Coordinated End Effector Attachment for Aircraft Fastening

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Solution Overview

Problem

The installation of fasteners on aircraft structures with contours is labor-intensive or requires complex robots due to alignment challenges, making existing methods inefficient.

Innovation Solution

The use of end effectors arranged on fixed tracks following the Inner Mold Line (IML) and Outer Mold Line (OML) of the structure, allowing for enforced alignment and movement relative to the structure for efficient fastener application at various positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If complex robots are used to install fasteners on contoured structures, then alignment precision is improved, but device complexity increases

Engineering Contradiction:

Improvealignment precisionVSAvoidrobot complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system divides the fastener installation task into two independent end effectors operating on separate fixed tracks (IML and OML). Each end effector handles one side of the structure, moving independently along its own track to reach fastener locations. This segmentation eliminates the need for a single complex robot while maintaining precise alignment through coordinated operation of the two simpler end effectors.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If labor-intensive methods are used to install fasteners on contoured structures, then device complexity is reduced, but productivity decreases

Engineering Contradiction:

Improvesystem simplicityVSAvoidinstallation speed

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The fixed tracks are designed to follow the contours of the structure (Inner Mold Line and Outer Mold Line), allowing the end effectors to self-align with the structure as they move along the tracks. The system uses the structure's own geometry to guide the end effectors, eliminating the need for complex active alignment mechanisms while enabling automated, high-speed fastener installation.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If fixed tracks following IML and OML are used, then alignment precision is improved, but device complexity increases

Engineering Contradiction:

Improveenforced alignmentVSAvoidtrack system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The fixed tracks serve as intermediary elements that translate the complex contoured geometry of the structure into simple linear motion paths. By following the Inner Mold Line and Outer Mold Line contours, the tracks mediate between the automated end effectors and the contoured structure, providing enforced alignment without requiring the end effectors themselves to be complex contoured mechanisms.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20220153432A1Coordinated End Effector Attachment of Fasteners to Aircraft Structure

Publication Date: 2022.05.19 THE BOEING CO

AI summary

Systems and methods are provided for applying fasteners to a structure. One embodiment is a method that includes disposing a first set of end effectors along a fixed inner track that follows an Inner Mold Line (IML) of a structure, disposing a second set of end effectors along a fixed outer track that follows an Outer Mold Line (OML) of the structure, aligning a first end effector at the fixed inner track with a second end effector at the fixed outer track, clamping the structure between the first end effector and the second end effector, by pressing the first end effector and the second end effector into the structure, and applying a fastener to the structure.