Continuous airplane verification to improve production build efficiency
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Solution Overview
Problem
The current process of building an airplane involves limited verification of assembled systems, leading to costly and time-consuming error corrections in late stages of production, as operational checks are typically conducted after the build is nearly or fully complete.
Innovation Solution
A verification system comprising airflow fittings with sensors, hydraulic fittings with sensors, electrical connectors, and a line replaceable unit (LRU) that automatically verifies the operational condition of aircraft components by generating and analyzing airflow, hydraulic, and electrical signals, and presenting the results via a display, allowing for continuous verification during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If verification is performed only after airplane build is nearly or fully complete, then the verification process is simpler to manage, but errors and faults are costly and time-consuming to correct
Solution Approach 1:
The patent implements preliminary verification actions by installing sensors and monitoring systems during the assembly process itself, rather than waiting until completion. This allows errors to be detected early when components are first installed, preventing propagation of faults through subsequent assembly steps and reducing correction time significantly.
Solution Approach 2:
The verification system operates continuously throughout the assembly process, with sensors monitoring airflow, hydraulic pressure, and electrical parameters in real-time as components are installed. This continuous verification ensures that any deviations from expected operational parameters are immediately detected and can be addressed without interrupting the overall build process.
2Reliability
If continuous verification systems with multiple sensors are installed in different aircraft sections, then error detection capability is improved, but device complexity increases
Solution Approach 1:
The verification system is divided into modular sensor units that can be independently installed in different aircraft sections. Each sensor package is self-contained and monitors specific parameters (airflow, hydraulic pressure, electrical signals) locally, then transmits data to a central verification system. This segmentation reduces the complexity burden on any single installation point while achieving comprehensive coverage.
Solution Approach 2:
The verification system uses multi-functional sensor packages that can monitor multiple parameters simultaneously (e.g., a single fitting that monitors both airflow and temperature). This universal approach reduces the total number of separate components needed compared to dedicated single-parameter sensors, thereby reducing overall system complexity while maintaining comprehensive verification capability.
3Ease of manufacture
If verification is performed late in the build process, then manufacturing cost is reduced, but productivity is reduced due to rework
Solution Approach 1:
By implementing continuous verification during assembly, the system enables rapid detection and immediate correction of errors before they propagate through subsequent assembly steps. This approach allows the build process to move forward more efficiently by skipping the time-consuming rework that would be required if errors were detected later, effectively rushing through potential problem areas before they become critical issues.
Data Source
AI summary
Systems, apparatuses and methods may provide for a verification system for an aircraft. 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, the hydraulic related signals may be obtained from a plurality of hydraulic fittings, and the electrical signals and associated impedances may be obtained from a plurality of electrical connectors. At least two of the airflow fittings, at least two of the hydraulic fittings, and at least two of the electrical connectors may be positioned in different aircraft sections before additional aircraft sections are assembled.