Aircraft Structure Fastening With Guided Hole Alignment
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Solution Overview
Problem
The challenge in aircraft manufacturing is the inefficiency and inaccuracies in joining components using threaded fasteners, particularly in spaces where access on both sides is limited, leading to misalignment and increased production time due to the need for precise drilling and reassembly.
Innovation Solution
A method involving the creation of a threaded opening in one component, attachment of an alignment insert, and guided drilling of the second component to align holes accurately, allowing for more efficient and accurate fastening without the need for disassembly and reassembly, using an alignment insert to guide the drilling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional matching drilling and fastening method is used, then joint strength can be achieved, but access on both sides is required and production time increases
Solution Approach 1:
The patent introduces a threaded insert as an intermediary component that is first installed in one component, then used to guide the drilling of the second component. This mediator enables the fastening operation to proceed from one side only, eliminating the need for bilateral access while maintaining joint integrity and reducing production time.
2Ease of operation
If threaded opening is provided in one component, then access from one side is enabled, but hole alignment precision deteriorates due to manufacturing variation
Solution Approach 1:
The threaded insert is installed in advance in the first component before the drilling operation. This preliminary action creates a precise guiding feature that ensures accurate hole alignment when drilling the second component, compensating for manufacturing variations and eliminating the need for post-drilling adjustments.
Solution Approach 2:
The threaded insert serves as a mediator that transfers the alignment function from the drilling operation to the insert itself. The insert's pre-installed position provides a stable reference for hole alignment, separating the alignment function from the fastening operation and ensuring precision despite manufacturing tolerances.
3Manufacturing precision
If components are positioned and drilled, then alignment can be achieved, but disassembly and reassembly are required forming threaded opening
Solution Approach 1:
The threaded insert is installed in advance before the drilling operation, creating a permanent alignment reference. This eliminates the need for temporary positioning and subsequent disassembly, as the insert remains in place throughout the entire fastening process, maintaining alignment while reducing production time.
4Manufacturing precision
If alignment insert is used to guide drilling, then hole alignment precision is improved, but device complexity increases
Solution Approach 1:
The threaded insert performs multiple functions: it provides the threaded opening for the fastener, serves as an alignment guide for drilling the second component, and maintains structural integrity. By combining these functions in a single component, the patent avoids the need for separate alignment fixtures, actually reducing overall device complexity while improving alignment precision.
Data Source
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AI summary
Two components (8, 12) of an aircraft structure are joined by providing a threaded opening in one of them and supporting an alignment insert (40) in that opening. The alignment insert (40) is used to guide drilling of the second component such that a hole is produced which is aligned with the threaded opening, for instance using an alignment projection (60) which physically guides a drill (70). The alignment insert (40) may then be removed. A fastener is then inserted through that hole and into the threaded opening, then tightened to form the completed joint.