Aircraft Pylon Assembly Modular Integration
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Solution Overview
Problem
The existing methods for assembling aircraft pylons are inefficient due to limited accessibility for installing internal systems, which increases the complexity and time required for assembly, as these systems need to be installed one after the other within a partially assembled primary structure.
Innovation Solution
A method that involves assembling a subassembly of upper and lower spars and lateral panels, followed by mounting an internal systems module with connected supports, allowing all internal systems to be positioned in a single step, thereby improving accessibility and reducing assembly time. This method includes pre-drilling and aligning holes for fasteners to facilitate the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If internal systems are installed one after the other within an already-assembled primary structure, then the structural integrity of the pylon is maintained, but the assembly time increases significantly and accessibility is limited
Solution Approach 1:
The primary structure is divided into modular components (spars, panels, reinforcements) that can be assembled in segments. The internal systems are pre-assembled into modules that can be integrated into the segmented primary structure, allowing parallel assembly operations and reducing overall assembly time while maintaining structural integrity through controlled joining sequences.
Solution Approach 2:
Internal systems are pre-assembled into complete modules before integration into the primary structure. This preliminary preparation allows for optimized internal system configuration and enables faster integration into the pylon structure, reducing on-site assembly time while ensuring proper installation of all internal components.
2Reliability
If internal systems are installed one after the other within an already-assembled primary structure, then the structural integrity of the pylon is maintained, but the complexity of the assembly process increases
Solution Approach 1:
Multiple internal systems are merged into integrated modules that are installed as single units into the primary structure. This consolidation reduces the number of separate installation operations, simplifies the assembly process, and maintains structural integrity by reducing the number of access points and joining operations required.
Solution Approach 2:
Modular interfaces and standardized connection mechanisms serve as intermediaries between the internal systems and the primary structure. These intermediaries simplify the coupling process, enable easier integration, and maintain structural integrity through standardized, reliable connection methods that reduce assembly complexity.
3Stability of the object's composition
If the primary structure is fully assembled before installing internal systems, then structural stability is ensured, but accessibility for installing internal systems is limited
Solution Approach 1:
The primary structure is segmented into modular sections with defined interfaces. Internal system modules are designed to fit into these segments, allowing assembly operations to proceed section by section. This segmentation maintains structural stability through controlled joining while providing adequate accessibility during each assembly stage.
Solution Approach 2:
The assembly approach transitions from a sequential single-dimension process to a parallel multi-dimension process. Multiple assembly operations can occur simultaneously in different spatial dimensions (different sections of the pylon), improving accessibility and reducing overall assembly time while maintaining structural stability through coordinated progression.
Data Source
AI summary
A method for assembling an aircraft pylon including a primary structure and at least one internal system positioned at least partially within the primary structure, wherein the assembly method includes a first step of assembling a part of the primary structure so that the interior of the primary structure remains accessible, a step of mounting an internal systems module including at least one support and at least one internal system connected to the support, a second step of assembling the internal systems module and the partially assembled primary structure, a third step of assembling any element of the primary structure not assembled in the first assembly step, and an aircraft pylon assembled by such a method.