Aircraft Fuselage Frame Installation Using Pulsed-Line Assembly
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Solution Overview
Problem
Traditional aerospace manufacturing processes face inefficiencies due to poor work density and process equipment pack density, leading to delays and increased production time, as components of an airframe are assembled in single process cells, where slower work completion rates can stall entire sections until all delayed work is finished.
Innovation Solution
The implementation of pulsed-line assembly techniques with frame installation stations that allow incremental movement and processing of fuselage sections, integrating transportation into assembly and using modular, redundant equipment to maintain production even if individual components fail.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are assembled in single process cells, then reliability of fabrication is maintained, but productivity decreases due to delays when work completion is slower than expected
Solution Approach 1:
The patent divides the assembly process into multiple parallel process cells instead of using a single process cell. Each cell can independently assemble different components or work on different portions of the fuselage, allowing simultaneous processing and eliminating the bottleneck where the entire section must wait for all work to be completed in one cell.
Solution Approach 2:
The patent implements continuous flow assembly where fuselage sections move continuously through multiple process cells rather than being stationary in a single cell until all work is complete. This allows work to proceed without interruption and eliminates idle time when sections must wait for delayed tasks to be finished.
2Manufacturing precision
If work is delayed at a specific portion of fuselage section, then manufacturing precision may be affected, but loss of time increases as entire section must remain at cell until all work is completed
Solution Approach 1:
By dividing the assembly into multiple process cells working in parallel, the patent allows different portions of the fuselage to be worked on simultaneously by different cells. If one cell experiences delays, other cells can continue their work without interruption, and the section can move forward through the assembly line without waiting for all work to be completed at a single location.
Solution Approach 2:
The patent implements a dynamic assembly system where the assignment of work to different cells can be adjusted based on real-time progress and capacity. This flexibility allows the system to optimize work distribution and minimize idle time when delays occur at specific locations.
3Productivity
If work delayed at one cell is completed at another work cell, then productivity is maintained, but device complexity increases due to coordination between multiple cells
Solution Approach 1:
The patent designs process cells with universal capabilities that can perform multiple types of assembly tasks. This multi-functionality allows any cell to potentially complete work originally assigned to another cell if needed, reducing the need for complex specialized coordination while maintaining flexibility in work distribution and completion.
4Productivity
If pulsed-line assembly is implemented, then productivity increases through simultaneous processing at multiple stations, but device complexity increases due to integration of transportation and assembly processes
Solution Approach 1:
The patent combines the transportation function and assembly function into an integrated pulsed-line system where fuselage sections are automatically moved between process cells and work is performed at each station in sequence. This merging eliminates the need for separate transportation and assembly operations, and the automated coordination reduces the complexity of managing multiple independent cells.
Data Source
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AI summary
Systems and methods are provided for assembling aircraft fuselages. One embodiment is a method for assembling a fuselage of an aircraft. The method includes indexing an arcuate section (120) of the fuselage to a frame installation station (140), feeding a frame (142) at the frame installation station into a concavity (126) defined by the arcuate section, placing the frame against an Inner Mold Line (IML) (128) of the arcuate section while the frame is within the concavity, and affixing the frame to the arcuate section.