Identical Geodesic Modules for Fuselage Assembly
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Solution Overview
Problem
The existing methods for manufacturing vehicle fuselages are time and labor intensive due to the use of numerous unique and distinct components in geodesic airframes and semi-monocoque structures, which complicates the assembly process.
Innovation Solution
A system and method utilizing identical geodesic modules with constant curvature and cross-sectional radius, formed from interconnected frame segments, which are self-similar and simplify the assembly process by reducing the number of unique components and fasteners required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If geodesic airframes with variable cross-section are used, then structural integrity is improved, but the number of unique parts increases and assembly complexity worsens
Solution Approach 1:
The fuselage is divided into multiple geodesic modules, each consisting of frame segments and skin panels. These modules are then assembled together to form the complete fuselage structure, making the complex structure manageable through modular construction
Solution Approach 2:
Standardized geodesic modules with uniform dimensions and configurations are used throughout the fuselage. Each module serves multiple functions: providing structural strength, defining cross-sectional geometry, and accommodating features like windows. This universality reduces the number of unique parts needed
2Strength
If numerous unique and distinct components are used in geodesic airframes, then structural integrity is improved, but assembly time and labor increase
Solution Approach 1:
The fuselage is divided into multiple geodesic modules, each consisting of frame segments and skin panels. These modules are then assembled together to form the complete fuselage structure, making the complex structure manageable through modular construction
Solution Approach 2:
Geodesic modules are pre-assembled with frame segments and skin panels before final fuselage assembly. This preliminary preparation of standardized modules reduces on-site assembly time and labor requirements
3Manufacturing precision
If semi-monocoque structures with fixed jigs are used, then manufacturing precision is improved, but assembly time and labor increase due to repetitive manual operations
Solution Approach 1:
The fuselage is divided into multiple geodesic modules, each consisting of frame segments and skin panels. These modules are then assembled together to form the complete fuselage structure, making the complex structure manageable through modular construction
Solution Approach 2:
The design transitions from traditional semi-monocoque construction to a geodesic modular system with standardized dimensions and configurations. This parameter standardization enables more efficient assembly processes while maintaining precision requirements
Data Source
AI summary
A system and method determine a size and a shape for identical geodesic modules that are used to form a structure. The system and method may include analyzing input data regarding a size and a shape of the structure to be formed, and determining the size and the shape for each of the identical geodesic modules based on the size and the shape of the structure to be formed. The structure may include a framework including the identical geodesic modules. Each of the geodesic modules has a size and a shape that are the same as all of the other of the geodesic modules. A forming system and method position a framework and a covering skin of the structure in relation to a mandrel, and drill and rivet the framework to the covering skin with a plurality of operating heads.