Modular wing portion, wing assembly and method of assembling same

Abstract

The present disclosure relates to a modular wing portion, a wing assembly and a method of assembling the same, the modular wing portion (390) for installation into a wing assembly (503) as a pre-assembly unit comprising at least one rib (300) and at least one internal fuel tank system component (340), and a cartridge clamp (101) for assembling the modular wing portion (390) away from an aircraft wing (501), the cartridge clamp (101) includes a plurality of auxiliary support members each configured to receive and support a rib (300) such that a fuel system component (340) may be mounted to the rib. Associated aircraft (500) and wing (501), transport frame (600) and methods of assembly are also disclosed.

Description

Technical Field

[0001] The present invention relates to modular wing sections and related subject matter. More particularly, but not exclusively, the present invention relates to modular wing sections that are installed as preassembled units into wing assemblies, wing assemblies for receiving modular wing sections, cassette fixtures for assembling modular wing sections, transport assemblies configured for installing modular wing sections, methods of assembling and installing modular wing sections, and wings and aircraft including modular wing sections. Background Art

[0002] Aircraft wings may be provided with fuel system components, such as fuel lines or hydraulics, extending across and through a plurality of ribs of the wing structure. The wing is assembled with the ribs received between the bottom and top covers of the wing, and the fuel system components are then installed in the wing.

[0003] After the wing box of the wing (including covers and beams) is fully assembled, the installation of the fuel tank system is performed through the manhole located in the lower cover.

[0004] Several attempts have been made to improve the manufacturing efficiency of the wing box by attaching at least some of the fuel system components to at least one of the ribs before connecting the ribs together. An example is the system disclosed in GB201214575A (Airbus Operations Ltd). GB201214575A discloses installing a rib into the wing box and then attaching the fuel system components to the rib before installing the second rib. By installing the fuel system components in this order, the wing box structure is constructed and the ease of installing the fuel system components into the wing box is improved.

[0005] GB2575841A (Airbus Operations Ltd.) discloses fitting suitable ribs into the wing so that relatively long fluid conduits can be fitted through the plane of several ribs. This improves the ease of fitting fuel system components into the wing box.

[0006] The above process is still relatively slow and can result in congestion on the main wing assembly line. In addition, installing the fuel system components in situ into the wing imposes operational limitations and ergonomic challenges on the operators assembling the wing box, as the known methods of manufacturing the wing discussed above may require the operators to assemble the wing with their arms raised above their heads as they fit the fuel system components while working underneath the wing box.

[0007] The present invention seeks to mitigate or overcome one or more of the above problems.Alternatively or additionally, the present invention seeks to provide an improved aircraft assembly jig and an improved method of installing a component at an aircraft. Summary of the invention

[0008] According to a first aspect of the present invention, there is provided a modular wing section for installation as a pre-assembled unit into a wing assembly, the modular wing section comprising at least one rib and at least one internal fuel tank system component.

[0009] The modular wing section may correspond to a section of an aircraft wing. This means that the modular wing section may be arranged to form a portion of the desired regional volume of the aircraft wing. At least one internal fuel tank system component may include a majority (i.e., for example, more than 50% based on the volume occupied or based on mass) of the fuel tank system components that need to be installed in the chord section or desired volume of the finished aircraft wing. At least one internal fuel tank system component may include more than 70% of the fuel tank system components that need to be installed in the chord section or desired volume of the finished aircraft wing. At least one internal fuel tank system component may include substantially all of the fuel tank system components that need to be installed in the chord section or desired volume of the finished aircraft wing. By increasing the number of fuel system components present in the modular wing section, the time spent installing the fuel system components directly to the wing at the main wing assembly station is reduced.

[0010] The modular wing sections are assembled as pre-assembled units. The modular wing sections are assembled as pre-assembled units allowing the modular wing sections to be assembled off-site away from the main production assembly line of the wing. This allows the manufacturing process to be improved / optimized because in known prior art systems, the main assembly line of the wing may be the rate-limiting step during production, and moving the production away from the main assembly line of the wing can increase the manufacturing speed of the wing. Another advantage is that by assembling the fuel system components and ribs off-site, the ergonomic environment of the operator is improved compared to when the operator installs the ribs and at least one fuel component on the wing itself. For example, the arrangement allows the operator to perform the system installation of the ribs and fuel system components in an offline station (the so-called "off-line station" refers to a position away from the aircraft wing and / or away from the final assembly line of the aircraft wing) with full access and the possibility of working at an optimized height, so that the ergonomics of the operator's installation is improved. By moving the installation of the ribs and fuel system components to the offline station, the installation of the fuel system components and the ribs is removed from the critical process of the final assembly line. The pre-assembled unit can be configured to be installed as a single piece.

[0011] The at least one internal fuel tank system component and the at least one rib may be configured to be spatially fixed relative to one another such that:

[0012] a. when at least one rib is installed in the wing assembly, at least one fuel tank system component is installed in the wing assembly, and

[0013] b. At least one rib is installed into the wing assembly when at least one fuel tank system component is installed.

