Fuselage Skin Waterline Tensioning for Precise Frame Pull-Up
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Solution Overview
Problem
The current assembly process of composite panels requires significant manpower and multiple iterations of attaching and reattaching frames to ensure proper alignment and fastening, which is inefficient and labor-intensive.
Innovation Solution
A device comprising brace members, arches, a strongback with clamps, and tension devices that apply controlled force to the skin, along with a method of aligning and tensioning the skin relative to a support platform to reduce manual intervention and improve alignment precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple fasteners are installed and frames are repeatedly attached and reinstalled to ensure proper alignment, then the alignment precision and structural reliability are improved, but the assembly time and labor requirements increase significantly
Solution Approach 1:
The skin is tensioned and pre-aligned on the support platform with arches and indexing members before the frame attachment process begins. This preliminary positioning ensures correct alignment is established early, reducing the need for repeated adjustments and reattachments during subsequent assembly steps
Solution Approach 2:
The support platform with arches, indexing members, and tensioning devices serves as an intermediary fixture system that temporarily holds and aligns the skin in the correct position. This intermediary structure enables precise alignment without requiring multiple iterations of frame attachment and removal
2Reliability
If multiple technicians are deployed to manually attach frames and check tie foot locations, then the quality control and gap verification are improved, but the manpower requirements and operational complexity increase
Solution Approach 1:
The support platform system with indexing members and tensioning devices performs self-alignment and self-positioning functions. The indexing members automatically guide the skin to correct positions, and the tensioning system automatically maintains proper alignment, reducing the need for multiple technicians to manually check and adjust tie foot locations
Solution Approach 2:
Manual inspection and adjustment operations performed by multiple technicians are replaced by a mechanical system consisting of indexing members, arches, and tensioning devices. This mechanical system automatically ensures proper alignment and gap control, reducing operational complexity and manpower requirements while maintaining quality control
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 solution reduces the need for multiple fasteners and minimizes the number of frame reattachments, enhancing efficiency and reducing manpower requirements by applying precise tension to the skin, thereby improving the assembly process of composite panels.
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.