Fuselage Section Metrology System for Precise Joining

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Solution Overview

Problem

The current methods for joining composite fuselage sections in aircraft manufacturing are time-consuming and labor-intensive, often resulting in undesired fits due to shape variations, which can lead to increased fuel consumption and noise during flight.

Innovation Solution

A method and apparatus utilizing a scanning system with a cradle system and metrology system to measure and adjust the shape of fuselage sections by applying forces to achieve a precise fit, with a feedback loop to ensure accurate alignment and fitting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If operators manually measure and adjust fuselage section shapes using traditional tools, then the process is simple and accessible, but the process becomes time-consuming and labor-intensive

Engineering Contradiction:

Improvejoining speedVSAvoidmeasurement and adjustment time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical measurement tools (feeler gauges) and mechanical adjustment tools (jacks) with an automated optical scanning system that uses laser beams to measure fuselage section shapes and a control system to coordinate adjustment mechanisms, eliminating manual labor and significantly reducing measurement and adjustment time

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The scanning system automatically measures the fuselage sections and the control system automatically calculates and directs adjustments without human intervention, making the system self-sufficient in the measurement and adjustment process, thereby improving productivity while reducing time loss

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If traditional measurement tools are used to check fuselage section shapes, then the equipment is simple, but the measurement precision is insufficient to achieve desired fit levels

Engineering Contradiction:

Improvefit accuracyVSAvoidshape measurement accuracy

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The patent replaces imprecise mechanical measurement tools with an optical scanning system that uses laser beams to capture detailed three-dimensional data of fuselage section shapes, providing measurement precision sufficient to achieve the desired fit accuracy between sections

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The scanning system provides precise measurement data that is fed back to the control system, which then directs adjustment mechanisms to modify fuselage section shapes until the desired fit is achieved, creating a closed-loop system that ensures manufacturing precision

Inventive Principle:

Principle #23Feedback

3Productivity

If fuselage sections are joined with shape variations, then the joining process is faster, but undesired airflow occurs leading to increased fuel consumption and noise

Engineering Contradiction:

Improvejoining efficiencyVSAvoidairflow disturbances

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The scanning system continuously measures fuselage section shapes and provides feedback to the control system, which adjusts the sections in real-time to eliminate shape variations that would cause airflow disturbances, ensuring both joining efficiency and aerodynamic performance

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent uses hydraulic or pneumatic adjustment mechanisms controlled by the system to precisely modify fuselage section shapes based on scanning data, enabling rapid adjustments that achieve desired fit levels without creating harmful airflow patterns

Inventive Principle:

Principle #29Pneumatics and hydraulics

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

This approach reduces the time and labor required for joining fuselage sections, achieving a desired level of fit and improving the performance and efficiency of the aircraft by minimizing airflow issues and noise.

Implementation Method 1

A reflected light is detected from a beam of light

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS9453720B2Metrology system for generating measurements of fuselage sections

Publication Date: 2016.09.27 THE BOEING CO

AI summary

A method and apparatus for processing fuselage sections. A scanning system is positioned between a first fuselage section held in a first cradle and a second fuselage section held in a second cradle. A group of beams of light is transmitted from the scanning system to targets on a first interior surface of the first fuselage section and a second interior surface of the second fuselage section. A reflected light is detected from a beam of light. Measurements of the first fuselage section and the second fuselage section are generated from using the reflected light generated in response to the beam of light. The measurements enable shaping at least one of the first fuselage section and the second fuselage section for joining the first fuselage section to the second fuselage section.