Aircraft Component Machining with Backup Upper Tool Units
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Solution Overview
Problem
Existing processing installations for aircraft structural components face challenges with service operations on upper tools, leading to complex and time-intensive procedures, resulting in prolonged downtimes due to the need for manual removal of jammed rivet elements and other service operations.
Innovation Solution
The implementation of a second upper tool unit allows for continued processing of aircraft structural components by enabling another upper tool to take over operations in case of failure, thereby reducing downtimes. This is achieved by positioning the second upper tool unit to cooperate with the common lower tool, allowing for uninterrupted processing and simplified service operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a service platform is moved into position below the upper tool for service operations, then service personnel can access the upper tool, but the processing operation must be interrupted and the service operation becomes complex and time-intensive
Solution Approach 1:
The upper tool unit is divided into separable components that can be quickly detached and replaced. The upper tool can be rapidly exchanged with a backup tool without requiring complex service operations, thereby reducing service downtime while maintaining accessibility.
Solution Approach 2:
A second upper tool unit is prepared in advance as a backup. When service is needed on the first upper tool, the pre-positioned second upper tool can immediately take over the processing operation, eliminating the need to interrupt processing for service access.
2Productivity
If the upper tool is positioned several meters above ground for processing operations, then the processing installation can accommodate large aircraft structural components, but service personnel cannot readily reach the upper tool
Solution Approach 1:
The upper tool unit is designed as a modular, separable system. The upper tool can be quickly detached from its elevated position and replaced with a backup tool, allowing service operations to be performed on the ground level while maintaining high processing capability during normal operation.
Solution Approach 2:
A second upper tool unit serves as a duplicate backup system. When the first upper tool requires service, the second upper tool can immediately assume the processing function from the elevated position, while service personnel work on the first tool from ground level.
3Device complexity
If a single upper tool unit is used for processing, then the processing installation is simpler, but any failure or service need stops the entire processing operation
Solution Approach 1:
The upper tool system is segmented into multiple independent upper tool units that can operate separately. This modular configuration allows one unit to continue processing while another undergoes maintenance, improving reliability without significantly increasing overall system complexity.
Solution Approach 2:
The system employs a backup upper tool unit that remains standby ready to take over if the primary unit fails or requires service. This redundancy ensures processing continuity while keeping the additional complexity minimal, as the backup unit is only activated when needed.
Data Source
AI summary
The disclosure relates to a processing installation for aircraft structural components having a processing station comprising a clamping frame, wherein the clamping frame extends along a station longitudinal axis, and a processing unit which has a first upper tool unit having an upper tool which is orientated along a first tool axis and a lower tool unit having a lower tool which is orientated along a second tool axis, wherein the first tool axis and the second tool axis can be orientated parallel with a vertical direction which is angled with respect to the longitudinal direction, and wherein in at least one processing position of the upper tool of the first upper tool unit and in at least one processing position of the lower tool of the lower tool unit the first tool axis and the second tool axis are orientated coaxially relative to each other.