Arcuate Aircraft Frame Assembly Line for High-Rate Fabrication

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Solution Overview

Problem

The existing methods for fabricating aircraft frames are inefficient, leading to delays in aircraft assembly due to slow production rates and require large assembly lines, which occupy significant factory space and fail to meet desired takt times.

Innovation Solution

The implementation of an assembly line system that fabricates frames as arcuate portions of a full circle, allowing multiple frames to be advanced synchronously through stations arranged in an arc, increasing work density and enabling high-rate fabrication while reducing the assembly line's footprint by leveraging the curved nature of the frames.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional linear assembly lines are used to fabricate frames, then the assembly line can process frames sequentially, but the production rate is slow and the factory space occupied is large

Engineering Contradiction:

Improveframe production rateVSAvoidassembly line footprint

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The assembly line is configured in a curved or arcuate arrangement rather than a traditional linear layout. Frames are advanced through stations arranged in an arc, allowing the assembly line to occupy less factory floor space while maintaining high work density. This curved configuration enables multiple frames to be processed simultaneously in a compact footprint.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The assembly line transitions from a one-dimensional linear arrangement to a two-dimensional curved layout. By utilizing the arcuate configuration, the system packs more processing stations into a smaller area, increasing work density and enabling higher production rates without proportionally increasing the factory space required.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If assembly lines are designed to meet desired takt times for aircraft assembly, then production efficiency increases, but the complexity of coordinating multiple frames through multiple stations increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidassembly line coordination complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The assembly line is divided into multiple discrete stations, each performing specific work on frames. This segmentation allows independent optimization of each station and enables parallel processing of multiple frames simultaneously. The modular station design simplifies coordination by assigning specific tasks to specific locations along the curved path.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple frames are advanced synchronously through the assembly line in a continuous flow, with each frame receiving work at each station in sequence. This continuous synchronous advancement ensures that the assembly line operates at the desired takt time without idle time, maintaining high production efficiency while the modular station design keeps coordination manageable.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS11845566B2Frame fabrication line

Publication Date: 2023.12.19 THE BOEING CO

AI summary

Systems and methods are provided for fabrication of frames for aircraft.