Split Longerons for Fuselage Barrel Assembly
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Solution Overview
Problem
The manufacturing of aircraft fuselage barrel assemblies is time-consuming and costly due to the use of single-piece longerons, which require additional assembly steps and extensive space, necessitating a more efficient method for structural support and assembly.
Innovation Solution
The implementation of split longerons, comprising a first and second longeron section attached to the fuselage barrel sections via section fasteners and a longeron joint connected with joint fasteners, allowing for direct contact and reduced need for shims, thereby simplifying the assembly process and providing structural support across barrel joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If single-piece longerons are used to provide structural support between barrel sections, then structural integrity is maintained, but assembly time and complexity increase
Solution Approach 1:
The longeron is divided into multiple sections (first longeron section, second longeron section, third longeron section) that can be assembled separately and then connected. This segmentation allows each section to be pre-assembled with adjacent barrel sections, reducing the overall assembly time while maintaining structural integrity through the connection of sections at the barrel joint.
Solution Approach 2:
The longeron sections are pre-assembled with the barrel sections before final assembly. The first longeron section is attached to the first barrel section, and the second longeron section is attached to the second barrel section in advance, allowing for preliminary structural preparation that simplifies the final assembly process.
2Strength
If single-piece longerons are used to reinforce barrel joints, then structural support is adequate, but additional assembly steps and space requirements increase
Solution Approach 1:
The longeron is segmented into multiple sections that can be independently positioned and attached to adjacent barrel sections. This segmentation simplifies the assembly process by allowing each section to be handled and positioned separately, reducing the complexity of manipulating a single long piece while still providing adequate joint reinforcement.
Solution Approach 2:
The longeron connection is achieved through a Z-shaped splice configuration that utilizes three-dimensional spatial arrangement. The longeron sections overlap and connect in a staggered pattern across the barrel joint, providing structural reinforcement through a multi-dimensional configuration rather than a simple linear connection.
3Strength
If single-piece longerons are used throughout the fuselage barrel assembly, then continuous structural support is provided, but manufacturing cost and assembly time increase
Solution Approach 1:
The continuous longeron is divided into multiple discrete sections that can be manufactured independently and then assembled. This segmentation maintains the continuous structural support function while improving productivity by allowing parallel manufacturing of sections and simplifying the assembly process through modular construction.
Solution Approach 2:
Longeron sections are pre-assembled with their corresponding barrel sections before final assembly. This preliminary action allows for concurrent manufacturing and preparation activities, improving overall productivity while ensuring continuous structural support is maintained through the connected sections.
Data Source
AI summary
Fuselage barrel assemblies and methods of assembling fuselage barrel assemblies are disclosed herein. The fuselage barrel assemblies include a first barrel section and a second barrel section, which is interfaced with the first barrel section to define a barrel joint between the first barrel section and the second barrel section. The fuselage barrel assemblies also include a split longeron, which extends across the barrel joint and is attached to both the first barrel section and the second barrel section. The split longeron includes a first longeron section, which is attached to the first barrel section, and a second longeron section, which is attached to the second barrel section. The split longeron also includes a longeron joint that attaches the first longeron section to the second longeron section. The methods include methods of assembling the fuselage barrel assemblies.