Fuselage Splice Assembly Tool for Shimless Section Alignment
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Solution Overview
Problem
Conventional methods for assembling aircraft fuselage sections using splice components often result in mismatches due to manufacturing variations, leading to gaps that require shims, increasing weight, cost, and time in the assembly process.
Innovation Solution
An assembly tool with a base plate, passageway, and bias assembly that allows for the movement of splice components relative to the base plate, enabling continuous contact without shims by urging the protrusion against a barrier element, facilitating alignment and attachment to fuselage structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional assembly methods are used with fixed splice components, then manufacturing simplicity is maintained, but gaps occur due to accumulated manufacturing variations requiring shims
Solution Approach 1:
The splice component is designed with movable elements that allow adjustment of its position and orientation relative to the base plate. The component can move in longitudinal and transverse directions to accommodate manufacturing variations in the fuselage sections, enabling continuous contact without shims while maintaining a relatively simple overall assembly tool structure
Solution Approach 2:
The assembly tool is divided into independent adjustment mechanisms for different degrees of freedom. The splice component has separate movement capabilities in longitudinal and transverse directions, allowing precise alignment to be achieved through modular adjustment rather than requiring a completely complex integrated system
2Manufacturing precision
If shims are installed to fill gaps, then continuous contact is achieved, but additional weight is added to the aircraft
Solution Approach 1:
The shim elements are completely removed from the assembly system. Instead of adding shims to fill gaps, the invention extracts the need for shims by providing adjustment capabilities directly in the splice component, allowing it to self-align and achieve continuous contact with the fuselage sections without any additional filler materials
Solution Approach 2:
The invention replaces permanent weight-added shims with a reusable adjustment mechanism built into the splice component. The movable elements allow the same component to adapt to manufacturing variations without requiring disposable shim materials, eliminating recurring weight additions for each assembly operation
3Manufacturing precision
If detailed dimensional analysis is performed to custom design shims, then gap filling precision is improved, but assembly time and cost increase
Solution Approach 1:
The splice component performs its own alignment function through built-in movement capabilities. Instead of requiring external dimensional analysis and custom shim design, the component self-adjusts to achieve proper alignment and continuous contact with the fuselage sections, eliminating time-consuming measurement and customization steps
Solution Approach 2:
The adjustment mechanisms are pre-built into the splice component during manufacturing. The component is designed in advance with the capability to move in multiple directions, so that during assembly it can immediately adapt to any manufacturing variations without requiring preliminary dimensional analysis or custom preparation of alignment elements
4Manufacturing precision
If individual splice components are fitted with shims, then alignment is achieved, but assembly cost and time increase
Solution Approach 1:
The splice component incorporates dynamic adjustment capabilities that allow it to be quickly positioned and aligned during assembly. The movement mechanisms enable operators to achieve proper alignment by simply adjusting the component's position rather than time-consuming shim fitting operations, significantly reducing assembly time while maintaining precise alignment
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 eliminates the need for shims, reduces assembly time and cost, and ensures a solid connection between fuselage sections by allowing precise alignment and attachment of splice components.
Implementation Method 1
The bias assembly may include a bias element that extends proximate to the passageway. The bias assembly may be configured to move resiliently in a direction extending along the first major face to urge the protrusion against the barrier element.
Data Source
AI summary
An apparatus for mounting a splice component for joining two or more workpieces includes a base plate and one or more bias assemblies. The base plate includes one or more passageways extending through the base plate and one or more barrier elements mounted proximate to the passageway(s). Each barrier element and associated passageway are configured to freely receive a protrusion of a splice component. The bias assembly includes a bias element that extends proximate to the passageway and is configured to move resiliently to urge the protrusion against the barrier element. The passageway, the barrier element, and the bias assembly are configured to allow movement of the splice component relative to the base plate transverse to a direction of force applied by the bias element on the protrusion.