Horizontal Pulsing Wing Assembly Line

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Solution Overview

Problem

Existing aircraft wing assembly processes are inefficient due to the need for large, expensive fixtures, manual labor, and impractical scheduling, which limits the ability to pulse wings through specialized assembly stations and requires high-value non-added time for rotating and reassembling components.

Innovation Solution

A horizontal pulsing assembly line using synchronized automated vehicles and multi-axis positioning systems for determinant assembly, with magnetic clamping, drilling, fastener insertion, and sealant application, allowing for reconfigurable and efficient assembly of wing structures without massive tooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If large floor mounted assembly fixtures are used to hold wing components, then the wing structure can be controlled and located during assembly, but the system becomes expensive, immobile, and incapable of pulsing through assembly stations

Engineering Contradiction:

Improvewing structure location controlVSAvoidassembly line pulsing capability

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The wing assembly system is segmented into multiple independent assembly stations (first position, second position, third position) rather than using a single large fixed fixture. Each station has its own positioning capabilities, allowing the wing to be assembled in sections and pulsed through the line efficiently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from static floor-mounted fixtures to dynamic overhead suspended fixtures that can move and reposition. The overhead fixtures can be dynamically adjusted to accommodate different wing configurations and enable pulsing through the assembly line at controlled rates.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If manual drilling and fastening operations are used, then flexibility in assembly process is maintained, but labor costs increase and ergonomic quality deteriorates

Engineering Contradiction:

Improveassembly process flexibilityVSAvoidlabor efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The assembly system incorporates automated drilling and fastening equipment that performs operations autonomously without requiring manual intervention for each fastener. The system self-regulates the drilling, countersinking, and fastener installation processes, improving both productivity and ergonomic quality while maintaining process flexibility through programmable control.

Inventive Principle:

Principle #25Self-service

3Speed

If overhead building cranes are used to transport wings, then wing movement between positions is enabled, but specialized crews are required and non-value added time increases

Engineering Contradiction:

Improvewing transport capabilityVSAvoidscheduling delays

Core Design Contradiction:

SpeedVSLoss of time

Solution Approach 1:

The system introduces automated transfer mechanisms as intermediaries between assembly stations, eliminating the need for overhead cranes and specialized crews. These automated transfer systems seamlessly move wings between positions, reducing scheduling delays and non-value added time while maintaining transport speed.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If large multi-ton weldments or cast tools are used to locate side of body components, then component location precision is achieved, but the tools become expensive and impractical to move through horizontal pulsing assembly line

Engineering Contradiction:

Improvecomponent location accuracyVSAvoidtool mobility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system replaces heavy mechanical weldments and cast tools with lightweight electronic positioning systems. Sensors, actuators, and computer-controlled mechanisms provide precise component location and alignment without requiring massive physical tooling, enabling the tools to be easily moved through the horizontal pulsing assembly line while maintaining manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10391543B2High rate pulsing wing assembly line

Publication Date: 2019.08.27 THE BOEING CO

AI summary

A single piece pulsed flow wing assembly method providing for horizontal wing manufacture is accomplished using synchronized automated vehicles guided in a predetermined manner to move and, locate wing structure in a plurality of assembly positions. Multi-axis assembly positioning systems (MAPS) are used at each assembly position to support and index components in the wing structure and determinant assembly techniques are used for indexing of the components. Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.