Automated Flip Door Guardrail for Aircraft Assembly Safety

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Solution Overview

Problem

In airplane production facilities, the frequent manual handling of heavy removable guardrails poses risks of repetitive lift injuries and falls, as personnel need to manually rotate, install, and remove these guardrails during the pulsing of the production line.

Innovation Solution

A system featuring a bracket, flip door, guardrail, and actuator that allows for automated extension and retraction of a flip door and integrated guardrail, eliminating the need for manual handling by using electric linear actuators and a remote control system to adjust the configuration between extended and retracted positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual handling of removable guardrails is used, then the guardrails can be installed and removed, but personnel are at risk of repetitive lift injuries and falls

Engineering Contradiction:

ImproveGuardrail installation and removalVSAvoidPersonnel safety

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces the manual mechanical system with an automated motorized system. The guardrail assembly includes a motorized actuator that automatically raises and lowers the guardrail, eliminating the need for personnel to manually handle the heavy guardrail sections. This substitution of manual mechanical operation with automated mechanical operation resolves the contradiction by improving safety while maintaining operational capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The guardrail system is designed to be self-operating through the motorized actuator that automatically controls the guardrail's movement between raised and lowered positions. The system serves itself by detecting when the door is opened and automatically adjusting the guardrail position without requiring personnel intervention, thereby eliminating safety risks associated with manual handling

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If removable guardrails are manually installed and removed, then clearance is provided for airplane movement, but frequent handling leads to repetitive lift injuries

Engineering Contradiction:

ImproveClearance provision for production line pulsingVSAvoidFrequency of guardrail handling

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent implements a dynamic guardrail system that automatically transitions between raised and lowered positions based on production line requirements. The motorized actuator enables the guardrail to dynamically adjust its position without manual intervention, allowing the system to adapt to varying operational conditions (production line pulsing vs. normal operation) while eliminating the repetitive manual handling that causes injuries

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The automated motorized system replaces the manual mechanical handling process. The actuator automatically raises the guardrail to provide clearance during production line pulsing and lowers it for normal operation, eliminating the need for personnel to repeatedly install and remove guardrails, thereby resolving the contradiction between adaptability and ease of operation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If guardrails are manually removed and reinstalled, then access is provided for production line pulsing, but personnel face risk of falling or dropping guardrails

Engineering Contradiction:

ImproveProduction line pulsing capabilityVSAvoidPersonnel safety during guardrail handling

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces manual guardrail handling with an automated motorized system that safely raises and lowers the guardrail to provide clearance for production line pulsing. This substitution eliminates personnel exposure to fall hazards and prevents dropping incidents, thereby maintaining productivity while significantly improving reliability and safety

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The motorized actuator serves as an intermediary between the control system and the guardrail mechanism. It mediates the movement of the heavy guardrail sections, providing controlled and safe operation that eliminates direct personnel involvement in hazardous manual handling tasks while enabling production line pulsing operations

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution reduces the risk of injuries and falls by automating the process of rotating and positioning guardrails, enhancing safety and compliance with safety guidelines during aircraft assembly line pulsing activities.

Implementation Method 1

automated extension and retraction of a flip door and integrated guardrail, eliminating the need for manual handling by using electric linear actuators

Methodology Applied

Scientific EffectElectric linear actuator: Linear Motor

Implementation Method 2

a linkage further coupling the flip door portion to the guardrail portion

Methodology Applied

Scientific EffectMechanical linkage: Four-Bar Linkage

Data Source

PatentUS11773606B2Flip door-to-guardrail

Publication Date: 2023.10.03 THE BOEING CO

AI summary

The present disclosure relates systems and methods involving movable/adjustable platforms and/or guardrails. An example system includes a bracket configured to be coupled to a fixed structure having a walking surface. The system also includes a flip door portion rotatably coupled to the bracket and a guardrail portion rotatably coupled to the flip door portion. The system includes a linkage further coupling the flip door portion to the guardrail portion. The system yet further includes an actuator configured to controllably adjust a configuration of the flip door portion, the linkage, and the guardrail portion between an extended configuration and a retracted configuration with respect to the walking surface.