[0014] At least one rib and at least one fuel tank system component can be interconnected to allow the arrangement to be operationally tested at a position away from the aircraft wing. The modular wing section can be configured to be connected to other modular wing sections, such as modular wing sections located in the position of the modular wing section in the adjacent wing assembly. The modular wing section can include a system joint, which is used to connect to the system joint of the wing assembly and / or the adjacent modular wing section. The modular wing section can include a structural joint, which is used to connect to the structural joint of the wing structure and / or the adjacent module. The modular wing section can include a mounting portion, which is used to be installed to the transport assembly that can carry the module. The mounting point can be a retractable protrusion or a quick closing clamp of a zero-point clamping system. At least one fuel tank system component can be (or include one or more of them) a fuel pipeline, a connector, a sensor or a wiring harness. At least one fuel tank system component can be an elongated and rigid fuel conduit, such as an elongated (fuel) pipeline.

[0015] Each of the at least one rib may have a planar surface defining a rib plane bounded by an outer rib edge, wherein at least one internal fuel tank system component passes through the rib plane. At least one fuel system component may pass through and / or be mounted to the rib at a location passing through the rib plane and completely within the outer rib edge.

[0016] Optionally, the at least one rib comprises two or more ribs, wherein at least one internal fuel tank system component passes through the plane of the rib and through the planar surface of each of the at least two ribs. Optionally, the fuel system component may pass through at least three ribs.

[0017] The modular wing section may have a length (corresponding to the longitudinal axis) and a width (corresponding to an axis orthogonal and transverse to the longitudinal axis). The one or more ribs may be a plurality of ribs distributed along the length of the modular wing section. The one or more ribs may be movable along the length of the modular wing section via mounting to an adjustment mechanism. The adjustment mechanism may include one or more tracks mounted parallel to the length of the modular wing section. The one or more tracks may be mounted to the outer periphery of the length of the cassette fixture. The one or more ribs may be mounted between two tracks. The one or more ribs may be mounted between the two tracks such that a first end of the one or more ribs is mounted to the first track and an opposite second end of the one or more ribs is mounted to the second track. The length of the first end of the one or more ribs located along the length of the modular wing section may be different from the length of the second end of the rib located along the length of the modular wing section.

[0018] Each rib may have a length (corresponding to a longitudinal axis of the rib), wherein the length of each rib is transverse to the length of the modular wing section. The length of each rib (corresponding to the axis of the length) may be substantially orthogonal and / or transverse to the length of the modular wing section. The length of each rib (corresponding to the axis of the length) may have an orientation between 70° and 110° relative to the length of the modular wing section.

[0019] Each rib may have a width. The width of each rib may be substantially parallel to the width of the modular wing section. Each rib may have a depth. The depth of each rib may be substantially perpendicular to both the width of the modular wing section and the length of the modular wing section.

[0020] The modular wing section may further include a removable box clamp. The removable box clamp may be configured to guide assembly and installation of the modular wing section. At least one rib and at least one internal fuel tank system component are removably mounted to the removable box clamp.

[0021] The removable box-type clamp may include a connection joint that is suitable for connecting and aligning the box-type clamp in a predetermined position relative to the wing assembly. The removable box-type clamp may include a system joint that is used to connect to the system joint of the wing structure and / or an adjacent modular wing section. The removable box-type clamp may include a structural joint that is used to connect to the structural joint of the wing structure and / or an adjacent module. The removable box-type clamp may include a mounting portion that is used to be mounted to a transport assembly that can carry a module. The mounting portion may be (or include) a retractable projection and / or a quick-closing clamp of a zero-point clamping system.

[0022] The removable box clamp may include an adjustment mechanism that allows the position of one or more ribs to be adjusted into place along the length of the removable box clamp. The adjustment mechanism may include a track mounted substantially parallel to the length of the removable box clamp.

[0023] One or more ribs may be removably mounted to the removable box clamp by an auxiliary support incorporated into the removable box clamp. Each of the one or more ribs may be mounted to an auxiliary support member. The auxiliary support member advantageously provides structural support for the rib, which helps prevent the rib from deforming during assembly.

[0024] The auxiliary support may be mounted to an adjustment mechanism. The adjustment mechanism may include one or more tracks extending parallel to the length of the cassette fixture. The auxiliary support may be mounted to one or more tracks of the adjustment mechanism. The adjustment mechanism may include a first track and a second track. The auxiliary support may be mounted between the first track and the second track of the adjustment mechanism. A first mounting point of the auxiliary support may be movably mounted to the first track, and an opposite second mounting point of the auxiliary support may be movably mounted to the second track. The first mounting point may be located at a first position of the auxiliary support, corresponding to a first distance along the length of the auxiliary support, corresponding to a first end of the auxiliary support. The second mounting point may be located at a second position of the auxiliary support, corresponding to a second end of the auxiliary support, the second end being located at an end of the auxiliary support opposite to the first end.

[0025] The first mounting point can be decoupled from the movement of the second mounting point so that the first and second mounting points of a given auxiliary support can be located at different distances along the length of the cassette clamp. This allows a given auxiliary support to be angled relative to the width of the cassette clamp.

