. 11 is a side view of a flexible rail apparatus with
multiple tools in accordance with an advantageous embodiment;
[0027] FIG. 12 is a diagram of a front view of a flexible rail
apparatus in accordance with an advantageous embodiment;
[0028] FIG. 13 is a diagram of a perspective view with a tool
module separated from a multi-axis carriage in accordance with an
advantageous embodiment;
[0029] FIG. 14 is a diagram illustrating another configuration of a
flexible rail apparatus in accordance with an advantageous
embodiment;
[0030] FIG. 15 is a diagram of a top view of a flexible rail
apparatus in accordance with an advantageous embodiment;
[0031] FIG. 16 is a diagram illustrating a flexible rail apparatus
on a curved surface in accordance with an advantageous embodiment;
and
[0032] FIG. 17 is a flowchart of a process for performing an
operation on a work piece in accordance with an advantageous
embodiment.
DETAILED DESCRIPTION
[0033] Referring more particularly to the drawings, embodiments of
the disclosure may be described in the context of aircraft
manufacturing and service method 100 as shown in FIG. 1 and an
aircraft 102 as shown in FIG. 2. During pre-production, aircraft
manufacturing and service method 100 may include specification and
design 104 of aircraft 102 and material procurement 106.
[0034] During production, component and subassembly manufacturing
108 and system integration 110 of aircraft 102 takes place.
Thereafter, aircraft 102 may go through certification and delivery
112 in order to be placed in service 114. While in service by a
customer, aircraft 102 is scheduled for routine maintenance and
service 116 (which may also include modification, reconfiguration,
refurbishment, and so on).
[0035] Each of the processes of aircraft manufacturing and service
method 100 may be performed or carried out by a system integrator,
a third party, and/or an operator (e.g., a customer). For the
purposes of this description, a system integrator may include, for
example, without limitation, any number of aircraft manufacturers
and major-system subcontractors; a third party may include, for
example, without limitation, any number of venders, subcontractors,
and suppliers; and an operator may be, for example, without
limitation, an airline, leasing company, military entity, service
organization, or other suitable entity.
[0036] As shown in FIG. 2, aircraft 102 produced by aircraft
manufacturing and service method 100 may include airframe 118, a
plurality of systems 120, and interior 122. Examples of systems 120
include one or more of propulsion system 124, electrical system
126, hydraulic system 128, and environmental system 130. Any number
of other systems may be included in this example. Although an
aerospace example is shown, the principles of the disclosure may be
applied to other industries, such as the automotive industry.
[0037] Apparatus and methods embodied herein may be employed during
any one or more of the stages of aircraft manufacturing and service
method 100. For example, components or subassemblies corresponding
to component and subassembly manufacturing 108 may be fabricated or
manufactured in a manner similar to components or subassemblies
produced while aircraft 102 is in service.
[0038] Also, one or more apparatus embodiments, method embodiments,
or a combination thereof may be utilized during component and
subassembly manufacturing 108 and system integration 110, for
example, without limitation, by substantially expediting assembly
of or reducing the cost of aircraft 102. Similarly, one or more of
apparatus embodiments, method embodiments, or a combination thereof
may be utilized while aircraft 102 is in service, for example,
without limitation, to maintenance and service 116.
[0039] The different advantageous embodiments recognize and take
into account that currently available flexible rail systems may
still have limitations that may be undesirable. The different
advantageous embodiments recognize and take into account that
currently available rail systems may be dual rail systems. With a
dual rail system, applying and maintaining the rails on a parallel
configuration with desired offset dimensions between the rails may
be difficult, especially when complex contours are present.
[0040] Further, the different advantageous embodiments recognize
that currently available positioning drilling units are integrated
as a single unit. In other words, the tool may be integrated as
part of the unit that travels on the rail. As a result, when
changes in the types of tools are required, additional setup time
may be needed. Further, by changing the entire unit, the different
advantageous embodiments recognize and take into account that
duplication of components may be required, increasing the expense
of maintaining tools.
