Eddy Current Sensor Assembly for Aircraft Part Separation Control
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Solution Overview
Problem
The current aircraft fuselage and wing assembly process relies heavily on manual operator intervention for verifying the separation between parts, which is time-consuming and prone to errors, as it involves intrusive measurements that can modify the separation values.
Innovation Solution
A system utilizing eddy current sensors to automatically determine the separation between parts at the assembly zone, guiding positioning tools to adjust the parts until the predetermined criterion is met, thereby eliminating the need for manual verification and ensuring non-destructive testing methods are used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual operator intervention is used to verify separation between parts, then measurement can be performed, but assembly time increases and reliability decreases
Solution Approach 1:
The patent replaces manual mechanical measurement operations with an automated sensor-based measurement system. Eddy current sensors and laser trackers automatically measure separation distances between parts, eliminating the need for operators to manually insert calibrated shims or probing devices. This substitution of mechanical manual operations with automated sensing systems simultaneously improves reliability (through consistent automated measurements) and reduces assembly time (by eliminating repetitive manual verification steps).
Solution Approach 2:
The measurement system performs self-verification by automatically comparing measured separation values against predetermined acceptance criteria. The system autonomously determines whether parts meet assembly specifications without requiring continuous operator intervention for evaluation and decision-making. This self-service capability enhances reliability through consistent criterion application and reduces time loss by eliminating the operator verification loop.
2Measurement precision
If intrusive measurement methods are used to verify separation, then separation can be measured, but the measurement action modifies the separation values
Solution Approach 1:
The patent replaces intrusive mechanical measurement methods (such as inserting calibrated shims or probing devices between parts) with non-contact or minimally intrusive eddy current sensors and laser trackers. These sensors measure separation distances through electromagnetic fields or light without physically inserting objects into the measurement space. This substitution eliminates the modification effect caused by intrusive tools while maintaining high measurement precision through sophisticated sensing technology.
Solution Approach 2:
The patent introduces electromagnetic fields (via eddy current sensors) and laser beams as intermediary measurement media that can determine separation distances without direct physical contact between measurement tools and the parts being measured. These intermediary fields allow precise measurement of the separation gap without the measurement tool itself altering the gap dimensions, thus preserving manufacturing precision while achieving measurement accuracy.
3Productivity
If automated positioning tools are used to juxtapose parts, then positioning speed increases, but automated verification of separation is still required
Solution Approach 1:
The patent merges the positioning function and verification function into an integrated automated system. The same sensor array (eddy current sensors and laser trackers) that monitors part positions during automated positioning also performs verification by comparing measured separations against acceptance criteria. This merging eliminates the need for separate verification equipment and operations, maintaining high positioning speed while managing device complexity through functional integration rather than adding independent verification subsystems.
Solution Approach 2:
The measurement system serves multiple functions: it continuously monitors part positions during automated positioning operations and simultaneously performs verification by checking whether separations meet specifications. This multi-functionality allows the system to maintain high productivity through continuous automated operations while avoiding the complexity of separate dedicated verification equipment. The universal sensor system handles both real-time positioning feedback and final verification requirements.
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 approach reduces assembly time, enhances reliability by automating the verification process, and allows for simultaneous multi-point separation measurements, improving the efficiency and accuracy of the assembly operations.
Implementation Method 1
a set of eddy current sensors (20) intended to be positioned in at least one of the at least two parts (A, B), the control means (500) being configured to acquire signals emanating from the sensors of the set of sensors (20) to determine the separation of the at least two parts (A, B)
Data Source
AI summary
A system for assembling two parts, in particular parts forming the fuselage or the wings of an aircraft, includes a positioning aid guiding positioning tools so as to juxtapose the two parts at the level of an assembly zone. The assembly system further includes a set of eddy current sensors positioned in at least one of the two parts to determine the separation of the two parts at the level of the assembly zone. If the separation does not conform to a predetermined criterion the positioning tools move at least one of the parts.