Automated Fuselage Assembly Using Movable Cradles
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Solution Overview
Problem
The assembly of large commercial aircraft fuselages is labor-intensive and production rates are subject to fluctuations due to heavy dependence on manual labor, leading to unstable production environments.
Innovation Solution
An automated facility with movable cradles and robots that can assemble fuselage panels in a single upright position, utilizing determinant assembly holes for precise panel alignment and fastening, and an automated guide vehicle system for efficient movement of cradles and robots across the assembly floor, reducing manual labor and increasing production stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual labor is used for assembling fuselage panels, then flexibility in assembly operations is maintained, but production rates fluctuate and production stability deteriorates
Solution Approach 1:
The assembly facility is divided into multiple independent cells, each capable of assembling fuselage panels. This segmentation allows the system to process multiple panels simultaneously while maintaining manageable complexity in each individual cell. The movable cradles are also segmented into discrete units that can be independently positioned and operated.
Solution Approach 2:
The movable cradles are designed as multi-functional units that can support various fuselage panel configurations and be repositioned to different locations. These cradles serve multiple purposes: positioning panels, supporting robotic operations, and enabling flexible cell reconfiguration. This universality reduces the need for specialized equipment for each assembly task.
2Adaptability or versatility
If fixed jigs and fixtures are secured to the floor for assembling panelized fuselages, then assembly precision is maintained, but facility flexibility and reconfigurability are reduced
Solution Approach 1:
The cradles are designed to be movable rather than fixed, allowing dynamic repositioning to different assembly locations. This mobility enables the facility to be reconfigured for different panel types and assembly sequences while maintaining precision through controlled positioning mechanisms and alignment systems during movement.
Solution Approach 2:
The movable cradles act as intermediary devices between the floor and the fuselage panels. Instead of directly securing fixtures to the floor, the cradles provide a mobile platform that interfaces with both the floor (for movement) and the panels (for precise positioning and support), thereby mediating between flexibility and precision requirements.
3Productivity
If heavy dependence on manual labor is maintained, then ease of operation is preserved, but productivity and production stability deteriorate
Solution Approach 1:
The robotic systems are equipped with autonomous capabilities to perform assembly operations with minimal human intervention. The movable cradles and robotic end effectors work together in an automated sequence, with the system serving itself by automatically positioning components, performing fastening operations, and transitioning between tasks without requiring constant manual oversight.
Solution Approach 2:
Manual mechanical operations are replaced with automated robotic systems that perform fastening, positioning, and assembly tasks. The robotic end effectors substitute for manual tools and operations, dramatically increasing productivity while the automated control systems manage the complexity, effectively replacing human operation with automated mechanical-intelligent systems.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
A facility for assembling aircraft fuselages comprises a plurality of movable cradles. Each cradle is configured to support a fuselage keel structure and assemble a panelized fuselage in a single upright build position (Fig.1).