Pivoting Assembly Jig for Non-Planar Floor Alignment

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Solution Overview

Problem

Existing assembly jigs for aircraft components face challenges when used on non-planar floor surfaces, leading to movement issues and increased costs due to the need for expensive foundation modifications and inefficient portable solutions like air pads.

Innovation Solution

The design of a floor-standing assembly jig with a pivoting beam and caster wheels that decouples the jig's critical features from the floor, allowing selective movement and accommodating non-planar surfaces without requiring complex foundation work, by using a pivotable beam that can adjust up to ±5° from horizontal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If fixed assembly jigs are installed on thick concrete slabs with steel reinforcements to maintain planarity, then the jig stability and orientation accuracy are improved, but the installation cost and foundation complexity increase significantly

Engineering Contradiction:
Improvejig orientation accuracyVSAvoidfoundation installation cost
Core Design Contradiction:
Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent applies the dynamics principle by making the beam pivotable rather than fixed. The beam can rotate about a vertical axis to adapt to non-planar floor surfaces, transforming the static jig into a dynamic system that automatically compensates for floor irregularities. This eliminates the need for expensive thick concrete slabs with steel reinforcements while maintaining jig orientation accuracy through active adaptation.

Inventive Principle:
Principle #15Dynamics

2Ease of operation

If portable assembly jigs use air pads for movement across slabs, then the ease of relocation is improved, but the energy consumption and noise increase

Engineering Contradiction:
Improverelocation easeVSAvoidair consumption
Core Design Contradiction:
Ease of operationVSUse of energy by moving object

Solution Approach 1:

The patent replaces the pneumatic air pad system with a mechanical wheel-based transport system. The wheel assembly with pivotable beam provides a purely mechanical solution for moving the jig across floor surfaces, eliminating the need for compressed air systems, reducing energy consumption, and lowering operational noise while maintaining ease of relocation.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If conventional travelling jigs use dock resting points with control pads to straighten the jig, then the positioning accuracy is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:
Improvepositioning accuracyVSAvoiddock structure complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the complex dock resting point system with control pads. Instead, the pivotable beam with wheel assembly provides inherent positioning capability through its ability to pivot and self-align on non-planar surfaces. This simplifies the overall device by removing the need for external docking infrastructure while maintaining positioning accuracy.

Inventive Principle:
Principle #2Taking out (Extraction)

4Length of moving object

If assembly jigs span multiple foundation slab segments, then the jig length and coverage area are improved, but the jig stability and planarity deteriorate due to slab movement and expansion joints

Engineering Contradiction:
Improvejig span lengthVSAvoidjig planarity
Core Design Contradiction:
Length of moving objectVSStability of the object's composition

Solution Approach 1:

The patent applies dynamics by enabling the beam to pivot dynamically in response to floor irregularities. When the jig spans multiple slabs with movement or expansion joints, the pivotable beam automatically adjusts its angle to maintain contact with the floor surface, preventing the jig from twisting or losing planarity while accommodating the full span length.

Inventive Principle:
Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables accurate assembly on non-planar surfaces without the need for costly foundation modifications, maintaining jig accuracy and reducing manufacturing inefficiencies by allowing the jig to adapt to varying floor conditions.

Implementation Method 1

a floor contacting transport assembly (212) connected to at least the pivotable beam (218) and configured to enable selective movement of the assembly jig relative to a floor surface

Methodology Applied
Scientific EffectFriction: Friction

Implementation Method 2

The floor contacting transport assembly may have at least one caster wheel

Methodology Applied
Scientific EffectRolling: Roller

Data Source

PatentUS11760506B2Assembly jig with flexible floor interface
Publication Date: 2023.09.19 THE BOEING CO
  • US11760506B2 patent drawing
  • US11760506B2 patent drawing
  • US11760506B2 patent drawing

AI summary

Apparatus and methods for an assembly jig are disclosed. The assembly jig includes an elongate support frame that has a first end and a second end, a fixed beam at the second end, transversely oriented to a long axis of the support frame, a pivotable beam at the first end, transversely oriented to the long axis and pivotable in a vertical plane that is substantially perpendicular to the long axis, and a floor contacting transport assembly connected to at least the pivotable beam and configured to enable selective movement of the assembly jig relative to a floor surface.