[0041] For example, when performing operations on a work piece such
as, for example, without limitation, a fuselage, a set of holes may
be drilled into the fuselage. Next, sealant may be applied to the
countersink area of the hole, and fasteners may be used to fasten
components in the fuselage to each other. This type of operation
may require changing the entire unit. This type of change may
require removal of the rails and placement of new rails and a new
unit onto the fuselage. In other types of dual rail systems, the
unit may be moved off of the rails and a new unit with the
appropriate tool may be coupled to the rails. This type of
operation may be time-consuming as well as more costly by requiring
duplicate rail systems and/or multiple units for different
operations.
[0042] Further, even with performing drilling operations, a
particular drill may be dedicated for a selected range of drilling
parameters based on spindle design. If desired drilling parameters
fall out of the selected range, a different drill may be required.
As a result, multiple units with drills having different ranges of
drilling parameters may be required. Changing a drill may require
moving the unit from the track and replacing the carriage with a
new unit. The unit may then be moved back to the desired position
and the operations may begin. This type of removal and replacement
of the unit may require time, increasing the time needed to
complete manufacturing of a component.
[0043] Thus, the different advantageous embodiments provide a
method and apparatus for performing operations on work pieces. In
one advantageous embodiment, a flexible rail system may be capable
of being attached to a work surface of a work piece. A multi-axis
carriage may be coupled to the flexible rail system. The multi-axis
carriage may be capable of moving along the flexible rail system
and may be capable of moving a tool in axes relative to the work
surface. A tool module may be removably coupled to the multi-axis
carriage. In this manner, the changing of tools may be quickly
performed without requiring removing and replacement of the
carriage. Further, the different advantageous embodiments also may
provide a capability to employ a flexible rail system with a single
rail.
[0044] A reaction unit may be used to stabilize a multi-axis
carriage during movement of the multi-axis carriage along the
flexible rail. Further, this reaction unit also may be capable of
stabilizing the multi-axis carriage during operation of the tool.
In other advantageous embodiments, the tool module may include a
capability to move or rotate the tool about an A-axis to maintain a
capability to drill a hole normal to the surface of the work
piece.
[0045] With reference now to FIG. 3, a block diagram of a flexible
rail apparatus is depicted in accordance with an advantageous
embodiment. Flexible rail apparatus 300 is an example of an
apparatus that may be used to perform operations on work piece 302.
In these examples, work piece 302 may take various forms. For
example, without limitation, work piece 302 may be a part, a
subassembly, a system, or some other structure. Work piece 302 may
be, for example, without limitation, multiple parts aligned to each
other for an operation to be performed using flexible rail
apparatus 300. Work piece 302 may be, for example, without
limitation, a fuselage, a wing, a tail, an aircraft door, an
aircraft empennage, an engine housing, an aircraft control surface,
or some other suitable object.
[0046] Flexible rail apparatus 300 may include flexible rail system
304, multi-axis carriage 306, and tool module 308. Flexible rail
system 304 may be removably coupled or attached to surface 310 of
work piece 302. In these examples, flexible rail system 304 may be
comprised of flexible rail 312, which may be attached to surface
310 of work piece 302 using vacuum cups 314. With flexible rail
312, flexible rail apparatus 300 may be attached to contour 318 in
surface 310 of work piece 302. This contour may be, for example,
without limitation, a curve in a fuselage. Contour 318 may be a
complex and/or compound curve.
[0047] With use of flexible rail 312 by itself, problems with
maintaining two or more rails parallel to each other with
appropriate space settings may be avoided. Additionally, flexible
rail 312 also avoids issues that may occur with dual rails that
follow complex contours. These types of contours may result in
undesirable stress on multi-axis carriage 306. Flexible rail
apparatus 300 may also minimize positioning inaccuracies. Further,
with the use of only flexible rail 312, less space, cost, and/or
weight may be present in flexible rail apparatus 300.
