Adjustable Aircraft Component Fixture for Precise Countersinking
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Solution Overview
Problem
The conventional manual process for forming countersunk pilot holes in aircraft components like Gap bands is prone to inconsistency and defects due to the sharp apex, leading to ergonomic challenges and material flexing, resulting in scrap components.
Innovation Solution
A fixture with a rib surface that matches the aircraft component's shape, featuring adjustable extensions and a groove for precise countersinking, along with a mount for secure attachment to a worksurface, minimizes movement and flexing, ensuring consistent pilot hole formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual countersinking process is used, then flexibility and adaptability are maintained, but manufacturing precision and reliability deteriorate due to material flexing and inconsistent pilot hole formation
Solution Approach 1:
The patent introduces a fixture as an intermediary device between the manual operator and the workpiece. The fixture includes a support surface that contacts the workpiece and a countersink tool holder that guides the countersink tool, mediating the interaction to ensure precise and consistent countersinking while maintaining manual operation flexibility
Solution Approach 2:
The patent replaces the direct manual mechanical operation with a guided mechanical system. The fixture provides mechanical guidance for the countersink tool through guides and support surfaces, substituting the technician's manual positioning with a mechanically guided system that ensures consistent positioning and pressure application
2Adaptability or versatility
If technician manually countersinks all pilot holes, then adaptability to material flexing is maintained, but productivity deteriorates due to repeated twisting, turning, and bending of the technician's body
Solution Approach 1:
The patent repositions the workpiece in a different spatial dimension by mounting it vertically on the fixture's support surface. This dimensional change allows the technician to work in a more ergonomic position, reducing the need for repeated twisting, turning, and bending of the body, thereby improving productivity while maintaining adaptability
Solution Approach 2:
The fixture is designed with adjustable components that allow dynamic adaptation to different workpiece configurations. The support surface and tool holder can be adjusted to accommodate variations in material flexing and workpiece geometry, maintaining adaptability while improving operational efficiency
3Device complexity
If conventional manual process is used, then device complexity is minimized, but manufacturing precision deteriorates due to inability to maintain consistent pressure and angle
Solution Approach 1:
The fixture acts as an intermediary that incorporates precision-guiding elements between the simple manual operation and the workpiece. The guides and support surfaces provide consistent positioning and pressure application without requiring complex automated systems, maintaining process simplicity while improving manufacturing precision
Solution Approach 2:
The fixture's support surface is designed to replicate or copy the ideal positioning and orientation needed for precise countersinking. By creating a physical template or guide that represents the correct position and angle, the fixture ensures consistent reproduction of accurate countersinks across multiple operations without requiring complex control systems
Data Source
AI summary
Ribs for working an aircraft component having an aircraft component surface, fixtures for the same, and methods for the same, are provided herein. The rib includes a rib surface configured to receive the aircraft component and to be in abutting contact with at least a portion of the aircraft component surface. The rib further includes an extension extending away from the rib and configured to couple to a worksurface. Orientation of the rib is configured to be adjustable relative to the worksurface for improving working of the aircraft component. The fixture includes a mount defining an aperture and configured to be coupled to the worksurface and the rib. The method includes providing the fixture including the rib. The method further includes coupling the extension to a worksurface. The method further includes disposing the aircraft component on the rib surface.