RFID-Tagged Temporary Hole Closures for Aircraft Assembly

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Solution Overview

Problem

The process of drilling and closing holes in aircraft parts with fasteners during manufacturing is inefficient, requiring substantial effort to reopen these holes for additional parts, leading to extra work and potential stress-related issues.

Innovation Solution

A method involving temporary closure members with RFID tags is used to close openings in aircraft parts, allowing for efficient detection and removal of these members, followed by installation of permanent fasteners, reducing the need for manual reopening.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If holes are closed with fasteners during early manufacturing stage, then openings are securely closed, but substantial effort is required to reopen them later for additional parts

Engineering Contradiction:

Improveclosure reliabilityVSAvoidreopening effort

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The closure system is segmented into temporary closure members (for initial closing) and permanent members (for final installation). The temporary closure members are designed to be easily removable and identifiable, separating the closing function from the permanent fastening function to eliminate the need for substantial reopening effort.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

RFID tags are introduced as intermediary elements attached to temporary closure members. These tags enable automatic detection and identification of closed openings, allowing the system to track which holes are closed and where, thereby facilitating easy location and removal of temporary closure members without substantial effort.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If permanent fasteners are installed early, then structural integrity is maintained, but removal and replacement requires substantial manufacturing effort

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

Temporary closure members are installed in advance to maintain structural integrity during early manufacturing stages. These temporary members preserve the structural strength needed for subsequent production steps while being designed for easy removal, allowing permanent fasteners to be installed later without requiring removal of original fasteners.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Temporary closure members are designed as disposable or short-lived components that serve their purpose during early manufacturing and are then removed. These temporary members are simpler and easier to remove than permanent fasteners, replacing the need for installing and later removing permanent fasteners multiple times.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If multiple holes are closed and later reopened, then additional parts can be installed, but extra work and stress-related issues occur

Engineering Contradiction:

Improvepart installation flexibilityVSAvoidreopening time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The RFID tagging system provides feedback about the status of closed openings. When permanent members need to be installed, the RFID tags enable quick identification and localization of temporary closure members that need to be removed, providing real-time information that reduces searching time and prevents errors.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The manual searching and identification process for locating closed openings is replaced by an automated RFID detection system. This substitution of mechanical/searching methods with electromagnetic detection significantly reduces the time and effort required to locate and reopen holes for additional part installation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 method streamlines the manufacturing process by enabling reliable and efficient closure and reopening of holes using RFID-tagged temporary closure members, minimizing extra work and stress-related issues.

Implementation Method 1

the closing member having an RFID tag; scanning for the RFID tag with an RFID scanning device based on the identification

Methodology Applied

Scientific EffectRFID (Radio Frequency Identification): Electromagnetic Induction

Data Source

PatentUS12566425B2Method for temporarily closing openings in aircraft parts

Publication Date: 2026.03.03 AIRBUS OPERATIONS GMBH

AI summary

A method for temporarily closing openings in an aircraft part during a manufacturing process by providing a first part that has a first opening and positioning a temporary closure member inside that first opening. The temporary closure member has an RFID tag that has stored on it a unique identification. At a later stage in the aircraft manufacturing process, a scanning device is used to scan for the RFID tag based on the identification. The temporary closure member is removed from the first opening and subsequently replaced by a permanent member.