Fuselage Skin Tensioning for Precise Frame Pull-Up Assembly
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Solution Overview
Problem
The current assembly process of composite panels in aircraft fuselages requires significant manpower, involving multiple technicians to attach frames, check for gaps, and reinstall components multiple times.
Innovation Solution
A device and method for assembling a skin and frame of an aircraft fuselage, which includes first and second brace members, arches, a strongback with clamps, and tension devices to apply tension to the skin, reducing the need for manual labor and multiple reinstallation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple technicians manually attach frames and perform multiple reinstallation steps, then assembly precision can be checked and adjusted, but the amount of manpower required increases significantly and assembly time increases
Solution Approach 1:
The skin tensioning device automatically applies and maintains tension to the skin during frame attachment, eliminating the need for multiple manual reinstallation steps. The system self-regulates tension through the tensioning mechanism, reducing dependence on multiple technicians for gap checking and adjustment while maintaining assembly precision.
Solution Approach 2:
The skin is pre-tensioned using the tensioning device before frame attachment begins. This preliminary tensioning establishes proper skin tightness from the start, preventing the need for subsequent reinstallation and gap adjustment steps that would otherwise require multiple technicians and extend assembly time.
2Manufacturing precision
If multiple fasteners are installed and frames are removed and reinstalled multiple times, then proper gap verification can be achieved, but the assembly process complexity increases
Solution Approach 1:
The tensioning device continuously maintains skin tension throughout the assembly process, automatically compensating for any positioning variations. This eliminates the need for complex multi-step removal and reinstallation procedures, simplifying the overall assembly process while maintaining gap verification accuracy.
3Manufacturing precision
If technicians manually check tie foot locations and door surrounds for gaps, then assembly quality can be monitored, but the time required for assembly increases
Solution Approach 1:
The skin tensioning device automatically maintains proper skin tightness and alignment during frame attachment, eliminating the need for manual gap checking at tie foot locations and door surrounds. The system self-monitors and maintains quality standards throughout the assembly process, significantly reducing the time required while preserving quality monitoring.
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
The solution significantly reduces the amount of manpower required during assembly by automating the tensioning process and minimizing the need for multiple frame installations, thereby enhancing efficiency and reducing assembly time.
Implementation Method 1
First and second tension devices apply tension to the skin at the strongback
Data Source
AI summary
A device to assemble a skin and a frame of an aircraft fuselage. The device includes first and second brace members that extend along opposing sides of a gap. Arches are spaced apart and fixedly connected to the first and second brace members and that extend across the gap. A strongback is attached to and movable along the first and second brace members with the strongback having a curved shape that matches the plurality of arches. The strongback includes clamps configured to engage with the frame. First and second tension devices apply tension to the skin at the strongback.