Aircraft Backing-Structure Assembly Tolerance Compensation
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Solution Overview
Problem
The integration of door-surrounding structures in aircraft or spacecraft structures is complex due to manufacturing tolerances, requiring cumbersome compensation methods like shims, which complicate the assembly process and increase costs.
Innovation Solution
A method using adjustable retaining devices to position and connect individual elements of the backing-structure assembly to a skin portion, allowing for precise tolerance compensation through measurement and adjustment, eliminating the need for shims and simplifying the assembly process by using fibre-composite materials and welding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional shim-based compensation methods are used to account for manufacturing tolerances, then tolerance compensation is achieved, but the assembly process becomes complex and costs increase
Solution Approach 1:
The retaining devices are designed to be adjustable in position and/or location, allowing dynamic adaptation to manufacturing tolerances. This adjustability enables the devices to compensate for dimensional variations without requiring complex pre-assembled shims or fixtures, thereby simplifying the overall assembly process while maintaining precision.
Solution Approach 2:
The position and location parameters of the retaining devices are made variable through adjustability mechanisms. By changing these parameters during assembly, the system can accommodate manufacturing tolerances of individual components and the skin portion, eliminating the need for fixed compensation elements and reducing assembly complexity.
2Manufacturing precision
If adjustable retaining devices are used to eliminate gaps through tolerance compensation, then assembly quality is improved, but the device complexity increases
Solution Approach 1:
The retaining devices serve multiple functions: they hold individual elements during assembly, provide adjustability for tolerance compensation, and enable gap elimination. This multi-functionality reduces the need for separate compensation devices and simplifies the overall system despite the added adjustability features.
Solution Approach 2:
The backing-structure assembly is divided into individual elements that are assembled separately using adjustable retaining devices. This segmentation allows each element to be positioned and adjusted independently to compensate for tolerances, achieving high assembly quality without requiring a monolithic complex fixture system.
3Manufacturing precision
If individual elements are joined to form a backing-structure assembly with tight tolerances, then structural quality is improved, but the number of components and assembly steps increases
Solution Approach 1:
The adjustable retaining devices are prepared and positioned before the actual joining of individual elements. This preliminary action allows for pre-adjustment and pre-positioning, which streamlines the subsequent assembly process and reduces the time required for tolerance compensation during final assembly.
Solution Approach 2:
The adjustable retaining devices enable self-adjustment to accommodate manufacturing tolerances. By allowing the assembly fixtures to adapt automatically through adjustment mechanisms, the system reduces the need for complex measurement and correction procedures, thereby improving assembly efficiency while maintaining tight joint gaps.
Data Source
AI summary
A method for integrating a backing-structure assembly in a structure of an aircraft or spacecraft is described. In this case, a plurality of individual elements is joined to form the backing-structure assembly. The individual elements for the backing-structure assembly and a skin portion for the structure are provided. The elements are arranged on a pre-assembly device which comprises retaining devices, which are each configured to hold one of the elements so as to be adjustable with respect to the position and/or location thereof. Some or all of the elements are connected to the skin portion. In the method, by adjusting the retaining devices for tolerance compensation, gaps between joint regions of the elements and the skin portion are eliminated or adjusted.