Fuselage Section Shape Alignment for Precise Aircraft Joining

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Solution Overview

Problem

The existing 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 system comprising a cradle system, a metrology system, and a controller that measures the current shape of fuselage sections and applies forces to adjust them to a desired shape for optimal fit, using a feedback loop to ensure precise alignment and connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual measurement and adjustment methods are used, then operators can measure shape differences using tools like feeler gauges and make changes using jacks, but the process becomes time-consuming and labor-intensive

Engineering Contradiction:

Improveease of joining fuselage sectionsVSAvoidtime required for joining process

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical measurement tools (feeler gauges) and adjustment tools (jacks operated by operators) with an automated optical measurement system and computer-controlled actuation system. The optical sensors automatically capture shape data, and computer-controlled actuators automatically apply forces to adjust the fuselage section shapes, eliminating the need for manual operations while reducing process time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables the fuselage sections to self-adjust their shapes through computer-controlled actuators that automatically apply forces based on measured deviations from desired shapes. The measurement and adjustment process becomes self-contained, with the system automatically identifying shape differences and applying corrective forces without continuous human intervention.

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If manual measurement and adjustment methods are used, then operators can make shape changes using jacks, but the shapes may still not achieve a desired level of fit

Engineering Contradiction:

Improvefit between fuselage sectionsVSAvoidcomplexity of joining process

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent implements a closed-loop feedback system where optical sensors continuously measure the shapes of fuselage sections, the computer compares measured shapes to desired shapes, and computer-controlled actuators automatically apply forces to correct deviations. This feedback loop ensures that the fuselage sections achieve the desired level of fit by iteratively measuring and adjusting shapes based on real-time data.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary measurement and analysis of fuselage section shapes before final joining. The computer calculates the specific forces needed to achieve desired shapes based on preliminary measurements, allowing operators to make precise adjustments before the actual joining operation, ensuring optimal fit.

Inventive Principle:

Principle #10Preliminary action

3Weight of moving object

If fuselage sections are manufactured in larger pieces, then weight decreases and performance improves, but gravity may cause deformation that changes the shape of the fuselage sections

Engineering Contradiction:

Improveweight of aircraftVSAvoidshape of fuselage section ends

Core Design Contradiction:

Weight of moving objectVSShape

Solution Approach 1:

The patent applies corrective forces to fuselage sections before final joining to compensate for gravity-induced deformations. The computer calculates the specific forces needed to restore desired shapes based on measurements taken while sections are in their deformed state, allowing preliminary adjustment that counteracts the effects of gravity and manufacturing size.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts physical parameters (forces applied to fuselage sections) to compensate for gravity-induced deformations. By changing the magnitude and direction of applied forces based on real-time measurements, the system restores fuselage section shapes to desired configurations despite the effects of gravity on large composite structures.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11131982B2Fuselage manufacturing system

Publication Date: 2021.09.28 THE BOEING CO

AI summary

A method and apparatus for processing fuselage sections. The apparatus comprises a cradle system, a metrology system, and a controller. The cradle system holds a first fuselage section and applies forces to the first fuselage section to change a current shape of the first fuselage section. The metrology system makes measurements of the current shape of the first fuselage section. The controller receives the measurements from the metrology system, identifies the forces needed to change the current shape of the first fuselage section towards a desired shape for connecting the first fuselage section to a second fuselage section, and sends commands to the cradle system to apply the forces to change the current shape of the first fuselage section towards the desired shape.