Strongback Clamp Assembly for Precise Flexible Stringer Placement
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Solution Overview
Problem
Conventional gantry systems for placing long, flexible composite stringers on aircraft wings are complex, costly, and require significant factory space, with challenges in positional accuracy and structural weight due to the need for multiple heads and extensive structural design compensations.
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 compensations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gantry system is used to place long flexible composite stringers, then the stringers can be supported at multiple locations, but the system complexity and cost increase significantly
Solution Approach 1:
The stringer support function is segmented into multiple discrete actuator-clamp assemblies distributed along the stringer length, each independently controlling a specific segment. This replaces the monolithic gantry structure with modular units that can be selectively activated, reducing overall system complexity while maintaining support reliability.
Solution Approach 2:
The system transitions from static gantry support to dynamic actuator-controlled support, where each clamp assembly can independently adjust its position and clamping force. This dynamic capability allows the system to adapt to different stringer configurations and placement requirements without requiring a complex fixed gantry structure.
2Adaptability or versatility
If a gantry system extends across the full width of the wing panel, then complete stringer placement is enabled, but factory floorspace occupation increases
Solution Approach 1:
The system transitions from a two-dimensional gantry plane extending across the wing width to a three-dimensional robotic manipulation system. The robotic arm operates in volumetric space, allowing the stringer to be picked up, manipulated, and placed from various angles and positions without requiring the gantry to physically span the entire wing width.
Solution Approach 2:
The robotic arm serves as an intermediary between the actuator-clamp assemblies and the stringer placement location. It transfers the stringer from the pickup location to the target position on the wing panel, enabling complete placement coverage without the need for a physically extensive gantry structure.
3Manufacturing precision
If compensated offset of stringer flanges is used for alignment, then placement tolerances can be compensated, but structural mass of the wing assembly increases
Solution Approach 1:
The mechanical compensation method using offset flanges and additional structural mass is replaced with an active control system. Sensors detect the actual stringer position and orientation, and the control system adjusts the robotic arm and actuator-clamp assemblies in real-time to achieve precise alignment, eliminating the need for compensating structural mass.
Solution Approach 2:
The system dynamically adjusts operational parameters (robotic arm position, actuator clamp positions, stringer orientation angles) based on real-time measurements of the stringer's actual location and orientation. This parametric control achieves placement precision without requiring fixed structural compensations that会增加 weight.
Data Source
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.