Identical Geodesic Modules for Fuselage Assembly
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Solution Overview
Problem
The existing methods for manufacturing vehicle fuselages are time and labor intensive due to the use of numerous unique and distinct components in geodesic airframes and semi-monocoque structures, which complicates the assembly process.
Innovation Solution
The implementation of a system and method using identical geodesic modules with constant curvature and cross-sectional radius, formed from interconnected frame segments, which are self-similar and simplify the assembly process by reducing the number of unique components and fasteners required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If geodesic airframes with variable cross-section are used, then structural complexity is reduced, but the number of unique components increases significantly
Solution Approach 1:
The fuselage is divided into modular geodesic modules that can be standardized and reused. Each module consists of identical frame segments arranged in geodesic patterns, allowing the complex structure to be built from repeating units rather than unique components.
Solution Approach 2:
The frame segments are designed as universal components that can be used across multiple geodesic modules. These identical segments serve multiple positions and functions throughout the fuselage structure, eliminating the need for numerous unique parts.
2Strength
If numerous fasteners are used to secure components, then assembly strength is improved, but assembly time and labor increase
Solution Approach 1:
Multiple fastening operations are merged into automated assembly systems that can simultaneously secure multiple components. The automated systems perform drilling, countersinking, and fastener installation in integrated operations, reducing the total time required compared to manual sequential operations.
Solution Approach 2:
Manual mechanical fastening operations are replaced with automated assembly systems that use controlled mechanical processes. The automated systems provide precise positioning and consistent fastening forces, achieving both strength and time efficiency.
3Manufacturing precision
If manual assembly with fixed jigs is used, then assembly precision is maintained, but productivity decreases
Solution Approach 1:
Manual assembly operations are replaced with automated assembly systems that maintain precision through computer-controlled positioning and fastening. The automated systems eliminate human variability while maintaining the tight tolerances required for semi-monocoque structures.
Solution Approach 2:
The assembly process parameters are optimized for automated operation, including adjusted feed rates, drilling depths, and fastener installation forces. These parameter changes enable automated systems to achieve the same precision as manual assembly with fixed jigs while dramatically improving productivity.
Data Source
AI summary
A system and method determine a size and a shape for identical geodesic modules that are used to form a structure. The system and method may include analyzing input data regarding a size and a shape of the structure to be formed, and determining the size and the shape for each of the identical geodesic modules based on the size and the shape of the structure to be formed. The structure may include a framework including the identical geodesic modules. Each of the geodesic modules has a size and a shape that are the same as all of the other of the geodesic modules. A forming system and method position a framework and a covering skin of the structure in relation to a mandrel, and drill and rivet the framework to the covering skin with a plurality of operating heads.