[0048] Multi-axis carriage 306 may be coupled to flexible rail 312
as shown by arrow 319. Multi-axis carriage 306 may include rail
motor 320, tool module motor 322, and controller 323. Rail motor
320 may move multi-axis carriage 306 along flexible rail 312. This
movement may move multi-axis carriage 306 along an axis, for
example, an X-axis. Tool module motor 322 may be used to move tool
module 308 along an axis, for example, a Y-axis.
[0049] Controller 323 may control the movement and operation of
flexible rail apparatus 300 with respect to work piece 302.
Controller 323 may be, for example, without limitation, a computer,
an application to a specific integrated circuit (ASIC), a control
circuit, or some other suitable device.
[0050] In these illustrative examples, tool module 308 may be
removably coupled to multi-axis carriage 306. Tool module 308 may
include frame 324 and tool 326. Tool 326 may be mounted on frame
324. Additionally, tool 326 also may be removably mounted to frame
324, allowing tool 326 to be exchanged with another tool.
[0051] In this example, tool module 308 also may include reaction
unit 328 and pressure unit 330. Reaction unit 328 may be located on
side 332 of frame 324, while pressure unit 330 may be located on
side 334 of frame 324. In this manner, reaction unit 328 and
pressure unit 330 may be located opposite to each other on tool
module 308. Further, these two reaction units may be located on
opposite sides of flexible rail 312.
[0052] Reaction unit 328 may be capable of stabilizing multi-axis
carriage 306 during movement of multi-axis carriage 306 along
flexible rail 312. Further, reaction unit 328 also may be capable
of stabilizing multi-axis carriage 306 during operation of tool
326. In these examples, pressure unit 330 may provide a capability
of providing force 336 that is normal to surface 310 as illustrated
by arrow 338.
[0053] Reaction unit 328 may contact surface 310 continuously or
only during certain operations. Reaction unit 328 may generate
reactive force 344 in the direction of arrow 339 to counter force
336. Reaction unit 328 may include feet 340 and/or rollers 342.
Reaction unit 328 may provide reactive force 344, which may be
applied to surface 310. Reactive force 344 may be applied during
movement of multi-axis carriage 306 along flexible rail 312 to
stabilize multi-axis carriage 306.
[0054] Additionally, reaction unit 328 may provide reactive force
344 to counter or provide stability to multi-axis carriage 306
during drilling operations and/or in response to force 336 being
generated by pressure unit 330. Pressure unit 330 may include foot
346 and/or rollers 348. Foot 346 may generate force 336. Rollers
348 may allow for further stabilization of multi-axis carriage 306
during movement as well as provide additional contributions to
force 336.
[0055] In this example, pressure unit 330 may generate force 336
prior to tool 326 performing drilling operations on work piece 302.
In these examples, tool 326 may take various forms. For example,
without limitation, tool 336 may be drill 350, fastener unit 352,
sealing unit 354, and/or some other suitable device. Drill 350 may
be used to drill holes 356 into work piece 302. Fastener unit 352
may be used to apply fasteners 358 to work piece 302. Sealing unit
354 applies sealant 359 to drill holes 356.
[0056] Further, pressure unit 330 along with tool 326 may be
movable about A-axis 360. This A-axis may be parallel to X-axis 362
along which multi-axis carriage 306 moves when moving along
flexible rail 312. By allowing pressure unit 330 and/or tool 326 to
move about A-axis 360, tool 326 may be maintained in a position
that is normal to surface 310 for performing different operations.
Further, pressure unit 330 and/or tool 326 may be locked into place
to fix these components with respect to A-axis 360 during an
operation.
[0057] With the use of multi-axis carriage 306 and tool module 308,
a reconfiguration capability may be provided for flexible rail
apparatus 300. This capability may allow for reconfiguration of
flexible rail apparatus 300 to perform different types of
operations by minimizing the time needed for reconfigurations. In
contrast to currently available flexible rail systems, flexible
rail apparatus 300 may be reconfigured by changing tool module
308.
