Airframe Micro-Pulsing Assembly With Indexing Features
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Solution Overview
Problem
Current airframe assembly processes face delays due to uneven completion times of components, require significant setup times, and rely on time-consuming and expensive automated inspection techniques.
Innovation Solution
A method and system for assembling airframes using micro pulsing and indexing features that allow simultaneous work at multiple stations, utilizing indexing features to convey instructions and perform work during pauses or pulses, maintaining structural loft without full scans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated optical inspection techniques and probes are used to inspect position of parts, then measurement precision is improved, but loss of time and device complexity increase
Solution Approach 1:
Indexing features are embedded in the structure during manufacturing, establishing a known reference framework before inspection occurs. This preliminary action eliminates the need for time-consuming scanning during assembly, as the reference data is already available from the indexing features.
Solution Approach 2:
Physical indexing features (such as holes, pins, or geometric elements) create a digital or positional copy of the structure's configuration. This copying mechanism allows the system to know the structure's state without performing physical measurements, significantly reducing inspection time while maintaining precision.
2Ease of operation
If components are moved between cells for assembly work, then ease of operation is improved, but loss of time increases due to setup time at each cell
Solution Approach 1:
The indexing features serve multiple functions: they guide the structure through the assembly line, provide reference for positioning at workstations, and enable rapid identification of the structure's configuration. This multi-functionality eliminates the need for separate setup procedures at each cell, reducing setup time while maintaining operational flexibility.
3Manufacturing precision
If the entire section remains at the cell until all work is completed, then manufacturing precision is maintained, but productivity decreases
Solution Approach 1:
The assembly process is segmented into discrete workstations along the pulsing line, with each station performing specific tasks. The indexing features enable each station to work independently on its assigned portion of the structure without requiring the entire section to wait, thereby maintaining precision through controlled positioning while improving throughput through parallel processing.
Solution Approach 2:
The pulsing line enables continuous movement and processing of structures through multiple workstations. Indexing features ensure that each workstation can immediately begin work when the structure arrives, eliminating idle time and maintaining continuous productive action while preserving manufacturing precision through accurate positional reference.
Data Source
AI summary
Systems and methods are provided for assembling a structure. The systems and method including micro pulsing a structure along a track in a process direction by less than a length of the structure. The structure is indexed to one or more work stations by mating indexing features in a manufacturing excess of the structure to complementary features at the work stations. The work stations would the perform work on the structure at the work stations while the structure is indexed to the work stations. Iteratively repeating the micro pulsing and indexing and working upon the structure until it is ready to advance to the next assembly process.