Aircraft Section Assembly Using Segmented Subcomponents
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Solution Overview
Problem
Conventional aircraft section production involves manual assembly in difficult ergonomic conditions, requiring extensive use of expensive geometrical stations and leading to inefficiencies and worker safety issues.
Innovation Solution
The method involves assembling preassembled subcomponents consisting of frames and panels that cover only a portion of the aircraft section's circumference, allowing for easier handling and assembly in ergonomic positions, and using reference markers and friction stir welding for precise assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional single-part production and traditional assembly sequence are used, then complete aircraft sections can be assembled, but the production process requires expensive geometrical stations with complex positioning systems and creates difficult ergonomic conditions for workers
Solution Approach 1:
The aircraft fuselage is divided into multiple circumferential subcomponents (e.g., upper, lower, left, right sections) that can be manufactured and assembled independently. Each subcomponent contains a portion of the frames and skin panels, allowing parallel production and simplified assembly operations that eliminate the need for complex geometrical stations.
Solution Approach 2:
Frames and skin panels are pre-assembled into subcomponents before final fuselage assembly. This preliminary assembly allows workers to perform drilling and riveting operations in accessible, ergonomically favorable positions rather than in the confined spaces of the complete fuselage structure.
2Productivity
If manual assembly operations are performed in the round cross-section aircraft section, then complete assembly can be achieved, but workers face difficult ergonomic situations with limited working space and difficult access
Solution Approach 1:
By segmenting the fuselage into open subcomponents during assembly, workers gain unrestricted access to all working areas. The segmented approach allows assembly operations to be performed on flat, accessible surfaces rather than in the confined round cross-section, dramatically improving ergonomic conditions and assembly efficiency.
Solution Approach 2:
The assembly process transitions from working within the constrained three-dimensional round cross-section to working on two-dimensional flat subcomponent surfaces. This dimensional change provides unlimited access to working areas and eliminates the spatial constraints of the fuselage's circular geometry.
3Device complexity
If frames are attached to skin panels using clips before longitudinal joining, then traditional assembly sequence can be followed, but many assembly operations require difficult access and body posture for working staff
Solution Approach 1:
Frames are pre-attached to skin panels in subcomponents using clips or other temporary fastening methods before final assembly. This preliminary action allows all drilling and riveting operations to be performed on accessible flat surfaces, eliminating the need for workers to assume difficult postures in the confined spaces of the complete fuselage structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the production process, reduces ergonomic challenges for workers, and achieves higher precision and efficiency in aircraft section assembly, enabling automated processes and reducing the need for extensive geometrical stations.
Implementation Method 1
The subcomponents are then assembled to one another with high precision, for example, by means of friction stir welding
Data Source
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AI summary
The present disclosure relates to a method of producing an aircraft section (10). The method comprises providing (S510) at least one frame (110) and a panel (105), and assembling (S520) a subcomponent (100) by mounting the at least one frame to the panel. The at least one frame and the panel have a circumferential extension corresponding to only a portion of the circumference of the aircraft section. Further, the assembling (S520) is performed multiple times to achieve a plurality of subcomponents (100), and the method further comprises placing (S530) a plurality of reference markers (112) in or on each of the assembled subcomponents (100), and assembling (S550) the aircraft section (10) by positioning each of the subcomponents relative to another one of the subcomponents employing the plurality of reference markers (112), and mounting the plurality of subcomponents (100) together using friction stir welding. Furthermore, disclosed is also an aircraft comprising a plurality of aircraft sections manufactured by such method.