Modular Assembly Cart for Composite Fuselage Barrel Stabilization
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Solution Overview
Problem
There is a need for equipment that can stabilize, hold, and transport large composite fuselage barrels with diameters of about 19 feet and lengths of more than 24 feet, as existing equipment cannot support the weight or align such structures for assembly in new generation aircraft like the Boeing 7E7, which uses composite materials that are not as stiff as traditional materials.
Innovation Solution
A modular assembly cart system with stabilizer rings and clamps that can be adjusted to fit the size and shape of the fuselage barrel, including casters and jack assemblies for mobility and alignment, allowing the barrels to be securely clamped and rotated for assembly and inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used for fuselage barrels, then weight is reduced and fuel efficiency is improved, but the material becomes less stiff and cannot support its own weight when moved
Solution Approach 1:
The fuselage barrel is divided into multiple modular sections that can be independently supported and assembled. The assembly cart system uses multiple separate ring assemblies (at least two rings) that can independently support different portions of the barrel, allowing the lightweight composite structure to be stabilized without requiring the material itself to bear the full structural load during assembly and transport.
2Ease of operation
If the inner mold line mandrel is removed after curing, then the fuselage barrel can be accessed and assembled, but the barrel collapses under its own weight without support
Solution Approach 1:
The assembly cart system is prepared in advance with adjustable ring assemblies and support structures positioned around the fuselage barrel before the mandrel is removed. This preliminary positioning of support structures ensures that as soon as the mandrel is extracted, the barrel is already stabilized and prevented from collapsing, allowing safe access and assembly operations.
Solution Approach 2:
The assembly cart system acts as an intermediary support structure between the mandrel and the final assembled fuselage. The adjustable rings and support mechanisms provide temporary stabilization during the critical transition period when the mandrel is removed and before the fuselage barrel is permanently assembled, preventing collapse while enabling access for assembly operations.
3Adaptability or versatility
If existing equipment is used for transporting fuselage barrels, then infrastructure can be maintained, but the equipment cannot align or support the large composite structures
Solution Approach 1:
The assembly cart system incorporates dynamically adjustable components including movable rings, adjustable support heights, and reconfigurable clamping mechanisms. These dynamic elements can be adapted to accommodate different fuselage barrel sizes, shapes, and assembly requirements, providing both transport capability and alignment functionality that existing static equipment cannot achieve.
Solution Approach 2:
The assembly cart system is designed as a multi-functional universal platform that combines transport, alignment, stabilization, and assembly support capabilities in a single system. The adjustable ring assemblies and support structures can accommodate various fuselage configurations and perform multiple operations, replacing the need for specialized equipment for each function.
4Adaptability or versatility
If modular assembly cart system is used, then adaptability to different fuselage sections is improved, but device complexity increases
Solution Approach 1:
The system uses segmented modular ring assemblies that can be independently configured and combined. Each ring assembly is a self-contained module that can be adjusted and positioned independently, allowing complex adaptability to be achieved through simple repetition and combination of standardized modules rather than requiring a completely custom complex system.
Solution Approach 2:
The modular components incorporate adjustable parameters such as ring diameter, support height, and clamping force that can be changed to accommodate different fuselage sections. This parameter adjustability within standardized modules provides versatility without requiring complex custom-designed components for each application.
Data Source
AI summary
A one-piece barrel assembly cart includes a right assembly cart base connected with a left assembly cart base and at least three stabilizer rings that are attached to the assembly cart base. The one-piece barrel assembly cart may be used to stabilize a tapered cured composite barrel, for example the large fuselage barrel of the aft section of a large new generation aircraft, such as a 7E7 Boeing airplane. A modular assembly cart includes at least two identical modules. Each of these modules includes a cart base and a stabilizer ring. The diameter of the inner surface of the stabilizer ring may vary as needed. Other modules including a fuselage support may be added. By providing modular assembly carts any shape and size of a one-piece composite barrel may be stabilized after curing of the composite material.