Continuous Floor Grid Installation in Inverted Fuselage Barrels

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Solution Overview

Problem

Current aircraft assembly methods require frequent scanning and indexing of airframe components in fixed cells, leading to inefficiencies and increased space requirements, as well as downtime due to the need for tools and technicians to enter barrel sections through small doorways.

Innovation Solution

Implementing a continuous line assembly system that allows airframe components to be moved through work stations while being assembled, with a method that includes receiving an inverted lower half barrel section of the fuselage, installing a floor grid, and using feeder lines to supply components just-in-time for assembly, reducing the need for tooling and technician access through small doorways.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If tools, equipment, and workers are brought to fixed cells for assembly work, then work can be performed on airframe components, but the process requires frequent scanning and indexing and increased space requirements

Engineering Contradiction:

Improveassembly processVSAvoidfactory space

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The patent inverts the traditional assembly approach by moving the airframe component through stationary work stations rather than bringing workers to fixed cells. The barrel section is inverted and conveyed through a continuous line assembly system with multiple work stations positioned along its length, eliminating the need for frequent scanning and indexing in fixed cells and reducing factory space requirements.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The system introduces dynamic movement of the airframe component through the assembly line. The barrel section is conveyed continuously or in pulses through work stations, allowing multiple operations to be performed simultaneously at different stations. This dynamic approach replaces the static fixed-cell method, improving manufacturing efficiency and reducing space needs.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If tools and technicians enter barrel sections through small doorways for installation work, then floor grids can be installed, but downtime occurs due to access constraints

Engineering Contradiction:

Improvefloor grid installationVSAvoidassembly downtime

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent inverts the installation approach by performing floor grid assembly outside the barrel section. Floor grid components are assembled on the barrel section while it is inverted and accessible from the exterior, then the completed floor grid is installed through the barrel opening. This eliminates the need for technicians to enter through small doorways and reduces assembly downtime.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The system performs preliminary assembly of floor grid components before final installation. Floor beams, intercostals, and panels are assembled together outside the barrel section while the barrel is inverted, allowing technicians easy access. The pre-assembled floor grid is then installed as a complete unit through the barrel opening, reducing the time components need to be inside the barrel and minimizing downtime.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If continuous line assembly is implemented with components moving through work stations, then throughput increases and space requirements reduce, but complex positioning and indexing systems are needed

Engineering Contradiction:

Improveassembly throughputVSAvoidpositioning and indexing system

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The assembly system is segmented into multiple discrete work stations positioned along the assembly line, each performing a specific function. The barrel section is divided into segments that can be independently worked on at different stations. This segmentation allows for standardized positioning mechanisms at each station, reducing overall system complexity while maintaining high throughput.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces an intermediary indexing system that coordinates movement between work stations. The indexing mechanism serves as a mediator that synchronizes the position of the barrel section with the operations at each work station. This centralized intermediary control simplifies the overall positioning system compared to having independent complex positioning mechanisms at each station.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentEP4001130A1Methods and systems for assembly and installation of airframe floor grids

Publication Date: 2022.05.25 THE BOEING CO

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AI summary

Systems and methods are provided for assembling an aircraft (10). One such method includes receiving a lower half barrel section (118) of fuselage (12) that is inverted to a keel-up orientation (563-3); and installing a floor grid (365) into the lower half barrel section (118) while inverted. One such system (500) comprises a plurality of work stations that install floor grid components onto a floor grid (365), a track (541) that advances the floor grid (365) in a process direction (199) through the work stations, and at least one feeder line associated with one of the work stations, the feeder line operable to provide a floor grid component to the work station just in time for installation onto the floor grid (365).