Dynamic Sequence Control for Aircraft Riveting Throughput
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Solution Overview
Problem
The existing methods for controlling clocked production lines in aircraft manufacturing face challenges in optimizing workpiece throughput due to varying sequences and occupancy of rivet processing stations, which require different sets of operations and are inefficient in handling structural components of different longitudinal dimensions.
Innovation Solution
The method involves re-evaluating and optimizing the processing sequence for each production cycle based on the expected or actual occupancy of the work area, considering structural components as sections, determining pending operations, and generating an optimized program flow from individual NC program parts to increase throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the fuselage sections are conveyed sequentially through the work area in a fixed cyclic sequence, then the production line operates with a predetermined rhythm, but the workpiece throughput cannot be optimized when different sections require different processing operations
Solution Approach 1:
The production line transitions from a fixed cyclic sequence to a dynamic, adaptive processing sequence. The control system continuously monitors the occupancy status of the work area and adjusts the processing sequence for each production cycle based on current conditions, allowing the system to adapt to varying fuselage section configurations and optimize throughput dynamically
Solution Approach 2:
The system implements feedback by determining the actual occupancy of the work area with fuselage sections before planning the processing sequence. This feedback mechanism allows the control system to make informed decisions about which operations to perform and in what sequence, optimizing throughput based on real-time production conditions
2Adaptability or versatility
If the work area is occupied by sections of different fuselage sections simultaneously, then the processing station can handle multiple components, but the programming must account for varying sequences and occupancy patterns
Solution Approach 1:
The system segments the fuselage sections into discrete units with specific processing requirements. Each section is analyzed independently to determine its occupancy status and required operations, allowing the control system to manage complex multi-section configurations through systematic breakdown rather than monolithic programming
Solution Approach 2:
The system changes operational parameters dynamically based on the specific configuration of fuselage sections in the work area. Instead of fixed programming, the control system adjusts processing sequences, operation selection, and resource allocation according to the actual occupancy patterns and section characteristics
3Productivity
If the processing sequence is optimized for each production cycle based on expected or actual occupancy, then the workpiece throughput increases, but the system requires real-time determination of occupancy and operations
Solution Approach 1:
The control system performs self-service by automatically determining the occupancy status and generating optimized processing sequences without external intervention. The system monitors its own work area, identifies pending operations, and plans the processing sequence autonomously, reducing the need for manual programming and operation complexity
Data Source
Figure 1
AI summary
The method involves processing mechanical operations e.g. riveting operations at each structural component section. Structural components (2a-2f) are successively conveyed through working areas (8a-8e) of processing stations (3a-3e). The areas are allocated with the components and/or the section according to a production cycle. A processing sequence is determined for the cycle. Estimated or actual allocation of the areas is determined. The operations are determined from the allocation. The sequence is optimized by the operations. The optimized sequence for automatic processing is stored. An independent claim is also included for a sequence control system for a linked production line for processing airplane-structural components.