[0026] The auxiliary support may include a plurality of recessed areas and / or cut-out areas in the plane of the rib so that at least a portion of the surface of the rib mounted on the auxiliary support is exposed. This allows access to the rib surface to allow the fuel component to be fitted to the rib.

[0027] The auxiliary support may include an upright member configured to support at least one rib attached to the auxiliary support. The upright member may be configured to abut a rib plane of a rib mounted to the auxiliary support. This may help prevent the rib from deforming during assembly and installation of the modular wing section.

[0028] The auxiliary support may include one or more linear actuators configured to align at least one rib mounted to the auxiliary support. The one or more actuators may allow for precise adjustment of the alignment of the rib mounted to the auxiliary support. The one or more actuators may be configured to align the rib mounted to the auxiliary support into a final position prior to installation in the wing assembly.

[0029] The auxiliary support structure may include a locating pin configured to align the auxiliary support structure mounted to the auxiliary support. The auxiliary support structure may include a suction cup configured to releasably retain a rib mounted to the auxiliary support. The suction cup allows the rib to be easily released from the auxiliary support to which it is mounted, so that the box clamp can be removed from the modular wing section.

[0030] The auxiliary support may include one or more actuators, preferably linear actuators, configured to align at least one rib mounted to the auxiliary support into a final position. The linear actuator may allow the auxiliary support structure to move in at least two axes. One of the at least two axes may be aligned with the width of the modular wing section (and optionally with the width of the cassette fixture). A first of the at least two axes may be substantially orthogonal to the length of the modular wing section (and optionally with the length of the cassette fixture), and a second of the at least two axes may be substantially orthogonal to the width and length of the modular wing section (and optionally with the length and width of the cassette fixture).

[0031] The modular wing section may further comprise a cover portion configured to cover the at least one rib.The cover portion may be part of an upper cover of a wing of the aircraft.

[0032] The modular wing section may include at least 5 ribs. The modular wing section may include at least 7 ribs. The modular wing section may include at least 10 ribs. The modular wing section may include at least 15 ribs. The modular wing section may include at least 20 ribs. The modular wing section may include less than 21 ribs.

[0033] According to a second aspect of the invention, a wing assembly is provided, which is configured to receive a modular wing section according to the first aspect of the invention. The wing assembly may be configured to receive at least two modular wing sections according to the first aspect of the invention, and the wing assembly may optionally be configured to receive at least four modular wing sections according to the first aspect of the invention. The wing assembly may be an aircraft fixture, which (once all components are mounted to the fixture) forms a portion or all of an aircraft wing. The wing assembly may form a chord section of an aircraft wing once completed. The wing assembly may include a system joint, which is used to connect to a system joint of an adjacent structure or a wing assembly. The wing assembly may include a structural joint, which is used to connect to a structural joint of an adjacent structure or a wing assembly. The wing assembly may include an upper cover. The wing assembly may include a plurality of spars, and may optionally include all spars required for the chord section of the aircraft wing to which the wing assembly corresponds. The wing assembly is preassembled before the modular wing section is installed. This allows modular wing sections to be quickly installed through an optional single installation operation (e.g., lifting the modular wing section into the wing assembly), and then drilling holes in the upper cover and wing spars and bolting ribs to the upper cover and wing spars to secure the module to the wing assembly.

[0034] The wing assembly may also comprise a modular wing section according to the first aspect of the invention.

[0035] According to a third aspect of the invention, a box-type fixture for assembling modular wing parts away from an aircraft wing assembly station is provided, the box-type fixture comprising a plurality of auxiliary support members. Each auxiliary support member can be configured to receive and support a rib so that a fuel system component can be installed in the rib. In this way, the box allows the fuel system component to be installed to a plurality of ribs at a position away from the main wing assembly station. The box-type fixture can have a length and a width, and a plurality of support members can be configured to be arranged so that a rib installed on a support member in a plurality of support members has a length that is substantially aligned with the width of the box-type fixture. A plurality of support members can be configured to be arranged so that a plurality of support members are distributed along the width of the box-type fixture.

[0036] The box clamp may include any of the features of the removable box clamp as described as part of the first aspect of the present invention. The box clamp may include a system interface for connecting to a wing structure and / or an adjacent module and / or a system interface of an adjacent box clamp. The box clamp may include a structural interface for connecting to a wing structure and / or an adjacent module and / or a structural interface of an adjacent box clamp. The box clamp may include a mounting portion for mounting to a transport assembly that can carry and transport the box clamp.

[0037] According to a fourth aspect of the present invention, a transport assembly is provided, which is configured to install the modular wing section of the first aspect of the present invention into the wing assembly of the second aspect of the present invention, wherein the transport assembly includes a plurality of mounting points for mounting the modular wing section according to the first aspect of the present invention or the box clamp according to the third aspect of the present invention.

