Horizontal Pulsing Wing Assembly Line
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Solution Overview
Problem
Existing aircraft wing assembly processes are inefficient due to the use of large, expensive, and impractical equipment that requires manual labor and specialized crews, leading to high costs and ergonomic and quality issues, especially when dealing with closed wing structures and high tolerance fasteners.
Innovation Solution
A horizontal pulsing assembly line system utilizing synchronized automated vehicles and multi-axis positioning systems for precise component placement and fastener installation, with magnetic clamping, drilling, and sealant application, allowing for reconfigurable and efficient assembly of wing structures without the need for massive tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If large floor mounted assembly fixtures and overhead building cranes are used for wing assembly, then the wing structure can be held and transported, but the system becomes expensive, requires high bay facilities, and reduces productivity
Solution Approach 1:
The assembly system is divided into multiple modular positions (first position, second position, third position) along a horizontal pulsing line. Each position has specialized fixtures for specific tasks, allowing continuous assembly flow rather than batch processing at single locations.
Solution Approach 2:
The system uses a pulsing mechanism that dynamically moves the wing assembly through different positions in sequence. The assembly progresses horizontally through multiple stations with automated transport, replacing static overhead crane operations with a dynamic flow system.
2Ease of operation
If manual drilling and fastening operations are used for high tolerance fasteners, then flexibility is maintained, but labor costs increase and quality consistency deteriorates
Solution Approach 1:
The system employs automated drilling and fastening machines that perform operations autonomously at each assembly position. The machines self-position and execute fastener installation without manual intervention, ensuring consistent precision while maintaining operational flexibility through programmable control.
3Manufacturing precision
If large expensive dock assembly systems are used for wing assembly, then the wing can be assembled with proper positioning, but the system cannot pulse to specialized assembly stations and requires high bay facilities
Solution Approach 1:
Each assembly position is equipped with multi-functional fixtures that can accommodate different wing components and assembly operations. The standardized positioning systems at each station provide universal support for various fastening, drilling, and assembly tasks across multiple positions.
Solution Approach 2:
The system transitions from vertical overhead assembly operations to horizontal pulsing assembly. The wing assembly moves horizontally through multiple positions along a pulsing line, utilizing horizontal space instead of vertical height, eliminating the need for high bay facilities.
4Length of moving object
If overhead building cranes are used to transport and position wings, then the wing can be moved between floors, but specialized crews are required and non-value added time increases
Solution Approach 1:
The wing assembly moves continuously through the pulsing line from one position to the next without interruption. Automated transport mechanisms maintain continuous flow, eliminating the stop-start operations and manual positioning required by overhead crane systems.
Solution Approach 2:
Manual crane operations are replaced with automated guided vehicles and robotic positioning systems. The mechanical transport system is controlled automatically, eliminating the need for specialized crane operators and reducing non-value added time.
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
This approach enables a more efficient, cost-effective, and ergonomic assembly process by automating the movement and fastening of wing components, reducing labor costs and improving quality through precise control and automation, while minimizing the need for large, expensive tooling.
Implementation Method 1
Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.
Data Source
AI summary
A single piece pulsed flow wing assembly method providing for horizontal wing manufacture is accomplished using synchronized automated vehicles guided in a predetermined manner to move and, locate wing structure in a plurality of assembly positions. Multi-axis assembly positioning systems (MAPS) are used at each assembly position to support and index components in the wing structure and determinant assembly techniques are used for indexing of the components. Modular automated manufacturing processes employing magnetic assembly clamping, drilling, fastener insertion, and sealant application are employed.