Automated Fuselage Section Alignment System
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Solution Overview
Problem
The current method for joining composite fuselage sections in aircraft manufacturing is time-consuming and labor-intensive, often resulting in an undesired fit due to shape variations, which can lead to increased fuel consumption and noise during flight.
Innovation Solution
A system comprising a cradle, metrology, and controller that measures and adjusts the shape of fuselage sections using forces applied by actuators or a weight system to achieve a precise fit, utilizing optical metrology for non-contact measurements and feedback loops to ensure accurate alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operators manually measure and adjust fuselage section shapes using feeler gauges and jacks, then the process is flexible and adaptable, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent replaces manual mechanical measurement tools (feeler gauges) and adjustment tools (jacks) with an automated optical measurement system and computer-controlled positioning system. The optical scanner captures 3D data of fuselage section ends, and a computer automatically calculates and controls the positioning of sections to achieve precise alignment, eliminating manual measurement and adjustment operations while dramatically increasing productivity.
Solution Approach 2:
The system enables the fuselage sections to be automatically measured, analyzed, and positioned without human intervention. The optical measurement system autonomously captures geometric data, the computer autonomously processes the data to determine alignment requirements, and the positioning system autonomously adjusts the sections to achieve the desired fit, making the entire joining process self-service and highly efficient.
2Ease of manufacture
If fuselage sections are manufactured with variations from design specification, then manufacturing is more feasible, but the shape accuracy at the ends deteriorates
Solution Approach 1:
The patent implements a feedback loop where the optical measurement system scans the actual geometry of fuselage section ends, the computer compares measured dimensions against design specifications to identify deviations, and the positioning system automatically compensates for these deviations by adjusting the relative positions of sections. This feedback mechanism allows the system to accommodate manufacturing variations while achieving precise alignment and fit.
Solution Approach 2:
The system dynamically changes the positioning parameters (location, orientation, and alignment) of fuselage sections based on measured geometric data. Instead of requiring strict adherence to nominal design dimensions during manufacturing, the system adjusts positioning parameters to compensate for actual manufacturing variations, thereby achieving the desired fit despite deviations from design specifications.
3Ease of manufacture
If fuselage sections are large enough to be manufactured in sections, then manufacturing is more practical, but gravity causes deformation that changes the shape
Solution Approach 1:
The patent applies preliminary measurement and compensation actions before the joining operation. The optical measurement system scans the fuselage sections while they are in their current (deformed) state, the computer calculates the precise positioning required to achieve the desired fit accounting for gravity-induced deformation, and the positioning system pre-positions the sections accordingly. This preliminary action ensures that even deformed sections achieve the correct fit when joined.
4Productivity
If the ends of fuselage sections do not have a desired shape, then joining is simpler, but the fit quality deteriorates
Solution Approach 1:
The patent replaces manual mechanical adjustment methods with an automated optical measurement and computer-controlled positioning system. The optical scanner rapidly captures 3D data of the actual end geometries, the computer automatically calculates the precise positioning required to achieve the desired fit, and the positioning system automatically adjusts the sections. This automated system maintains joining simplicity while dramatically improving fit quality by eliminating manual measurement and adjustment errors.
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 the time and labor required for joining fuselage sections, achieving a desired level of fit that enhances aircraft performance by minimizing fuel consumption and noise.
Implementation Method 1
The metrology system makes measurements of the current shape of the first fuselage section
Implementation Method 2
The system applies forces to the first fuselage section to change a current shape of the first fuselage section
Data Source
AI summary
A method and apparatus for processing fuselage sections. A first fuselage section is held in a cradle system. A current shape of the first fuselage section in the cradle system is measured. Forces to change the current shape of the first fuselage section to a desired shape for connecting the first fuselage section to a second fuselage section are identified. The forces identified are applied using a system to change the current shape of the first fuselage section towards the desired shape.