Multipiece Wing Ribs for Faster Aircraft Skin Assembly
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Solution Overview
Problem
Assembling aircraft wings is a time-consuming process due to the difficulty in attaching upper and lower wing skins to ribs, as accessibility is limited once both skins are in place, complicating the assembly process.
Innovation Solution
The wing ribs are constructed from multiple pieces or portions, allowing for improved accessibility and alignment by forming complementary engagement surfaces through mechanical separation of a single unitary rib structure, which can be secured using fasteners and shims as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unitary rib structures are used, then structural integrity is maintained, but assembly time and complexity increase due to limited accessibility
Solution Approach 1:
The rib structure is divided into multiple segments (first rib portion and second rib portion) that can be assembled separately and then joined together. This segmentation allows workers to access and assemble rib portions from different sides of the wing assembly, significantly reducing assembly time while maintaining structural integrity through the joining mechanism
Solution Approach 2:
The rib portions are designed to nest within the wing assembly structure during assembly, with engagement surfaces that interface with both the wing skin and adjacent rib portions. This nesting approach allows for compact assembly while preserving the structural characteristics of a unitary rib
2Reliability
If unitary rib structures are used, then structural integrity is maintained, but assembly complexity increases due to accessibility constraints
Solution Approach 1:
By segmenting the rib into multiple portions, the assembly process becomes less complex as each portion can be independently positioned and secured. The segmentation eliminates the need to maneuver a single large unitary rib through tight spaces, reducing assembly complexity while maintaining structural integrity
Solution Approach 2:
Rib portions are pre-positioned and secured to the wing assembly in a sequential manner, with preliminary securing of fasteners allowing subsequent rib portions to be installed more easily. This preliminary action reduces overall assembly complexity by breaking down the complex task into manageable steps
3Ease of operation
If rib portions are mechanically separated, then accessibility and alignment are improved, but manufacturing complexity increases
Solution Approach 1:
The mechanical separation of ribs into portions is achieved through segmentation, which improves accessibility during assembly. The segmentation is designed with standardized engagement surfaces that simplify the manufacturing process, offsetting the increased complexity of producing multiple rib portions
Solution Approach 2:
The rib portions are designed with specific geometric parameters including engagement surfaces, fastener holes, and dimensional tolerances that facilitate easy manufacturing. By optimizing these parameters, the manufacturing complexity is minimized while maintaining the accessibility benefits of mechanical separation
Data Source
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AI summary
A wing assembly includes an upper wing skin (60), a lower wing skin (64), and ribs (50) extending between an upstream spar (82) and a downstream spar (84) with the upper wing skin and the lower wing skin at least partially enclosing the ribs. Each of the ribs includes a first rib portion having an upper wing skin engagement surface and a first rib engagement surface located on an opposite side of the first rib portion for the upper wing skin engagement surface and a second rib portion having a lower wing skin engagement surface and a second rib engagement surface. The second rib engagement surface on the second rib portion is secured to the first rib engagement surface on the first rib portion with rib fasteners (88, 96).