Aircraft Fuselage Transverse Joint Assembly Method

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Solution Overview

Problem

The existing methods for manufacturing aircraft fuselages face challenges such as radial gaps due to component tolerances, which require laborious compensation and a large number of connecting elements, especially in carbon fiber reinforced plastic (CFRP) fuselages, leading to prolonged assembly processes and increased costs.

Innovation Solution

The method involves aligning and preparing transverse joint elements before manufacturing the fuselage barrels, allowing the barrels to be constructed around these elements, thereby eliminating the need for tolerance compensation and reducing the number of connecting elements required, with ring-type connecting segments and tension bolts used to simplify the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If fuselage barrels are joined using traditional overlap joints with rivets, then the fuselage structure is formed, but radial gaps occur due to component tolerances requiring laborious compensation and filler application

Engineering Contradiction:

Improvegap closure precisionVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The transverse joint elements are pre-aligned and prepared before the fuselage barrels are manufactured. The barrels are then constructed around these pre-positioned elements, eliminating the need for post-assembly gap compensation and filler application.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Transverse joint elements serve as intermediary components that mediate the connection between fuselage barrels. These elements are prepared in advance and used as reference objects around which the barrels are constructed, ensuring proper alignment and eliminating tolerance gaps.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If multiple connecting elements (rivets and stringer couplings) are used to join fuselage barrels, then the structural connection is achieved, but the assembly process becomes protracted and complex

Engineering Contradiction:

Improvejoint strengthVSAvoidnumber of connecting elements

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Multiple separate connecting elements (rivets and stringer couplings) are merged into a single integrated transverse joint element. This consolidation maintains the structural connection function while dramatically simplifying the assembly process and reducing the number of components required.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The transverse joint element is designed as a universal component that performs multiple functions simultaneously: it provides structural connection, accommodates tolerance variations, and eliminates the need for separate rivets and stringer couplings. This multi-functionality reduces overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If filler is used to compensate for tolerance gaps in CFRP fuselages, then the gaps are closed, but accurate metering and positioning becomes difficult and time-intensive due to limited accessibility

Engineering Contradiction:

Improvegap compensation accuracyVSAvoidfiller application ease

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The transverse joint elements are pre-aligned and prepared before the fuselage barrels are manufactured and assembled. This preliminary positioning eliminates the need for filler application, as the barrels are constructed around the already-positioned elements, ensuring proper alignment and eliminating tolerance gaps without requiring difficult-to-apply filler materials.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If fuselage barrels are separated after drilling for cleaning rivet holes and overlapping surfaces, then the cleaning is achieved, but the assembly process becomes protracted

Engineering Contradiction:

Improvehole cleanlinessVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The transverse joint elements are pre-aligned and prepared before the fuselage barrels are manufactured. The holes for connecting elements are appropriately prepared in advance during this preliminary stage. During the final assembly process, it is only necessary for the connecting elements to be inserted, eliminating the need for subsequent removal, cleaning, and reaming operations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS9359090B2Method for producing an aircraft fuselage and aircraft fuselage

Publication Date: 2016.06.07 AIRBUS OPERATIONS GMBH

AI summary

Disclosed is a method for the manufacture of an aircraft fuselage with at least two fuselage barrels wherein connecting segments are firstly prepared for the formation of a transverse joint region for a later transverse joint, and the fuselage barrels are then constructed around the connecting segments; also disclosed is an aircraft fuselage with ring-type connecting segments for the formation of such a transverse joint.