[0038] The transport assembly may include mounting points for mounting a box clamp and / or modular wing section as described above to the transport assembly. The mounting points may be part of a zero-point clamping system. The mounting points may be (or include) retractable tabs and / or quick-close clamps of the zero-point clamping system. The transport assembly may include a latch configured to hold the rib in a rotated position. As described above, being able to hold the rib in a rotated position may increase the ease of installing the fuel tank system components. By enabling the transport assembly itself to rotate, the box clamp or modular wing section mounted on the transport assembly does not need to be removed from the transport assembly prior to performing a rotation operation.

[0039] According to a fifth aspect of the invention there is provided a method of assembling a modular wing section suitable for installation into a wing assembly, the method comprising the steps of:

[0040] a. providing at least one rib and at least one fuel system component at a location away from the main assembly line of the aircraft wing; and

[0041] b. Installing at least one fuel tank system component relative to at least one rib to form a modular wing section (e.g., at a location away from the main assembly line, preferably at the same location as in step "a"), the modular wing section being a pre-assembled unit for installation into a wing assembly.

[0042] The method may include providing a plurality of ribs and / or a plurality of fuel system components. The method may include the steps of providing a box-type fixture including a plurality of auxiliary support members, mounting each of the plurality of ribs to one of the support members, and mounting the fuel system components to the plurality of ribs. The fuel system components may be mounted such that each fuel system component passes through the rib plane of some of the ribs, or alternatively, through the rib plane of all of the ribs.

[0043] The cassette clamp may comprise any of the features described in relation to the cassette clamp described in the first, second and / or third aspects of the present invention.

[0044] The box clamp may include an adjustment mechanism that allows the position of one or more ribs to be adjusted along the length of the removable box clamp. The auxiliary support may be mounted to the adjustment mechanism. The adjustment mechanism may include one or more tracks extending parallel to the length of the box clamp. The auxiliary support may be mounted to one or more tracks of the adjustment mechanism. The auxiliary support may be mounted between two tracks of the adjustment mechanism. The adjustment mechanism may include a first track and a second track. The first mounting point of the auxiliary support may be movably mounted to the first track, and the opposite second mounting point of the auxiliary support may be movably mounted to the second track. The first mounting point may be located at a first position of the auxiliary support, corresponding to a first distance along the length of the auxiliary support, corresponding to a first end of the auxiliary support. The second mounting point may be located at a second position of the auxiliary support, corresponding to a second end of the auxiliary support, and the second end is located at an end of the auxiliary support opposite to the first end.

[0045] The method may comprise a first mounting step of mounting the rib to the auxiliary support.The rib may be mounted to the auxiliary support by using a reversible mounting device, for example by using a suction cup and / or using alignment pins.

[0046] The method may include a second mounting step of moving the auxiliary support structure carrying the ribs along the length of the cassette fixture and spatially arranging them in predetermined positions along the length of the cassette fixture after mounting the ribs to the auxiliary support structure and before mounting the fuel system component. The second mounting step may be performed at an assembly station located remote from the aircraft wing and / or the main aircraft wing assembly station.

[0047] The method may include the step of rotating at least one rib so that the at least one rib is rotated to an upright configuration prior to the step of mounting at least one fuel system component to the at least one rib. The method may include the step of mounting at least one fuel tank system component at a second station remote from the main assembly line of the aircraft wing, wherein the second station is located at a different location than the first station. This arrangement may allow for increased / optimized throughput and assembly speed of modular aircraft sections, such that modular wing sections may be assembled quickly. This arrangement also allows for improved / optimized operator ergonomics at each station. The method may include the step of moving at least one rib between the first station and the second station by transporting the rib on a transport assembly as previously described.

[0048] The auxiliary support member may comprise an actuator, preferably a linear actuator. The auxiliary support may comprise one or more linear actuators configured to align at least one rib mounted to the auxiliary support. The one or more actuators may allow for precise adjustment of the alignment of the rib mounted to the auxiliary support. The method may comprise the steps of aligning the rib mounted to the auxiliary support into a final position prior to mounting in the wing assembly by actuating the actuator.

[0049] The step of testing the modular wing section may be performed after installing at least one fuel tank system component relative to at least one rib and before installing the modular wing section into the wing assembly. For example, there may be a step of testing the functionality of one or more fuel tank system components while in situ relative to one or more ribs of the modular wing section prior to installation into the aircraft wing assembly. This may improve the efficiency of the installation procedure and rear wing assembly testing.

[0050] After the step of installing the modular wing section into the wing assembly, and preferably only after that step, a portion of the lower cover for the wing is installed in a position extending above and below the footprint of the modular wing section (and preferably over the entire footprint of the modular wing section).

[0051] It will be appreciated that any structural features or spatial arrangements of the ribs, tank components and any equipment as previously described in the first to fourth aspects of the invention may also be used in the method of the fifth aspect of the invention.

[0052] According to a sixth aspect of the present invention, a method for installing a modular wing section into a wing assembly is provided, the method comprising the following steps: providing a modular wing section as described in the first aspect of the present invention or manufactured according to the method of the fifth aspect of the present invention; and providing a wing assembly as described in the second aspect of the present invention; and installing the modular wing section into the wing assembly.

[0053] The modular wing section may be raised into the wing assembly. Alternatively, the wing assembly may be lowered onto the modular wing section. The modular wing section may be moved by a transport assembly configured to install the modular wing section into the wing assembly.

