BACKGROUND INFORMATION

1. Field

The present invention relates to factory level automation, and in particular to a compound contour vacuum track for automation of final assembly from the interior of a fuselage.

2. Description of the Related Art

Factory level automation for aircraft assembly includes the automated drilling of holes and insertion of fasteners. For example, the joining of different sections of a fuselage may be automated in such a manner.

The fuselage may comprise a monocoque or semi-monocoque shell, wherein a series of hoop-wise frames in the shape of the fuselage cross sections are attached to longitudinal stringers that are covered with a skin of material. Most modern large aircraft use several large sections, which are then joined by fastening, riveting or bonding to form the complete fuselage.

In aircraft assembly, limited access to structures within the fuselage has posed a problem for automation. Currently, only the drilling of holes and the insertion of fasteners, such as lockbolts, has been automated, from the outside of the fuselage.

For example, an automated multi-axis drilling machine positioned outside the fuselage is currently used for the drilling of holes and the insertion of fasteners. The multi-axis drilling machine comprises a carriage with an end effector traveling on dual tracks. The end effector drills holes in fuselage and inserts fasteners into the holes.

Currently, manual fastening of collars onto the fasteners is performed on the inside of the fuselage. Specifically, the process inside the fuselage requires mechanics to install gap management tools and provide clamps for the drilling of holes and the insertion of fasteners. Mechanics also need to follow and align the multi-axis drilling machine positioned outside the fuselage, and manually install and swage collars from inside the fuselage.

However, manual fastening poses a number of issues, including ergonomic and safety considerations, product lead time and rework. On the other hand, the track used for the automated multi-axis drilling machine positioned outside the fuselage is not suitable for use inside the fuselage.

What is needed, then, are improved methods of factory automation, especially for final assembly inside a fuselage. The present invention satisfies this need.

SUMMARY

To overcome the limitations in the prior art described above, and to overcome other limitations that will become apparent upon reading and understanding the present specification, the present invention discloses a compound contour vacuum track, and an automated fastening machine using the track, for automation of final assembly inside an aircraft fuselage.

The devices and methods of the present invention are embodied in many ways, including, but not limited to, the following embodiments listed below.

1. A device or method for fastening a structure, comprising mounting a track interior to a structure in order to access a first surface of the structure, wherein the first surface has one or more holes through which fasteners are inserted. An automated fastening machine is mounted on the track to traverse the track while performing fastening functions, wherein the track allows the automated fastening machine to make contact with the first surface, such that the automated fastening machine aligns with the holes in the first surface, and the automated fastening machine installs the fasteners in the holes.

2. The device or method of embodiment 1, wherein the track is mounted at an angle to the first surface.

3. The device or method of embodiment 1, wherein the first surface is an inside surface of an aircraft fuselage.

4. The device or method of embodiment 1, wherein the track is shaped to match the first surface.

5. The device or method of embodiment 1, wherein the track is mounted so that its width is at an angle to the first surface.

6. The device or method of embodiment 1, wherein the track is at an angle of about 90 degrees to the first surface.

7. The device or method of embodiment 1, wherein the track is at an angle ranging from about 80 degrees to about 100 degrees to the first surface.

8. The device or method of embodiment 1, wherein the track is mounted on a second surface at an angle to the first surface.

9. The device or method of embodiment 8, wherein the second surface is an aft pressure bulkhead of an aircraft fuselage.

10. The device or method of embodiment 1, wherein the track is mounted directly on the first surface.

11. The device or method of embodiment 1, wherein the track is mounted along X-Axis and Z-Axis directions, the X-Axis direction comprises a lateral position, and the Z-Axis direction comprises a vertical position.

12. The device or method of embodiment 11, wherein the automated fastening machine is positioned along the track in at least the X-Axis and Z-Axis directions.

13. The device or method of embodiment 1, wherein the track is comprised of one or more sections.

14. The device or method of embodiment 13, wherein splices are used for connecting between the sections.

15. The device or method of embodiment 1, wherein the track is mounted interior to the structure using one or more removable attachment devices.

16. The device or method of embodiment of claim1, wherein the track includes a drive rack for engaging and moving the automated fastening machine along the track.

