Rib-Spar Joint Assembly Using Coordination Features

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Solution Overview

Problem

The existing method for forming rib-spar joints in aircraft wing assembly is manual, prone to operator error, time-consuming, and requires extensive tooling, especially with the use of composite materials, and is complicated by the shift to horizontal assembly orientations due to gravity.

Innovation Solution

A method involving pre-formed coordination and tooling features in spar and rib components, allowing for precise alignment and drilling of fastener holes using minimal reusable tooling, reducing operator error and assembly time, and enabling efficient assembly in both vertical and horizontal orientations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual gap measurements with feeler gauges and tooling gauges are used to form rib-spar joints, then the assembly can be performed with simple tools, but the assembly process is time-consuming and requires multiple checking and adjusting cycles

Engineering Contradiction:

Improvesimplicity of toolsVSAvoidassembly time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

Coordination features and tooling features are pre-formed in the rib and spar components during manufacturing, enabling direct alignment during assembly without manual measurement and adjustment cycles. This preliminary preparation eliminates the need for multiple checking cycles while maintaining ease of assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manual measurement system using feeler gauges is replaced with a precision mechanical alignment system using coordination features (holes with locating pins) and tooling features that provide automatic positional reference, eliminating operator-dependent manual gauging.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If manual manipulation of structural wing components is performed during assembly in horizontal orientation, then the wing can be assembled in level flight orientation with advantages, but the manipulation becomes more difficult due to gravity

Engineering Contradiction:

Improveassembly orientation flexibilityVSAvoidcomponent manipulation difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

Tooling components act as intermediaries between the rib and spar, providing precise alignment through coordination features. The tooling component with drill bushings and locating features facilitates accurate assembly in horizontal orientation by eliminating the need for manual manipulation and adjustment of components against gravity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Manufacturing precision

If pre-formed coordination and tooling features are used in rib and spar components, then alignment accuracy and productivity are significantly improved, but the manufacturing complexity of individual components increases

Engineering Contradiction:

Improvealignment accuracyVSAvoidcomponent manufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The alignment system is segmented into distinct coordination features (in rib/post) and tooling features (in tooling component), allowing each to be manufactured and verified independently. This segmentation enables the precision features to be integrated into standard component manufacturing processes without requiring complex overall redesign.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The tooling component serves multiple functions: it provides alignment through coordination features, establishes drilling positions through drill bushings, and facilitates fastening. This multi-functionality consolidates several operations into a single tooling device, offsetting the increased component feature complexity with reduced process complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of operation

If traditional best fit approach is used for rib-spar assembly, then operator flexibility is maintained, but operator error increases and aerodynamic profile accuracy decreases

Engineering Contradiction:

Improveoperator flexibilityVSAvoidaerodynamic profile accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The coordination features and tooling features enable the components to self-align during assembly. The locating pins fit into coordination holes, and the tooling component automatically positions drill bushings, eliminating operator-dependent best-fit adjustments while maintaining operational simplicity.

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP2433860B1Aircraft rib-spar joint

Publication Date: 2017.03.01 AIRBUS OPERATIONS LTD

AI summary

A method of forming a rib-spar joint during assembly of an aircraft wing, the method comprising: providing a spar with a fixedly attached rib post, the rib post having a first coordination feature; providing a rib having a web with a first tooling feature; providing a tooling component having a second tooling feature for cooperating with the first tooling feature, a second coordination feature for cooperating with the first coordination feature, and a plurality of drill bushings; fixedly attaching the tooling component to the rib web by aligning the first and second tooling features; aligning the rib with the spar by aligning the first and second coordination features; drilling fastener holes in the rib and the rib post off the drill bushings of the tooling component; removing the tooling component from the rib web; and fastening the rib to the rib post using the fastener holes to form a rib-spar joint. The method may be applied to form front and/or rear rib-spar joints.