[0054] It will be appreciated that any spatial arrangement of ribs, tank components and any equipment as previously described in the first to fourth aspects of the invention, or any method steps previously described in the fifth aspect of the invention may be used in the method of the sixth aspect of the invention.

[0055] According to a seventh aspect of the invention, there is provided a wing comprising a modular wing section installed into a wing assembly, the wing comprising a modular wing section as described in the first aspect of the invention or manufactured according to the method of the sixth aspect of the invention, and a wing assembly as described in the second aspect of the invention.

[0056] According to an eighth aspect of the present invention, there is provided an aircraft comprising a wing as described in the seventh aspect of the present invention.

[0057] The aircraft is preferably a passenger aircraft. The passenger aircraft preferably comprises a passenger cabin comprising a plurality of rows and columns of seating units for accommodating a plurality of passengers. The aircraft may have a capacity of at least 20 passengers, more preferably at least 50 passengers, and more preferably more than 50 passengers. The aircraft may be a commercial aircraft, such as a commercial passenger aircraft, such as a single-aisle or double-aisle aircraft.

[0058] It will of course be understood that features described with respect to one aspect of the invention may be incorporated into other aspects of the invention. For example, the method of the invention may be incorporated with any features described with reference to the apparatus of the invention, and the apparatus of the invention may be incorporated with any of the features described with reference to the method of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] Embodiments of the invention will now be described by way of example only with reference to the accompanying schematic drawings, in which:

[0060] Figure 1 shows a box-type clamp frame for assembling a modular wing section according to a first embodiment of the invention, wherein the ribs mounted to the box-type clamp are not shown;

[0061] Figure 2 is a schematic diagram showing an aircraft having a wing including a wing assembly having modular wing sections;

[0062] Figure 3is a schematic diagram showing a cassette clamp in an upright position, with a plurality of ribs mounted to the cassette clamp via a strongback plate;

[0063] Figure 4 is a schematic diagram showing the wing assembly in a partially assembled state and the elevator for transporting the assembly and supporting the box-type fixture;

[0064] Figure 5 is a schematic diagram showing the lift in an extended position raising the cassette clamp into the wing assembly;

[0065] Figure 6 is a schematic diagram showing one of the strongbacks in more detail;

[0066] Figure 7 is a schematic diagram showing a detailed view of the strongback of the box clamp mounted to the track at a first mounting point;

[0067] Fig. 8A is a schematic diagram showing a transport assembly with the lift in an extended position in which the rotatable platform is supported;

[0068] Figure 8B is a schematic diagram showing the transport assembly with the lift in an extended position and the platform rotated;

[0069] Fig. 9 is a schematic diagram of the station and process plan where modular wing sections can be assembled;

[0070] Fig.10 is a flow chart of a method of assembling modular wing sections; and

[0071] Fig.11 is a flow chart of a method of installing modular wing sections into a wing assembly. DETAILED DESCRIPTION

[0072] The modular wing section according to the first embodiment of the invention can be assembled and subsequently used. Figure 1 The cassette fixture 101 shown in FIG. Figure 2 A wing 501 of an aircraft 500 is shown, the wing comprising a wing assembly 503. The wing assembly 503 comprises an upper cover portion 504.

[0073] A cassette clamp 101 for use in the assembly and installation of modular wing sections will be described in more detail below. Although in this embodiment of the invention the cassette clamp 101 does not include any fuel or hydraulic systems as the cassette clamp does not form part of a modular wing section or part of a finished wing, it is possible that in some alternative embodiments of the invention where the cassette clamp 101 does form part of a modular wing section and therefore part of a finished wing, the fuel system etc. will be mounted directly in the cassette clamp.

[0074] Reference Figure 1 , there are a plurality of strongbacks 102 mounted to the box clamp 101. The strongbacks 102 serve as a secondary support structure for a plurality of ribs (not shown) which are mounted to the modular wing section 101 via the strongbacks 102. The strongbacks 102 also serve to provide mounting points for the ribs (not shown). The strongbacks 102 are arranged so that any ribs mounted to the strongbacks 102 are mounted in an upright configuration. The strongbacks 102 have a length extending along the width of the box clamp 101 and substantially span the box clamp 101. Figure 3 , a configuration of a box clamp 101 is shown with ribs attached.

[0075] There are cassette clamp system connection points 108 on the outer periphery of the cassette clamp 101. These cassette clamp system connection points 108 allow a control system (such as control of motors, actuators, etc.) that is part of the cassette clamp 101 to be controlled by electrical control signals.

[0076] Each of the strongbacks 102 is mounted to the box clamp 101 via a pair of tracks 114, 116. Tracks 114, 116 extend parallel to the length of the box clamp 101. The first mounting point 221 of each strongback 102 mounts the strongback to the first track 114 to allow linear movement along the track. The second mounting point 222 of each strongback 102 mounts the strongback to the second track 116 to allow linear movement along the track. The positions of the first mounting point 221 and the second mounting point 222 can be independently controlled so that the length of each strongback 102 can be maintained at a non-zero angle relative to the axis corresponding to the width of the box clamp 101. In some embodiments of the present invention, the second mounting point 222 may include a pivotable joint.

