Fuselage Pulse Assembly Line With Friction Track Indexing

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Solution Overview

Problem

The aerospace industry faces inefficiencies in the transport and assembly of airframe components due to the need for repeated scanning and indexing in fixed cells, leading to increased space requirements, reduced throughput, and prolonged downtime.

Innovation Solution

A system and method that involves affixing plates along the length of a fuselage section to form a frictional fit with a track, using drive units to advance the section in a process direction, and engaging indexing elements to pause and perform work, allowing tools to operate on the section without realignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If fixed cells with repeated scanning and indexing are used for airframe component assembly, then tools and equipment can be brought to each portion of the structure needing work, but space requirements increase and throughput decreases

Engineering Contradiction:

Improveability to bring tools to structure portionsVSAvoidfactory floor space

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

Instead of bringing tools to the structure in fixed cells, the patent inverts the approach by moving the structure through a continuous track system where tools are stationary. The fuselage section moves along the track and is indexed to stationary workstations, eliminating the need for repeated scanning and repositioning of tools while reducing space requirements.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces dynamic movement of the fuselage section along a continuous track system with multiple workstations. The structure is advanced incrementally through the assembly line and indexed to specific workstations as needed, creating a dynamic flow that replaces the static fixed-cell approach and improves space utilization.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If fixed cells with repeated scanning and indexing are used for airframe component assembly, then tools can service each structure portion, but production throughput is reduced

Engineering Contradiction:

Improvetool access to structureVSAvoidassembly throughput

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent implements a continuous assembly line where the fuselage section moves continuously through multiple workstations without stopping for repeated scanning. Each workstation performs its operation as the structure passes by, eliminating idle time and maintaining continuous productive action throughout the assembly process.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent pre-positions multiple workstations along the track in advance, each equipped to perform specific operations. The fuselage section is advanced to the appropriate workstation before each operation is needed, eliminating the time-consuming scanning and indexing process that occurs in fixed-cell systems.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If fixed cells with repeated scanning and indexing are used for airframe component assembly, then each structure portion can be serviced, but downtime is prolonged

Engineering Contradiction:

Improvestructure servicing capabilityVSAvoidassembly downtime

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent pre-positions multiple workstations along the track, each prepared to perform specific operations on the fuselage section. The structure is advanced to the appropriate workstation before each operation is needed, eliminating the time-consuming scanning and indexing process that causes downtime in fixed-cell systems.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The continuous movement of the fuselage section through the assembly line ensures that operations are performed without interruption. The structure is constantly advancing through the process, and each workstation is ready to service it immediately upon arrival, eliminating the downtime associated with repeated scanning and repositioning.

Inventive Principle:

Principle #20Continuity of useful action

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 space requirements, increases production throughput, and minimizes downtime by enabling synchronized work on multiple fuselage sections with reduced need for tool alignment.

Implementation Method 1

a track configured to form a frictional fit with the plates. The track includes drive units configured to form nips retaining the series of plates, and that are configured to advance the fuselage section along the track in a process direction

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11685552B2Fractional pulse assembly line

Publication Date: 2023.06.27 THE BOEING CO

AI summary

Systems and methods are provided for advancing a fuselage section of an aircraft. One embodiment is a system that includes a series of plates configured to be sequentially affixed along a length of the fuselage section, and a track configured to form a frictional fit with the plates. The track includes drive units configured to form nips retaining the series of plates, and that are configured to advance the fuselage section along the track in a process direction, and indexing elements that are configured to engage with indexing elements at the plates during pauses between operation of the drive units. The system also includes tools configured to perform work on the fuselage section while the indexing elements of the track are engaged.