Aircraft Assembly Variation Analysis for Tolerance Verification
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Solution Overview
Problem
Aircraft manufacturing is labor-intensive and costly due to the need for precise assembly of complex parts with tight tolerances, and redesigning parts at later stages can be costly and affect multiple components, making it challenging to maintain quality and functional integrity.
Innovation Solution
A method that determines structural dimensional requirements and assembly tolerances for aircraft components, develops datum and index specifications, and performs variation analysis to verify that these specifications meet assembly tolerances, allowing for efficient assembly and reducing costly redesigns by identifying potential issues early in the design process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aircraft parts are redesigned at later stages of the design process, then functional requirements can be met, but cost increases and more parts need to be redesigned
Solution Approach 1:
The patent applies preliminary action by performing variation analysis and developing datum specifications during the early design stage rather than waiting until later stages. The computer-implemented method analyzes assembly variations and identifies potential tolerance issues before manufacturing begins, allowing designers to make corrections when changes are less costly and affect fewer parts
2Manufacturing precision
If aircraft parts are assembled with high accuracy to meet tight tolerances, then assembly quality is improved, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent performs variation analysis and develops datum specifications in advance during the design stage. By predicting assembly variations computationally before manufacturing, the method establishes appropriate tolerances and assembly sequences upfront, simplifying the actual assembly process while ensuring high precision outcomes
Solution Approach 2:
The patent uses computer-generated three-dimensional models and virtual assembly simulations to replicate and analyze the assembly process before physical assembly occurs. This digital copying allows for virtual testing and optimization of assembly sequences and tolerance allocations without the complexity of physical trial-and-error
3Manufacturing precision
If more aircraft parts are redesigned to accommodate changes, then assembly tolerances can be maintained, but the number of parts affected by redesign increases
Solution Approach 1:
The patent implements feedback through its variation analysis capability, which computationally predicts how variations in one part will propagate through the assembly. This feedback mechanism identifies the actual impact scope of design changes, allowing engineers to make targeted adjustments to minimize the number of parts that need redesigning while maintaining assembly tolerances
Data Source
AI summary
A method for producing an aircraft includes determining structural dimensional requirements for mating parts and for assembly tolerances between the mating parts. The method develops a datum specification for the mating parts and develops an index specification for mating the mating parts. The method performs a variation analysis based on the datum specification and the index specification to determine assembly analysis results for the mating parts. The method compares the assembly analysis results for the mating parts with the corresponding assembly tolerances defined in the structural dimensional requirements for the mating parts to verify that the datum specification and the index specification meet the assembly tolerances between the mating parts.