Modular Wing Portions for Fuel System Integration
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Solution Overview
Problem
Existing methods for installing fuel system components in aircraft wing assemblies are inefficient, leading to slow manufacturing processes, congested assembly lines, and ergonomic challenges for operators.
Innovation Solution
The introduction of modular wing portions, which are pre-assembled units comprising ribs and internal fuel tank system components, allowing for offsite assembly and installation as a single piece, thereby reducing the need for on-site installation and improving ergonomic conditions for operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fuel system components are installed in situ into the wing box during assembly, then the fuel system components can be integrated into the wing structure, but the manufacturing process becomes slow and the assembly line becomes congested
Solution Approach 1:
The wing assembly process is segmented into two independent parallel processes: (1) assembling the wing box structure with ribs and covers, and (2) pre-assembling fuel system components separately. This segmentation allows both processes to occur simultaneously without interfering with each other, thereby maintaining structural integration while improving manufacturing throughput and reducing assembly line congestion.
Solution Approach 2:
Fuel system components are pre-assembled and prepared in advance at a separate location before being installed into the completed wing box. This preliminary action eliminates the need to perform fuel system installation during the critical wing assembly path, thereby improving overall manufacturing speed without compromising the integration of fuel systems into the wing structure.
2Manufacturing precision
If fuel system components are installed while working underneath the wing box, then the components can be positioned correctly, but operators face ergonomic challenges with arms raised above heads
Solution Approach 1:
The fuel system component installation process is extracted from the constrained environment underneath the wing box and relocated to a separate pre-assembly area. In this extracted setting, operators can work at optimized heights with proper ergonomics while still achieving correct positioning of components. The pre-assembled fuel system is then installed into the wing box as a unit, maintaining positioning accuracy while eliminating ergonomic challenges.
3Reliability
If fuel system components are installed sequentially during rib installation, then the components can be integrated as the wing is built, but the assembly process becomes congested and slow
Solution Approach 1:
Fuel system components are pre-assembled and prepared in advance at a separate location before being installed into the completed wing box. This preliminary action eliminates the need to perform fuel system installation during the critical wing assembly path, thereby improving overall manufacturing speed without compromising the integration of fuel systems into the wing structure.
Solution Approach 2:
The wing assembly process maintains continuous productive action by having the fuel system pre-assembled in parallel. While the wing box is being assembled continuously without interruption, the fuel system components are simultaneously prepared in another area. This continuous parallel action eliminates idle time and ensures both processes are completed efficiently, reducing total manufacturing time while maintaining proper integration.
Data Source
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AI summary
The present disclosure concerns a modular wing portion (390) for installation into a wing assembly (503) as a pre-assembled unit, the modular wing portion comprising at least one rib (300) and at least one internal fuel tank system component (340), and a cartridge jig (101) for the assembly of said modular wing portion (390) away from an aircraft wing 501, the cartridge jig (101) comprising a plurality of secondary support members, each secondary support member configured to receive and support a rib (300) such that a fuel system component (340) can be installed to the rib. Associated aircraft (500) and wings (501), transport frames (600) and methods of assembly are also disclosed.