Flexible Member Assembly Using Contour-Matching Pogo Fixtures
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Solution Overview
Problem
Conventional methods for assembling aircraft components, such as side-of-body chords and wing panels, often require extensive manual force due to non-complementary contours, leading to inefficiencies and increased production time.
Innovation Solution
A system utilizing a dimensional reader and positioning fixture with axially movable reader and positioning pogos, coupled with an automated handling mechanism, to measure and clamp a flexible member into a contour complementary to the detail, allowing for automated assembly without manual force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual force is applied to install the side-of-body chord onto the wing panel, then the components can be assembled, but the assembly process becomes time-consuming and labor-intensive
Solution Approach 1:
The system performs preliminary measurement of the wing panel contour using reader pogos before the actual assembly operation. This advance measurement allows the positioning pogos to be pre-configured with the correct positions, enabling the side-of-body chord to be installed without time-consuming manual force application during the assembly operation itself.
Solution Approach 2:
The patent replaces manual mechanical force application with an automated positioning system. The positioning pogos, controlled by a computer based on measured contour data, automatically deflect the flexible member into the correct contour, eliminating the need for manual force and reducing assembly time.
2Productivity
If manual force is applied to install the side-of-body chord, then assembly can be completed, but the process requires extensive manual labor
Solution Approach 1:
The system is self-servicing in that it automatically measures the wing panel contour, processes the measurement data, and positions the side-of-body chord without requiring manual intervention. The reader pogos measure, the computer processes, and the positioning pogos execute the assembly, creating an autonomous assembly process that eliminates manual labor.
Solution Approach 2:
Manual mechanical operations are replaced by an automated computer-controlled system. The positioning pogos are actuated by a computer based on measured contour data, substituting manual labor with automated mechanical positioning that improves productivity while reducing the need for manual operation.
3Adaptability or versatility
If the side-of-body chord is fabricated with non-complementary contour, then manufacturing flexibility is improved, but the component cannot fit without extensive force
Solution Approach 1:
The system performs preliminary measurement of the actual wing panel contour before assembly. This advance measurement allows the positioning system to compensate for any non-complementary contours in the side-of-body chord by deflecting it into the correct shape during positioning, eliminating the need for extensive installation force.
Solution Approach 2:
The patent changes the physical state of the flexible member by deflecting it into the correct contour using positioning pogos. This parameter change in the flexible member's shape, controlled by the positioning system, allows non-complementary contours to be adjusted during assembly without requiring extensive installation force.
4Extent of automation
If automated handling mechanism is used, then assembly automation is improved, but the system complexity increases
Solution Approach 1:
The positioning fixture serves multiple functions: it holds the wing panel, positions the side-of-body chord, and provides the measurement reference. The pogos serve dual purposes as both measurement probes and positioning elements. This multi-functionality reduces overall system complexity while maintaining high automation.
Solution Approach 2:
The system creates a digital copy of the wing panel contour through measurement, then uses this copied information to control the positioning process. This copying approach allows automation without requiring complex physical guides or templates, simplifying the automated system while maintaining precision.
Data Source
AI summary
A method of assembling a detail to a flexible member includes positioning the detail against a plurality of reader pogos, and axially displacing the plurality of reader pogos to substantially conform to a detail contour. The method additionally includes recording reader pogo position data representing the detail contour, clamping a flexible member against a plurality of positioning pogos, and axially displacing the plurality of positioning pogos complementary to the reader pogo position data. In addition, the method includes deflecting, using the positioning pogos, the flexible member into a contour corresponding to the reader pogo position data, and assembling the detail to the flexible member.