Curved Rail Assembly for Precise Aircraft Fuselage Interior Alignment
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Solution Overview
Problem
Automating internal assembly of aircraft fuselages is challenging due to restricted accessibility, requiring costly and complex metrological systems for accurate tool alignment, which complicates the process and increases installation effort.
Innovation Solution
A simplified linear mechanical system with two assembly rails and a movable assembly axis that follows the curvature of the fuselage, allowing tools to be automatically aligned without additional measurements, using lightweight design and modular components for adaptability to complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If robot-based approaches with costly measuring systems are used to achieve accurate tool alignment inside the fuselage, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex optical/mechanical measuring systems with a purely mechanical guidance system. The tool carrier unit is guided along rails that are fixed to the fuselage, and the tool axis is mechanically constrained to remain perpendicular to the fuselage surface through the rail geometry itself, eliminating the need for separate measurement and control systems
Solution Approach 2:
The rail system automatically provides the necessary alignment and positioning functions without requiring external measuring devices. The geometry of the rails inherently ensures that the tool carrier moves along the correct path and maintains proper orientation, making the system self-aligning and self-positioning
2Manufacturing precision
If complex metrological or mechanical systems are used to achieve exact vertical alignment of tools, then manufacturing precision is improved, but ease of operation and installation effort worsen
Solution Approach 1:
The rails are designed with curvature that matches the fuselage surface geometry, allowing the tool carrier to follow the contoured surface while maintaining perpendicular tool alignment. This curved rail design naturally adapts to the fuselage shape without requiring complex adjustment mechanisms
Solution Approach 2:
Complex adjustment mechanisms and metrological systems are replaced by a simple mechanical rail-guided system where the rail geometry itself provides the alignment function, significantly simplifying installation and operation
3Extent of automation
If automated assembly systems with measuring devices are implemented inside the fuselage, then extent of automation is improved, but device complexity increases
Solution Approach 1:
Electronic measuring and control systems are replaced with a mechanical guidance system where the rail geometry provides automatic guidance and positioning. The automation is achieved through the mechanical constraints of the rail system rather than through complex sensors and control algorithms
Solution Approach 2:
The patent extracts and eliminates the measuring and control systems from the automated assembly process, relying instead on the inherent mechanical guidance provided by the rail system to achieve automation with minimal complexity
Data Source
AI summary
An assembly system for an automated internal assembly on a curved assembly surface of an aircraft fuselage includes two assembly rails shaped in accordance with a curvature of the assembly surface such that they follow a longitudinal direction or a peripheral direction of the aircraft fuselage, so that the assembly rails are fastenable in the aircraft fuselage, along the longitudinal direction or along the peripheral direction of the aircraft fuselage, parallel to one another and parallel to the assembly surface of the aircraft fuselage; an assembly slide configured to slide along the assembly rails; and a tool supported by the assembly slide and configured to perform an assembly step; wherein the assembly slide has an assembly axis, along which the tool is movable relative to the assembly slide; and wherein the assembly axis is configured such that it follows the curvature of the assembly surface of the aircraft fuselage.