Track-aligned process tools and process of using
During an assembly process for an aircraft, segments of the fuselage are fabricated separately prior to joining the segments together to form the complete fuselage. In order to ensure that abutting ends of the segments mate together correctly, a machining process is performed along the edges of the segments at their ends. A trim-tool assembly includes an indexing cart mounted to a track secured to a surface of the workpiece, where a setting on the indexing cart varies a distance between a centerline of the track and an edge of a workpiece. The trim-tool assembly further includes a tool cart mounted to the track and translatable along the track. The tool cart includes a process tool that performs a machining process on the workpiece at a fixed distance from the centerline of the track.
1. A method of operating a trim-tool assembly, the method comprising:
prior to securing a track to a surface of a workpiece, aligning the track to an edge of the workpiece using indexing carts mounted on the track and disposed towards ends of the track, wherein variable settings on the indexing carts are configured to modify a position of the track relative to the edge of the workpiece to define a process line that intersects the workpiece;
installing a tool cart on the track that includes a process tool that performs a machining process along the process line defined by the variable settings on the indexing carts;
securing the track to the surface of the workpiece; and
after securing the track to the surface of the workpiece, performing the machining process along the process line by translating the tool cart along the track.
2. The method of claim 1 , wherein:
the process tool comprises a trim saw; and
the machining process comprises using the trim saw to make a cut along the process line.
3. The method of claim 1 , wherein:
the variable settings on the indexing carts define a width between the edge of the workpiece and the process line that is different at each of the indexing carts.
4. The method of claim 1 , further comprising:
calibrating the indexing carts to the tool cart to identify a zero setting for the variable settings that places the process line at the edge of the workpiece at each of the indexing carts.
5. The method of claim 1 , wherein:
the workpiece comprises one segment of a plurality of segments that comprise a fuselage for an aircraft.
6. The method of claim 1 , wherein:
the indexing carts are mounted on the track using grooves in rollers on the indexing carts that engage with edges of the track.
7. The method of claim 1 , wherein:
the variable settings on the indexing carts are configured to modify a distance between a contact surface on the indexing carts, that contacts the edge of the workpiece, and a centerline of the track.
8. The method of claim 1 , further comprising:
removing the indexing carts from the track after the track is secured to the surface of the workpiece.
9. A trim-tool assembly configured to perform a machining process on a workpiece, the trim-tool assembly comprising:
a track configured to adhere to a surface of the workpiece;
a plurality of indexing carts mounted on the track and disposed towards ends of the track, each indexing cart of the indexing carts comprises:
a base member;
an edge-engaging member movably coupled to the base member; and
an indexing guide extending from the edge-engaging member and configured to contact an edge of the workpiece;
wherein variable settings on the indexing carts are configured to modify a position of the track relative to the edge of the workpiece prior to securing the track to the surface of the workpiece and to define a process line that intersects the workpiece; and
a tool cart disposed on the track and comprising a process tool configured to perform the machining process along the process line defined by the variable settings on the indexing carts as the tool cart translates along the track when the track is secured to the surface of the workpiece.
10. The trim-tool assembly of claim 9 , wherein:
the process tool comprises a trim saw; and
the machining process comprises using the trim saw to make a cut along the process line.
11. The trim-tool assembly of claim 9 , wherein:
the variable settings on the indexing carts are configured to define a width between the edge of the workpiece and the process line that is different at each of the indexing carts.
12. The trim-tool assembly of claim 9 , wherein:
the indexing carts are calibrated to the tool cart to identify a zero setting for the variable settings that places the process line at the edge of the workpiece at the indexing carts.
13. The trim-tool assembly of claim 9 , wherein:
the workpiece comprises one segment of a plurality of segments that comprise a fuselage for an aircraft.
14. The trim-tool assembly of claim 9 , wherein:
the tool cart and the indexing carts include pairs of adjacent rollers with grooves that engage with edges of the track.
15. The trim-tool assembly of claim 9 , wherein:
each indexing cart further comprises:
front rollers and back rollers extending from a bottom surface of the base member, and coupled with edges of the track;
wherein the front rollers are separated from the back rollers by a distance defined by a width of the track.
16. The trim-tool assembly of claim 15 , wherein:
the edge-engaging member is movably coupled to the base member using one or more indexing pins that are inserted into indexing holes of the base member.
17. A trim-tool assembly configured to perform a machining process on a workpiece, the trim-tool assembly comprising:
a track;
a plurality of indexing carts mounted on the track, and configured to align the track to an edge of the workpiece;
each indexing cart of the indexing carts comprises:
a base member;
an edge-engaging member movably coupled to the base member; and
an indexing guide extending from the edge-engaging member and configured to contact the edge of the workpiece;
wherein a setting on each of the indexing carts is configured to adjust a distance between a centerline of the track and the edge of the workpiece prior to securing the track to a surface of the workpiece; and
a tool cart movably mounted to the track, the tool cart being translatable along the track when the track is secured to the surface of the workpiece, wherein the tool cart includes a process tool configured to perform the machining process on the workpiece at a fixed distance from the centerline of the track.
18. The trim-tool assembly of claim 17 , wherein:
the process tool comprises a trim saw; and
the machining process comprises using the trim saw to make a cut through the workpiece at the fixed distance from the centerline of the track.
19. The trim-tool assembly of claim 17 , wherein:
each indexing cart further comprises:
front rollers and back rollers extending from a bottom surface of the base member, and coupled with edges of the track;
wherein the front rollers are separated from the back rollers by a distance defined by a width of the track.
20. The trim-tool assembly of claim 19 , wherein:
the edge-engaging member is movably coupled to the base member using one or more indexing pins that are inserted into indexing holes of the base member.