One-Up Assembly Sequencing for Aircraft Drilling
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Solution Overview
Problem
Current methods for assembling aircraft structures using one-up assembly processes are inefficient due to inconsistencies and increased time and expense caused by drilling forces, gaps between layers, and burrs, which require disassembly and reassembly, leading to quality defects and costly mistakes.
Innovation Solution
A method and apparatus for automating the assembly sequence using adjacent hole clamping, which involves creating an adjacency list from points on the workpiece, controlling an assembly machine based on this list, identifying potential errors, and determining a revised sequence to ensure accurate drilling and fastening operations, thereby maintaining the one-up assembly process requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If drilling operations are performed on assembled workpiece layers, then manufacturing precision deteriorates due to inconsistencies, gaps between layers, and burrs, but disassembling and reassembling parts increases assembly time and expense
Solution Approach 1:
The system performs preliminary sequencing of drilling operations by identifying adjacency relationships between holes and determining an optimal drilling sequence before actual drilling begins. This preliminary planning ensures that drilling forces are applied in an order that maintains layer alignment and prevents gaps, eliminating the need for subsequent disassembly and reassembly operations.
Solution Approach 2:
The system incorporates feedback mechanisms by continuously monitoring the workpiece state during drilling operations, comparing actual drilling results against the planned sequence, and adjusting the drilling sequence in real-time to maintain manufacturing precision while avoiding operations that would require disassembly.
2Manufacturing precision
If drilling operations are performed without adjacent hole clamping, then device complexity is reduced, but manufacturing precision deteriorates due to drilling forces causing inconsistencies and gaps
Solution Approach 1:
The clamping system is segmented into localized clamps positioned at specific adjacent holes rather than a comprehensive clamping apparatus. This segmentation provides the necessary support at critical locations to maintain layer alignment during drilling, while avoiding the complexity of a full-system clamping mechanism. The adjacency list identifies which specific holes require clamping support.
Solution Approach 2:
The system introduces intermediary clamping elements at adjacent holes that act as mediators to distribute and control drilling forces. These intermediaries provide localized support where needed to prevent gaps and inconsistencies, rather than requiring a complex overall clamping structure. The clamps serve as intermediaries between the drilling force and the workpiece layers.
3Reliability
If a fixed drilling sequence is used, then device complexity is reduced, but reliability deteriorates due to unidentifiable errors and inability to adapt to potential issues
Solution Approach 1:
The system performs preliminary identification of potential errors and determination of an optimized drilling sequence before drilling begins. By analyzing the workpiece geometry, material properties, and drilling parameters in advance, the system identifies potential failure points and adjusts the sequence to prevent errors, thereby improving reliability without requiring complex real-time intervention systems.
Solution Approach 2:
The system incorporates feedback loops that monitor drilling operations and compare actual results against expected outcomes based on the predetermined sequence. When deviations are detected, the system can identify potential errors and adjust the remaining drilling sequence accordingly, improving reliability while maintaining manageable system complexity through rule-based decision making.
Data Source
AI summary
A method, a device, and a computer-readable storage medium is provided for performing the method for automating an assembling sequence operation for a workpiece using an one-up assembly process that uses adjacent hole clamping. The method can include obtaining an adjacency list from points for the workpiece to be assembled; controlling an assembly machine for assembling the workpiece using a sequence of assembly operations based on the adjacency list; identifying potential errors in the sequence of assembly operations; determining a revised sequence of assembly operations based on the potential errors that are identified; and controlling the assembly machine based on the revised sequence of assembly operations.