Segmented Fuselage Panel Contour Retention Braces

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Solution Overview

Problem

Aircraft fuselage panels often deviate from their desired contour when removed from assembly structures, leading to alignment issues during the assembly of barrel sections, complicating the process and requiring additional shimming and alignment efforts.

Innovation Solution

The use of enhanced, temporary, and removably attached braces that enforce and maintain the desired contour on panels, comprising a segmented ring assembly, spreader bar, and struts, which travel with the panels to ensure accurate assembly without occupying space in the completed aircraft.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If panels are removed from assembly structures before forming barrel sections, then panels can be transported to assembly locations, but panel contours change away from desired shapes

Engineering Contradiction:

Improvepanel transportabilityVSAvoidpanel contour accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The brace is attached to the panel before transport to preemptively counteract the tendency of the panel to deviate from its desired contour. The brace applies a pre-positioning force that maintains the panel's shape during handling and transport, preventing the contour change problem rather than correcting it afterward.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The brace is installed on the panel prior to transport and assembly operations. This preliminary action ensures the panel maintains its desired contour throughout subsequent handling, transport, and assembly processes, eliminating the need for contour correction later.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If large support structures are used to hold panel contours during assembly, then panel alignment is maintained, but the structures are heavy and cannot be transported with panels

Engineering Contradiction:

Improvepanel contour maintenanceVSAvoidsupport structure weight

Core Design Contradiction:

Manufacturing precisionVSWeight of moving object

Solution Approach 1:

The support structure is divided into discrete, modular brace components that can be individually attached to and removed from panels. Each brace is a self-contained unit with standardized attachment interfaces, allowing multiple braces to work together to maintain panel contours while remaining lightweight and transportable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The braces are designed as temporary, disposable fixtures rather than permanent structural components. They are inexpensive enough to be discarded after use, eliminating the need for heavy-duty permanent support structures. The braces serve their purpose during transport and assembly, then are removed and discarded without occupying space in the final aircraft.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Manufacturing precision

If permanent support structures remain in the completed barrel section, then panel contours are maintained, but space within the aircraft is occupied

Engineering Contradiction:

Improvepanel contour enforcementVSAvoidinternal space occupation

Core Design Contradiction:

Manufacturing precisionVSVolume of moving object

Solution Approach 1:

The braces are designed as temporary fixtures that are discarded after serving their purpose. Once panels are assembled into the barrel section and properly positioned, the braces are removed and discarded, leaving no permanent structures that would occupy internal aircraft space. This allows the braces to provide necessary support during assembly without compromising the final aircraft configuration.

Inventive Principle:

Principle #34Discarding and recovering

4Manufacturing precision

If braces are used to maintain panel contours, then alignment during assembly is improved, but additional assembly steps are required

Engineering Contradiction:

Improvepanel alignment accuracyVSAvoidassembly process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The braces are designed with universal attachment interfaces that can be applied to multiple different panel types and configurations. The same basic brace design can serve multiple functions: maintaining contour during transport, providing alignment references during assembly, and working with different panel geometries. This multi-functionality reduces the need for specialized fixtures for each scenario.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10822071B2Contour retention in segmented fuselage assemblies

Publication Date: 2020.11.03 THE BOEING CO

AI summary

Systems and methods are provided for enforcing contours onto parts of an aircraft. One embodiment is a method for enforcing a contour onto aircraft parts. The method includes removably attaching segmented ring details to aircraft skin details, attaching stringers to skin details to create skin assemblies, positioning skin assemblies at a support structure defining a contour, and fastening frames to the skin assemblies to create a panel. The method also includes removably installing a spreader section onto the panel to complete assembly of a brace prior to removal of the panel, transporting the panel while the brace enforces the contour, attaching the brace to braces for other panels to form a barrel section of a fuselage for an aircraft while the brace enforces the contour, and removing the brace from the barrel section after the barrel section has been formed.