Robotic Strongback Pick-and-Place for Flexible Stringer Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional gantry systems for placing long, flexible composite stringers in aircraft wing assembly are complex, costly, and require significant factory space, with challenges in positional accuracy and structural weight due to the need for multiple supports and precise alignment.
Innovation Solution
A pick-and-place system featuring a rigid elongate strongback supported by a robotic arm, equipped with actuator-clamp assemblies that include multi-axis actuators and jaw assemblies to clamp and orient the stringers, ensuring precise alignment and placement without the need for extensive structural compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gantry system is used to support long flexible composite stringers at multiple locations, then the stringer can be supported and placed, but the system complexity and cost increase significantly
Solution Approach 1:
The stringer support function is segmented into multiple discrete pickup points along the stringer length, with each point having an independent actuator-clamp assembly. This allows the stringer to be supported and manipulated at specific locations rather than requiring a continuous gantry structure, reducing overall system complexity while maintaining support reliability
Solution Approach 2:
A robotic arm serves as an intermediary device that holds the strongback with multiple pickup points, replacing the need for a complex gantry system. The robotic arm provides the necessary support and positioning functionality while being simpler in structure and easier to control
2Productivity
If a gantry system extends across the full width of the wing panel to place complete stringer sets, then all stringers can be placed, but the factory floorspace occupied increases significantly
Solution Approach 1:
The system transitions from a static gantry structure to a dynamic robotic arm that can move and reposition. This allows the same device to place multiple stringers by moving to different positions rather than requiring a fixed structure spanning the entire wing width, significantly reducing floorspace requirements
Solution Approach 2:
The robotic arm with reconfigurable pickup points serves multiple functions - it can place different stringers at different locations by adjusting its position and the configuration of pickup points, replacing the need for dedicated gantry structures for each stringer placement task
3Manufacturing precision
If compensated offset of stringer flanges is used to define a theoretical centerline, then placement tolerances can be compensated, but the structural mass of the wing assembly increases
Solution Approach 1:
The system replaces mechanical compensation methods (offset flanges adding structural mass) with active control systems. Sensors detect the actual stringer position and the controller adjusts pickup point positions and robotic arm movements to achieve precise centerline alignment, eliminating the need for additional structural mass for compensation
Solution Approach 2:
The system uses feedback from sensors that detect the actual position and orientation of stringers. This information is fed to the controller which adjusts the pickup points and robotic arm movements in real-time to ensure precise placement alignment with the intended centerline, achieving high precision without increasing structural mass
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A pick-and-place system includes a rigid elongate strongback, configured to be supported by a robotic arm of a robotic device. In addition, the pick-and-place system includes a plurality of actuator-clamp assemblies, mountable in spaced relation to each other on the strongback. Each actuator-clamp assembly includes one or more jaw assemblies, each configured to clamp onto a localized segment of a workpiece. Each actuator-clamp assembly also includes a multi-axis actuator, configured to couple the one or more jaw assemblies to the strongback and adjust an orientation of the localized segment prior to placement of the workpiece onto a mating structure.