Autonomous Fuselage Assembly Fixtures for Flexible Panel Joining
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Solution Overview
Problem
Current methods for building aircraft fuselages are labor-intensive, time-consuming, and costly, often requiring manual fastening processes that are inefficient and limited to specific assembly facilities.
Innovation Solution
An autonomous flexible manufacturing system comprising drivable towers, cradle fixtures, and an autonomous panel joining system, which automates the process of building a fuselage assembly by autonomously driving and positioning fixtures, and using autonomous tools to join panels and support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual fastening processes are used with human operators, then flexibility in assembly facility location is maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The autonomous assembly system is divided into separate functional modules including drivable towers, fixtures for positioning, and panel joining systems. Each module operates independently but coordinates through a control system, allowing the complex automation task to be managed through modular components rather than a monolithic system.
Solution Approach 2:
The drivable towers and fixtures are designed as multi-functional units that can perform multiple operations (positioning, fastening, inspection) and adapt to different assembly configurations. This universality reduces the overall number of specialized devices needed, managing system complexity while maintaining high automation capability.
2Productivity
If manual fastening operations are used, then system complexity remains low, but assembly time and labor costs increase
Solution Approach 1:
The autonomous fastening system operates continuously without interruption by coordinating multiple drivable towers and panel joining systems that work simultaneously on different sections of the fuselage. This eliminates idle time between operations and maintains continuous productive action throughout the assembly process.
Solution Approach 2:
Components such as skin panels and support members are pre-positioned using fixtures before the fastening operation begins. This preliminary positioning ensures that when the autonomous fastening system engages, all components are ready for immediate joining, eliminating setup time during the actual fastening process.
3Ease of operation
If handheld tools are used by human operators, then equipment cost is lower, but labor intensity and ergonomic challenges increase
Solution Approach 1:
Manual handheld fastening tools operated by human workers are replaced with autonomous panel joining systems mounted on drivable towers. These automated systems perform all fastening operations without human physical intervention, completely eliminating ergonomic challenges associated with manual tool operation while achieving high-level automation.
4Manufacturing precision
If current manual assembly methods are used, then assembly facility requirements are flexible, but assembly precision and mold line compliance may be inconsistent
Solution Approach 1:
The autonomous positioning system incorporates sensors and control systems that continuously monitor the position of skin panels and support members relative to mold line requirements. Real-time feedback allows the system to detect and correct positioning deviations, ensuring consistent precision without requiring overly complex mechanical positioning mechanisms.
Solution Approach 2:
The fixtures and drivable towers are designed with dynamic adjustment capabilities that allow real-time modification of positioning parameters during assembly. This dynamic adaptability enables the system to accommodate variations in component dimensions and achieve precise mold line compliance without requiring extremely rigid and complex fixed positioning structures.
Data Source
AI summary
A method and apparatus for building a fuselage assembly for an aircraft. A number of fixtures may be drive across a floor to an assembly area to form an assembly fixture. The fuselage assembly may be built on the assembly fixture.