Aircraft Frame Assembly Installation Tooling
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Solution Overview
Problem
The installation of frame assemblies in commercial aircraft with one-piece composite bodies faces challenges due to mislocation of frame elements, leading to undesired stresses and non-conformance issues, resulting in significant costs for rework, repair, and replacement.
Innovation Solution
A tooling assembly with ribcage design and positioning devices is used to support and locate frame elements accurately at predetermined engineering locations on the body, ensuring precise installation and alignment of frame assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual frame elements are placed and fastened separately, then the frame assembly can be installed on the body, but mislocation occurs leading to undesired stresses and non-conformance issues
Solution Approach 1:
The frame assembly is divided into multiple individual frame elements that can be handled and installed separately. Each frame element is supported by dedicated tooling elements that enable individual placement while maintaining overall assembly precision through the ribcage structure.
Solution Approach 2:
A tooling assembly with ribcage structure acts as an intermediary device between the frame elements and the body. This tooling assembly includes positioning devices that locate and support each frame element at predetermined engineering locations, ensuring accurate placement without direct handling that could cause mislocation.
2Strength
If frame elements are fastened at predetermined locations, then structural rigidity is provided to the body, but mislocation causes rework, repair, and replacement costs
Solution Approach 1:
The tooling assembly with ribcage structure and positioning devices is prepared in advance to establish precise locations for frame element installation. The positioning devices are configured before installation to ensure that each frame element is located at the correct predetermined engineering location, preventing mislocation before it occurs.
Solution Approach 2:
The invention replaces manual placement and measurement methods with a mechanical tooling system that provides automated positioning. The ribcage structure with integrated positioning devices mechanically ensures accurate location of frame elements, eliminating the variability and errors associated with manual installation methods.
3Manufacturing precision
If a tooling assembly with ribcage design is used to support frame elements, then placement accuracy is improved, but device complexity increases
Solution Approach 1:
The tooling assembly with ribcage structure serves multiple functions: it supports multiple frame elements simultaneously, provides positioning at predetermined locations, maintains structural rigidity during installation, and enables accurate placement. This multi-functionality reduces the need for separate specialized tools for each task.
Solution Approach 2:
The tooling assembly features a ribcage structure where tooling elements are nested within the framework of the ribcage. The positioning devices are integrated into the ribcage structure, allowing compact arrangement of multiple components within a unified framework, which manages complexity through organized integration.
Data Source
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AI summary
An apparatus (10) and method for installation of a frame assembly (14) to a body (16) may include a tooling assembly (12) configured to support the frame assembly, the tooling assembly being positionable with respect to the body, wherein the frame assembly is positioned with respect to the body at a plurality of predetermined engineering locations.