Automated Handler System for Aircraft Fuselage Positioning

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Solution Overview

Problem

Current methods for handling large components in manufacturing environments, such as overhead cranes, are cumbersome, inaccurate, and cause scheduling delays, and lack adaptability, making them inefficient for positioning and securing large components during assembly.

Innovation Solution

A handler system with multiple end effectors is used to automate the engagement and handling of structures, allowing for secure transport and precise positioning of components using a laser guidance system, eliminating the need for massive manipulators and improving adaptability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If overhead cranes are used to transport large components, then the components can be moved across the manufacturing environment, but the system becomes cumbersome and less accurate in positioning

Engineering Contradiction:

Improveease of transportVSAvoidpositioning accuracy

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The system divides the transport function into multiple independent handler systems, each with multiple end effectors that can independently engage fittings on the structure. This segmentation allows precise positioning while maintaining transport capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces the purely mechanical overhead crane system with an automated handler system that uses laser guidance and automated engagement mechanisms, substituting manual mechanical operation with automated control systems for improved precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If larger tooling apparatuses are used to position large components, then positioning capability is improved, but the apparatus becomes large, expensive, and immobile

Engineering Contradiction:

Improvepositioning capabilityVSAvoidapparatus size

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The handler system is designed to be universally applicable to multiple structures and assemblies. The end effectors can engage with various fittings, and the system can be repositioned to handle different components, eliminating the need for dedicated large tooling apparatuses for each task.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system transitions from static, immobile tooling apparatuses to dynamic, movable handler systems that can be repositioned as needed. The automated engagement and disengagement capabilities allow the same system to be used for multiple positioning tasks throughout the manufacturing environment.

Inventive Principle:

Principle #15Dynamics

3Productivity

If overhead cranes are used for transporting components, then transport capability is provided, but scheduling issues and delays occur due to manual operation

Engineering Contradiction:

Improvetransport capabilityVSAvoidscheduling delays

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The handler system performs automated engagement, transport, and disengagement operations without requiring manual intervention. The system services itself by automatically positioning end effectors, engaging fittings, moving structures, and releasing components, eliminating scheduling delays caused by manual operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The automated system enables continuous operation without the interruptions and pauses required by manual crane operation. Multiple handler systems can operate simultaneously and continuously, maintaining productive action throughout the manufacturing process without scheduling conflicts.

Inventive Principle:

Principle #20Continuity of useful action

4Adaptability or versatility

If manual crane operation is used, then flexibility in handling is maintained, but adaptability to different structures is limited

Engineering Contradiction:

Improvehandling flexibilityVSAvoidmanual operation requirement

Core Design Contradiction:

Adaptability or versatilityVSExtent of automation

Solution Approach 1:

The handler system with multiple end effectors is designed to accommodate various structure types and configurations. The system can adapt to different fittings and structures through automated positioning and engagement, providing both versatility and automation simultaneously.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 significantly reduces handling time by up to 9 hours per aircraft, enhances safety, and improves production rates by enabling efficient and accurate positioning of large components, such as fuselage side panels, within manufacturing environments.

Implementation Method 1

The handler system positions the structure in a selected position relative to the assembly using a laser guidance system.

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS10870180B2Automated engagement and handling of a structure

Publication Date: 2020.12.22 THE BOEING CO

AI summary

A method and apparatus for automated handling a structure. A handler system comprises a plurality of towers and a plurality of end effectors coupled to the plurality of towers. Each of the plurality of end effectors is movably coupled to a tower of the plurality of towers. Each of the plurality of end effectors comprises an arm coupled to the tower and a coupling device for use in automated engagement of a corresponding fitting coupled to the structure.