Portable Programmable Machine for Confined Space Operations

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Solution Overview

Problem

Manufacturing processes within aircraft wing interiors pose ergonomic challenges due to the need for technicians to perform physically demanding tasks in confined spaces, leading to injuries such as sprains and strains.

Innovation Solution

A portable, semi-autonomous programmable machine with a counterbalanced telescoping arm and articulating wrist, powered by a rechargeable battery and programmable computer, that can autonomously or semi-autonomously perform tasks within confined spaces, allowing operators to remain outside and intervene for fine-tuning, equipped with a reference camera for real-time adjustments.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If technicians perform manual operations within confined aircraft wing interiors, then manufacturing tasks can be completed, but ergonomic injuries such as sprains and strains occur

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidergonomic injuries

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the manual mechanical system (technician's body and tools) with an automated robotic arm system that can be programmed to perform fastening, sealing, and cleaning operations. The robotic arm with articulating wrist and tool interface eliminates the need for human technicians to physically enter confined wing interiors, thereby preventing ergonomic injuries while maintaining manufacturing productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a robotic arm as an intermediary between the operator and the work environment. The operator controls the robotic arm from outside the confined space, allowing tasks to be performed within the wing interior without direct human exposure to ergonomic hazards. The articulating wrist and tool interface serve as intermediaries to manipulate fasteners, sealants, and cleaning tools in difficult-to-reach areas

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a portable programmable machine is used to automate operations, then technician safety is improved, but device complexity increases

Engineering Contradiction:

Improveergonomic injuriesVSAvoidmachine structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The robotic system is segmented into modular components: a telescoping arm with multiple sections, an articulating wrist with separate rotational joints, and an interchangeable tool interface. This segmentation allows each component to be optimized independently and facilitates easier maintenance and programming while reducing overall system complexity through standardized interfaces

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs dynamic components including a telescoping arm that can extend and retract, an articulating wrist with multiple degrees of freedom, and programmable motion control. These dynamic elements allow the system to adapt to different wing geometries and task requirements without requiring complex fixed structures, simplifying the overall design while maintaining versatility

Inventive Principle:

Principle #15Dynamics

3Ease of operation

If a telescoping arm with articulating wrist is employed, then access to confined spaces is improved, but device complexity increases

Engineering Contradiction:

Improveaccess to confined spacesVSAvoidarm structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The telescoping arm employs a nested structure where multiple arm sections are housed within each other, allowing compact storage when retracted and extended configuration when needed. This nesting principle reduces the overall footprint and simplifies the mechanical structure compared to using multiple separate articulated arms, while still providing access to confined wing interiors

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent incorporates counterbalancing mechanisms in the telescoping arm to offset the weight of the arm sections and attached tools. This counterbalancing reduces the force required to move and position the arm, simplifying the drive mechanisms and making the system easier to operate while maintaining access to difficult-to-reach areas within the wing structure

Inventive Principle:

Principle #8Anti-weight (Counterweight)

Data Source

PatentUS10773829B2Method of making a portable programmable machine

Publication Date: 2020.09.15 THE BOEING CO

AI summary

A portable programmable machine enhances efficiency and ergonomics associated with conducting otherwise manual operations within confined spaces. A main body supports a programmable telescoping arm configured to extend through an access port to reach a confined space. The arm includes an articulating wrist for holding and manipulating tools for autonomously processing work parts. The machine can also act semi-autonomously to accommodate interventions of an operator for overriding and fine-tuning interaction of a tool with a work part for proper processing of the part. The arm communicates with a computer in the main body for processing numerical data, and the operator may use a reference camera to fine tune any particular process. The machine incorporates multiple processing functions, for example collar swaging, nut running, cleaning, and/or application of sealants, all through an aircraft wing access port. The main body has lockable wheels for securing the main body near the access port.