Indexed Drill Jig Assembly for Precise Aircraft Hole Alignment

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Solution Overview

Problem

The assembly of aircraft components, particularly large structures like wings, faces challenges in aligning predrilled holes within designated tolerances due to manufacturing tolerances and the use of different materials, leading to fitment issues and contamination during drilling, which traditional robotic systems are cumbersome and expensive.

Innovation Solution

A method and system utilizing jigs with indexing features and a carriage-mounted drill to align and drill components at separate factory locations, ensuring precise hole alignment and minimizing contamination, using a jig with a body, track, and carriage system for accurate positioning and drilling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional robotic systems are used for drilling and assembly, then automation and productivity are improved, but device complexity and cost increase significantly

Engineering Contradiction:

ImproveautomationVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent divides the manufacturing process into separate stages: drilling is performed at the component level using simple jigs, while assembly is performed at the assembly level. This segmentation allows each stage to use appropriately complex equipment, avoiding the need for complex robotic systems throughout the entire process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces jigs as intermediary tools that facilitate precise drilling and alignment without requiring complex robotic systems. The jigs act as mediators between the drilling operation and the final assembly, enabling accuracy through simple, reusable fixtures rather than complex automation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If components are predrilled at different locations, then manufacturing flexibility is improved, but hole alignment precision deteriorates due to cumulative tolerances

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidhole alignment

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent incorporates alignment feedback mechanisms where the position and orientation of predrilled holes are measured and used to adjust subsequent drilling or assembly operations. This feedback loop compensates for cumulative tolerances and ensures precise hole alignment even when components are manufactured at different locations.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent performs preliminary drilling operations at component manufacturing locations using jigs that establish accurate hole positions. By completing drilling before assembly and using precise jig-based positioning, the system prepares components in advance with pre-established alignment references that simplify final assembly.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If drilling is performed at assembly location, then hole alignment is improved, but contamination of fay seal and exposure of bare metal occur

Engineering Contradiction:

Improvehole alignmentVSAvoidcontamination

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The patent performs drilling operations as a preliminary step before final assembly and sealing operations. By completing all drilling and cleanup operations beforehand, the system prevents drilling debris from contaminating fay seals and avoids exposing bare metal that would require additional protection during assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the manufacturing process into distinct phases: drilling and cleanup at the component level, followed by assembly and sealing at the assembly level. This segmentation ensures that harmful activities like drilling are separated from sensitive operations like seal application, eliminating contamination risks.

Inventive Principle:

Principle #1Segmentation

4Productivity

If large robotic systems are used for assembly, then automation is improved, but space requirements and infrastructure needs increase

Engineering Contradiction:

ImproveautomationVSAvoidspace requirement

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The patent segments assembly operations into smaller, modular tasks performed by simple equipment rather than large integrated robotic systems. Components are prepared separately using compact jigs and fixtures, then assembled using straightforward positioning and fastening operations that require minimal space and infrastructure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs simple, inexpensive jigs and fixtures that can be easily stored and transported, replacing the need for large, expensive robotic systems. These temporary tools enable precise operations without requiring permanent infrastructure investments in reinforced flooring or extensive workspace.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS12544868B2Precision assembly process and advance tooling methods of use

Publication Date: 2026.02.10 THE BOEING CO

AI summary

A jig for use in performing an operation on a component includes a body including a back surface and a front surface opposite the back surface. The front surface defining a nominal shape of the component. The jig also includes a track extending at least partially along a length of the body. The jig further includes a carriage mounted to the track and adjacent the back surface. The carriage configured for movement in an X direction along the track and in a Y direction perpendicular to the X direction. The jig also includes a drill mounted to the carriage.