[0077] Figure 3The cassette fixture 101 is shown in an upright position with the plurality of ribs 300 mounted to the cassette fixture 101 via a strongback plate 102 so that the cassette can be worked from a platform 400. This configuration is an approximately 90° rotation of the cassette fixture and the plurality of ribs when compared to the orientation of the ribs when the cassette fixture 101 is stationary on the ground. This allows for better access when compared to known wing manufacturing methods (e.g., working under an aircraft wing and installing ribs at an altitude above shoulder height), with good ergonomics for the operator installing the ribs, and most of the work occurs at or below the operator's shoulder height.

[0078] Each rib 300 defines a rib plane bounded by an outer edge, and each rib has a plurality of mounting points 320 (shown only in some of the ribs for clarity) for mounting fuel system components (not shown in this figure). The fuel system components can then be mounted between and through the ribs 300 at the mounting points 320. The fuel system components and ribs mounted relative to each other form a modular wing section 390 that takes the form of a single modular unit that can be mounted as a single piece in the wing assembly 503. Figure 4 Fuel system components mounted to the ribs are shown in FIG.

[0079] Figure 4 The wing assembly 503 is shown in a partially assembled state. The modular wing section 390 is mounted to the wheeled transport assembly 600, to which the modular wing section 390 is mounted via the mounting portion 112. The wheeled transport assembly includes a lift 610 that can be used to raise or lower the modular wing section 390 so that the modular wing section can be installed into the wing assembly 503. There is also a latch 630 that allows a box clamp mounted to the lift 610 to be rotated 90° relative to the axis along which the lift 610 can raise or lower the modular wing section. This allows fuel system components to be installed into the modular wing section in an ergonomic manner that is consistent with the ergonomics of the assembly. Figure 3 The arrangement shown in allows for ergonomic installation of fuel system components in a similar manner.

[0080] exist Figure 4 In the embodiment, the modular wing section 390 is in a horizontal position, wherein the plurality of ribs 300 are mounted to the box clamp 101 via the strongback 102. Figure 3, this configuration is an approximately 90° rotation of the cassette clamp 101 and the plurality of ribs 300 when compared to the orientation shown in . At a plurality of mounting points in the plane of the major surface of the rib 300 are mounting points 320 to which the fuel system component 340 is mounted, thereby allowing the fuel system component 340 to be mounted to the cassette clamp 101 along its longitudinal axis L corresponding to the length of the cassette clamp 101. The length of the rib 300 is substantially aligned with the width of the cassette clamp and the width of the wing assembly 503, although some of the ribs 300 are mounted to the rail 114, but they are rotated by a non-zero angle relative to the axis corresponding to the width of the cassette clamp 101, so that the first mounting point 221 and the second mounting point 222 of the rib are located at different positions along the length of the cassette clamp 101, such as Figure 1 as shown in .

[0081] This arrangement allows the ribs 300 to be fitted to a cassette fixture in a first off-line station remote from the wing assembly 503. The ribs can then be moved to a second off-line station where the fuel system components 340 can be added between the ribs 300. They can then be transferred to the wing assembly 503 for installation as a single module 100.

[0082] Figure 5 Lifter 610 is shown in an extended position so that cassette clamp 101 is raised into wing assembly 503. Thus, ribs 300 and fuel system components 340 of wing module 100 can be installed by raising cassette clamp 101 from the underside of wing assembly 503 so that ribs 300 and fuel system components 340 are installed into wing assembly 503 simultaneously. This advantageously results in the fuel system components being installed with the ribs, meaning that the fuel system components do not need to be installed between the ribs after the ribs have been installed into the wing assembly. Additionally, installing multiple ribs and fuel system components as a single installation action increases the speed with which the wing can be assembled. Figure 5 In the embodiment of FIG. 5 , the fuel system component 340 is a rigid fuel pipe.

[0083] Figure 6One of the strongbacks 102 is shown in more detail. The strongback 102 is mounted on a track. A pair of linear actuators 710 allow for precise positioning of the strongback (and therefore any ribs held by the strongback) relative to the box clamp on which the strongback is mounted, and therefore allow for precise positioning (e.g., on the order of 0.5 mm) of any rib mounted to the strongback 102 relative to the modular wing section in a first direction D1 and a second direction D2 orthogonal to the first direction D1. The strongback includes an upright 730 that is configured to support any rib mounted to the upright. A pair of suction cups 740 and locating pins 750 are used to hold and align the ribs with the support member 102 when the ribs are mounted, and then the clamps 760 can engage to hold the ribs in place.

[0084] Figure 7 A detailed view of the strongback 102 of the box clamp 101 mounted to the track 114 at the first mounting point 221 is shown. The first mounting point includes an actuator 770 configured to actuate the first mounting point 221 to move along the track 114 in a linear direction D3. This can allow the first mounting point to move along the track with a tolerance of approximately 3 mm. The actuators 710, 770 and the elevator 610 allow for six-axis positioning of the rib relative to the wing assembly 503.

