Aircraft Assembly Verification Using Multi-Signal Condition Checks
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Solution Overview
Problem
The current airplane assembly process lacks efficient methods for verifying the operational condition of complex systems during construction, leading to costly and time-consuming error detection in late stages of production.
Innovation Solution
A verification system comprising airflow fittings, hydraulic fittings, electrical connectors, and a verification function subsystem that automatically checks the operational condition of aircraft components using sensors and line replaceable units, presenting results via displays during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If verification testing is performed after airplane build is nearly or fully complete, then the airplane structure can be assembled without interruption, but errors and faults are detected late making them costly and time-consuming to correct
Solution Approach 1:
The patent applies preliminary action by performing verification testing of airplane systems during the assembly process itself, rather than waiting until the build is complete. Sensors are integrated into the assembly line to continuously monitor system operational conditions as components are installed, allowing errors to be detected and corrected immediately while the work area is still accessible.
2Reliability
If continuous verification testing is implemented during assembly, then errors can be detected early reducing correction costs, but the verification system complexity and initial setup time increase
Solution Approach 1:
The patent applies self-service by designing a verification system that automatically monitors and evaluates system operational conditions without requiring manual intervention. The integrated sensors continuously collect data and the verification system automatically compares readings against expected parameters, generating pass/fail indications autonomously during the assembly process.
Solution Approach 2:
The verification system is designed with multi-functionality to handle various system types (electrical, hydraulic, pneumatic, environmental) using a unified approach. The same sensor integration and verification methodology can be applied across different airplane systems and assembly stages, reducing the need for separate specialized verification equipment for each system type.
3Ease of manufacture
If manual verification methods are used during assembly, then the verification process can be simple to implement, but the verification speed and productivity are limited
Solution Approach 1:
The patent replaces manual mechanical verification processes with automated electronic sensing and data processing systems. Instead of manually testing each system connection and operation, integrated sensors automatically detect electrical continuity, hydraulic pressure, pneumatic flow, and environmental conditions, with results processed and displayed in real-time, dramatically increasing verification speed while maintaining ease of implementation through standardized sensor integration.
Data Source
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AI summary
Systems and methods are provide for a verification system for an aircraft to improve production build efficiency. The verification system includes a verification function subsystem to automatically verify an operational condition of one or more components of an aircraft based on airflow related signals, hydraulic related signals, and electrical signals and associated impedances and present the operational condition via a display. The airflow related signals may be obtained from a plurality of airflow fittings (26, 36), the hydraulic related signals may be obtained from a plurality of hydraulic fittings (28, 38), and the electrical signals and associated impedances may be obtained from a plurality of electrical connectors (24, 34). At least two of the airflow fittings, at least two of the hydraulic fittings, and at least two of the electrical connectors are positioned in different aircraft sections before additional aircraft sections are assembled.