Bonding Tool for Aircraft Ribs Using Bladder Pressure

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The manual and time-consuming process of installing sacrificial pads on aircraft ribs during wing assembly, which affects the structural integrity and increases assembly time due to the need for precise machining on these pads rather than the ribs themselves.

Innovation Solution

A bonding tool that secures sacrificial pads to the rib perimeter using a rib receptacle, compression forms, and a bladder to apply uniform pressure, significantly speeding up the process and ensuring a consistent bond line.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual process is used to install sacrificial pads on ribs, then each pad can be individually positioned, but the assembly time increases significantly

Engineering Contradiction:

Improvepad positioning precisionVSAvoidassembly speed

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The bonding tool automatically positions and applies sacrificial pads to the rib perimeter through its mechanical structure, eliminating the need for manual positioning while maintaining precision. The tool self-adjusts to the rib geometry and automatically places pads at correct locations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical positioning process with an automated bonding tool that uses mechanical guides and fixtures to precisely position pads. The tool incorporates mechanical mechanisms for automatic pad placement and bonding pressure application.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If multiple sacrificial pads are installed manually on each rib, then the bonding process can be performed, but additional man-hours are required for each rib

Engineering Contradiction:

Improvebonding process reliabilityVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The bonding tool combines multiple functions into a single device: it holds the rib, positions multiple sacrificial pads simultaneously, applies bonding pressure, and maintains alignment. This integration allows all pads on a rib to be installed in one operation rather than sequentially by hand.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The bonding tool is designed to accommodate multiple ribs with different geometries through adjustable fixtures and universal clamping mechanisms. A single tool can perform the bonding operation on various rib types, replacing multiple specialized manual operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If sacrificial pads are bonded without uniform pressure, then the bonding process is simpler, but the bond line consistency deteriorates

Engineering Contradiction:

Improvebonding process simplicityVSAvoidbond line consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The bonding tool incorporates pressure distribution mechanisms that ensure uniform pressure application across all bonding locations. The tool design includes pressure equalization features and controlled force application to maintain consistent bond lines while keeping the process simple.

Inventive Principle:

Principle #35Parameter changes

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

The bonding tool greatly increases the speed and consistency of applying sacrificial pads, improving the manufacturing process by reducing manual labor and ensuring structural integrity through uniform pressure application.

Implementation Method 1

at least one bladder proximate to the compression forms that expands between a wall of the base member and the compression forms to press the sacrificial pads against the bonding locations

Methodology Applied

Scientific EffectPressure: Pressure Increase

Implementation Method 2

a vacuum plate disposed within the rib receptacle that applies a vacuum to a major surface of the rib to secure the rib to the base member

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentUS11498702B2Bonding tool for aircraft structural parts

Publication Date: 2022.11.15 THE BOEING CO

AI summary

A bonding tool is described that is used to secure sacrificial pads to bonding locations on a perimeter of a rib during a bonding process. In one embodiment, the bonding tool includes a base member having a rib receptacle dimensioned to receive a rib of a wing, a plurality of compression forms disposed around at least a portion of the rib receptacle and proximate to a perimeter of the rib, where the compression forms include a plurality of sacrificial pads that face towards bonding locations on the perimeter of the rib, and at least one bladder proximate to the compression forms that expands between a wall of the base member and the compression forms to press the sacrificial pads against the bonding locations while the sacrificial pads bond to the bonding locations.