[0085] Fig. 8A The transport assembly 600 is shown with the lift 610 in an extended position. The lift 610 includes a platform 800 including a plurality of mounting points 810 adapted to receive and mount the cassette fixture 100. The mounting points 810 are zero-point mounting points. The lift assembly 600 includes a latch 630 that allows the cassette fixture mounted to the lift 610 at the platform 800 to rotate 90° relative to an axis about which the lift 610 can raise or lower a modular wing section. Figure 8B A platform 800 is shown rotated 90° relative to the axis of the lift 610 that can raise or lower the modular wing section.

[0086] Fig. 91 is a schematic diagram of a station and process plan 1000 at which a modular wing section can be assembled. The manufacturing footprint is located at a location 1050 remote from where the final aircraft is manufactured (i.e., remote from the final assembly line, and therefore "offline"). The manufacturing footprint includes a first station 1100 in which auxiliary support structures 102 are distributed along the length of a cassette fixture to their approximate final positions. A plurality of ribs 300 are attached to the cassette fixture 100 via the auxiliary support structures 102. The cassette fixture is then transported to a second station 1200 and rotated 90° so as to allow better access. The fuel system components 340 can then be installed to the cassette fixture by an operator between and through the ribs 300. This arrangement of the ribs 300 and the fuel system components 340 forms a modular wing section 390. The cassette fixture is then rotated back to its initial position and transported to the third station 1300 where the ribs 300 and fuel system components 340 are installed into the main wing assembly 503 by placing the cassette fixture below the main wing assembly 503 and raising the cassette fixture upward and into the main wing assembly. The linear actuator 760 enables any final precision adjustments to be made before installation to adjust the position of the ribs. The system of modular wing sections 390 is then connected to the main wing assembly 503. The modular wing sections 390 are considered to be installed at this stage. The suction cups 740 are then released and the cassette fixture 101 and the elevator 610 are then lowered. By assembling the modular wing sections 390 away from the main wing assembly station 1300, the manufacturing speed of the wing 501 is increased.

[0087] Fig.10 A flow chart depicting an embodiment of the method according to the invention is shown. Fig.10 A method of assembling a modular wing section is shown, the method comprising the following steps:

[0088] a. providing 2002 at least one rib and at least one fuel system component at a location away from the main assembly line of the aircraft wing; and

[0089] b. Mounting 2004 at least one fuel tank system component to at least one rib so as to form a modular wing section, the modular wing section being a pre-assembled unit for installation into a wing assembly.

[0090] In some embodiments of the present invention, the method may further include the step of installing a fuel system component at a mounting point of at least one of the ribs. The method may include the step of rotating the rib to an upright configuration prior to the step of installing at least one fuel system component to at least one rib. The method may include the step of spatially arranging a plurality of ribs relative to each other at a first station of a main assembly line remote from the aircraft wing. The method may include the step of installing at least one fuel tank system component at a second station of a main assembly line remote from the aircraft wing, wherein the second station is located at a different position from the first station. This arrangement may allow for increased / optimized production volume and assembly speed of modular aircraft sections, so that modular wing sections may be assembled quickly. This arrangement also allows for improved / optimized operator ergonomics at each station. The method may include the step of moving at least one rib between a first station and a second station by transporting the rib on a transport assembly as previously described.

[0091] Fig.11 A flow chart depicting an embodiment of the method according to the invention is shown. Fig.11 A method 3000 of installing a modular wing section into a wing assembly is shown, the method comprising the steps of providing 3002 a modular wing section and providing 3004 a wing assembly and installing 3006 the modular wing section into the wing assembly.

[0092] In some embodiments of the invention, the modular wing section may be raised into the wing assembly. Alternatively, the wing assembly may be lowered onto the modular wing section.

[0093] Although the present invention has been described and illustrated with reference to specific embodiments, it will be understood by those skilled in the art that the present invention itself is applicable to many different variations not specifically described herein. For example, it should be understood that one aspect of the present invention is that, in its broadest sense, a modular wing section is provided in which at least one rib is mounted to a box clamp via at least one auxiliary support. This aspect of the present invention itself is not limited to the types of auxiliary supports or box clamps associated with the embodiments of the present invention described above. Those skilled in the art will appreciate that there are other types of auxiliary supports in addition to the strongback, which are suitable for use in installing the ribs in a removable manner so that the ribs and fuel system components can be installed to form a modular wing section at a location away from the main assembly line of the aircraft. In addition, it should be noted that the elevator can take different forms. For example, the elevator can be alternatively mounted to the wing assembly so that the wing assembly can be lowered onto the modular wing section.

[0094] Furthermore, while in the described and illustrated embodiments of the invention illustrated herein, the cassette clamp is removable and is removed after the modular wing sections are installed, alternative designs are possible in which the cassette clamp is left in the wing assembly as part of the final assembled wing. In these alternative embodiments, the fuel system components may be embedded within the cassette clamp or mounted directly to the cassette clamp.

