Rigid Rib Reinforcement Structure for Automated Positioning and Drilling
Find Innovative SolutionsGenerate Solutions
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 human error and damage during assembly.
Innovation Solution
A rigid temporary reinforcement structure with aligned datum features and auxiliary features like photogrammetry targets and magnetic through-thickness sensors is used to support the resilient rib component, allowing for automated positioning and drilling, reducing manual labor and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual placement of gauges and sensors is used to position ribs, then positioning capability is achieved, but labor intensity and time consumption increase
Solution Approach 1:
The positioning system is segmented into multiple independent features: datum attachment features for rigid structure attachment, photogrammetry targets for optical tracking, and magnetic sensors for through-skin detection. Each feature performs a specific function, allowing parallel operation and reducing overall assembly time while maintaining positioning accuracy.
Solution Approach 2:
Manual mechanical positioning using gauges and sensors is replaced by an automated optical-magnetic positioning system. Photogrammetry cameras capture images of targets on the rigid structure, and magnetic sensors detect positions through the skin, enabling automated determination of rib positions without manual gauge placement.
2Manufacturing precision
If rigid temporary reinforcement structure is attached to resilient rib, then positioning accuracy is improved, but rib flexibility is reduced
Solution Approach 1:
The rigid temporary reinforcement structure is attached to the resilient rib before the rib is installed into the final assembly. This preliminary attachment provides the rib with the necessary rigidity for accurate positioning during assembly operations, and the structure is removed after installation is complete, allowing the rib to regain its flexibility for final adjustments and load distribution.
Solution Approach 2:
The rigid temporary reinforcement structure acts as an intermediary between the flexible rib and the positioning system. It provides a stable reference frame that carries datum attachment features and photogrammetry targets, enabling precise positioning of the rib without requiring the rib itself to be rigid.
3Productivity
If automated positioning and drilling is implemented, then labor intensity decreases, but system complexity increases
Solution Approach 1:
The rigid temporary reinforcement structure serves multiple functions simultaneously: it provides mechanical support to the flexible rib, carries datum attachment features for positioning, displays photogrammetry targets for optical tracking, and incorporates magnetic sensors for through-skin detection. This multi-functionality reduces the need for separate positioning devices and simplifies the overall system architecture.
Solution Approach 2:
Multiple positioning systems (optical photogrammetry and magnetic sensing) are merged into a single integrated rigid structure. The datum attachment features, photogrammetry targets, and magnetic sensors are combined on the same structure, allowing coordinated operation and reducing the number of separate components needed for automated positioning and drilling.
4Adaptability or versatility
If multiple auxiliary features are attached to rigid structure, then functionality is enhanced, but attachment complexity increases
Solution Approach 1:
Multiple auxiliary features are nested on the rigid temporary reinforcement structure in a hierarchical manner. Photogrammetry targets are mounted on the external surface, magnetic sensors are embedded within the structure, and datum attachment features are integrated into the structure's geometry. This nested arrangement allows all features to coexist without interfering with each other and simplifies the attachment process by organizing features at different levels.
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 the aircraft wing rib installation process, enhances assembly accuracy, reduces operator risk, and decreases potential damage and rework costs by enabling automated positioning and drilling, thereby increasing manufacturing efficiency.
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
Figure 1
Figure 2~3
Figure 4~5
AI summary
A resilient component (118) for attachment to a rigid temporary reinforcement structure (150), and a rigid temporary reinforcement structure(150) for attachment to a resilient component (118). The temporary reinforcement structure (150) having one or more datum attachment features (170) for releasably attaching the temporary reinforcement structure (150) to corresponding datum attachment features of the resilient component (118), where the datum attachment features (170) and the datum features of the resilient component (118) have a common datum, and the temporary reinforcement structure (150) is configured to rigidly support the resilient component (118) during assembly of the resilient component (118) to a structural assembly.