Aircraft Fuselage Panel Assembly Tool with Sliding Supports

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Solution Overview

Problem

Current methods for assembling aircraft fuselage components are difficult to automate, particularly in controlling internal stresses and using frames with Z-shaped cross sections, as they require manual installation of attachment elements and struggle with non-developable reference surfaces.

Innovation Solution

A method and tool that involve shaping panels on support surfaces with sliding support surfaces for frames, allowing automatic installation of attachment elements and using frames with Z-shaped cross sections, while controlling internal stresses through clamping forces and shim placement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If manual installation of attachment elements is used for assembling fuselage components, then flexibility in handling complex geometries (Z-shaped frames, non-developable surfaces) is maintained, but automation capability is lost and productivity decreases

Engineering Contradiction:

Improveautomation of attachment element installationVSAvoidcomplexity of tooling for Z-shaped frames and non-developable surfaces

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The tool is divided into multiple independent support surfaces, each capable of supporting a different frame (Z-shaped or otherwise) at its correct position and orientation. This segmentation allows each support surface to be independently designed and positioned, enabling automated attachment element installation while accommodating complex frame geometries without requiring a monolithic complex tooling system.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If rigid support surfaces are used for shaping panels, then shape accuracy and reference surface quality are improved, but adaptability to different frame positions and internal stress control deteriorates

Engineering Contradiction:

Improveaccuracy of panel reference surfaceVSAvoidadaptability to different frame positions and internal stress management

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The support surfaces are designed to be movable rather than fixed, allowing them to be positioned at different locations along the panel and adjusted to accommodate different frame positions. This dynamic positioning capability enables the rigid support surfaces to maintain shape accuracy while adapting to various assembly configurations and controlling internal stresses through proper force distribution.

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If multiple separate tools are used for panel shaping and frame positioning, then each tool can be optimized for its specific function, but assembly complexity and time increase

Engineering Contradiction:

Improveoptimization of panel shaping and frame positioning functionsVSAvoidtime for assembling multiple tools and components

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

Multiple support surfaces for different frames are integrated into a single unified tool structure. This merging allows the tool to simultaneously perform panel shaping and frame positioning functions, eliminating the need to switch between multiple separate tools and reducing assembly time while maintaining the optimized functionality for each specific task.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If attachment elements are installed before frame positioning, then assembly sequence is simplified, but control over internal stresses and positioning accuracy deteriorates

Engineering Contradiction:

Improveassembly sequence efficiencyVSAvoidframe positioning accuracy and internal stress control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The support surfaces are pre-positioned on the tool at the correct locations and orientations before the assembly process begins. This preliminary positioning ensures that when frames are placed on the support surfaces and attachment elements are installed, the frames are automatically positioned with high accuracy and internal stresses are properly controlled, without requiring complex post-positioning adjustments.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10029414B2Method for producing part of an aircraft fuselage and tool for implementing said method

Publication Date: 2018.07.24 AIRBUS OPERATIONS (SAS)

AI summary

The subject matter disclosed herein relates to a method for assembling at least one panel and frames for producing part of an aircraft fuselage, the method including shaping the panel on support surfaces of a tool, wherein it includes holding each frame clamped against at least one sliding support surface arranged in a transverse plane, the sliding support surfaces of the various frames and the support surfaces being secured to the same tool and positioned relative to one another, and in putting in place permanent attachment elements for connecting the panel and the frames. The subject matter disclosed herein also proposes a tool for implementing the assembly method.