Movable Gantry Interface for Multi-Size Aircraft Jigs
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Solution Overview
Problem
Current aircraft manufacturing processes, particularly drilling operations, are labor-intensive, prone to defects, and inflexible, with manual tools being error-prone, semi-automated tools requiring frequent reconfiguration, and monumental robotic installations being costly and inflexible for adapting to different models or production increases.
Innovation Solution
A Movable Gantry System (MGS) that integrates with existing manual assembly cells to automate drilling, reaming, and countersinking operations, using a movable gantry system with interchangeable end effectors and RFID-based part identification for real-time data management, enabling precision and adaptability across various aircraft components and models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual drilling tools are used, then flexibility in operation is maintained, but labor intensity and defect generation increase significantly
Solution Approach 1:
The automated drilling system performs operations autonomously without continuous human intervention. The controller automatically sequences drilling, reaming, and countersinking operations based on pre-programmed parameters, allowing the system to serve itself and eliminating the need for operators to manually perform each drilling step.
Solution Approach 2:
Manual mechanical drilling operations are replaced with an automated mechanical system. The patent substitutes human-operated hand tools with an automated drilling apparatus that uses mechanical actuators and computer control to perform all drilling operations, thereby reducing labor intensity while maintaining operational flexibility through programmable control.
2Extent of automation
If monumental robotic installations are used, then automation and precision are achieved, but cost and inflexibility increase
Solution Approach 1:
The drilling system is divided into modular functional components including separate drilling units, reaming units, and countersinking units that can be independently controlled and configured. This segmentation allows the system to achieve automation through coordinated modules rather than requiring a single complex robotic installation, reducing overall system cost and increasing flexibility.
Solution Approach 2:
The automated drilling system is designed to perform multiple operations (drilling, reaming, countersinking) and can accommodate different aircraft components and configurations through programmable control. This multi-functionality eliminates the need for separate specialized machines for each operation, reducing device complexity and cost while maintaining high automation levels.
3Manufacturing precision
If application-specific drilling jigs are used, then drilling precision is improved, but reconfiguration time increases when design changes occur
Solution Approach 1:
The system employs dynamic, programmable control parameters that can be adjusted and reconfigured through software rather than requiring physical retooling. The controller can dynamically modify drilling paths, speeds, and operation sequences to accommodate design changes, maintaining drilling precision while enabling rapid adaptation to new configurations.
Solution Approach 2:
The system maintains manufacturing precision by controlling critical parameters through programmable logic rather than fixed mechanical jigs. When design changes occur, operators can modify parameter sets (drilling depths, speeds, tool paths) in software, allowing the system to adapt to new requirements without physical reconfiguration, thereby reducing reconfiguration time while preserving precision.
4Extent of automation
If semi-automated tools are used, then some automation is achieved, but labor intensity and reconfiguration requirements remain high
Solution Approach 1:
The system merges multiple automated functions (drilling, reaming, countersinking) into a single integrated apparatus that operates autonomously. By combining these operations in one coordinated system rather than using separate semi-automated tools, the patent eliminates the need for operators to reconfigure equipment between operations and reduces overall labor intensity while maintaining high automation levels.
Data Source
AI summary
A movable gantry system is configured to interface with jigs of different types or sizes and/or with different positions of a same jig and/or to perform operations on different parts mounted in such jigs. To do so, the movable gantry system includes an end effector, a gantry, and a computing system. The end effector is mounted within the gantry and provides at least rotational movement to perform operations on a part. The gantry is movable and interfaces with a jig holding the part. Further, the gantry provides translational movement to the end effector. The computing system identifies the gantry and the part and controls the gantry and the end effector, thereby facilitating the operations on the part. The computing system stores, in a data store, information about an operation upon performed by the end effector after a datuming process based translational data and on rotational data.