Half Barrel Fuselage Assembly for Continuous Aircraft Line Joining
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Solution Overview
Problem
Current aircraft assembly methods require frequent scanning and indexing of airframe components in fixed cells, leading to inefficient use of space and increased downtime due to the need for tools and technicians to enter through barrel ends or doorways, limiting accessibility and productivity.
Innovation Solution
A continuous line assembly system that advances half barrel sections through multiple work stations simultaneously, allowing for continuous processing and reduced space requirements, with processor-assisted monitoring and control to facilitate efficient joining of upper and lower half barrels using a butt splice with a splice plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fixed cell assembly methods are used with scanning and indexing, then tools and equipment can be positioned for specific work portions, but space efficiency deteriorates and downtime increases due to repeated setup and repositioning
Solution Approach 1:
Instead of bringing tools and technicians to the structure in fixed cells, the patent inverts the approach by bringing the structure to the tools and technicians through continuous movement on a conveyor system. The airframe moves continuously through the assembly line while work stations remain stationary, eliminating the need for repeated scanning, indexing, and repositioning of tools and equipment.
Solution Approach 2:
The patent transitions from static fixed cell assembly to dynamic continuous movement. The airframe is continuously moved through the assembly line at a controlled pace, allowing multiple work stations to perform operations simultaneously on different portions of the structure. This dynamic approach eliminates downtime associated with repeated setup and repositioning in fixed cells.
2Ease of operation
If tools and technicians enter through barrel ends or doorways in fixed cells, then access to specific portions is achieved, but accessibility deteriorates and time loss increases due to entry/exit requirements
Solution Approach 1:
The patent eliminates the need for tools and technicians to enter and exit through barrel ends or doorways by inverting the traditional approach. Instead of accessing the structure through limited openings, technicians work at stationary stations while the structure is continuously brought to them. This provides continuous, unrestricted access without the time loss associated with entry and exit operations.
3Productivity
If continuous line assembly is implemented with simultaneous advancement through multiple work stations, then productivity and space efficiency improve, but system complexity increases due to coordination requirements
Solution Approach 1:
The patent employs a universal conveyor system that can accommodate multiple work stations and perform various assembly operations simultaneously. The continuous movement mechanism serves multiple functions: transporting the airframe, positioning it for different operations, and coordinating the sequence of work station interactions. This multi-functional approach manages system complexity while maximizing productivity.
Solution Approach 2:
The patent maintains continuous movement of the airframe through the assembly line, eliminating idle time and ensuring that useful work is performed continuously. The conveyor system coordinates multiple work stations to operate simultaneously on different portions of the structure, maintaining continuous productive action without the start-stop cycles inherent in fixed cell assembly.
4Measurement precision
If fixed cell assembly with repeated scanning and indexing is used, then precise positioning is achieved, but space requirements increase and fabrication efficiency decreases
Solution Approach 1:
The patent inverts the traditional fixed cell approach by maintaining stationary work stations and moving the structure continuously through them. This eliminates the need for multiple fixed cells and the space required for repeated scanning and indexing operations. Precise positioning is achieved through the controlled movement of the conveyor system rather than repeated repositioning of tools and equipment.
Data Source
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 across multiple stations 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 and lower 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 of the fuselage. Multiple joined circumferential sections are joined together to form an elongated extent of the fuselage. Indexing features 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.