Robot-Guided Airframe Assembly for Predrilled Hole Alignment
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Solution Overview
Problem
The production of aircraft airframes faces challenges in achieving precise assembly due to difficulties in producing separate sections with sufficient precision, often requiring lengthy and costly shimming processes, and traditional assembly fixtures are rigid and specific to each component set.
Innovation Solution
A method and system utilizing digital models of aircraft airframe components, robot arms, and position measurement systems to align and assemble parts with precision, eliminating the need for extensive shimming and reducing the reliance on custom assembly fixtures by using predrilled holes and shims produced through additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate airframe sections are produced independently, then production flexibility is improved, but assembly precision deteriorates due to difficulty in achieving tight tolerance bounds
Solution Approach 1:
The patent applies preliminary action by pre-drilling fastener holes in component parts before assembly and using digital models to pre-plan the assembly sequence and positioning. This allows sections to be produced independently with pre-prepared features that ensure precise alignment during assembly, resolving the contradiction between production flexibility and assembly precision.
2Stability of the object's composition
If conventional rigid assembly fixtures are used for each component set, then assembly stability is improved, but device complexity and production cost increase due to need for dedicated fixtures
Solution Approach 1:
The patent applies universality by using a robotic arm with interchangeable end effectors that can handle multiple component types and assembly operations. The digital model guides the robot to provide stable positioning for different component sets without requiring dedicated rigid fixtures for each, thus maintaining assembly stability while reducing device complexity.
Solution Approach 2:
The patent replaces conventional mechanical assembly fixtures with a robotic arm system controlled by digital models. The robot provides stable positioning and alignment through programmable motion control and sensor feedback, eliminating the need for complex physical fixtures while maintaining or improving assembly stability.
3Adaptability or versatility
If manual shimming processes are used to fill gaps between airframe sections, then assembly adaptability is improved, but loss of time and production cost increase
Solution Approach 1:
The patent replaces manual shimming processes with automated robotic positioning guided by digital models. The robot arm precisely positions component parts based on digital measurements and pre-calculated alignment data, eliminating the need for time-consuming manual measurement and shimming while maintaining adaptability to handle various assembly configurations.
Solution Approach 2:
The patent uses digital models as virtual copies of the final assembled airframe to guide the physical assembly process. The digital model contains precise positioning information that replaces manual shimming operations, allowing the robotic system to automatically achieve correct alignment without time-consuming iterative adjustments.
4Productivity
If predrilled holes are used for fasteners, then assembly speed is improved, but manufacturing precision requirements increase for hole alignment
Solution Approach 1:
The patent uses a robotic arm with sensor systems and digital model guidance to achieve precise hole alignment automatically. The robot measures actual positions of predrilled holes and compensates for variations through programmable motion control, maintaining high assembly speed while meeting strict alignment precision requirements without manual intervention.
Data Source
AI summary
An assembly method comprising: providing a digital model of an aircraft airframe (200), the digital model comprising digital models of component parts (202, 204) of the airframe (200); providing the component parts (202, 204), each comprising one or more predrilled fastener holes; fixing a first component part (202a) to a support structure (1102); fixing a second component part (204a) to an end effector (1112) of a robot arm (1110); using the airframe digital model, controlling the robot arm (1110) to move the second component part (204a) relative to the first component (202a) as specified in the airframe digital model to cause one or more predrilled holes in the second component (204a) part to align with one or more predrilled holes in the first component part (202a); and attaching the second component part (204a) to the first component part (202a) using fasteners through the aligned predrilled holes.