Electro-Active Tolerance Compensation for Aircraft Component Alignment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The complexity and time-consuming nature of manually compensating for production tolerances in assembling aircraft components, such as fuselage and cabin modules, lead to increased costs and reduced efficiency in aircraft production, maintenance, and repair.

Innovation Solution

A tolerance compensation subassembly utilizing an electro-active polymer actuator that can switch between a fixed and non-fixed state when voltage is applied, allowing for automated compensation of dimensional deviations between aircraft components, enabling precise positioning and fixing of components with reduced manual intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional manual tolerance compensation methods are used, then production precision can be maintained, but device complexity and production time increase significantly

Engineering Contradiction:

Improvedimensional tolerance compensationVSAvoidfixing system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical adjustment systems with an electro-active polymer actuator that uses electrical signals to control the fixing state. The actuator transitions between fixed and non-fixed states through voltage application, eliminating the need for manual mechanical adjustments and complex tolerance compensation mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state of the fixing actuator through parameter changes - specifically, applying or removing voltage to transition the electro-active polymer between expanded and contracted states. This allows dynamic control of the fixing region's displacement capability, enabling precise positioning without complex mechanical systems.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If manual tolerance compensation is performed, then component alignment can be achieved, but production time and costs increase

Engineering Contradiction:

Improvecomponent alignment precisionVSAvoidassembly speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces time-consuming manual alignment operations with an automated electro-active polymer actuator system. The actuator can rapidly transition between states and adjust the fixing region position electrically, significantly reducing assembly time while maintaining precise component alignment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements preliminary positioning capability where the fixing actuator can be placed in a non-fixed state before component assembly, allowing pre-alignment and tolerance compensation to be performed efficiently. Once aligned, the actuator transitions to the fixed state to secure the components, streamlining the overall assembly process.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If fixed fixing regions are used, then structural stability is maintained, but adaptability to dimensional variations is lost

Engineering Contradiction:

Improvefixing structure stabilityVSAvoidtolerance compensation capability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The patent transforms the fixing region from a static, fixed structure to a dynamic system using an electro-active polymer actuator. The actuator can switch between fixed and non-fixed states, and the fixing region can be displaced in specific directions when voltage is applied. This dynamic capability allows the structure to adapt to dimensional variations while maintaining stability when needed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent uses parameter changes (voltage application) to control the state of the fixing actuator, enabling transition between stable fixed state and adaptable non-fixed state. This allows the same structure to provide both structural stability and tolerance compensation capability as needed during different phases of assembly or operation.

Inventive Principle:

Principle #35Parameter changes

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 solution automates the tolerance compensation process, reducing production time and costs while ensuring precise alignment and fixing of aircraft components, thereby improving the efficiency and quality of aircraft assembly, maintenance, and repair.

Implementation Method 1

a fixing actuator (54) which contains an electro-active material, in particular an electro-active polymer

Methodology Applied

Scientific EffectElectro-active polymer: Electroactive Polymer

Data Source

PatentUS11492142B2Tolerance compensation subassembly, aircraft component provided therewith and aircraft

Publication Date: 2022.11.08 AIRBUS OPERATIONS GMBH

AI summary

A tolerance compensation subassembly in the form of a tolerance compensation element or a tolerance compensation region to improve the production, maintenance and repair of aircraft. The tolerance compensation subassembly contains an actuator which is formed from an electro-active polymer so that the tolerance compensation subassembly is electrically switchable between a fixed state and a non-fixed state. As a result, automation of the assembly of aircraft components on each other can be enabled or facilitated.