[0058] Tool module 308 may be removed and/or detached from
multi-axis carriage 306. For example, if tool module 308 includes
drill 350, after drilling holes in work piece 302, tool module 308
may be removed and another version of tool module 308 may be
attached to multi-axis carriage 306 to fasten parts for pieces of
work piece 302. Further, with this type of configurability, less
expense may be needed for flexible rail apparatus 300 because the
motors and components in multi-axis carriage 306 do not have to be
replicated for each type of tool.
[0059] Further, the capability to rotate tool 326 and pressure unit
330 about A-axis 360 in flexible rail apparatus 300 may control
pressure unit 330 in a manner to provide positioning of pressure
unit 330 and tool 326 normal to surface 310. The change in A-axis
360 only occurs in these examples during pressure unit 330 clamping
or changing to allow for normalization when multi-axis carriage 306
moves to another position.
[0060] Further, the different advantageous embodiments provided by
reaction unit 328 may allow for easier placement of flexible rail
apparatus 300 on work piece 302 because only a single flexible rail
312 may be needed rather than two or more rails. Further, by using
a singular flexible rail 312, the cost of flexible rail apparatus
300 also may be reduced.
[0061] The illustration of flexible rail apparatus 300 in FIG. 3 is
not meant to imply physical or architectural limitations to the
manner in which different advantageous embodiments may be
implemented. This illustration of flexible rail apparatus 300 in
FIG. 3 is provided for purposes of illustrating some features that
may be found in different advantageous embodiments.
[0062] For example, without limitation, in other advantageous
embodiments, flexible rail system 304 may include two or more
flexible rails rather than just a single flexible rail 312. In yet
other advantageous embodiments, tool module motor 322 may be
located within tool module 308 rather than within multi-axis
carriage 306.
[0063] Further, although tool 326 has been described with respect
to drill 350, fastener unit 352, and sealing unit 354, tool 326,
may include other types of tools in other advantageous embodiments.
For example tool 326 may include one or more other tools in
addition to or in place of these. These tools may include, for
example, without limitation, a drill, a measurement probe, a rivet
hammer, a router, a trimming saw, a grinding wheel, and/or some
other suitable tool.
[0064] Although the different advantageous embodiments described in
this example are with respect to aircraft and aircraft parts, other
advantageous embodiments may be applied for use in performing
operations on other types of work pieces. For example, work piece
302 may be, for example, without limitation, a spacecraft a
submarine, a ship, a tank, a power plant structure, a building,
bus, train, or some other suitable object.
[0065] With reference now to FIG. 4, a diagram of a perspective
view of a flexible rail apparatus may be depicted in accordance
with an advantageous embodiment. In this illustrative example,
flexible rail apparatus 400 includes flexible vacuum rail 402,
multi-axis carriage 404, and tool module 406. Multi-axis carriage
404 may include rail motor 408, tool module motor 410, and
controller 412. Tool module 406 may be removably coupled to
multi-axis carriage 404.
[0066] In these illustrative examples, flexible vacuum rail 402 may
be removably attached using vacuum forces attached to surface
414.
[0067] Multi-axis carriage 404 may move along X-axis 416, while
moving along flexible vacuum rail 402. Additionally, multi-axis
carriage 404 may move tool module 406 along Y-axis 418 using tool
module motor 410. Through this movement, drill 420 may be movable
about X-axis 416 and/or Y-axis 418.
[0068] Tool module 406 also may include pressure foot 424, reaction
foot 426, and reaction foot 428. Pressure foot 424 is an example of
an implementation of pressure unit 330 in FIG. 3. Reaction foot 426
and reaction foot 428 are examples of an implementation of reaction
unit 328 in FIG. 3. Reaction foot 426 and reaction foot 428 may
move along Z-axis 430 to engage surface 414 after multi-carriage
404 moves to a location on surface 414.
