Temporary Rib Reinforcement Structure for Accurate Wing Assembly
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Solution Overview
Problem
The assembly of aircraft wing ribs is labor-intensive and time-consuming due to the flexibility of the ribs, which makes accurate positioning challenging, and existing methods rely on manual placement of gauges and sensors, increasing the risk of errors and injuries.
Innovation Solution
A resilient component with datum attachment features is attached to a rigid temporary reinforcement structure, allowing for precise alignment and support during assembly, using a common datum system that includes auxiliary features like photogrammetry targets and magnetic through-thickness sensors to facilitate automated positioning and drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual placement of gauges and sensors is used to position ribs, then positioning accuracy can be achieved, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-attaching photogrammetry targets and magnetic sensors to the rib and strongback structure before assembly. This allows automated systems to locate and position components without manual gauge placement during the assembly process, thereby maintaining positioning accuracy while significantly improving assembly speed and reducing labor intensity.
Solution Approach 2:
The patent replaces the manual mechanical system of gauge and sensor placement with an automated optical and magnetic detection system. Photogrammetry targets enable automated visual positioning, while magnetic sensors provide automated detection of rib position and orientation, eliminating the need for manual mechanical measurement tools and operations.
2Ease of operation
If manual manipulation and positioning of ribs is performed, then positioning can be controlled, but the risk of operator injury and errors increases
Solution Approach 1:
The patent applies self-service by enabling the rib and strongback structures to self-position through automated detection systems. The photogrammetry targets and magnetic sensors allow the assembly system to automatically determine component positions and orientations without requiring manual manipulation, thereby maintaining positioning control while eliminating operator exposure to injury risks.
Solution Approach 2:
The patent introduces intermediary elements (photogrammetry targets and magnetic sensors) that mediate between the physical components and the automated positioning system. These intermediaries carry the positioning information and enable automated systems to control rib positioning without direct human manipulation, reducing operator injury risk while maintaining precision.
3Manufacturing precision
If rigid temporary reinforcement structure is used to stiffen the rib, then positioning accuracy improves, but the device complexity increases
Solution Approach 1:
The patent applies universality by designing the strongback structure to serve multiple functions simultaneously: it provides rigid temporary reinforcement to stiffen the rib, carries photogrammetry targets for automated visual positioning, and supports magnetic sensors for detection. This multi-functionality reduces the need for separate devices and minimizes overall system complexity while maintaining positioning accuracy.
Solution Approach 2:
The patent merges the reinforcement function with the measurement and detection functions by integrating photogrammetry targets and magnetic sensors directly onto the strongback structure. This combination eliminates the need for separate reinforcement devices and measurement tools, reducing device complexity while ensuring the rib maintains accurate positioning during assembly.
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 simplifies and accelerates the assembly process, reduces operator risk, and enhances accuracy, enabling the automation of rib installation and reducing the need for manual placement of sensors, thereby improving manufacturing efficiency and reducing rework costs.
Implementation Method 1
magnetic through-thickness sensors—commonly known as through skin sensors (TSS)—manually placed inside the wing box in pilot/datum holes are used to navigate the drilling of fastener holes
Data Source
AI summary
A resilient component for attachment to a rigid temporary reinforcement structure, and a rigid temporary reinforcement structure for attachment to a resilient component are disclosed. The temporary reinforcement structure having one or more datum attachment features for releasably attaching the temporary reinforcement structure to corresponding datum attachment features of the resilient component, where the datum attachment features and the datum features of the resilient component have a common datum, and the temporary reinforcement structure is configured to rigidly support the resilient component during assembly of the resilient component to a structural assembly.