Aerodynamic Structure Assembly Using Measured Link Selection
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Solution Overview
Problem
The manufacturing of aerodynamic structures, such as aircraft wing tips, often requires frequent rejigging and use of shims to achieve accuracy, which slows down the manufacturing process.
Innovation Solution
A method involving the use of upper and lower covers with lugs and a selection of different sized links to connect them, allowing for precise alignment and assembly without significant rejigging, using measurement and selection tools to ensure accurate fitting within manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing methods using jigs and shims are employed to achieve required accuracy, then manufacturing precision is improved, but productivity deteriorates due to frequent rejigging and slow assembly
Solution Approach 1:
The structure is divided into modular components (upper cover, lower cover, and links) that can be independently manufactured and assembled. The links serve as discrete connection elements that can be selectively chosen to match measured distances, eliminating the need for complex jigs and shims while maintaining assembly precision.
2Device complexity
If fixed-size connection elements are used, then device complexity is reduced, but manufacturing precision deteriorates due to inability to compensate for tolerance variations
Solution Approach 1:
The connection system uses links with varying lengths (different parameters) to accommodate tolerance variations in lug positioning. By selecting links with appropriate lengths based on measured distances between lugs, the system maintains alignment accuracy without requiring complex adjustment mechanisms.
3Manufacturing precision
If measurement and selection of different sized links is implemented, then manufacturing precision is improved by compensating for tolerances, but device complexity increases due to multiple link sizes
Solution Approach 1:
Multiple links of different sizes are prepared in advance before assembly. The measurement step determines which pre-prepared link size is appropriate, eliminating the need for on-site adjustment or complex selection mechanisms during assembly.
4Ease of manufacture
If traditional joining methods are used, then ease of manufacture is maintained, but loss of time increases due to frequent adjustments and rejigging
Solution Approach 1:
The measurement and link selection process is performed directly at the assembly location using simple tools. The links are designed to be self-aligning through the lug connection points, eliminating the need for external jigs and multiple adjustment operations.
Data Source
AI summary
A method of manufacturing an aerodynamic structure, for example, an aircraft wing tip, is disclosed. The method includes providing an upper cover having a plurality of lugs, providing a lower cover having a plurality of lugs, measuring the distance between a lug on the upper cover and corresponding lug on the lower cover, selecting, from the plurality of different sized links, a link suitably sized to correspond to the measured distance between the lug on the upper cover and corresponding lug on the lower cover, connecting the selected link to the lug on the upper cover and corresponding lug on the lower cover; and repeating those steps such that each lug on the upper cover is joined to a corresponding lug on the lower cover.