[0069] Surface 414 may have z-axis 430 that changes as movements
are made in the direction of x-axis 416 and/or y-axis 418. Flexible
vacuum rail 402 may accommodate and/or accept curvature along a
plane defined by y-axis 418 and z-axis 430. The rotation of
pressure foot 424 and/or drill 420 around A-axis 440 may
accommodate changes in a plane defined by x-axis 416 and z-axis
430. In this manner, z-axis 430 remains normal to surface 414.
[0070] After reaction foot 426 and reaction foot 428 engage surface
414, pressure foot 424 also may move along Z-axis 430 to engage
surface 414. Pressure foot 424 may engage surface 414 to provide a
preload force on surface 414 prior to a drilling operation to be
performed by drill 420. In these examples, pressure foot 424 may
merely apply pressure downward onto surface 414. In some
advantageous embodiments, pressure foot 424 also may engage surface
414 using a vacuum.
[0071] The force applied by pressure foot 424 may be greater than
the force applied by drill 420 as a drilling operation occurs.
Reaction foot 426 and/or reaction foot 428 may counteract the force
generated by pressure foot 424 to stabilize multi-access carriage
404. The counter balance may be to react against any moments about
rail 402. In this depicted example, reaction foot 426 and/or
reaction foot 428 may be moved along Z-axis 430 using biasing
mechanism 432 and biasing mechanism 434.
[0072] After reaction foot 426 and reaction foot 428 are in place,
locking mechanisms 435 and 437 may be used to lock reaction foot
426 and/or reaction foot 428 in place. These locking mechanisms may
be used after biasing mechanisms 432 and 434 move reaction foot 426
and/or reaction foot 428 to surface 414. Pressure foot 424 may be
moved along the Z-axis 430 by biasing mechanism 436.
[0073] Biasing mechanisms 432, 434, and 436 may be any kind of
actuator. In this illustrative example, a pneumatic cylinder may be
used in biasing mechanism 434. Other examples of biasing mechanisms
include, for example, without limitation, a pneumatic clamp, a
quick acting nut, a cam lock, an electrical solenoid type brake, a
spring, and/or some other suitable device.
[0074] Further, in these advantageous embodiments, pressure foot
424 and/or drill 420 may be moved along A-axis 440. More
specifically, drill 420 may be mounted on pressure foot 424, which
may be rotatable around A-axis 440. Drill 420 may be removably
attached to pressure foot 424 in housing 438. Pressure foot 424
also may be rotatable around Z-axis 430 in these examples. In the
depicted example, A-axis 440 may be substantially parallel to
X-axis 416.
[0075] The rotation of pressure foot 424 and/or drill 420 around
A-axis 440 may be performed using biasing mechanism 436 to maintain
these components substantially normal to surface 414. After
pressure foot 424 and/or drill 420 have been positioned with
respect to A-axis 440, these components may be locked using locking
mechanism 439. In this manner, holes drilled into surface 414 may
be substantially normal to surface 414 rather than at an angle less
than normal. Rotation of drill 420 and/or pressure foot 424 in
housing 438 around A-axis 440 may be performed to compensate for
local contours in surface 414.
[0076] Biasing mechanism 436 also may be locked with pressure foot
424 in place to prevent movement about A-axis 440. Through locking
mechanism 439, stability of pressure foot 424 may be maintained
during drilling operations using drill 420.
[0077] Fastener 442 and/or fastener 444 may be used to couple tool
module 406 to multi-axis carriage 404. Additionally, handle 446 and
handle 448 may be attached to frame 422 of tool module 406. Handle
446 and/or handle 448 may provide an operator the capability to
more easily remove and/or place tool module 406 onto multi-axis
carriage 404.
[0078] In these examples, fasteners 442 and 444 may be, for
example, without limitation, bolts, screws, cam lock, and/or some
other suitable fastening mechanisms. These fasteners may be
manipulated to engage and disengage tool module 406 from multi-axis
carriage 404. In this manner, the different advantageous
embodiments may provide a capability to change the configuration of
flexible rail apparatus 400 with reduced effort as compared to
changing the entire apparatus.
