Fuselage Alignment System Using Transmitter-Reflector Targets
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Solution Overview
Problem
Current alignment systems for fuselage structures in aerospace vehicles are time-consuming and labor-intensive, requiring numerous manual measurements and trial-and-error calculations to achieve assembly alignment.
Innovation Solution
A system comprising transmitters and reflector targets indexed to seat tracks on fuselage structures, coupled with a manipulator system, to provide precise measurements for automatically moving fuselage structures into alignment, reducing human intervention and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual measurement and trial-and-error methods are used for fuselage alignment, then measurement flexibility is maintained, but alignment time and labor requirements increase significantly
Solution Approach 1:
The patent replaces manual mechanical measurement tools with an automated optical measurement system using transmitters and reflector targets. This substitution eliminates the need for hand tools and manual measurement processes, directly reducing alignment time while the automated calculation system handles the complexity of processing measurement data.
Solution Approach 2:
The measurement system is designed to be self-sufficient by automatically acquiring measurements from multiple transmitters and reflector targets, then autonomously calculating the required fuselage structure movements. This self-service capability eliminates the need for numerous human operators to manually record and process measurements, significantly reducing labor requirements.
2Productivity
If numerous separate measurements are acquired using hand tools, then measurement coverage is comprehensive, but labor intensity and operational complexity increase
Solution Approach 1:
The patent merges multiple separate measurement operations into a single integrated automated system. Instead of using numerous hand tools for separate measurements, the system combines multiple transmitters and reflector targets into one coordinated measurement network that simultaneously captures all necessary alignment data, dramatically improving productivity.
Solution Approach 2:
The patent introduces transmitters and reflector targets as intermediary elements between the fuselage structures and the measurement system. These intermediaries enable automated measurement acquisition without requiring direct human intervention for each measurement point, simplifying operation while maintaining comprehensive measurement coverage.
3Measurement precision
If manual recording and uploading of measurements is performed, then data accuracy can be verified, but time consumption and labor requirements increase
Solution Approach 1:
The patent replaces manual recording and data upload processes with automated electronic data capture and transmission. The measurement system directly transmits position data from transmitters and reflector targets to the calculation system, eliminating manual recording steps while maintaining measurement precision through automated data acquisition.
4Extent of automation
If trial-and-error methods are used to calculate fuselage movement distances, then flexibility in adjustment is maintained, but the number of iterations and time required increase
Solution Approach 1:
The patent replaces trial-and-error calculation methods with an automated computational system that directly calculates the required fuselage structure movements based on measured position data. This substitution eliminates iterative adjustments while the calculation system handles the complexity of determining precise movement distances and directions.
Solution Approach 2:
The patent implements a feedback mechanism where the measurement system continuously monitors fuselage structure positions and the calculation system determines required adjustments. This closed-loop feedback enables automated alignment without trial-and-error iterations, as the system directly computes the corrective movements needed based on real-time position measurements.
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
The system significantly reduces the time and labor required for fuselage alignment, enabling quicker manufacturing turnaround with enhanced precision and accuracy, allowing for automated or manual alignment based on continuous position measurements.
Implementation Method 1
The first transmitter and the first reflector target cooperate to provide a first measurement indicative of position of the first fuselage structure relative to the second fuselage structure
Data Source
AI summary
A system for moving first and second fuselage structures into assembly alignment, the system including a first transmitter indexed to a first seat track of the first fuselage structure, a first reflector target indexed to a first seat track of the second fuselage structure, a second transmitter indexed to a second seat track of the first fuselage structure, a second reflector target indexed to a second seat track of the second fuselage structure, wherein the first and second transmitters and the first and second reflector targets cooperate to provide first and second measurements indicative of position of the first fuselage structure relative to the second fuselage structure, and a manipulator system including at least one assembly actuator coupled to the first fuselage structure to move the first fuselage structure into assembly alignment with the second fuselage structure based upon the first and second measurements.