Mobile Hexapod Tool for Aircraft Assembly

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Solution Overview

Problem

Current aircraft assembly methods are inefficient, requiring manual operations, extensive reorientation of aircraft structures, and use of large, immovable automated systems, leading to increased production time and costs due to the need for extensive space and labor.

Innovation Solution

An autonomous tool system featuring a hexapod motion platform and overhead support system that allows for the simultaneous use of multiple tools to perform operations like drilling and fastening from above the aircraft structure, enabling flexible and efficient assembly without the need for manual reorientation or fixed monument fixtures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual assembly operations are performed by human operators, then flexibility in performing operations is maintained, but production time and labor costs increase significantly

Engineering Contradiction:

Improveproduction rateVSAvoidmanual operation requirement

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The patent replaces manual mechanical assembly operations with an automated mobile robotic system. The robotic device performs drilling, countersinking, and fastener installation operations that were previously done manually, thereby increasing production rate while reducing labor requirements

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The robotic system is designed to be mobile rather than fixed, allowing it to move dynamically to different work locations on the aircraft structure. This mobility enables automation to adapt to various assembly positions without requiring the entire structure to be reoriented or moved

Inventive Principle:

Principle #15Dynamics

2Productivity

If automated systems are used for assembling aircraft structure, then productivity increases, but system size and weight increase

Engineering Contradiction:

Improveassembly efficiencyVSAvoidautomated system weight

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

The automated assembly system is divided into separate modular components: a mobile robotic platform, interchangeable end effectors, and portable tooling. This segmentation allows the system to be compact and mobile rather than a large fixed installation, reducing the weight and size of individual components while maintaining high productivity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The robotic system employs universal end effectors and tooling that can perform multiple assembly operations (drilling, countersinking, fastener installation) with a single device. This multi-functionality eliminates the need for multiple specialized heavy machines, thereby reducing overall system weight and size

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If aircraft structure is reoriented or moved between locations for assembly operations, then access to different sides is achieved, but assembly time and facility space requirements increase

Engineering Contradiction:

Improveaccess to structureVSAvoidreorientation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The robotic system features mobile platforms that can dynamically reposition themselves to access different sides and locations of the aircraft structure. This eliminates the need to statically reorient heavy aircraft components, significantly reducing assembly time and allowing operations to proceed without moving the main structure

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The mobile robotic system acts as an intermediary between the operator and the aircraft structure. Instead of moving the structure to access different sides, the robotic mediator moves itself to perform operations on all sides of the structure, thereby eliminating reorientation time

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If fixed monument fixtures are used for automated assembly, then positioning precision is improved, but facility reconfigurability and flexibility decrease

Engineering Contradiction:

Improvepositioning accuracyVSAvoidfacility reconfigurability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system replaces fixed monument fixtures with dynamic mobile robotic platforms that can be repositioned as needed. The robots achieve precise positioning through active control systems and sensors, maintaining manufacturing precision while allowing the facility to be reconfigured for different assembly tasks by simply moving the robotic platforms to new locations

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP2939796B1Mobile automated overhead assembly tool for aircraft structures

Publication Date: 2022.08.10 THE BOEING CO

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AI summary

A method and apparatus for performing an operation (111) on a work surface (116) (116) of a structure (106). The apparatus may comprise a motion platform (122) and an overhead support system (118). The motion platform (122) may be configured to be positioned above the work surface (116) (116) of the structure (106) to perform the operation (111) on the work surface (116) (116). The overhead support system (118) may be configured to carry the motion platform (122) across a floor (107) of a manufacturing environment (100) from a first location (117) to a second location (121).