[0079] Further, increased flexibility may be provided through the
use of housing 438, which may be configured to removably accept a
tool, such as, for example, without limitation, drill 420. In this
manner, different tool configurations may be generated for flexible
rail apparatus 400 through removability of tool module 406 and/or
drill 420.
[0080] With reference now to FIG. 5, a diagram of a top view of a
flexible rail apparatus is depicted in accordance with an
advantageous embodiment. As can be seen in this illustrative
example, tool module motor 410 in multi-axis carriage 404 may move
motorized rail 500. Movement of motorized rail 500 may cause
movement of tool module 406 along Y-axis 418. Although motorized
rail 500 is illustrated, other types of devices may be used to move
tool module 406 along Y-axis 418. For example, without limitation,
a bell screw, a racking pinion mechanism, a belt driven mechanism,
a linear actuator, and/or some other suitable device may be
used.
[0081] With reference now to FIG. 6, a diagram of a front view of a
flexible rail apparatus is depicted in accordance with an
advantageous embodiment. Next, FIG. 7 is a diagram of a side view
of a flexible rail apparatus in accordance with an advantageous
embodiment.
[0082] Next, FIG. 8 is a diagram of a perspective view of a
flexible apparatus in which tool module 406 may be disengaged from
multi-axis carriage 404 in accordance with an advantageous
embodiment. In this particular example, rail 800 and rail 802 also
may be seen. Frame 422 may engage rail 800 and/or rail 802. These
rails may provide for movement along Y-axis 418. In this example,
attachment point 804 and attachment point 806 may be located on
rail 800 and rail 802. Attachment point 804 and attachment point
806 may provide points of attachment and/or engagement for fastener
442 and fastener 444.
[0083] Further, frame 422 also may include end hook 808 which may
attach to rail 802 to aid in securing frame 422 to rail 802.
Another end hook (not shown) may be used to aid in securing frame
422 to rail 800. Also in this view, motorized rail 500 may include
engagement points 810, 812, 814, and 816, which may engage frame
422 to allow motorized rail 500 to move frame 422 on rails 800 and
802 along Y-axis 418.
[0084] With reference now to FIG. 9, a diagram of another
perspective view of a tool module detached from a multi-axis
carriage is depicted in accordance with an advantageous embodiment.
In this example end hook 808 and end hook 900 may be seen on bottom
902 of frame 422. End hook 808 and end hook 900 may engage rail 800
and rail 802 to aid in coupling frame 422 to multi-axis carriage
404.
[0085] Flexible rail apparatus 400 illustrated in FIGS. 4-9 has
been provided for illustrating one manner in which a flexible rail
apparatus may be implemented. This illustration is not meant to
imply physical and/or architectural limitations to a manner in
which other advantageous embodiments may be implemented.
[0086] For example, in other advantageous embodiments only one
reaction foot may be employed rather than both reaction foot 426
and reaction foot 428. In other embodiments, motorized rail 500 may
be attached to frame 422 rather than multi-axis carriage 404.
[0087] With reference now to FIG. 10, a diagram of a flexible rail
apparatus is depicted in accordance with an advantageous
embodiment. In this example, flexible rail apparatus 400 has been
reconfigured to include tool module 1000 in place of tool module
406 in FIG. 4.
[0088] In this example, tool module 1000 may include frame 1002.
Reaction foot 1004 and reaction foot 1006 are examples of an
implementation of reaction unit 328 in FIG. 3 and may be attached
to frame 1002. In this example, housing 1008 may include multiple
tools. As illustrated, housing 1008 may include drill 1010, seal
applicator module 1012, and bolt insertion module 1014.
[0089] Housing 1008 also may include pressure foot 1016, which may
be used with drill 1010 to perform drilling operations. Pressure
foot 1016 is an example of an implementation of pressure unit 330
in FIG. 3.
