Dome Pressure Bulkhead Installation in Aircraft Tail Sections
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Solution Overview
Problem
The integration of a pressure bulkhead into a one-piece CFRP tail section for an aircraft fuselage poses challenges due to the lack of tolerance compensation and complex production technology, especially with the vertical installation of a dome-shaped pressure bulkhead, which complicates the assembly process and increases weight.
Innovation Solution
A method involving horizontal assembly and pivoting of the tail section using a swing frame to center and join the pressure bulkhead, allowing for horizontal positioning and alignment, followed by vertical integration with a self-centering mechanism, and the use of a device comprising pre-assembly, joining, and pressure bulkhead construction sites with drilling and riveting capabilities to facilitate efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a one-piece CFRP tail section is used to reduce weight, then weight savings are achieved, but tolerance compensation becomes impossible when integrating a pressure bulkhead
Solution Approach 1:
The tail section is divided into multiple CFRP shells that are assembled together to form the one-piece structure. This segmentation allows for tolerance compensation during assembly while maintaining the weight benefits of a unified structure. The pressure bulkhead is integrated into this segmented construction process.
Solution Approach 2:
The pressure bulkhead is pre-positioned and centered in the connection area before final assembly. This preliminary action enables tolerance compensation by allowing adjustments to be made during the assembly process rather than requiring perfect precision in the final positioning.
2Strength
If a vertical pressure bulkhead installation is used, then structural integrity is maintained, but the production process becomes complex with different working heights
Solution Approach 1:
Instead of installing the pressure bulkhead vertically in the conventional manner, the method inverts the approach by first positioning the bulkhead horizontally in the connection area, then pivoting the entire tail section to a vertical position. This inversion simplifies the production process by providing uniform working heights during assembly while maintaining structural integrity through the final vertical orientation.
Solution Approach 2:
The tail section is made dynamic through the use of a pivoting frame that allows transition between horizontal and vertical positions. This dynamic capability enables simplified horizontal assembly with uniform working heights, then transforms to the required vertical installation position for structural integrity.
3Ease of operation
If a horizontal assembly position is used for the pressure bulkhead, then working height is simplified and self-centering is achieved, but additional pivoting equipment is required
Solution Approach 1:
The pivoting frame serves multiple functions: it provides horizontal positioning for simplified assembly and self-centering, enables the tail section to be rotated to vertical position for final installation, and supports the entire tail section during the transition. This multi-functionality justifies the additional equipment by eliminating the need for multiple separate positioning systems.
Data Source
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AI summary
The invention relates to a method for installing an especially dome-shaped pressure bulkhead 5,25 on a one-piece, substantially conical rear section 1,13,18 of an aircraft, wherein said rear section comprises a connection area 3,35 and an end area 9, comprising the steps: a) horizontally accommodating a prefabricated rear section 1,13,18 in a horizontal support 12, b) inserting the rear section 1,13,18 into a pivoting frame 17, c) pivoting the rear section 1,13,18 into a vertical position using the pivoting frame 17, wherein the connection area 3,35 of the rear section 1,13,18 points upward, d) horizontally placing and centering the pressure bulkhead 5,25 on the connection area 3,35, and e) joining of the pressure bulkhead 5,25 with the rear section 1,13,18 in the area of the connection area 3,35. Because the rear section 1,13,18 is in a vertical position during the installation of the pressure bulkhead, the pressure bulkhead 5,25 to be integrated can be oriented in a horizontal position in relation to a connection area 3,35 of the rear section 1,13,18, positioned, and joined with the connection area 3,35 using a preferably combined drilling and riveting device 19 with a gantry design. The invention further relates to an apparatus 10 for carrying out the method using a pivoting frame 17 for tilting the rear section 1,13,18 into a vertical position for installing the pressure bulkhead 5,25.