Moving-Line Fuselage Cut-Out Indexing for Window and Door Openings

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Solution Overview

Problem

The fabrication of large composite aircraft parts is inefficient due to the need for complex tasks like cutting out windows and doors, which requires substantial time and resources, as these parts must be transported and indexed for various operations, leading to space and resource inefficiencies in factory floors.

Innovation Solution

The implementation of integrated cut-out stations along a continuous-line assembly process for composite parts, utilizing indexing units and RFID technology to precisely cut out windows and doors as the fuselage moves through a series of stations, allowing for rapid and precise manufacturing without the need for extensive repositioning of tools and technicians.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If composite parts are transported to different cells for various operations, then complex tasks can be performed on the parts, but substantial time and resources are occupied and factory floor space is inefficiently used

Engineering Contradiction:

Improveability to perform complex tasksVSAvoidtime for transportation and repositioning

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The assembly process is segmented into multiple workstations arranged in series along a continuous line. Each workstation performs a specific operation (cutting, drilling, sealing, etc.) on the fuselage section as it passes through. This segmentation eliminates the need to transport the entire fuselage to different cells, as each operation is brought to the fuselage in sequence at dedicated stations along the continuous line.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from a static, batch-processing approach to a dynamic, continuous-flow approach. The fuselage sections move continuously through the assembly line on supports, allowing multiple operations to be performed simultaneously on different sections at different workstations. This dynamic flow eliminates idle time and transportation delays associated with moving parts between fixed cells.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If tools and technicians are brought to the site for cutting operations, then windows and doors can be cut out, but substantial time and resources are occupied

Engineering Contradiction:

Improveability to perform cutting operationsVSAvoidmanufacturing efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

Instead of bringing tools and technicians to the fuselage section at various locations, the fuselage section is moved to a series of fixed workstations where cutting tools are already positioned. The inversion is in the direction of movement: rather than tools moving to the workpiece, the workpiece moves to the tools in a controlled, continuous manner through the assembly line.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

Manual cutting operations performed by technicians with portable tools are replaced by automated cutting machines mounted at fixed workstations. These machines use computer-controlled mechanisms to perform precise cutting operations as the fuselage passes through, eliminating the need for manual tool handling and setup time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If multiple sections of fuselage are processed in series, then work can be performed at multiple stations, but setup time and resource allocation become complex

Engineering Contradiction:

Improvework density along assembly lineVSAvoidcomplexity of coordinating multiple stations

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The fuselage sections are prepared in advance by pre-attaching them to supports that include indexing features. These indexing features are predetermined and pre-positioned on the supports, allowing the sections to be automatically indexed and positioned at the correct locations along the assembly line without complex real-time coordination. The preliminary preparation of supports simplifies the coordination required during actual assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The indexing features on the supports automatically guide and position each fuselage section at the correct workstation locations. The system uses self-indexing mechanisms where the physical features on the supports (such as tabs, slots, or geometric constraints) automatically align the fuselage section with the corresponding workstations, eliminating the need for complex external positioning systems or manual alignment procedures.

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP4011522A1Cut-out process for moving-line structure

Publication Date: 2022.06.15 THE BOEING CO

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AI summary

The application relates to apparatus and methods that are provided for fabrication of a structure (120), for example, a half barrel section of a fuselage. The apparatus includes an indexing unit (130) dimensioned for coupling to an indexing feature (124) disposed on the structure. The structure proceeds along a process direction (199) during fabrication. A cutting station (140) cuts out manufacturing excess (129,135) from the structure to form, for example, openings for windows and doors. A method for fabrication of a structure includes indexing a structure to a cutting station based on an indexing feature associated or located on the structure. The method includes operating the cutting station to cut manufacturing excess from the structure. A method includes removing cut sections of the manufacturing excess and routing these sections away from the cutting station.