[0090] Handle 1018 and handle 1019 may be attached to frame 1002 of
tool module 1000. Handle 1018 and handle 1019 may provide grips for
an operator to use in attaching and/or detaching tool module 1000
from multi-axis carriage 404. In this illustrative example, drill
1010, seal applicator module 1012, and bolt exertion module 1014
may all rotate around A-axis 1020.
[0091] With reference next to FIG. 11, a side view of a flexible
rail apparatus with multiple tools is depicted in accordance with
an advantageous embodiment. In this example, another view of
flexible rail apparatus 400 is depicted with tool module 1000.
[0092] With reference now to FIG. 12, a diagram of a front view of
a flexible rail apparatus is depicted in accordance with an
advantageous embodiment. In this example, a front view of
multi-axis carriage 404 with tool module 1000 is shown.
[0093] With reference next to FIG. 13, a diagram of a perspective
view with a tool module separated from a multi-axis carriage is
depicted in accordance with an advantageous embodiment. In this
example, tool module 1000 may be uncoupled from multi-axis carriage
404.
[0094] Thus, different tool modules may be placed and/or coupled
with multi-axis carriage 404 to reconfigure flexible rail apparatus
400. These reconfigurations may be more quickly performed as
compared to currently available flexible rail systems. This
modularity may allow for quick replacement of tools. Further, the
different tools illustrated in these examples also may be removable
from their housings.
[0095] With reference now to FIG. 14, a diagram illustrating
another configuration of a flexible rail apparatus is depicted in
accordance with an advantageous embodiment. In this additional
illustrative example, flexible rail apparatus 400 may have tool
module 1400 coupled to multi-axis carriage 404. In this
illustrative example, handle 1401 may be attached to multi-axis
carriage 404 to provide for easier handling by an operator.
[0096] Tool module 1400 may include frame 1402. Housing 1406 may be
attached to frame 1402 and may hold rivet gun 1408. Rivet gun 1408
also may be removable from housing 1406 in these examples. Reaction
rollers 1404 may be attached to frame 1402. In this embodiment,
rollers may be used in place of reaction feet. Reaction rollers
1404 may be another example of an implementation of reaction unit
328 in FIG. 3.
[0097] As illustrated in this example, pressure foot car 1410 may
be attached to housing 1406 along with rollers 1412 and 1414. The
use of these rollers with pressure foot car 1410 and reaction
rollers 1404 may provide for additional stability of multi-axis
carriage 404 when moving along flexible rail 402.
[0098] Handle 1416 and handle 1418 may be attached to frame 1302.
Handle 1416 and handle 1418 may be used to remove tool module 1400
from multi-axis carriage 404. In this example, fastener 1420 may be
used to engage and/or attach tool module 1400 to multi-axis
carriage 404.
[0099] With reference now to FIG. 15, a diagram of a top view of a
flexible rail apparatus is depicted in accordance with an
advantageous embodiment. In this view, rollers 1500 and 1502 also
may be seen attached to housing 1406.
[0100] With reference now to FIG. 16, a diagram illustrating a
flexible rail apparatus on a curved surface is depicted in
accordance with an advantageous embodiment. In this example,
flexible rail apparatus 400 may be placed on curved surface 1600.
Further, in this view, pressure foot 1602 may be seen attached to
pressure foot car 1410. Pressure foot car 1410 and reaction rollers
1404 may be angled to more closely match contours in curved surface
1600. The axis angularity of pressure foot car 1410 may be
maintained using elastomeric cushion 1604 in these examples.
[0101] The illustration of the different configurations for
flexible rail apparatus 400 in FIGS. 4-16 are not meant to imply
physical or architectural limitations to the manner in which a
flexible rail apparatus 400 may be constructed and/or implemented
in providing different features of the advantageous embodiments.
For example, although the different advantageous embodiments
illustrate the tools on tool module 406 being to the right side of
multi-axis carriage 404, in other advantageous embodiments, one or
more tools may be located on the left side. In yet other
advantageous embodiments, a tool may be located on both sides of
multi-axis carriage 404. Further, in other advantageous
embodiments, a reaction unit containing components such as, for
example, reaction feet, may be unnecessary.
