Shimless Fuselage Splice Assembly via Verification Holes
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Solution Overview
Problem
The current process of assembling fuselage barrel sections in aircraft manufacturing is time-consuming and labor-intensive due to the need for shimming and manual inspection to ensure dimensional tolerances, which complicates the alignment and joining of these sections.
Innovation Solution
A method and system that uses metrology devices and computer numerical control machines to fabricate a splice based on precise measurements of the surface profiles and verification holes, allowing for self-verification of gap tolerances without the need for shims, by aligning verification holes in the structures and splice to ensure accurate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shimming and manual inspection are used to ensure dimensional tolerances, then assembly precision is improved, but assembly time and labor intensity increase
Solution Approach 1:
The splice is pre-fabricated with verification holes and precise gap features before assembly. Surface profiles are measured and the splice is manufactured in advance with built-in verification capabilities, eliminating the need for shimming and manual inspection during the assembly process itself.
Solution Approach 2:
The splice design incorporates self-verification features including verification holes and gap features that automatically ensure dimensional tolerances are met. The splice serves its own inspection function by providing built-in verification mechanisms that eliminate the need for separate manual inspection steps.
2Manufacturing precision
If shimming is used to account for surface profile deviations, then assembly precision is improved, but device complexity increases
Solution Approach 1:
The shimming step is completely removed from the assembly process. Instead of adding shims to compensate for surface deviations, the invention extracts this corrective function and integrates it into the splice design itself through pre-fabricated verification features and gap control mechanisms.
Solution Approach 2:
The verification holes and gap features act as intermediaries between the surface profile deviations and the final assembly precision. These features mediate the alignment process by providing measurable reference points that automatically account for surface variations without requiring additional shimming components.
3Manufacturing precision
If manual inspection of gaps and shims is performed, then assembly precision is verified, but labor intensity increases
Solution Approach 1:
The splice performs self-verification through its built-in verification holes and gap features. The design automatically ensures gap tolerances are met through its structure, eliminating the need for labor-intensive manual inspection with filler gauges or hole inspection methods.
Solution Approach 2:
Manual mechanical inspection methods (filler gauges, hole inspection) are replaced by the built-in verification hole system. The verification holes provide a mechanical substitute that automatically verifies precision without requiring manual measurement and judgment steps.
Data Source
AI summary
A method for joining structures includes steps of: (1) fabricating a splice based on measurements of a first-structure surface of a first structure and a second-structure surface of a second structure along a joint formed between the first structure and the second structure; (2) installing the splice using a plurality of verification holes formed in the first structure, the second structure, and the splice; and (3) self-verifying that a gap between a splice surface of the splice and each one of the first-structure surface and the second-structure surface is less than or equal to a maximum allowable dimension of the gap by installing the splice.