Crawler Assembly System for Fuselage Drilling
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Solution Overview
Problem
Current methods for attaching parts in manufacturing, such as those used in aircraft construction, are time-consuming and expensive, especially when large machines cannot be used due to the shape of the structure or location of fasteners, requiring manual operation by operators which increases time and expense.
Innovation Solution
A crawler assembly system with a frame system, suction cups, and a controller that applies vacuum and pressure to attach and detach frames relative to each other on a workpiece, allowing for efficient movement and operation on complex surfaces using an end effector for tasks like drilling and fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If operators manually perform drilling and fastener installation operations, then the process can be completed on complex structures, but the time and expense increase significantly
Solution Approach 1:
The crawler assembly system is self-propelled and self-positioning on the workpiece surface using suction cups and electromagnetic units, eliminating the need for external positioning equipment. The system autonomously moves to required locations and performs operations without manual intervention for positioning, thereby reducing both time and labor costs while maintaining accessibility to complex structures
Solution Approach 2:
The patent replaces traditional mechanical positioning systems (large computer-controlled machines) with a combination of suction cup adhesion and electromagnetic attraction. This substitution enables the system to navigate complex surfaces that would be inaccessible to conventional mechanical equipment, while the integrated end effector performs drilling and fastening operations automatically
2Extent of automation
If large computer-controlled machines are used for drilling and fastener installation, then automation is improved, but the equipment cannot access certain locations due to structure shape and fastener location
Solution Approach 1:
The crawler assembly system features dynamic mobility, allowing it to move freely across the workpiece surface to reach any location. The system transitions between stationary operation modes and mobile transit modes, enabling it to access confined or irregularly shaped areas that static large machines cannot reach, while maintaining automated drilling and fastening capabilities
Solution Approach 2:
The system concentrates automation functions (drilling, fastening) in a compact end effector mounted on the movable crawler platform. This localized configuration of automated tools on a small, agile platform provides both the automation of large machines and the accessibility of small portable devices to various locations on the workpiece
3Adaptability or versatility
If operators perform all operations manually, then flexibility to work on any structure is maintained, but the expense and time consumption become excessive
Solution Approach 1:
The crawler assembly system performs operations autonomously once positioned on the workpiece. The integrated end effector automatically executes drilling and fastening sequences without continuous manual intervention, significantly reducing the time required for fastener installation while maintaining the flexibility to adapt to different structural configurations through programmable control
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 system reduces assembly time and cost by enabling efficient attachment and movement on complex surfaces, allowing for automated operations that would be difficult or slow with traditional methods, improving the efficiency and speed of manufacturing processes.
Implementation Method 1
a first number of suction cups connected to the first frame by the first number of legs in which the first number of suction cups is configured for attachment to the workpiece
Implementation Method 2
an electromagnetic unit associated with the first frame in which the electromagnetic unit is configured to attract a magnetic material associated with the workpiece such that the electromagnetic unit holds the first frame on the workpiece
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A method and apparatus for performing operations on a workpiece. A first frame in a frame system may be held on the workpiece by applying a vacuum to the first frame. A second frame in the frame system may be detached from the workpiece by applying a pressure to the second frame. The second frame may be moved to a location on the workpiece. The second frame may be attached to the workpiece by applying the vacuum to the second frame. An operation may be performed on the workpiece.