Precision Assembly Tooling for Predrilled Aircraft Hole Alignment
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Solution Overview
Problem
The assembly of aircraft components, particularly large structures like wings, faces challenges in aligning predrilled holes within designated tolerances, especially when using interference fit fasteners, which can lead to fitment issues and contamination of fay seals during drilling.
Innovation Solution
A method and system involving the use of jigs at multiple factory locations for precise alignment and drilling of components before final assembly, allowing for the drilling of holes to the exact size of fasteners, thereby mitigating alignment issues and maintaining a clean assembly environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If components are predrilled at different locations by different manufacturers, then manufacturing flexibility and distribution are improved, but alignment precision of corresponding holes within designated tolerance deteriorates
Solution Approach 1:
The patent introduces a fixture system with precision positioning mechanisms as an intermediary between components from different manufacturers. The fixture includes定位 features such as precision machined surfaces, dowel pins, and clamping mechanisms that mediate the alignment process, ensuring that components predrilled at different locations can be accurately positioned relative to each other during assembly.
Solution Approach 2:
The patent applies preliminary alignment and positioning actions through the fixture system before the final assembly is completed. The fixture pre-positions components and pre-drills or repositions holes to ensure proper alignment, addressing alignment issues before the components are permanently assembled together.
2Manufacturing precision
If robotic systems are used to drill holes and apply fasteners at assembly time, then alignment precision and fitment quality are improved, but system complexity, cost, and space requirements deteriorate
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: component preparation at supplier locations, transportation, and final assembly at the customer location. The fixture system is a simplified, portable device that performs only the essential alignment and drilling functions needed at the assembly stage, rather than using a complex robotic system that would need to perform all functions.
Solution Approach 2:
The patent employs a relatively simple, portable fixture system that can be set up and used at the assembly location without the need for expensive, permanent robotic infrastructure. The fixture is designed to be moved and reused across different assembly locations, providing cost-effective alignment and drilling capabilities.
3Manufacturing precision
If drilling is performed at assembly location, then alignment accuracy is improved, but contamination risk to fay seals and assembly environment deteriorates
Solution Approach 1:
The patent extracts the drilling operation from the final assembly environment by using a portable fixture system that can be positioned close to the assembly location but operates as a separate, contained process. The fixture creates a localized drilling zone that isolates the assembly area from drilling debris and contamination.
Solution Approach 2:
The patent performs drilling operations quickly and efficiently using the portable fixture system, minimizing the time that drilling debris and contamination risks are present in the assembly environment. The process is designed to complete drilling rapidly before contamination can affect the fay seals or assembly area.
4Productivity
If large robotic systems are deployed for assembly operations, then automation extent and productivity are improved, but facility space requirements and infrastructure costs deteriorate
Solution Approach 1:
The patent transitions from static, permanent robotic assembly systems to a dynamic, portable fixture system that can be moved to different assembly locations as needed. This dynamic approach allows the same fixture to serve multiple assembly positions, reducing the need for dedicated space for each assembly operation.
Solution Approach 2:
The portable fixture system is designed with universal features that allow it to accommodate different component configurations and assembly locations. The fixture can be repositioned and reconfigured for various assembly tasks, providing multi-functional capabilities that replace multiple specialized robotic systems.
Data Source
AI summary
Aspects of the present disclosure relate generally to the manufacture of assemblies of components, and in particular to methods, apparatus, and systems for performing manufacturing operations. In one aspect, a method of manufacturing an assembly of components includes positioning first and second components into a nominal configuration with respect to each other at a first factory location. The method further includes drilling a fastener joining hole through an interface of the first and second components at the first factory location. The method further includes positioning the first and second components for fastener joining at a second factory location. The method further includes inserting a fastener into the fastener joining hole to couple the first and second components together.