Airframe Pulsed-Line Assembly with Indexing Features
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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 structures along a track, indexing them to multiple work stations with complementary features, and iteratively repeating the process to enable simultaneous work on multiple sections of the airframe, reducing setup time and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are assembled in predefined cells on a factory floor, then structural integrity and assembly quality are maintained, but assembly time increases due to frequent moves between cells and setup time
Solution Approach 1:
The airframe assembly process is segmented into multiple work stations arranged in sequence, with each station performing specific assembly tasks. The fuselage is divided into sections that can be worked on simultaneously at different stations, eliminating the need to complete entire sections at one cell before moving to the next.
Solution Approach 2:
The system transitions from static cell-based assembly to dynamic pulsed-line assembly, where the fuselage moves continuously through work stations in controlled pulses. This allows the assembly line to adapt to varying work requirements at different stations while maintaining overall flow efficiency.
2Measurement precision
If automated optical inspection techniques and probes are used to inspect position of parts, then measurement precision is improved, but inspection time and cost increase significantly
Solution Approach 1:
Indexing features are incorporated into the airframe components during manufacturing, establishing precise positional relationships before assembly. This preliminary action eliminates the need for time-consuming post-assembly inspection, as the features inherently provide accurate positioning information.
Solution Approach 2:
The system uses indexing features that replicate precise positional information throughout the airframe structure. These features serve as distributed reference points that convey configuration data without requiring physical measurement or inspection at each location.
3Reliability
If the entire fuselage section remains at one cell until all work is completed, then work quality is ensured, but productivity decreases due to idle time
Solution Approach 1:
The fuselage assembly process is divided into multiple work stations, each handling specific tasks. This segmentation allows different sections to be worked on simultaneously by different teams, eliminating the bottleneck where the entire section must wait for the slowest task to complete.
Solution Approach 2:
The pulsed-line assembly system maintains continuous productive action by keeping multiple work stations actively engaged at different phases of the assembly process. While one station completes a task, another station is already preparing the next operation, ensuring no idle time in the overall process.
4Adaptability or versatility
If frequent moves between cells are performed, then assembly flexibility is maintained, but setup time increases substantially
Solution Approach 1:
The system implements a dynamic pulsed-line configuration where work stations are fixed in position and the fuselage moves through them. This eliminates repeated setup operations associated with moving entire cells, while maintaining flexibility through the pulsed movement pattern that can be adjusted to match production requirements.
Data Source
Figure 1
Figure 1A
Figure 1B
AI summary
Systems and methods are provided for assembling a structure (120). The systems and method including micro pulsing (181) a structure along a track (110) in a process direction (199) by less than a length (196) of the structure. The structure is indexed (129) to one or more work stations (140) by mating indexing features (124) in a manufacturing excess (125,170,180) of the structure to complementary indexing features (134) at the work stations (140). 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 (181) and indexing (129) upon the structure (120) until it is ready to advance to the next assembly process.