Eddy Current Gap Sensing for Precise Aircraft Panel Assembly
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Solution Overview
Problem
Current aircraft fuselage and wing assembly processes require significant manual intervention for precise spacing checks, which are time-consuming and prone to errors, as they rely on intrusive measurements that can disrupt the assembly process.
Innovation Solution
An automated system utilizing eddy current sensors to determine and adjust the spacing between parts during assembly, guided by positioning aid means, allowing for non-destructive, real-time monitoring and control of the assembly process to ensure precise alignment and secure fixing without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement methods (calibrated wedges or probes) are used to check spacing, then measurement can be performed, but operator intervention is required and the process is time-consuming
Solution Approach 1:
The patent replaces manual mechanical measurement tools (calibrated wedges and probes) with an automated optical measurement system. The system uses a camera to capture images of the assembly zone and automatically processes these images to determine spacing between parts, eliminating the need for operator intervention and manual measurement operations.
Solution Approach 2:
The measurement system performs self-assessment by automatically capturing images, processing them through image analysis algorithms, and determining spacing values without requiring operator intervention. The system autonomously completes the entire measurement process from image capture to spacing determination.
2Measurement precision
If intrusive measurement methods (probes) are used, then spacing can be measured, but the measurement process can interact with and modify the spacing during measurement
Solution Approach 1:
The patent replaces intrusive mechanical probes with a non-contact optical measurement system. The camera-based system captures images of the assembly zone and determines spacing through image processing, completely avoiding physical contact with the parts being measured and thus eliminating measurement-induced spacing modifications.
3Reliability
If multiple spacing checks are performed manually, then comprehensive spacing verification is achieved, but the assembly process is significantly extended
Solution Approach 1:
The patent combines multiple measurement functions into a single automated system. One camera captures images of the entire assembly zone, and image processing algorithms simultaneously analyze multiple locations to determine spacing between different parts, replacing the need for multiple separate manual measurement operations.
Solution Approach 2:
The automated measurement system operates continuously during the assembly process, capturing images and determining spacing in real-time without interrupting the assembly workflow. This eliminates the time loss associated with stopping the assembly process for manual measurements.
4Manufacturing precision
If automated positioning tools are used to bring parts into contact, then positioning precision is improved, but manual assessment of the gap is still required
Solution Approach 1:
The patent replaces manual gap assessment with an automated optical measurement system. The camera-based system captures images of the assembly zone and automatically processes these images to determine spacing, completing the automation chain from positioning to measurement without requiring operator intervention.
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
This system reduces assembly time, enhances precision, and improves reliability by enabling simultaneous multi-point measurements and non-destructive testing, minimizing operator intervention and ensuring accurate spacing without disrupting the assembly process.
Implementation Method 1
a set of eddy current sensors intended to be positioned in at least one of said at least two parts, said control means being configured for the acquisition of the signals coming from the sensors of the set of sensors, to determine the spacing of said at least two parts
Data Source
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AI summary
A system for assembling two parts (A, B), particularly parts forming the fuselage (100) or wing of an aircraft, includes positioning aids (400) that guide positioning tools to juxtapose the two parts (A, B) at an assembly area (300). The assembly system further includes a set of eddy current sensors (20) positioned in at least one of the two parts (A, B) to determine the gap (d) between the two parts (A, B) at the assembly area (300). If the gap (d) does not conform to a predetermined criterion, the positioning tools move at least one of the parts (A, B).