Fastener Stackup Selection for Tolerance-Driven Aircraft Assembly
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Solution Overview
Problem
In aircraft assembly, the variation in manufacturing tolerances leads to significant dimensional differences in fastener components, making it challenging to determine the correct fastener components for secure joining without individual measurement of each assembly fastener location, resulting in inefficiencies and potential misalignment.
Innovation Solution
A method and system that measure the dimensions of parts and available fastener components, determine the part stackup dimensions, and select appropriate fastener components based on criteria to ensure secure assembly, using a data processing system to identify the necessary fastener components before assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual measurement of each assembly fastener location is performed to determine correct fastener components, then manufacturing precision is improved, but productivity deteriorates due to time-consuming measurements and selections
Solution Approach 1:
The system performs preliminary determination of fastener components by receiving nominal dimensions of parts and calculating the required fastener specifications before the actual assembly process. This allows mechanics to know in advance which fastener components are needed, eliminating the need for on-site measurements and selections during assembly.
Solution Approach 2:
The system uses nominal design dimensions as a representative model to determine fastener requirements, creating a virtual representation of the assembly that allows fastener selection without physically measuring each location. This copying approach maintains precision while dramatically reducing time requirements.
2Productivity
If fastener components are selected based on nominal design dimensions without accounting for tolerance variations, then productivity is improved, but manufacturing precision deteriorates due to accumulated dimensional variations
Solution Approach 1:
The system incorporates tolerance parameters into the fastener determination calculation. By receiving tolerance values for each part and performing a stackup analysis, the system adjusts the nominal dimensions to account for accumulated variations, determining fastener components that will work across the full range of expected dimensional variations.
3Adaptability or versatility
If on-site measurement and selection of fastener components is performed, then adaptability is improved, but loss of time increases due to individual location processing
Solution Approach 1:
The system determines all fastener components for an assembly in advance by processing the nominal dimensions and tolerances of all parts together. This preliminary calculation provides a complete fastener list that adapts to the specific assembly configuration without requiring time-consuming on-site measurements.
Data Source
AI summary
Systems and methods are used to determine a defined fastener for fastening two parts together at an assembly fastener location. The defined fastener comprises fastener components selected from a plurality of different fastener components available for use in an assembled fastener. The fastener components of the defined fastener may be selected based on criteria defining characteristics of an assembly stackup including the two parts and the assembled defined fastener. Dimensions of the two parts at respective fastener locations forming the assembly fastener location may be used to determine a part stackup dimension for the assembled fastener at the assembly fastener location.