Clamping Robot for Aircraft Fuselage Fastener Termination

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Solution Overview

Problem

The assembly of large commercial aircraft fuselages is labor-intensive due to the high dependence on manual labor for fastener termination, leading to unstable production rates and increased production times.

Innovation Solution

A robotic system with a frame and multiple arms that clamp onto frame members to position an end effector for performing manufacturing operations, such as fastener termination, within the fuselage, providing stability and precision through adjustable arms and a tool positioning mechanism with multiple degrees of freedom.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual labor is used for fastener termination, then flexibility in operation is maintained, but production rates become unstable and production times increase

Engineering Contradiction:

Improveproduction rate stabilityVSAvoidautomation level

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The robotic system performs fastener termination operations autonomously without requiring manual intervention. The robot clamps onto frame members, positions the end effector, and executes drilling and fastener insertion operations automatically, enabling the system to serve itself and eliminating dependency on manual labor for these repetitive tasks.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical operations are replaced with an automated robotic system. The robot uses mechanical arms with clamps to grip frame members and an end effector with multiple degrees of freedom to perform fastener termination, substituting human-operated mechanical processes with automated robotic mechanics to achieve stable production rates.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If a robotic system with multiple arms and clamps is used, then manufacturing precision and production efficiency are improved, but device complexity increases

Engineering Contradiction:

Improvepositioning precisionVSAvoidrobotic system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The robotic system is divided into distinct functional segments: multiple arms for clamping onto frame members, an end effector for fastener operations, and a positioning mechanism with multiple degrees of freedom. This segmentation allows each component to be optimized independently while working together to achieve precise positioning and manufacturing accuracy.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic system incorporates dynamic positioning capabilities with multiple degrees of freedom in the end effector, allowing it to adapt its position and orientation precisely along the frame members. The arms and clamps can adjust dynamically to accommodate variations in frame geometry while maintaining manufacturing precision.

Inventive Principle:

Principle #15Dynamics

3Productivity

If fastener termination is performed manually, then adaptability to varying conditions is maintained, but labor intensity increases and production stability decreases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidautomation level

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS9610693B2Robot for clamping onto upright frame members

Publication Date: 2017.04.04 THE BOEING CO

AI summary

A system includes a frame having spaced apart first and second upright members, and a robot including an end effector and a plurality of arms. The arms extend from the end effector and clamp onto the first and second frame members to position the end effector between the first and second frame members.