[0102] With reference now to FIG. 17, a flowchart of a process for
performing an operation on a work piece is depicted in accordance
with an advantageous embodiment. The process illustrated in FIG. 17
may be implemented using a flexible rail apparatus such as, for
example, without limitation, flexible rail apparatus 300 in FIG.
3.
[0103] The process may begin by attaching flexible vacuum rail 402
in FIG. 4, with multi-axis carriage 404 coupled to flexible vacuum
rail 402, to surface 310 of work piece 302 in FIG. 3 (operation
1700). The process may also begin by attaching the flexible vacuum
rail to the surface of the work piece, and subsequently attaching
the multi-axis carriage to the flexible vacuum rail. The process
then may couple tool module 406 to multi-axis carriage 404
(operation 1702). The process may then move multi-axis carriage 404
to a location (operation 1704).
[0104] An operation may be performed at the location (operation
1706). This operation may be, for example, without limitation, a
drilling operation, a sealing operation, a fastening operation, a
measuring operation, and/or some other suitable operation. A
determination may be then made as to whether additional operations
are to be performed (operation 1708).
[0105] If additional operations are to be performed, a
determination may be made as to whether a different tool module may
be needed (operation 1710). If a different tool module is needed,
the process may replace the current tool module with another tool
module (operation 1712) with the process then returning to
operation 1704. If a different tool module is not needed, the
process may then proceeds directly to operation 1704 as described
above. With reference again to operation 1708, if more operations
are not needed, the process then terminates.
[0106] The illustration of the operations in FIG. 17 is not meant
to limit the manner in which operations may be performed on a work
piece. Other operations may be performed in addition to or in place
of the operations illustrated. Also, operations illustrated in the
process in FIG. 17 may be performed in different orders depending
on the particular implementation. In some advantageous embodiments,
operation 1702 may be performed prior to operation 1700. As another
non-limiting example, multi-axis carriage 404 may be attached to
flexible vacuum rail 402 after flexible vacuum rail 402 has been
attached to the work surface.
[0107] Thus, the different advantageous embodiments provide a
method and apparatus for performing operations on a work piece. In
the different advantageous embodiments, a flexible rail system may
be attached to a work surface. A multi-axis carriage may be coupled
to a flexible rail system in which the multi-axis carriage may be
capable of moving along the flexible rail system and may be capable
of moving a tool in axes relative to the work surface. Further, a
tool module capable of being removably coupled to the multi-axis
carriage may be employed in which the tool has a frame and the tool
may be mounted to the frame.
[0108] In the different advantageous embodiments, a single flexible
rail may be used. A reaction unit may be used to stabilize the
multi-axis carriage during the operation of the tool and possibly
during the operation of movement of the multi-axis carriage.
[0109] The use of the phrase "at least one of" when used with a
list of items means that different combinations of one or more of
the items may be used. This list may mean that more than one of
each type of item in the list may be needed. For example, "at least
one of item A, item B, and item C" may include, for example,
without limitation, item A or item A and item B. This example also
may include item A, item B, and item C. Also, this example may
include two of item A, one of item B, and three of item C. Of
course any suitable combination of items and number of items may be
employed depending on the particular implementation.
[0110] The description of the different advantageous embodiments
has been presented for purposes of illustration and description,
and is not intended to be exhaustive or limited to the embodiments
in the form disclosed. Many modifications and variations will be
apparent to those of ordinary skill in the art. Further, different
advantageous embodiments may provide different advantages as
compared to other advantageous embodiments.
[0111] The embodiment or embodiments selected are chosen and
described in order to best explain the principles of the
embodiments, the practical application, and to enable others of
ordinary skill in the art to understand the disclosure for various
embodiments with various modifications as are suited to the
particular use contemplated.
* * * * *