Aircraft Frame Assembly Using Dual-Tool Segmentation

Solution Overview

Problem

Conventional aircraft assembly tools face challenges in precisely positioning and attaching aircraft components without causing deformation during machining, especially when supporting the frame only along its side edges, which can lead to inefficiencies and increased assembly time.

Innovation Solution

The method involves using two distinct tools: a first tool that supports the frame's surfaces during machining to prevent deformation and a second tool that contacts only the frame's side edges for attaching aircraft panels, allowing for precise machining and simultaneous skin attachment without obstructing the surfaces, facilitating efficient assembly and reducing the risk of frame damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the frame is supported only along its side edges during assembly, then the assembly tool can access both surfaces for panel attachment, but the frame may deform during machining

Engineering Contradiction:

Improveaccess to both surfaces for panel attachmentVSAvoidframe deformation during machining

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The assembly tool is divided into two distinct tools: a first tool configured to support the frame during machining operations, and a second tool configured to support the frame during panel attachment. This segmentation allows each tool to be optimized for its specific function, preventing frame deformation during machining while enabling access to both surfaces for panel attachment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame is machined to form attachment features before the panels are attached. By completing all necessary machining operations on both surfaces of the frame before panel attachment, the frame is stabilized and positioned correctly in advance, preventing deformation during subsequent assembly operations.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If the frame is supported on a single tool for both machining and assembly, then the process is simplified, but machining and assembly cannot occur simultaneously on both surfaces

Engineering Contradiction:

Improvenumber of toolsVSAvoidassembly time

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The assembly tool is divided into two distinct tools: a first tool configured to support the frame during machining operations, and a second tool configured to support the frame during panel attachment. This segmentation allows each tool to be optimized for its specific function, enabling simultaneous machining and assembly operations on both surfaces of the frame, thereby reducing overall assembly time despite the increased number of tools.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame is machined to form attachment features before the panels are attached. By completing all necessary machining operations on both surfaces of the frame before panel attachment, the frame is stabilized and positioned correctly in advance, preventing deformation during subsequent assembly operations.

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If machining is performed before assembly, then precise attachment features can be created, but assembly time increases due to sequential operations

Engineering Contradiction:

Improveattachment feature precisionVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The assembly tool is divided into two distinct tools: a first tool configured to support the frame during machining operations, and a second tool configured to support the frame during panel attachment. This segmentation allows each tool to be optimized for its specific function, enabling simultaneous machining and assembly operations on both surfaces of the frame, thereby reducing overall assembly time despite the increased number of tools.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame is machined to form attachment features before the panels are attached. By completing all necessary machining operations on both surfaces of the frame before panel attachment, the frame is stabilized and positioned correctly in advance, preventing deformation during subsequent assembly operations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP3331761B1Aircraft part assembly

Publication Date: 2020.10.07 BAE SYSTEMS PLC

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AI summary

A method of producing part of an aircraft (2) comprising: providing a frame (4) having a first surface (10), a second surface (12), and one or more side edges (14) between the first and second surfaces; mounting the frame (4) to a first tool (20), the first tool (20) comprising a support surface(22) that contacts the second surface (12) of the frame (4) to opposing movement of the frame (4); while the frame (4) is mounted to the first tool (20), machining the first surface (10) to form attachment features; mounting the machined frame (4) to a second tool (30) which contacts with the frame (4) at only the one or more side edges (14); and, while the frame (4) is mounted to the second tool (30), attaching, using the attachment features, to the first and second surfaces (10, 12), aircraft panels (6, 8) to form an outer skin.