Aircraft Crown Module Assembly on a Continuous Fuselage Line
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Solution Overview
Problem
Current aircraft assembly methods require frequent scanning and indexing of airframe components, leading to inefficiencies and increased space requirements in the factory floor, as well as downtime due to the need for tools and technicians to enter barrel sections through small doorways for assembly.
Innovation Solution
Implementing a continuous line assembly system that allows airframe components to be moved along a track for assembly, with workstations positioned to efficiently install crown modules into the upper half barrel section of the fuselage, using a ceiling grid that advances through stations with components provided just-in-time via feeder lines, enabling simultaneous work on multiple components during pauses or continuous movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fixed cell assembly methods are used, then tools and technicians can work on airframe components, but frequent scanning and indexing is required and large factory space is needed
Solution Approach 1:
The patent transforms the static fixed cell assembly system into a dynamic continuous line system where the airframe component moves continuously through the assembly line on a track, and workstations are positioned along the path. This dynamic arrangement eliminates the need for frequent scanning and indexing, reducing factory space requirements while maintaining assembly capability.
Solution Approach 2:
The assembly process is segmented into multiple workstations positioned along the continuous line, each performing specific assembly tasks on different sections of the airframe component. This segmentation allows simultaneous work on multiple components at different stations, increasing throughput while reducing the space needed for each individual assembly operation.
2Ease of manufacture
If tools and technicians enter barrel sections through small doorways for assembly, then work can be performed inside the fuselage, but downtime occurs due to entry and exit operations
Solution Approach 1:
The patent positions workstations and tools along the continuous line before the airframe component reaches them, allowing assembly operations to be performed continuously as the component passes by. This eliminates the need for tools and technicians to repeatedly enter and exit through small doorways, significantly reducing downtime while maintaining assembly access.
Solution Approach 2:
The continuous line track system acts as an intermediary, bringing the airframe component to stationary workstations where tools and technicians can work efficiently. This eliminates the need for personnel to physically enter the barrel sections through constrained doorways, reducing downtime while maintaining assembly capability.
3Ease of manufacture
If traditional assembly methods with frequent scanning and indexing are used, then airframe components can be assembled, but throughput is reduced and production efficiency decreases
Solution Approach 1:
The patent implements a continuous line assembly system where the airframe component moves continuously through the assembly line on a track, and workstations perform operations without interruption. This continuous action eliminates the downtime associated with frequent scanning and indexing, significantly increasing throughput and production efficiency while maintaining full assembly capability.
Data Source
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AI summary
Systems and methods are provided for assembling an aircraft (10). The method may include receiving an upper half barrel section (116, 126) of fuselage (12) that is in a crown up orientation, and installing a crown module (364) into the upper half barrel section (116, 126). The method may include a method for fabricating a crown module (364), comprising pulsing a ceiling grid in a process direction (199), providing additional components (162) for the crown module (364) just in time to a plurality of work stations (152) that perform assembly of the crown module (364); and operating the work stations (152) to assemble the crown module (364) during pauses between pulses.