Mirrored Wing Panel Assembly Layout for Higher Throughput
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Solution Overview
Problem
Current aircraft wing fabrication and assembly processes face inefficiencies due to uneven work density, excessive floor space usage, and time-consuming automated inspection techniques, leading to delays and increased costs.
Innovation Solution
Implementing an assembly line system where wing panels are arranged in mirrored orientations and transported in pulses or continuously, allowing work stations to perform tasks during pauses or while moving, integrating transportation into assembly and reducing the amount of work per movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are fabricated and assembled in predefined cells on a factory floor, then structural integrity and design parameters are maintained, but assembly efficiency decreases due to frequent moves between cells and setup time
Solution Approach 1:
The patent transforms the static cell-based assembly system into a dynamic flow line system where components move continuously through multiple workstations. The mirrored arrangement of wing panels allows the assembly line to adapt dynamically to different assembly sequences without requiring physical reconfiguration of the entire system, thereby maintaining reliability while improving productivity.
Solution Approach 2:
The mirrored assembly line configuration enables workstations to serve multiple functions by processing both left and right wing panels simultaneously. This universal approach allows the same equipment and personnel to work on both sides of the assembly, eliminating the need for separate dedicated cells for each wing panel and reducing overall setup time.
2Measurement precision
If automated optical inspection techniques and probes are used to inspect position of parts, then measurement precision is improved, but inspection time and cost increase substantially
Solution Approach 1:
The patent creates a digital twin or virtual model of the wing panel assembly that mirrors the physical assembly. This digital copy contains all the design parameters and expected positions, allowing for rapid virtual inspection and comparison against the actual assembly without requiring time-consuming physical measurements with optical equipment.
Solution Approach 2:
The system performs preliminary positioning and alignment of components during the assembly process itself, using the mirrored configuration to ensure symmetry and correct positioning before final assembly. This preliminary action reduces or eliminates the need for subsequent time-consuming inspection and repositioning operations.
3Ease of operation
If work density at a component portion is low and too much floor space is devoted to each portion, then ease of operation is improved, but productivity decreases due to delays when work takes longer than expected
Solution Approach 1:
The patent transitions from a two-dimensional cell-based layout to a three-dimensional flow line configuration where multiple wing panels are assembled simultaneously at different stages. The mirrored arrangement allows workstations to operate on both sides of the assembly line, effectively doubling the utilization of floor space and eliminating idle time caused by low work density in traditional cell layouts.
4Adaptability or versatility
If components are moved between cells frequently, then adaptability to different assembly needs is improved, but loss of time increases due to setup time required for each movement
Solution Approach 1:
The mirrored assembly line creates a continuous flow where wing panels move steadily through multiple workstations without interruption. The symmetrical configuration ensures that both left and right wing panels progress through assembly simultaneously, eliminating the need to stop and reconfigure equipment when switching between different assembly tasks, thus maintaining adaptability while removing setup time delays.
Data Source
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AI summary
Systems and methods are provided for assembly line (100) processing of aircraft wing panels (150). The method includes inputting wing panels (150) into an assembly line (100), the assembly line (100) having a number of work stations (120), the wing panels (150) oriented such that leading edges (155) are all on a first side (166) of the work stations (120), and trailing edges (157) are all on a second side (165) of the work stations (120), and advancing the wing panels (150) in a process direction (181) through the number of work stations (120), at least a first portion of the work stations (120) dedicated to wing panel leading edge (155) processing, and a second portion of the work stations (120) dedicated to wing panel trailing edge (157) processing.