Aeronautical Hardpoint Alignment Using Laser-Guided Adaptive Tooling
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Solution Overview
Problem
Aeronautical assembly processes face high costs and inaccuracies due to the need for precise alignment of hardpoints, with existing methods like dedicated and modular tooling being costly and inflexible, and jigless techniques lacking rigidity for accurate final operations.
Innovation Solution
An adaptive tooling method using a laser positioning system to align assembly tools dynamically, allowing for flexible positioning and accurate alignment of hardpoints, incorporating a laser collimator, coaxiality sensors, and driven linear tables to adjust tool positions based on real-time measurements, ensuring precise alignment without the need for pre-determined jig positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated tooling with fixed devices is used, then assembly accuracy is maintained, but manufacturing cost and modification time increase significantly
Solution Approach 1:
The patent transforms fixed, static tooling into a dynamic system where positioning devices can be adjusted and repositioned. The modular positioning devices with adjustable support structures allow the tooling system to adapt to different assembly requirements without requiring complete tooling replacement, thereby reducing manufacturing costs while maintaining accuracy.
Solution Approach 2:
The dedicated tooling system is divided into modular positioning devices that can be independently adjusted and repositioned. This segmentation allows individual components to be modified or replaced without affecting the entire tooling system, reducing overall manufacturing and modification costs while preserving assembly accuracy.
2Ease of manufacture
If modular tooling with standardized profiles is used, then cost is reduced through recyclability, but positioning accuracy and flexibility decrease
Solution Approach 1:
The patent incorporates measurement devices that provide feedback on the actual positions of hardpoints. This feedback mechanism allows the system to detect and compensate for positioning deviations, ensuring that even with modular, recyclable components, the assembly accuracy requirements are met through real-time measurement and adjustment.
3Manufacturing precision
If laser trackers are used for in situ calibration, then positioning accuracy reaches 10 microns, but equipment cost and preparation time increase
Solution Approach 1:
The patent integrates measurement capabilities directly into the positioning devices, allowing for preliminary measurement and adjustment to be performed during the assembly process itself rather than requiring separate calibration steps with expensive laser trackers. This reduces preparation time while maintaining the required 10-micron accuracy through built-in measurement and compensation mechanisms.
4Adaptability or versatility
If assembly processes are made flexible to adapt to deviations, then cost overruns are reduced, but maintaining high accuracy becomes more difficult
Solution Approach 1:
The system uses measurement devices to continuously monitor hardpoint positions and provides feedback to the positioning system. This feedback loop enables the flexible tooling to automatically compensate for deviations and maintain alignment accuracy within tolerances, combining adaptability with precision.
Solution Approach 2:
The patent replaces rigid mechanical alignment systems with a combination of measurement-based detection and computational compensation. Instead of relying solely on mechanical precision, the system uses optical or electronic measurement devices to detect positions and calculates necessary adjustments, enabling flexible adaptation while maintaining accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces assembly costs and improves accuracy by allowing flexible adaptation to assembly deviations, enabling precise drilling and riveting operations while maintaining high accuracy, thus increasing the number of compliant products and reducing material and time expenditures.
Implementation Method 1
a laser collimator for emitting a laser beam defining an axis
Implementation Method 2
at least one coaxiality sensor for detecting a position where the laser beam strikes it
Data Source
AI summary
The present disclosure relates to a method of assembling hardpoints in aeronautical structures, and more specifically, the disclosed method allows knowing the relative deviation of the hardpoints and of the positioning elements of the hardpoints with respect to a laser beam emitted by a laser collimator fixed to an adjustable support which can be adjusted in at least two directions in space, and by using a correction algorithm, it is possible to know the displacement necessary for locating the positioning elements such that they are aligned with respect to the hardpoints, the positioning elements in turn being moved as a result of the movement of the driven linear tables in one or in several iterative steps, at which time the position thereof is fixed and they are ready for the rest of the hardpoints to be assembled.