Aircraft Pressure Bulkhead Assembly With Jigless CNC Hole Drilling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for assembling pressure bulkheads in aircraft, which rely on drill jigs, result in oversized holes, require multiple measurement and alignment steps, and lead to production lags, labor inefficiencies, and material wastage, especially when dealing with flexible carbon fiber materials.
Innovation Solution
A method and system that utilize a spatial relation apparatus with a measurement machine and computer system to determine precise locations and orientations of holes in both the pressure bulkhead and splice angles, allowing for accurate drilling of full-size holes using a Computer Numerically Controlled machine, minimizing the need for shims and reducing assembly time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If drill jigs are used to assemble pressure bulkheads, then assembly can be performed with traditional tooling, but holes become oversized, requiring multiple measurement and alignment steps, and causing production lags
Solution Approach 1:
The system performs preliminary measurement and determination of hole locations and orientations on the pressure bulkhead and splice angles before assembly. By pre-determining the precise locations where holes need to be drilled and the orientations of splice angles, the system eliminates the need for multiple measurement and alignment steps during assembly, thereby improving hole size accuracy and reducing production time
Solution Approach 2:
The patent replaces traditional mechanical drill jigs with a computerized system that uses measurement machines and CNC drilling equipment. This substitution of mechanical tooling with automated measurement and drilling systems enables precise hole placement without the need for physical jigs, eliminating the problems of oversized holes and multiple alignment steps while reducing production time
2Manufacturing precision
If drill jigs are used to assemble pressure bulkheads, then assembly can be performed with traditional tooling, but multiple measurement and alignment steps are required, increasing labor requirements
Solution Approach 1:
The system replaces manual measurement and alignment operations with automated measurement machines and computer-controlled positioning systems. The measurement machine automatically determines hole locations and splice angle orientations, and the CNC drilling system automatically positions and drills holes with high precision, eliminating the need for multiple manual measurement and alignment steps and significantly improving labor efficiency
Solution Approach 2:
The system creates a digital representation or model of the pressure bulkhead and splice angles, storing the precise locations and orientations of holes and angles. This digital copy is then used to guide the drilling operation, replacing multiple physical measurement and alignment steps with a single reference to the digital model, thereby improving hole location accuracy and reducing labor requirements
3Manufacturing precision
If drill jigs are used to assemble pressure bulkheads, then assembly can be performed with traditional tooling, but the process is not readily automated, increasing labor requirements
Solution Approach 1:
The patent replaces traditional mechanical drill jigs with a fully automated system consisting of measurement machines, computer processing units, and CNC drilling equipment. The measurement machine automatically captures geometric data, the computer processes this data to determine precise hole locations and orientations, and the CNC drilling system automatically executes the drilling operation. This complete automation chain maintains high assembly accuracy while enabling full automation of the process
Solution Approach 2:
The system enables the pressure bulkhead and splice angles to essentially drill their own holes by first measuring their own geometric features (hole locations, orientations, surface profiles) and then using this self-acquired information to guide the drilling of splice angles. This self-referential approach eliminates the need for external jigs and manual positioning, achieving both high precision and full automation
4Manufacturing precision
If drill jigs are used to assemble pressure bulkheads, then assembly can be performed with traditional tooling, but shims or spacers must be designed larger than desired, leading to material wastage
Solution Approach 1:
The system performs preliminary measurement of the pressure bulkhead's hole locations and orientations, and preliminary determination of the precise positions where splice angles need to be drilled, before any material removal or assembly. By pre-determining these locations with high precision, the system ensures that holes align perfectly without requiring oversized shims or spacers, thereby preventing material wastage
Solution Approach 2:
The replacement of mechanical drill jigs with a computerized measurement and positioning system enables precise determination of hole locations and orientations. This precision eliminates the need for conservative, oversized shim designs that would be required when using traditional tooling, thereby reducing material waste in the form of shims and spacers
Data Source
AI summary
A method for making a pressure bulkhead assembly of an aircraft includes determining first locations and first orientations of a plurality of first holes, pre-drilled in an aft pressure bulkhead. The method also includes determining a first surface profile of a first interface surface of the aft pressure bulkhead and determining a second surface profile of a second interface surface of each one of a plurality of splice angles. The method also includes determining second locations and second orientations of a plurality of second holes to be drilled in each one of the plurality of splice angles corresponding to the plurality of first holes in the aft pressure bulkhead and drilling the plurality of second holes in each one of the plurality of splice angles at the second locations and second orientations.