Manufacturing system for aircraft structures and other large structures

A production system for processing a workpiece, comprising:

• a plurality of index devices removably affixed to the workpiece in known locations thereof, each index device being proximate a different zone of the workpiece, each index device having a machine-readable sensor in which is stored an identifier unique to said index device;
• a reader operable to read the identifier stored in the sensor of each index device;
• a controller connected with the reader for receiving the identifier therefrom, the controller being preprogrammed with process information for each zone of the workpiece including information prescribing locations of holes to be drilled in the workpiece, the process information for each zone being correlated with the identifier stored in the sensor of the index device located proximate said zone, and the controller being operable to retrieve the process information for each zone based on the identifier read by the reader;
• and
• a drilling device connected with the controller and operable to be controlled by the controller so as to drill holes in the locations prescribed in the process information for each zone of the workpiece.

A production system for processing a workpiece, comprising:

• an index system including a plurality of index devices removably mounted on the workpiece at known longitudinally spaced locations therealong, and a longitudinally extending index member releasably engaged with at least two of the index devices such that a position and orientation of the index member are fixed relative to the workpiece by the index devices, the index member having position-indicating features therealong;
• and
• a machine module mounted for longitudinal movement along the index member and operable to perform an operation, the machine module being operable to detect the position-indicating features on the index member and thereby determine a position of the machine module relative to the workpiece,
• wherein the index member includes a first index arm operable to engage one of the index devices and a second index arm operable to engage another of the index devices such that the position of the index member relative to the workpiece is fixed by the index devices, the first index arm being fixed relative to the index member and the second index arm being adjustable in longitudinal position along the index member, each of the index devices having a machine-readable sensor mounted therein, the sensor in each index device storing information including an identifier unique to said respective index device, and each index arm including a reader operable to read the information stored in the index device engaged by the index arm.

A production system for processing a workpiece, comprising:

• an index system including a plurality of index devices removably mounted on the workpiece at known longitudinally spaced locations therealong, and a longitudinally extending index member releasably engaged with at least two of the index devices such that a position and orientation of the index member are fixed relative to the workpiece by the index devices, the index member having position-indicating features therealong;
• and
• a machine module mounted for longitudinal movement along the index member and operable to perform an operation, the machine module being operable to detect the position-indicating features on the index member and thereby determine a position of the machine module relative to the workpiece,
• wherein the index system includes an index support system for supporting the index member, the index support system including a pair of clamp assemblies operable to apply clamping forces to the workpiece from opposite sides thereof, the index support system being operable to allow relative movement between the index member and workpiece prior to engaging the index devices installed in the workpiece and the index support system being operable to lock up after the index system engages the index devices so as to immobilize the index member relative to the workpiece.

A production system for processing a workpiece, comprising:

• an index system including a plurality of index devices removably mounted on the workpiece at known longitudinally spaced locations therealong, and a longitudinally extending index member releasably engaged with at least two of the index devices such that a position and orientation of the index member are fixed relative to the workpiece by the index devices, the index member having position-indicating features therealong;
• a machine module mounted for longitudinal movement along the index member and operable to perform an operation, the machine module being operable to detect the position-indicating features on the index member and thereby determine a position of the machine module relative to the workpiece, wherein the machine module comprises a drill mounted on a frame that is traversable along the index member;
• and
• a fastener insertion device mounted on the frame and operable to insert a fastener into a hole drilled in the workpiece by the drill,
• wherein the frame includes a clamp mechanism operable to clamp together parts of the workpiece to be joined by a fastener, the clamp mechanism being operable to measure a stack-up thickness of the clamped parts through which the fastener must extend to enable selection of a proper length fastener for insertion into the hole in the workpiece.