Robotic Clamp Positioning for One-Way Wing Box Assembly
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Solution Overview
Problem
The assembly of aircraft wing boxes is time-consuming and complex due to the need for drilling and subsequent disassembly for cleaning and deburring, which hinders the implementation of a one-way assembly process where components are drilled and fastened without intermediate disassembly, and a practical clamping force is essential to prevent inter-laminar burring.
Innovation Solution
An automated clamp system with motorized jaws and position sensors, integrated with a robot end effector, allows for precise clamping of rib webs to rib posts or integrated rib feet, enabling automated drilling and fastening while maintaining a clamping load, facilitating one-way assembly by accurately positioning and securing components without clashing with other wing box components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional drilling and fastening process is used without clamping, then assembly process is simpler, but inter-laminar burring occurs during drilling requiring disassembly for cleaning
Solution Approach 1:
The clamp applies clamping force to the workpiece before drilling begins, pre-compressing the laminate layers to prevent them from separating during the drilling process. This preliminary compression action eliminates inter-laminar burring without requiring subsequent disassembly for cleaning.
Solution Approach 2:
The clamp counteracts the harmful effect of layer separation during drilling by applying compressive force that opposes the tensile stresses generated during drilling. This preliminary anti-action prevents the harmful inter-laminar burring from occurring in the first place.
2Manufacturing precision
If clamping force is applied during drilling, then inter-laminar burring is prevented, but assembly process requires disassembly and reassembly
Solution Approach 1:
The clamp is designed to maintain continuous clamping force throughout the entire drilling and fastening process without requiring interruption. The robotic system continuously applies compression while drilling and fastening operations proceed, eliminating the need to stop, disassemble, clean, and reassemble.
Solution Approach 2:
The robotic clamp system acts as an intermediary that maintains the workpiece in a compressed state throughout the entire manufacturing process. This intermediary compression force allows drilling and fastening to proceed continuously without interruption or disassembly.
3Productivity
If robotic clamp system is implemented for one-way assembly, then assembly time is reduced, but device complexity increases
Solution Approach 1:
The robotic clamp system is designed to perform multiple functions: positioning the workpiece, applying clamping force, maintaining compression during drilling, and sustaining force during fastening. This multi-functional design consolidates what would otherwise require multiple separate devices into a single integrated system.
Solution Approach 2:
The robotic clamp system automatically adjusts and maintains the required clamping force throughout the process without human intervention. The system self-regulates the compression levels and maintains them continuously, eliminating the need for manual adjustment or monitoring during drilling and fastening operations.
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
The automated clamp system enables efficient and accurate clamping and fastening operations within the confined spaces of an aircraft wing box, reducing assembly time and preventing inter-laminar burring, thus facilitating the one-way assembly process by maintaining a consistent clamping load during drilling and fastening.
Implementation Method 1
a motor to move the clamp jaw
Implementation Method 2
at least one position sensor for detecting a position of the clamp relative to the aircraft wing box
Implementation Method 3
a practical clamping force is essential to prevent inter-laminar burring
Data Source
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Figure 5
AI summary
An automated clamp (70) has a clamp frame (71), motorised clamp jaws (72, 73, 75), and a robot end effector connector (74). One of the clamp jaws can receive a drilling tool and/or a fastening tool. One of the clamp jaws has a position sensor for detecting a position of the clamp. The clamp forms part of an automated clamping system. The clamping system is used to automatically clamp a rib web to a rib post or integrated rib foot of an aircraft wing box for automated drilling and/or fastening the rib web to a rib post or integrated rib foot.