Flexible header system for machining workpieces

Abstract

A manufacturing system includes a configurable positioning apparatus and machining system for processing a workpiece retained by the positioning apparatus. The positioning apparatus has different configurations for retaining different types of workpieces, such as panels, fuselages, airfoil skins, and engine housings. The positioning apparatus includes a first support rail and a second support rail spaced apart from the first support rail. The first and second support rails support a plurality of stackable headers that cooperate to position the workpiece. The headers have adjustable heights along their lengths in order to accommodate the shape of the workpiece.

What is claimed is: 
     
         1 . A manufacturing system for processing a workpiece, the system comprising:
 a stationary frame and a plurality of headers wherein the frame has a first support rail and a second support rail, each of the headers including a row of movable actuators adapted to support at least a portion of a workpiece processed by a machining system, wherein the first support rail includes a plurality of spaced apart discrete first mounting regions formed therein and the second support rail includes a plurality of spaced apart discrete second mounting regions formed therein, such that corresponding transverse pairs of the first mounting regions and the second mounting regions define installation positions, the plurality of headers being positioned at respective installation positions and wherein each header is configured to be fixedly coupled to a corresponding pair of the first and second mounting regions and includes a locking mechanism having a locked state for fixedly coupling to the frame and an unlocked state for moving with respect to the frame.   
     
     
         2 . The system of  claim 1 , wherein at least one of the headers includes at least one stationary holder that cooperates with the panel of actuators to support the workpiece or couple to a tool. 
     
     
         3 . The system of  claim 2 , wherein the at least one stationary holder is an elongate rod or an arch with a platform. 
     
     
         4 . The system of  claim 1 , wherein at least one of the headers has first and second locking mechanisms each including a locating pin configured to pass through one of the first and second mounting regions. 
     
     
         5 . The manufacturing system of  claim 1 , wherein at least one of the actuators is movable between laterally offset positions with respect to a longitudinal axis of a beam of one of the headers. 
     
     
         6 . The manufacturing system of  claim 1 , wherein at least one of the headers has an elongate member and an actuator that includes a mounting plate adapted to mate with a mounting region of the elongate member to define a plurality of preset actuator mounting positions. 
     
     
         7 . The manufacturing system of  claim 1 , further comprising at least one cover supported by the first support rail and the second support rail, the cover fills substantially all of a gap between an adjacent pair of the headers. 
     
     
         8 . The manufacturing system of  claim 7 , wherein at least one of the covers is sufficiently wide to define a walkway. 
     
     
         9 . The manufacturing system of  claim 1 , further comprising a plurality of covers each having a width that is generally equal to or a multiple of half a width of one of the headers. 
     
     
         10 . The manufacturing system of  claim 1 , further comprising a cover between an adjacent pair of components to shield a space generally beneath the adjacent components from water and debris as a workpiece is processed. 
     
     
         11 . The manufacturing system of  claim 11 , wherein the cover forms a fluid tight seal with at least one of the adjacent components that is in the form of a header. 
     
     
         12 . The manufacturing system of  claim 1 , wherein the plurality of headers are connected to one another to form fluid tight seals between one another. 
     
     
         13 . The manufacturing system of  claim 1 , wherein one of the headers includes an inflatable sealing device adapted to engage an adjacent header or cover. 
     
     
         14 . The manufacturing system of  claim 1 , wherein the actuators are adapted to be mountable at a plurality of different eccentric positions. 
     
     
         15 . A method of processing a workpiece, the method comprising:
 positioning a plurality of headers on a plurality of first mounting regions formed in a stationary first support rail and a plurality of second mounting regions formed in a stationary second support rail spaced apart from the first support rail such that the plurality of headers extend transversely between the first support rail and the second support rail;   fixedly coupling the headers to the first and second support rails using locking mechanisms of the headers having a locked state and an unlocked state such that each locking mechanism is received by one of the first and second mounting regions;   placing a workpiece on the actuators of the headers;   processing the work piece using a movable machining assembly;   removing the processed workpiece from the actuators; and   decoupling one of the headers from the first and second support rails using the locking mechanisms.   
     
     
         16 . The method of  claim 15 , further comprising:
 moving at least one of the headers with respect to the first and second rails after decoupling the header from the first and second rails.   
     
     
         17 . The method of  claim 16 , further comprising:
 eccentrically positioning at least one of the actuators with respect to a beam of one of the headers supporting the at least one actuator.