Profilometer-Guided Docking Control for Aircraft Fuselage Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for aligning aircraft fuselage parts during riveting operations are imprecise, leading to frequent misalignments, collisions, and time-consuming manual adjustments, with existing camera-controlled robotic systems failing to ensure accurate docking.
Innovation Solution
An automated docking method using profilometers to measure and align the profiles of movable and stationary parts, generating precise movement setpoints through servo-control, ensuring accurate and rapid alignment without collisions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual positioning and iterative adjustment by operators are used, then flexibility and adaptability are maintained, but alignment precision deteriorates and time consumption increases
Solution Approach 1:
The patent replaces manual mechanical positioning and iterative adjustment with an automated optical measurement and control system. Profilometers capture precise geometric profiles of part interfaces, and a control system automatically calculates positioning corrections and actuates the movable part, eliminating manual measurement and adjustment cycles while achieving sub-millimeter alignment precision in a single operation.
Solution Approach 2:
The patent uses profilometers to create precise digital copies (profiles) of the physical part interfaces. These digital profiles are then processed by the control system to determine exact positioning adjustments needed, replacing manual visual inspection and physical trial-and-error adjustment with automated digital measurement and calculation.
2Extent of automation
If camera-controlled robotic systems are used, then automation is improved, but measurement precision deteriorates leading to collisions and friction
Solution Approach 1:
The patent replaces camera-based optical systems with profilometer-based measurement systems. Profilometers provide direct contactless geometric measurement with higher precision than vision systems, enabling the automated robotic system to achieve sub-millimeter docking accuracy without collisions or friction between parts.
3Manufacturing precision
If iterative manual adjustment is performed, then adaptability is maintained, but manufacturing precision deteriorates due to operator error and tool deformation
Solution Approach 1:
The patent replaces manual iterative adjustment with an automated measurement and control system. The profilometers and control system automatically compensate for tool deformation and alignment errors through precise digital measurement and calculation, eliminating operator error while maintaining simple mechanical interfaces.
4Length of moving object
If global positioning with laser-tracking is used, then overall position is improved, but local interface alignment precision deteriorates
Solution Approach 1:
The patent segments the measurement task into global positioning (handled by laser-tracking) and local interface alignment (handled by profilometers). The profilometers focus specifically on measuring the geometric profiles at the docking interface, providing high-precision local measurement that complements the global positioning system.
Solution Approach 2:
The patent applies different measurement technologies to different spatial scales: laser-tracking for global position and profilometers for local interface geometry. This local quality approach ensures that each measurement system operates in its optimal performance range, with profilometers providing high-precision local alignment data.
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
The method achieves precise alignment of aircraft fuselage parts in under a minute, reducing misalignments and collisions, and enabling efficient riveting operations with high repeatability and minimal deformation.
Implementation Method 1
measuring a profile of the end of the movable part by the profilometers
Implementation Method 2
positioning of multiple profilometers around the docking interface so that the docking interface is located in the field of view of the profilometers
Data Source
AI summary
The invention relates to a method for automated docking of a stationary part (1) with a movable part (2) capable of being moved towards the stationary part by a robot (3), the stationary part (1) and the movable part (2) each comprising an end (4, 5), the two ends forming a docking interface (6). The method comprises the steps of positioning of multiple profilometers around the docking interface so that the docking interface is located in the field of view of the profilometers, determination of a target profile of the end of the movable part, measurement of a profile of the end of the movable part by the profilometers, comparison of the target profile and the measured profile, generating a speed setpoint in the measurement space, and movement of the movable part towards the stationary part (1) by the robot (3) on the basis of this speed setpoint.