Aircraft Component Machining Layout for Fast Workpiece Exchange
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Solution Overview
Problem
The existing processing systems for aircraft structural components face significant downtime due to the complexity and time-consuming process of replacing components on the clamping frame, which restricts accessibility and requires cumbersome movement of heavy components using transport receptacles, leading to increased manufacturing costs.
Innovation Solution
The system allows the positioning device to move the aircraft structural component from the work area to a separate loading area for unloading and loading, utilizing an array of rails and a crane or controllable locking means to facilitate rapid exchange, enabling parallel pre-processing and post-processing, thus reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the aircraft structural component is processed in a clamping frame with positioning towers, then the machining operation can be performed, but the replacement of the component becomes complex and time-consuming
Solution Approach 1:
The system is divided into separate functional areas: a work area for machining operations and a loading area for component replacement. The clamping frame remains stationary in the work area while the positioning towers can move independently to transport components between areas, allowing machining and replacement operations to occur in parallel without interfering with each other.
Solution Approach 2:
The positioning towers act as intermediary devices that can operate in both the work area and loading area. These towers serve as mediators to transfer components between areas and can perform positioning functions in both zones, enabling seamless coordination between machining operations and component replacement activities.
2Weight of moving object
If the aircraft structural component is moved using a transport receptacle via tramline, then the heavy component can be transported, but the loading and unloading process becomes lengthy
Solution Approach 1:
The loading area is prepared in advance with proper positioning and support structures ready to receive components. The clamping frame can be positioned in the loading area where components are already staged, eliminating the need for complex transport operations. Components can be pre-positioned in the loading area before the machining cycle begins, allowing for rapid exchange during production.
Solution Approach 2:
The component replacement function is extracted from the work area and relocated to the dedicated loading area. This separation removes the time-consuming transport operations from the critical machining path, as components can be loaded and unloaded in the loading area without interrupting the machining operations in the work area.
3Device complexity
If the processing station processes one component at a time, then the machining operation is simple, but the overall productivity is reduced due to downtime
Solution Approach 1:
The system enables continuous useful action by allowing the positioning towers to transport components and perform positioning operations in the loading area while the machining operation continues in the work area. This parallel operation ensures that the machining station is never idle, as new components are prepared and positioned in advance in the loading area, maintaining continuous productive activity throughout the system.
Solution Approach 2:
Components are pre-positioned and prepared in the loading area before they are needed for machining. The positioning towers can perform preliminary positioning and preparation work in advance, so that when a component is ready for machining, it is already in the correct position and ready to be quickly transferred to the work area, eliminating idle time between machining operations.
Data Source
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AI summary
The invention relates to a machining system for aircraft structural components with a machining station (1) comprising a positioning device (2) for receiving and moving an aircraft structural component (3a,b) and a manipulator (4) with a tool (5), preferably a riveting machine (5a), wherein the manipulator (4) is configured to move the tool (5), wherein a working area (6) of the machining station (1) is defined by the area in which the aircraft structural component (3a,b) received by the positioning device (2) can be machined by the tool (5).The invention is characterized in that the processing system comprises a loading area (7) spaced apart from the working area (6) for loading and/or unloading the aircraft structural component (3a,b), and that the processing system comprises a traversing device (9) which is configured to move an aircraft structural component (3a,b) picked up by the positioning device (2), in particular completely, between the working area (6) and the loading area (8). The invention further relates to a method for processing aircraft structural components.