Fractional Pulse Fuselage Line for Indexed Aircraft Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current aircraft assembly processes require frequent scanning and indexing of airframe components in fixed cells, leading to inefficiencies and increased operational costs due to the need for constant reconfiguration and alignment of tools and equipment.
Innovation Solution
A system and method involving a series of plates affixed along the length of a fuselage section, forming a frictional fit with a track, where drive units advance the section incrementally and indexing elements engage to pause and stabilize the section for work, allowing tools to perform operations without re-alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If fixed cells with frequent scanning and indexing are used, then tools and equipment can be brought to each portion of the structure, but operational downtime increases and throughput decreases
Solution Approach 1:
The system transitions from static fixed cells to a dynamic continuous track system where the fuselage section moves continuously through the assembly line. The fractional pulsing mechanism allows the fuselage to be advanced in controlled increments while maintaining overall continuous motion, eliminating the need to stop and reconfigure tools at each cell.
Solution Approach 2:
The track system serves multiple functions simultaneously: it transports the fuselage section, provides positioning references for tools, enables fractional pulsing, and maintains alignment across multiple work stations. This multi-functional track eliminates the need for separate scanning and indexing operations at each cell.
2Manufacturing precision
If frequent scanning and indexing operations are performed, then structure alignment is maintained, but operational time increases and efficiency decreases
Solution Approach 1:
The fuselage section is pre-aligned with the track system before assembly operations begin. The track itself provides continuous alignment references, eliminating the need for repeated scanning and indexing operations during the assembly process. Tools are pre-positioned relative to the track, ensuring consistent alignment throughout.
Solution Approach 2:
The patent replaces the mechanical scanning and indexing operations with a continuous optical or electronic tracking system integrated into the track. The track incorporates alignment features that can be detected by sensors, providing continuous position feedback without requiring physical contact or mechanical reconfiguration.
3Adaptability or versatility
If fixed assembly cells are used with full reconfiguration for each structure, then each portion can be worked upon, but space requirements and device complexity increase
Solution Approach 1:
The assembly system is divided into multiple work stations arranged along the continuous track, each capable of performing specific operations on different portions of the fuselage section. The fuselage itself is segmented into multiple sections that can be independently positioned and worked on, allowing parallel operations without requiring full system reconfiguration.
Solution Approach 2:
The system uses dynamic positioning where the fuselage section can be pulsed to specific positions along the track for different operations. Tools and work stations remain fixed, but the fuselage moves dynamically to bring different portions to the appropriate work stations, eliminating the need to reposition heavy equipment.
4Productivity
If continuous movement along track is used, then throughput increases, but control precision and positioning accuracy may be compromised
Solution Approach 1:
The continuous movement is interrupted by periodic fractional pulsing operations where the fuselage is advanced in controlled increments and held at each position for assembly operations. This periodic stopping and starting allows precise positioning at each work station while maintaining overall continuous flow through the system.
Solution Approach 2:
The track system acts as an intermediary between the moving fuselage and the fixed work stations. It provides a stable reference frame with encoded position information that enables precise measurement and control of the fuselage position, allowing accurate positioning even during continuous movement.
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 operational downtime, increases throughput, and minimizes space requirements by enabling synchronized work on multiple sections with reduced need for tool alignment, enhancing the efficiency and accuracy of aircraft assembly.
Implementation Method 1
a track configured to form a frictional fit with the plates. The track includes drive units configured to form nips retaining the series of plates
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
Systems and methods are provided for advancing a fuselage section (330) of an aircraft. One embodiment is a system that includes a series (329) of plates (320) configured to be sequentially affixed along a length (L) of the fuselage section (330), and a track (310) configured to form a frictional fit with the plates. The track (310) includes drive units (312) configured to form nips retaining the series of plates (320), and that are configured to advance the fuselage section (330) along the track (310) in a process direction, and indexing elements (316) that are configured to engage with indexing elements (326) at the plates (320) during pauses between operation of the drive units (312). The system also includes tools (360, 370) configured to perform work on the fuselage section (330) while the indexing elements (316) of the track (310) are engaged.