Aircraft Positioner Spring Modeling for Faster Assembly Simulation
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Solution Overview
Problem
Current digital simulations for aircraft positioners require extensive computations and are sensitive to defects in the assembly line floor's flatness and homogeneity, necessitating lengthy cycles and inaccurate results, especially when modifications occur.
Innovation Solution
A simulation method using a digital model of aircraft loads and positioners represented as three equivalent springs defined by eigenvectors and eigenvalues, reducing simulation time and allowing for compensation with a calibrated rigidity adapter to account for floor defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If digital simulations are performed using finite element models of positioners to ensure suitability with respect to fuselage and airfoil loads, then modelling accuracy of interactions is improved, but simulation time increases to several days
Solution Approach 1:
The patent transforms the complex finite element model into a simplified spring-based model by changing the representation parameters. Instead of using detailed geometric and material properties of the positioner structure, the invention uses equivalent spring constants (kx, ky, kz) that capture the essential mechanical behavior. This parameter transformation reduces computational complexity while preserving the key load-bearing characteristics, enabling rapid simulation without sacrificing critical accuracy.
Solution Approach 2:
The invention creates a simplified copy of the positioner system using spring elements that replicate the essential mechanical behavior. Rather than simulating the complete finite element model, the patent uses an equivalent spring system that copies the load-deflection characteristics. This simplified copy allows for rapid assessment of positioner suitability while maintaining the necessary accuracy for decision-making.
2Measurement precision
If a new simulation cycle is performed to assess modifications of positioner placement or load plan changes, then accuracy of assessment is improved, but time consumption increases
Solution Approach 1:
The spring-based model uses simplified parameters (spring constants and positions) that can be rapidly adjusted to assess modifications. When positioner placement or load plans need to be evaluated, the invention allows quick recalculation using the spring model rather than re-running complex finite element analyses. This enables multiple assessment cycles to be performed efficiently, improving productivity while maintaining assessment accuracy through the calibrated spring parameters.
3Measurement precision
If finite element model simulations are used to ensure high accuracy, then modelling precision is improved, but sensitivity to floor defects of assembly line increases
Solution Approach 1:
The invention extracts the positioner from its sensitive environmental context (the assembly line floor) and models it as an isolated spring system with defined mechanical properties. By separating the positioner's intrinsic mechanical behavior from the external floor conditions, the simulation becomes less sensitive to floor defects. The spring model captures the essential load-bearing behavior without being influenced by variations in floor flatness or homogeneity that affect finite element models.
Data Source
AI summary
A simulation of efforts applied to positioners to support the fuselage and the airfoil of an aircraft during operations of assembly is performed. The efforts are defined in a digital model of a load plan of the aircraft in assembly phase. The simulation is performed using the load plan digital model of the aircraft in assembly phase and a digital model of each positioner in the form of a set of three equivalent springs defined by three respective eigenvectors associated with three respective eigenvalues, in which the eigenvalues provide rigidity values and the eigenvectors provide directions on which the respective eigenvalues are applied. Thus, the simulation times are reduced.