Airframe Micro-Pulse Indexing for Continuous Assembly Flow
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Solution Overview
Problem
Current airframe assembly processes face delays due to uneven fabrication rates and require extensive setup and cataloging, with automated inspection techniques being time-consuming and expensive.
Innovation Solution
A method and system involving micro pulsing of airframes along a track, indexing to work stations with complementary features, and iterative repetition of pulsing and working, allowing multiple work stations to operate simultaneously and reduce setup time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If components are assembled in predefined cells on a factory floor, then structural integrity is maintained, but assembly time increases due to frequent moves and setup
Solution Approach 1:
The airframe assembly process is segmented into multiple workstations along a continuous track, with each workstation responsible for specific tasks. The airframe itself is segmented into sections that can be independently accessed and worked on simultaneously by different workstations, eliminating the need to move the entire structure between cells.
Solution Approach 2:
The system transitions from static predefined cells to a dynamic continuous flow assembly line. The airframe moves continuously through the assembly process on a track system, with workstations positioned along the path. This dynamic approach allows the assembly process to adapt to varying fabrication rates at different workstations while maintaining continuous progress.
2Measurement precision
If automated optical inspection techniques and probes are used to inspect position of parts, then measurement precision is improved, but productivity decreases due to time-consuming processes
Solution Approach 1:
Indexing features are incorporated into the airframe design and manufacturing process before assembly begins. These features serve as pre-established reference points that enable rapid positioning and inspection at workstations, eliminating the need for time-consuming post-manufacturing cataloging and inspection procedures.
Solution Approach 2:
The physical indexing features on the airframe are complemented by digital representations and models. The system uses these digital copies to track and manage the position and configuration of parts throughout the assembly process, reducing the need for repeated physical inspections while maintaining precision.
3Reliability
If the entire airframe section remains at the cell until all work is completed, then work quality is ensured, but loss of time increases due to waiting
Solution Approach 1:
The airframe assembly is divided into multiple sections or segments that can be worked on independently at different workstations. Each segment can progress through the assembly line at its own pace, allowing concurrent work on multiple sections without requiring the entire airframe to wait for the slowest task to complete.
Solution Approach 2:
The continuous track system enables uninterrupted movement of the airframe through the assembly process. Workstations are positioned along the track to perform tasks continuously as the airframe passes, eliminating idle waiting time while maintaining quality through systematic process control and indexing features.
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.