Movable Gantry Interface for Multi-Jig Aircraft Drilling

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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 redesign for each aircraft variant, and monumental robotic installations being costly and inflexible, limiting scalability and reconfiguration.

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 a computing system, RFID for part identification, and interchangeable end effectors to process multiple jigs and adapt to different aircraft designs, enabling real-time data updates and flexible production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual drilling tools are used, then flexibility in operation is maintained, but labor intensity increases and defect generation occurs

Engineering Contradiction:

ImproveflexibilityVSAvoidlabor intensity

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The system uses RFID tags and automated identification to self-determine which jig is being processed, eliminating the need for manual setup and reducing labor intensity while maintaining flexibility across different jig types

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual drilling operations are replaced with an automated robotic end effector that performs drilling, reaming, and countersinking operations automatically, reducing labor intensity while maintaining operational flexibility through programmable control

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If semi-automated drilling tools are used, then drilling precision is improved, but reconfiguration is required for each aircraft variant

Engineering Contradiction:

Improvedrilling precisionVSAvoidreconfiguration flexibility

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system is designed to universally interface with multiple jig types through standardized mounting mechanisms and RFID-based identification, allowing a single automated drilling unit to handle different aircraft variants without physical reconfiguration

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system dynamically adapts to different jigs by reading RFID tags and automatically adjusting drilling parameters, hole patterns, and operational sequences through software control, eliminating the need for physical reconfiguration

Inventive Principle:

Principle #15Dynamics

3Extent of automation

If monumental robotic installations are used, then automation extent is improved, but cost and foundation requirements increase

Engineering Contradiction:

Improveautomation levelVSAvoidsystem complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The automated drilling system is segmented into a modular end effector that can be mounted on existing manual assembly cell gantries, avoiding the need for monumental robotic installations while maintaining high automation levels through distributed control

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system uses RFID tags as intermediaries between the automated end effector and the jig, enabling automatic identification and parameter transmission without complex mechanical interfaces or foundation requirements

Inventive Principle:

Principle #24Intermediary (Mediator)

4Manufacturing precision

If fixed monumental machines are used, then manufacturing precision is maintained, but reconfiguration time increases

Engineering Contradiction:

ImproveprecisionVSAvoidreconfiguration time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The system dynamically reconfigures for different aircraft variants by reading RFID tags and automatically loading appropriate drilling programs, hole patterns, and parameters, maintaining precision while eliminating reconfiguration time through software-based adaptation

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system maintains manufacturing precision by dynamically changing operational parameters (drilling depth, speed, hole pattern coordinates) based on RFID-identified jig type, without requiring physical reconfiguration of the equipment

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11740605B2Movable gantry system configured to interface with jigs of different sizes

Publication Date: 2023.08.29 WILDER SYST INC

AI summary

A movable gantry system is described. In an example, the 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.