Laser Hardpoint Alignment for Flexible Aerostructure Assembly
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Solution Overview
Problem
The aeronautical industry faces high costs and inaccuracies in assembling aircraft structures due to the complexity and number of elements, with existing methods like dedicated and modular tooling being costly and inflexible, and jigless techniques lacking rigidity for precise operations like drilling and riveting.
Innovation Solution
An adaptive tooling method using a laser positioning device to align and position assembly tools dynamically, allowing for flexible and accurate alignment of hardpoints in aeronautical structures, incorporating a laser collimator, coaxiality sensors, and driven linear tables to adjust tool positions with high precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated tooling with fixed devices is used, then assembly accuracy is improved, but manufacturing cost and modification time increase significantly
Solution Approach 1:
The dedicated tooling system is divided into modular components (support devices, positioning elements, alignment devices) that can be independently manufactured and reconfigured. This segmentation allows standard parts to be reused across different assembly tasks, reducing overall manufacturing cost while maintaining positioning accuracy through precise modular interfaces.
Solution Approach 2:
The tooling system transitions from fixed, static positioning to dynamic, adjustable positioning. Positioning elements can be moved along guides and reconfigured for different assembly scenarios, allowing the same tooling to adapt to various hardpoint configurations without requiring expensive custom tooling for each variant.
2Ease of manufacture
If modular tooling with standardized profiles is used, then manufacturing cost is reduced, but positioning precision and rigidity deteriorate
Solution Approach 1:
Traditional mechanical alignment methods are replaced with optical alignment using laser devices. The laser provides a precise reference axis that compensates for the inherent imprecision of modular components, enabling accurate hardpoint alignment even with standardized, reusable tooling elements.
Solution Approach 2:
The system uses adjustable positioning elements that can be fine-tuned along guides to achieve precise positioning. The combination of modular components with adjustable parameters (position along guide, orientation) allows the system to maintain precision while using standardized parts.
3Adaptability or versatility
If jigless techniques are used, then flexibility and cost are improved, but rigidity and measurement precision for drilling and riveting deteriorate
Solution Approach 1:
A laser alignment device serves as an intermediary reference system between the flexible modular tooling and the precision requirements of drilling/riveting operations. The laser provides a stable, precise reference that enables accurate positioning without requiring rigid dedicated tooling, bridging the gap between flexibility and precision.
4Measurement precision
If laser trackers are used for in situ calibration, then measurement precision is improved, but device complexity and preparation time increase
Solution Approach 1:
The complex laser tracker system is replaced by extracting only the essential alignment function and implementing it through a simpler laser device integrated into the modular tooling. This provides sufficient measurement precision for the application without the complexity and cost of industrial laser trackers.
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 method reduces costs and improves accuracy in assembling aeronautical structures by allowing flexible adaptation of tool positions, enabling precise alignment and assembly operations like drilling and riveting, while maintaining competitive costs compared to guided robots.
Implementation Method 1
a laser collimator (7) for emitting a laser beam (7')
Implementation Method 2
at least one coaxiality sensor (9) for detecting a position where the laser beam (7') strikes
Data Source
AI summary
The present disclosure relates to a method of assembling hardpoints in aeronautical structures, and more specifically, the disclosed method allows knowing the relative deviation of the hardpoints and of the positioning elements of the hardpoints with respect to a laser beam emitted by a laser collimator fixed to an adjustable support which can be adjusted in at least two directions in space, and by using a correction algorithm, it is possible to know the displacement necessary for locating the positioning elements such that they are aligned with respect to the hardpoints, the positioning elements in turn being moved as a result of the movement of the driven linear tables in one or in several iterative steps, at which time the position thereof is fixed and they are ready for the rest of the hardpoints to be assembled.