Airframe Floor Grid Assembly in Inverted Fuselage Barrels
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Solution Overview
Problem
Current aircraft assembly methods require frequent scanning and indexing of airframe components, leading to inefficiencies and increased space requirements in the factory floor, as well as downtime due to the need for tools and technicians to enter barrel sections through small doorways.
Innovation Solution
A continuous line assembly system that allows airframe components to be moved continuously through work stations, with a method involving the inversion of the lower half barrel section of the fuselage to install floor grids, utilizing a track system and feeder lines to provide components just-in-time for assembly, reducing the need for tooling and technician access through small doorways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tools, equipment, and workers are brought to the structure in fixed cells with frequent scanning and indexing, then work can be performed on the airframe components, but the process requires increased factory space and causes downtime due to repeated setup and access through small doorways
Solution Approach 1:
The patent inverts the traditional approach by moving the airframe component (barrel section) to the workers and equipment rather than bringing workers and equipment to the component. The barrel section is transported through a continuous line assembly system where it passes under work stations, allowing workers to access components from below without entering through small doorways, thereby eliminating access-related downtime.
Solution Approach 2:
The system implements dynamic movement of the barrel section through the assembly line, allowing the component to be continuously transported between work stations. This dynamic approach replaces the static fixed-cell methodology, enabling the barrel section to move efficiently through the assembly process without requiring repeated setup and indexing at fixed locations.
2Ease of manufacture
If tools and tooling are set up in place within the barrel section, then work can be completed, but the tools and tooling must be transported out through barrel ends or doorways, increasing complexity and time
Solution Approach 1:
Instead of bringing tools and tooling into the barrel section through small doorways and removing them through the same or different openings, the patent inverts the approach by transporting the barrel section itself through the assembly line. The tools remain stationary at work stations while the component moves beneath them, eliminating the complexity of tooling setup and transport.
Solution Approach 2:
The continuous line assembly system acts as an intermediary mechanism that facilitates the interaction between stationary work stations and moving barrel sections. This intermediary system enables efficient tooling utilization without requiring physical access through limited doorways, simplifying the overall assembly process.
3Productivity
If fixed cells are used for assembly operations, then work can be performed on airframe components, but the amounts of space required for fabrication and assembly at the factory floor increase
Solution Approach 1:
The patent transitions from static fixed-cell assembly to a dynamic continuous line system where barrel sections move continuously through the assembly process. This dynamic approach consolidates multiple fixed cells into a streamlined linear path, reducing the total factory space required while maintaining or increasing assembly capability.
Solution Approach 2:
The continuous line assembly system enables uninterrupted flow of barrel sections through multiple work stations, eliminating the need for repeated setup and indexing that characterizes fixed-cell operations. This continuous action increases productivity while reducing the space required for each individual work cell.
Data Source
AI summary
Systems and methods are provided for assembling an aircraft. The method includes receiving a lower half barrel section of fuselage that is inverted to a keel-up orientation; and installing a floor grid into the lower half barrel section while inverted.