Flexible Track System for Curved Fuselage Alignment
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Solution Overview
Problem
Current track systems used in aircraft manufacturing fail to maintain a constant distance from the fuselage surface, particularly in curved sections, leading to incorrect fastener installation due to deviations in distance or angle, which affects the accuracy and efficiency of manufacturing operations.
Innovation Solution
A vacuum track manufacturing system with flexible tracks and a variable height base system that adjusts to maintain a desired distance and angle relative to the fuselage surface, using vacuum cups and a positioning system to ensure accurate alignment and operation of crawler robots for manufacturing tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a fixed track system is used, then the structure is simple and stable, but the track cannot maintain a constant distance from the curved fuselage surface
Solution Approach 1:
The track system employs adjustable height bases that can dynamically change their vertical position to accommodate the varying curvature of the fuselage surface. Each base unit includes height adjustment mechanisms that allow the track to adapt its profile while maintaining structural stability during manufacturing operations.
Solution Approach 2:
The system changes the height parameter of individual track segments relative to the fuselage surface. By adjusting the height of each base unit independently, the track can conform to curved surfaces while maintaining a constant working distance from the skin, resolving the contradiction between stability and adaptability.
2Adaptability or versatility
If the track distance from the fuselage surface varies, then the track can follow curved surfaces, but fastener installation accuracy deteriorates
Solution Approach 1:
Each base unit in the track system has independent height adjustment capability, allowing local adaptation to the fuselage contour while maintaining uniform working distance at the tool interface. This local quality adjustment ensures that while the track follows the curve, the manufacturing tools maintain precise positioning relative to the skin surface.
Solution Approach 2:
The track is divided into multiple segmented base units, each capable of independent height adjustment. This segmentation allows different portions of the track to adapt to local curvature variations while maintaining overall track integrity and consistent tool positioning accuracy throughout the fuselage section.
3Strength
If a rigid track system is used, then the structure is stable, but the system cannot adjust to different fuselage curvatures
Solution Approach 1:
The track system transitions from a completely rigid structure to a dynamically adjustable system where individual base units can change height independently. This dynamic capability allows the track to adapt to various fuselage curvatures while maintaining structural strength through the rigid track beams and secure mounting mechanisms.
Solution Approach 2:
The track system incorporates flexible elements in the form of adjustable height bases that can bend or extend to match fuselage curvature. These flexible base units connect rigid track segments, creating a hybrid structure that maintains strength while achieving the flexibility needed to follow curved surfaces.
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
Enables precise and automated manufacturing operations by maintaining the required distance and angle, allowing crawler robots to perform tasks like drilling and fastener installation with improved accuracy and efficiency, even on curved surfaces.
Implementation Method 1
These types of tracks are often attached to the surface of the fuselage using a vacuum system in which vacuum cups connected to the tracks apply a vacuum to hold the tracks on the surface of the fuselage.
Data Source
AI summary
A method for installing a flexible track system is presented. At least one of a number of heights or a number of angles is selected for a variable height base system that connects a base attaching system and flexible tracks in the flexible track system to each other, wherein at least one of the number of heights or the number of angles for the variable height base system maintains at least one of a desired distance between the flexible tracks and a surface of a structure to which the base attaching system is attached to the flexible tracks in the flexible track system matching a contour of the surface of the structure. The flexible track system is attached to the surface of the structure.