Fuselage Shell Stringer Positioning Using Segmented Formed Parts
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Solution Overview
Problem
Current methods for producing fuselage shells with fibre composite materials face challenges such as difficulty in handling and producing elongated formed parts, tight tolerances, and inability to actively guide stringers during the transfer process, leading to increased production effort and imprecision.
Innovation Solution
The use of adjustable short formed parts with abutment surfaces and lifters allows for precise positioning and guiding of stringers, eliminating the need for elongated formed parts and enabling easier handling and alignment, with magnetic connections and elastic clamping for secure placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If elongated formed parts are used for positioning stringers, then stringer placement is achieved, but handling and production become difficult with tight tolerances required
Solution Approach 1:
The elongated formed parts are divided into multiple separate positioning elements that can be individually handled and positioned. Each positioning element has specific engagement features that interface with corresponding features on the stringer, allowing precise positioning without requiring complex elongated components. This segmentation reduces manufacturing complexity while maintaining placement precision.
2Manufacturing precision
If elongated formed parts are used for stringer positioning, then stringer placement is achieved, but active guidance during transfer process is not possible
Solution Approach 1:
Positioning elements with abutment surfaces serve as intermediaries between the stringer and the mounting structure. These elements provide active guidance during the transfer process by mechanically guiding the stringer into the correct position through their geometric features. The abutment surfaces engage with corresponding features on the stringer to ensure precise alignment and positioning without requiring complex active control systems.
3Adaptability or versatility
If adjustable positioning elements are used, then adaptability to thermal or chemical changes is achieved, but device complexity increases
Solution Approach 1:
The positioning elements are designed with adjustable features that allow modification of their position or configuration in response to thermal or chemical changes during the manufacturing process. This adjustability is achieved through simple mechanical means such as movable components or reconfigurable geometries that can be easily adjusted without complex control systems, maintaining adaptability while minimizing added complexity.
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 simplifies and enhances the precision of stringer placement, reduces production effort, and allows for adjustment to accommodate thermal or chemical changes, while minimizing cleaning and handling complexities.
Implementation Method 1
At least one magnetic element is provided, which, by application of magnetic force, creates a magnetic connection in a force-locking manner onto the formed part
Implementation Method 2
several compression springs are disposed spaced apart from one another between the main frame and the positioning insert, which are maintained in the retracted position by the process vacuum
Implementation Method 3
the compression springs are pressed out of the mounting device by means of the compression springs in direction of the LABU
Data Source
AI summary
An apparatus for the production of a fuselage shell for an aircraft made of fiber composite, which is to be equipped with a plurality of stringers disposed spaced apart for reinforcement, comprising a main frame to form a supporting substructure having an outwardly curved mounting surface for positive mounting, having longitudinal mounting grooves for receiving of formed parts for deformably positioning the stringers relative to the mounting surface, wherein a plurality of short formed parts spaced apart from each other are disposed in each mounting groove, and which are adjustable relative to the corresponding mounting groove in the transverse direction (Y) by means of adjusters, and which can be raised in the vertical direction (Z) by means of lifters for guiding the stringers in the direction of a laminating adhesive bonding unit brought over the mounting surface.