Compound Contour Vacuum Track for Interior Fuselage Assembly

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Solution Overview

Problem

Current aircraft assembly automation is limited by the need for manual fastening inside the fuselage, which poses ergonomic, safety, and productivity issues, and existing automated systems are not suitable for internal use due to access constraints.

Innovation Solution

A compound contour vacuum track and automated fastening machine are mounted inside the fuselage, allowing the machine to traverse and position an end effector perpendicular to the surface for automated fastening, using sensors and a cantilevered track design to access and fasten internal structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual fastening is performed inside the fuselage, then access to internal structures is achieved, but ergonomic issues and safety risks arise

Engineering Contradiction:

Improveaccess to internal structuresVSAvoidergonomic issues and safety risks

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces manual mechanical fastening operations with an automated fastening machine that performs drilling, fastener insertion, and collar installation. This substitution eliminates ergonomic issues and safety risks associated with manual fastening while maintaining access to internal fuselage structures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The automated fastening machine is designed to perform all fastening operations autonomously inside the fuselage, including positioning, drilling, fastener installation, and collar application. The system serves itself by integrating multiple functions into a single automated unit that requires no manual intervention during operation.

Inventive Principle:

Principle #25Self-service

2Extent of automation

If automated multi-axis drilling machine is positioned outside the fuselage, then drilling and fastener insertion are automated, but the track is not suitable for use inside the fuselage

Engineering Contradiction:

Improvedrilling and fastener insertion automationVSAvoidtrack suitability for internal use

Core Design Contradiction:

Extent of automationVSAdaptability or versatility

Solution Approach 1:

The patent creates a universal fastening system that can operate from both outside and inside the fuselage. The automated fastening machine is designed with a track system that adapts to internal constraints while maintaining automated drilling, fastener insertion, and collar installation capabilities. This multi-functional design allows the same system to serve both external and internal fastening needs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent transitions from an external track system to an internal track configuration. By repositioning the automated fastening machine inside the fuselage and designing a compact track system that fits within internal space constraints, the solution moves the automation to a different spatial dimension while maintaining full functionality.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Extent of automation

If manual fastening is performed inside the fuselage, then current automation limitations are accepted, but productivity and assembly time are reduced

Engineering Contradiction:

Improvecurrent automation limitationVSAvoidassembly time

Core Design Contradiction:

Extent of automationVSProductivity

Solution Approach 1:

The patent merges multiple separate operations (drilling, fastener insertion, collar installation) into a single automated fastening machine. This consolidation eliminates the need for multiple mechanics performing sequential manual tasks, thereby significantly improving productivity and reducing assembly time while maintaining full automation inside the fuselage.

Inventive Principle:

Principle #5Merging (Combining)

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 enables efficient and automated fastening within the fuselage, reducing manual labor and safety risks while improving assembly efficiency and productivity by allowing the automated system to align and clamp the end effector for precise fastening operations.

Implementation Method 1

A compound contour vacuum track and automated fastening machine are mounted inside the fuselage

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentEP3650356B1Automated fastening machine using a compound contour vacuum track for automation of final assembly from the interior of a fuselage

Publication Date: 2021.05.19 THE BOEING CO

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AI summary

A compound contour vacuum track, and an automated fastening machine using the track, for automation of final assembly inside an aircraft fuselage. The track is mounted at an angle to a surface, such as an inside surface of the fuselage, wherein the surface has one or more holes through which fasteners are inserted. The automated fastening machine is mounted on the track to traverse the track while performing fastening functions and steps. The automated fastening machine includes a carriage, arm, and end effector, wherein the arm is mounted on the carriage and the end effector is mounted on the arm. The carriage is attached to the track for positioning the arm and end effector, the arm is attached to the carriage for positioning the end effector, and the end effector is attached to the arm for installing the fasteners into the holes of the surface.