Half-Barrel Fuselage Assembly for Continuous Aircraft Production
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Solution Overview
Problem
Current aircraft assembly methods require frequent scanning and indexing of airframe components, leading to inefficient use of space and increased downtime due to the need for tools and technicians to enter and exit through small barrel sections, limiting accessibility and increasing manufacturing steps.
Innovation Solution
A continuous line assembly system that allows airframe components to be fabricated and assembled in a linear process, with half barrel sections advancing through multiple work stations simultaneously, enabling simultaneous work on multiple sections and reducing the need for tool and technician movement by bringing the structure to the tools and technicians.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tools and technicians enter through barrel ends or doorways to work on full barrel sections, then work can be performed on the structure, but accessibility is limited and manufacturing steps increase
Solution Approach 1:
The patent inverts the traditional approach by having technicians work on inverted half barrel sections positioned on the assembly line, rather than entering through barrel ends. The half barrels are positioned with their open edges facing upward, allowing technicians to access the interior surfaces from above, fundamentally changing the workflow and improving accessibility.
Solution Approach 2:
The patent divides the full barrel section into two separate half barrel sections that are assembled afterward. This segmentation allows each half barrel to be worked on independently while positioned on the assembly line, improving accessibility and reducing the complexity of maneuvering tools and technicians within the confined space of a complete barrel.
2Productivity
If fixed cells are used for assembly with scanning and indexing, then work can be performed on specific portions, but space efficiency decreases and downtime increases
Solution Approach 1:
The patent implements a continuous assembly line where half barrel sections move continuously through multiple work stations without repeated stopping, scanning, and indexing. The sections progress along the line while receiving various manufacturing operations, eliminating the downtime associated with fixed cell operations and significantly improving throughput.
Solution Approach 2:
The patent transitions from static fixed cells to a dynamic continuous assembly line system. The half barrel sections are moved continuously through the assembly process, with work stations positioned along the line to perform operations as the sections pass by, creating a fluid and efficient manufacturing flow.
3Area of stationary object
If tools and tooling are set up in place within full barrel sections, then work can be completed, but space requirements increase and movement efficiency decreases
Solution Approach 1:
The patent positions half barrel sections in an inverted orientation on the assembly line with open edges facing upward, allowing technicians and tools to access the interior from above rather than entering through barrel ends. This inversion eliminates the need for large setup spaces within the barrel sections themselves, reducing overall manufacturing space requirements while maintaining productivity.
Data Source
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AI summary
Systems and methods are provided for assembling an airframe of an aircraft, including receiving a half barrel section (24) of fuselage (12) in an assembly line (110,120), coupling a splice plate (597,920,920-1) to the half barrel section, aligning the half barrel section and coupled splice plate to another half barrel section (24); and joining the half barrel section together via the splice plate. A product of the assembly process is further provided, with an extent of the fuselage being formed of sections of joined half barrel sections that are joined together with circumferential joints. The outer surface of the fuselage optionally has a visual appearance indicating the position of joining the half barrels, appearing as an elongated line extending down an extent of the fuselage with small circular features on each side of the elongated line.