[0095] Where reference is made in the foregoing description to an integer or element that has a known, obvious or foreseeable equivalent, such equivalent is incorporated herein as if set forth individually. Reference should be made to the claims to determine the true scope of the invention, which should be interpreted as including any such equivalent. The reader will also understand that the integers or features of the invention described as preferred, advantageous, convenient, etc. are optional and do not limit the scope of the independent claims. Furthermore, it should be understood that such optional integers or features, while potentially beneficial in some embodiments of the invention, may not be desirable in other embodiments and therefore may not be present.

[0096] Unless the context requires otherwise, the term "or" should be construed as "and / or".

Claims

1. A modular wing section for installation into a wing assembly as a preassembled unit, the modular wing section comprising at least one rib and at least one internal fuel tank system component.

2. A modular wing section according to claim 1, wherein: The at least one internal fuel tank system component and the at least one rib are configured to be spatially fixed relative to each other such that: a. when the at least one rib is installed in the wing assembly, the at least one fuel tank system component is installed in the wing assembly, and b. The at least one rib is installed into the wing assembly when the at least one fuel tank system component is installed.

3. A modular wing section according to claim 1 or claim 2, wherein: Each of the at least one rib has a planar surface defining a rib plane bounded by an outer rib boundary, wherein the at least one internal fuel tank system component passes through the rib plane and is completely within the outer rib boundary.

4. A modular wing section according to any preceding claim, wherein: The modular wing section has a length and a width, and wherein the at least one rib is a plurality of ribs distributed along the length of the modular wing section.

5. A modular wing section according to any preceding claim, wherein: Each rib has a length, wherein the length of each rib is substantially transverse to a length of the modular wing section.

6. A modular wing section according to any preceding claim, wherein: Each rib has a width, wherein the width of each rib is substantially parallel to a width of the modular wing section.

7. A modular wing section according to claim 6, wherein: Each rib has a depth, wherein the depth of each rib is substantially perpendicular to both a width of the modular wing section and a length of the modular wing section.

8. A modular wing section according to any preceding claim, wherein: The modular wing section also includes a removable box clamp configured to guide assembly and installation of the modular wing section, wherein the at least one rib and the at least one internal fuel tank system component are removably mounted to the removable box clamp.

9. A modular wing section according to claim 8, wherein: The removable cassette clamp includes a connection interface adapted to connect and align the cassette clamp in a predetermined position relative to a wing assembly.

10. A modular wing section according to claim 8 or 9, wherein: The removable cassette clamp includes an adjustment mechanism that allows the position of the at least one rib to be adjusted along the length of the removable cassette clamp.

11. A modular wing section according to any one of claims 8 to 10, wherein: The at least one rib is removably mounted to the removable cassette clamp by means of an auxiliary support incorporated into the removable cassette clamp.

12. A modular wing section according to claim 11, wherein: The auxiliary support comprises one or more actuators configured to align the at least one rib mounted to the auxiliary support into a final position.

13. A modular wing section according to any one of claims 11 or 12, wherein: The auxiliary support includes an upright member configured to support at least one rib attached to the auxiliary support.

14. A modular wing section according to any preceding claim, wherein: The modular wing section comprises at least 5 ribs.

15. A wing assembly configured to receive a modular wing section according to any preceding claim.

16. A wing assembly according to claim 15, further comprising a modular wing section according to any one of claims 1 to 14.

17. A cassette fixture for assembling modular wing sections remote from an aircraft wing assembly station, the cassette fixture comprising a plurality of auxiliary support members, each auxiliary support member being configured to receive and support a rib to enable fuel system components to be mounted to the rib.

18. The cassette fixture according to claim 17, wherein: The cassette clamp has a length and a width, and wherein the plurality of support members are configured to be arranged such that a rib mounted on one of the plurality of support members has a length that is substantially aligned with the width of the cassette clamp.

19. The cassette fixture according to claim 17 or 18, wherein: The cassette fixture has a length and a width, and wherein the plurality of support members are configured to be arranged such that the plurality of support members are distributed along the width of the cassette fixture.

20. A transport assembly configured to install a modular wing section according to any one of claims 1 to 14 into a wing assembly according to claim 15, wherein: The transport assembly includes a plurality of mounting points for mounting the modular wing section.

21. A method of assembling a modular wing section, the method comprising the steps of: a. providing at least one rib and at least one fuel system component at a location away from the main assembly line of the aircraft wing; as well as b. Mounting the at least one fuel tank system component relative to the at least one rib so as to form a modular wing section that is a pre-assembled unit for installation into a wing assembly.

22. A method of installing a modular wing section into a wing assembly, the method comprising the steps of: Providing a modular wing section according to any one of claims 1 to 14 or a modular wing section manufactured by the method according to claim 21; and providing a wing assembly according to any one of claims 15 and 16; and installing the modular wing section into the wing assembly.

23. A wing comprising a modular wing section mounted into a wing assembly, the wing comprising a modular wing section according to any one of claims 1 to 14 or a modular wing section manufactured according to the method of claim 21, and a wing assembly according to any one of claims 15 and 16.

24. An aircraft comprising a wing according to claim 23.

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