Inner Outer End Effector Clamping for Wing Box Fastening
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Solution Overview
Problem
The challenge lies in automating the precise positioning and orientation of fasteners within the confined and tight spaces of an aircraft wing box, particularly due to space constraints and the need for synchronization between robots inside and outside the wing box, which is complicated by the weight and size of the end effector and tight aircraft tolerances.
Innovation Solution
A robotic system utilizing an inner end effector with a clamping block and an outer end effector equipped with an electromagnet, along with two telescoping lead screw assemblies cantilevered from an actuator assembly, allows for precise translation and rotation of the inner end effector to achieve desired orientation within the wing box, with the outer end effector magnetically attracting the clamping block to clamp the wall between the inner and outer end effectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robot enters the narrow space via the access port to perform fastening operations, then automation is achieved, but the robot cannot navigate past stringers inside the narrow space due to space constraints
Solution Approach 1:
The robotic system is divided into two separate robots: one operating inside the confined space and another outside. This segmentation allows each robot to be optimized for its specific operating environment, with the internal robot being compact enough to navigate past stringers while maintaining automated fastening capabilities.
Solution Approach 2:
The end effector is designed with nested components including telescoping lead screw assemblies that can extend and retract. This nesting allows the end effector to compactly fit within the narrow confined space while still achieving the necessary reach and positioning capability for fastening operations.
2Manufacturing precision
If the end effector is positioned precisely over the target, then fastening accuracy is improved, but the end effector cannot achieve desired orientation due to space constraints
Solution Approach 1:
The end effector incorporates dynamic positioning mechanisms including telescoping lead screw assemblies that can extend and retract independently. This dynamic capability allows the end effector to adjust its position and orientation in real-time to achieve precise alignment with fastener targets while navigating space constraints within the confined structure.
Solution Approach 2:
The positioning system utilizes multiple dimensions of movement including linear translation along lead screw axes and rotational adjustment. By operating in multiple dimensional spaces, the end effector can achieve precise three-dimensional positioning and orientation of fasteners despite the constrained access environment.
3Stability of the object's composition
If the end effector is made heavier to maintain stability during operations, then operational stability is improved, but the robot cannot position the end effector precisely due to weight constraints
Solution Approach 1:
The system replaces traditional heavy mechanical positioning systems with electrically actuated lead screw mechanisms. These electric drive systems provide precise control and positioning capability while being significantly lighter than equivalent mechanical systems, enabling both stability and precision within the weight constraints of the confined space robot.
4Productivity
If the robot inside the narrow space performs fastening operations, then productivity is improved, but synchronization with the robot outside the wing box becomes complex
Solution Approach 1:
The dual-robot system incorporates feedback mechanisms where the robots communicate their positions, operations status, and synchronization state. This feedback loop allows the control systems to coordinate the internal and external robots, ensuring that fastening operations on opposite sides of the structure are properly synchronized while maintaining high productivity.
Solution Approach 2:
Both robots are equipped with similar end effectors and control systems, creating a universal platform that can perform complementary functions. This multi-functionality allows the system to handle various fastening operations (drilling, countersinking, fastener insertion, and termination) with a standardized approach, simplifying synchronization while improving overall productivity.
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 solution enables the automation of fastening operations within the wing box, improving productivity and reducing worker injuries by achieving precise and synchronized operations within the tight space constraints of aircraft wing boxes, while adhering to stringent aircraft tolerances.
Implementation Method 1
positioning an outer end effector over the target, the outer end effector carrying an electromagnet; energizing the electromagnet such that the outer end effector magnetically attracts the clamping block to clamp the wall between the inner and outer end effectors
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A method of manufacture within a confined space defined in part by a wall, comprises the following steps: moving an inner end effector (550) into the confined space, the inner end effector (550) having a clamping block (556) attached thereto; using first and second parallel telescoping lead screw assemblies (530, 540) to translate and rotate the inner end effector (550) until the inner end effector achieves a desired orientation with respect to a target within the confined space; positioning an outer end effector (640) over the target, the outer end effector (640) carrying an electromagnet; and energizing the electromagnet such that the outer end effector (640) magnetically attracts the clamping block (556) to clamp the wall between the inner and outer end effectors (550, 640).