Aircraft Fuselage Panel Carrier With Indexing Features
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Solution Overview
Problem
The existing methods for assembling aircraft fuselages are time-consuming and resource-intensive, requiring multiple sets of tooling and significant factory space, which limits flexibility and increases manufacturing costs.
Innovation Solution
A carrier and operational frame system comprising multiple panel carriers with frames and indexing features that support and align fuselage panels, allowing for efficient manufacturing operations and reduced tooling transfers by using a single set of tooling for multiple functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple sets of tooling are used for assembling fuselage panels, then manufacturing precision and structural support are improved, but manufacturing time and resource consumption increase
Solution Approach 1:
The panel carrier is designed to perform multiple functions: it serves as both the assembly tooling and the structural support for fuselage panels. The same panel carrier is used throughout the entire assembly process from panel attachment to final assembly, eliminating the need to transfer panels between multiple sets of tooling while maintaining alignment precision through integrated indexing features
Solution Approach 2:
The invention merges the functions of multiple separate tooling systems into a single integrated panel carrier system. The panel carrier combines structural support, panel attachment, alignment indexing, and operational platform functions that were previously distributed across multiple separate tooling sets, thereby reducing assembly time while maintaining precision
2Manufacturing precision
If multiple sets of assembly tooling are deployed, then manufacturing precision is improved, but factory space requirements and device complexity increase
Solution Approach 1:
The panel carrier serves as a universal platform that performs multiple functions including structural support, panel attachment, alignment reference, and operational platform. This multi-functionality eliminates the need for multiple separate tooling systems, thereby reducing factory floor space requirements while maintaining manufacturing precision through integrated indexing features
Solution Approach 2:
The assembly system is segmented into multiple interchangeable panel carriers that can be configured in different arrangements. Each panel carrier is a self-contained modular unit with integrated functions, allowing the system to be reconfigured for different assembly needs without requiring additional tooling or increasing overall space requirements
3Strength
If traditional assembly tooling is used, then structural support for panels is improved, but productivity and manufacturing efficiency decrease
Solution Approach 1:
The panel carrier provides both strong structural support for fuselage panels and enables efficient manufacturing operations through integrated operational platforms. The same structure that supports the panel also provides mounting points for manufacturing tools, eliminating the need for separate support and operation systems, thereby improving productivity while maintaining structural strength
Solution Approach 2:
The panel carrier is designed to be self-sufficient, providing both structural support and operational capabilities without requiring external tooling. The operational platforms are integrated directly onto the panel carrier structure, allowing manufacturing operations to be performed directly on the supported panels without additional equipment, thereby enhancing productivity
Data Source
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AI summary
A carrier and operational frame system (200) and methods of assembling a structure are presented. The carrier and operational frame system comprises a plurality of panel carriers (202), each panel carrier comprising a frame configured to act as a strongback to a panel (206) and indexing features configured to interface with at least one other panel carrier (202) of the plurality of panel carriers.