Aircraft Assembly Jig with Machined Pickup Mounting Plates
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Solution Overview
Problem
The production of aircraft airframes faces challenges in achieving precise assembly due to difficulties in producing separate sections with tight tolerance bounds, often requiring lengthy and expensive shimming processes, and traditional assembly tools are cumbersome and costly, necessitating a more efficient method for aligning and supporting components during assembly.
Innovation Solution
The method involves machining pickup device mounting plates to be parallel to the supporting surface and fixing them to the jig frame, with pickup devices attached to align components accurately relative to a reference structure, allowing for precise positioning and orientation of airframe components during assembly, reducing the need for shimming and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional dedicated assembly tools are used for each assembly process, then components can be supported in correct relative positions, but the device complexity and cost increase significantly
Solution Approach 1:
The patent applies universality by designing a single multi-functional assembly tool that can support multiple airframe components (frames and longerons) in various configurations. The tool uses adjustable pick-up devices with releasable fastening means that can be positioned at different locations along elongate members, allowing one tool to perform functions that traditionally required multiple dedicated tools, thereby reducing device complexity while maintaining assembly precision
Solution Approach 2:
The patent applies dynamics by incorporating adjustable and reconfigurable elements in the assembly tool. The pick-up devices can be moved along the elongate members and repositioned using releasable fastening means, allowing the tool configuration to adapt to different assembly requirements. This dynamic adjustability enables a single tool to accommodate various component sizes and assembly scenarios, reducing the need for multiple dedicated tools
2Productivity
If separate airframe sections are produced independently, then production flexibility is improved, but assembly difficulty increases due to tolerance accumulation
Solution Approach 1:
The patent applies the intermediary principle by introducing a reference structure as a mediator between separately produced airframe sections. The reference structure serves as a common datum that both sections can be independently assembled against, ensuring that tolerance accumulation is minimized. This intermediary reference allows independent production of sections while maintaining tight overall assembly tolerances
Solution Approach 2:
The patent applies preliminary action by pre-establishing the reference structure with precisely defined positions and orientations before assembly begins. The reference structure is prepared in advance with accurate geometric relationships, allowing subsequent components to be assembled independently against this pre-established datum, thereby preventing tolerance accumulation that would occur if sections were assembled sequentially without a common reference
3Strength
If conventional welded steel assembly tools are used, then structural strength is sufficient, but manufacturing time and cost increase
Solution Approach 1:
The patent applies segmentation by dividing the assembly tool into modular components: elongate members, pick-up devices, and fastening means that can be independently manufactured and then assembled. This segmentation allows parallel manufacturing of components and eliminates the need for time-consuming welding operations, reducing tool manufacturing time while maintaining structural strength through the modular connection system
Solution Approach 2:
The patent applies the principle of using simpler, less permanent construction methods for the assembly tool. Instead of creating permanent welded steel structures, the tool uses reversible fastening means (such as clamps or adjustable connectors) that can be quickly assembled and disassembled. This approach reduces manufacturing time and cost while providing sufficient strength for the assembly operation, treating the tool as a temporary rather than permanent fixture
Data Source
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AI summary
A method of producing an assembly tool (60) for assembling an assembly (6), the method comprising: providing at least a portion of a jig frame (62); fixing support plates (65) to the jig frame (62); machining the one or more support plates (65) such that a surface of each of the support plates (65) lies in a common plane (130); positioning the jig frame (62) such that the machined surfaces of the support plates (65) contact with a supporting surface (138); fixing pickup device mounting plates (140a, 140b) to the jig frame (62); machining, with respect to the supporting surface (138), the pickup device mounting plates (140a, 140b) such that a surface of each mounting plate (140a, 40b) has a respective predetermined position and orientation with respect to the supporting surface (138); and fixing, to the machined surfaces of the mounting plates (140a, 140b), a respective pickup device (66-72).