Optical Imaging Wing Panel Alignment System
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Solution Overview
Problem
Conventional methods for accurately positioning members during structure assembly, such as aircraft wing manufacturing, are prone to errors due to reliance on operator skill and visual judgment, especially when using plumbs, leading to potential misalignment and the need for costly repairs.
Innovation Solution
The implementation of an imaging device system that captures and displays images of holes on one member onto a monitor screen, allowing for precise alignment of members by moving them relative to preset markings, enabling accurate positioning even with inclined axes, and reducing labor costs by allowing single-worker operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If plumb is used for positioning members, then positioning can be performed on curved surfaces, but positioning accuracy deteriorates due to operator skill dependency and visual judgment errors
Solution Approach 1:
The patent replaces the mechanical plumb positioning system with an optical imaging system. A camera captures images of positioning holes through the transparent member, and a display device shows the hole positions. This substitution eliminates dependency on operator skill and visual judgment, providing objective and accurate positioning information while maintaining the ability to work with curved surfaces.
Solution Approach 2:
The patent creates a visual copy of the positioning hole positions by capturing images with a camera and displaying them on a screen. This copy allows operators to see the exact position and alignment of holes without directly observing them, enabling precise positioning while accommodating curved surface geometries that would make direct observation difficult.
2Stability of the object's composition
If plumb weight is positioned between members during assembly, then positioning can be maintained, but operation complexity increases due to the need to remove the plumb before final contact
Solution Approach 1:
The patent replaces the mechanical plumb weight system with an optical imaging and display system. The camera continuously captures hole positions, and the display shows real-time alignment information. This eliminates the need to physically remove the positioning aid before final member contact, as the optical system provides continuous guidance without interfering with the assembly process.
Solution Approach 2:
The patent introduces an optical intermediary (camera and display system) that mediates the positioning process. Instead of using a physical plumb weight that must be removed, the optical system acts as an intermediary that provides positioning information without physically interfering with the final contact between members, simplifying the operation sequence.
3Manufacturing precision
If multiple workers are used for positioning operations, then positioning accuracy can be improved through collaboration, but labor costs increase
Solution Approach 1:
The patent enables the positioning system to serve itself by providing automated visual feedback through the camera and display. The system automatically captures images, processes them, and presents alignment information without requiring multiple operators to coordinate their observations and judgments. This self-service capability maintains high positioning accuracy while reducing labor requirements to a single operator.
Solution Approach 2:
The patent implements a feedback mechanism where the camera continuously monitors hole positions and the display provides real-time visual feedback to the operator. This feedback loop enables one worker to achieve positioning accuracy that previously required multiple workers, as the system continuously guides the alignment process with objective visual information.
Data Source
AI summary
The method for manufacturing the structure includes an imaging device installation process in which a camera that obtains an image of a target hole formed in an upper panel is installed on the rear spar, and a positioning process in which relative positions are positioned by relatively moving the upper panel and the rear spar while the image of the target hole obtained by the camera and displayed on a monitor screen is aligned with a target line preset on the monitor screen.