Half-Barrel Fuselage Assembly With Indexed Continuous Joining Flow
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Solution Overview
Problem
Current aircraft assembly methods require frequent scanning and indexing of airframe components, leading to inefficiencies in tool and technician access, increased downtime, and higher space requirements due to the need for tools and equipment to be transported through barrel sections, which limits throughput and accessibility.
Innovation Solution
A continuous line assembly system that allows airframe components to be fabricated and assembled in a moving process direction, with work stations positioned along the path to perform tasks such as frame installation, window cutting, and sealing, enabling simultaneous work on multiple sections of the airframe, and utilizing processor-assisted monitoring and control to coordinate the progression of half barrel sections for efficient joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tools and equipment are transported through barrel sections for assembly work, then accessibility to work areas is achieved, but assembly time increases and throughput decreases
Solution Approach 1:
The patent inverts the conventional approach by having the airframe components move to stationary work stations rather than having tools and technicians move through the barrel sections. This reversal of motion direction eliminates transportation time and setup time while maintaining full accessibility to all work areas.
Solution Approach 2:
The assembly process is segmented into multiple specialized work stations positioned along the conveyor path, each dedicated to specific tasks such as frame installation, window cutting, and sealing. This segmentation allows simultaneous performance of multiple operations on different sections of the airframe, eliminating sequential bottlenecks.
2Manufacturing precision
If fixed cell assembly methods are used with scanning and indexing, then precise positioning is achieved, but production efficiency decreases due to repeated setup
Solution Approach 1:
The patent implements continuous motion of airframe components through the assembly line without stopping for scanning and indexing. The conveyor system maintains constant movement while work stations perform operations, eliminating the repeated setup cycles inherent in fixed cell methods and sustaining continuous productive action.
Solution Approach 2:
The airframe components are pre-positioned and pre-aligned before entering the assembly line, eliminating the need for repeated scanning and indexing operations at each work station. This preliminary preparation ensures that components are ready for immediate processing throughout the continuous assembly process.
3Ease of manufacture
If tools and equipment are set up within full barrel section, then work can be performed in place, but transportation time increases when moving between cells
Solution Approach 1:
Instead of moving tools and equipment into the barrel section for work, the patent inverts the approach by bringing the barrel section to stationary work stations. This eliminates the need for tool transportation and setup while maintaining in-place working capability at each specialized station.
4Manufacturing precision
If frequent scanning and indexing are performed, then component alignment is maintained, but downtime increases and throughput decreases
Solution Approach 1:
The continuous conveyor system maintains component alignment through constant motion without interruption for scanning and indexing. The synchronized movement of multiple airframe sections through the assembly line ensures proper positioning is maintained throughout the process without stopping, maximizing throughput.
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 of fuselage, advancing the half barrel section in a process direction (199) across multiple stations (114,124,312,322,332) to separately and simultaneously perform work on the half barrel sections, and subsequently joining the half barrel segments to form a section of the airframe. Each pair of half barrel sections, such as upper (116) and lower (118) half barrels, are progressed through assembly line processes to be delivered to a joining station for joining the half barrels together to form a circumferential section (138) of the fuselage. Multiple joined circumferential sections are joined together to form an elongated extent of the fuselage. Indexing features (133) are provided in the assembly process to monitor and control the progression of the half barrel sections in the work stations of the assembly line process and optionally direct the half barrel sections to ancillary work stations or delay progression through the assembly line to provide additional work on one of the half barrels as may be required, and assuring proper timing of the half barrel sections to the joining station. 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.