Strongback Vacuum Decoupling for One-Piece Fuselage Mandrels
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Solution Overview
Problem
Existing processes for decoupling caul plates from a fuselage or decoupling a fuselage from a mandrel require specialized equipment and are costly, complex, and labor-intensive due to the use of segmented mandrels that need disassembly and reassembly.
Innovation Solution
A strongback apparatus with actuators and vacuum suction cups is used to pull a tubular structure radially outward, allowing for the decoupling of a fuselage from a one-piece mandrel without disassembling the mandrel, utilizing a one-piece mandrel that remains intact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a segmented mandrel is used for decoupling, then the mandrel can be disassembled and reassembled, but the process complexity and labor requirements increase
Solution Approach 1:
The mandrel is divided into multiple segmented sections that can be independently manipulated. This allows the mandrel to be collapsed into a compact configuration for removal from the fuselage, then expanded and reassembled for future use, resolving the contradiction between reusability and complexity by enabling controlled disassembly of individual segments
Solution Approach 2:
The mandrel incorporates dynamic expansion and collapse capabilities through hydraulic or mechanical actuation systems. The mandrel can transition between expanded (for fuselage formation) and collapsed (for removal) states, allowing single-use operation without permanent disassembly while maintaining adaptability for repeated use
2Ease of operation
If specialized equipment is used to support mandrel disassembly, then the mandrel can be taken apart, but the cost and equipment requirements increase
Solution Approach 1:
The mandrel system incorporates self-contained hydraulic or mechanical actuation mechanisms that enable the mandrel to collapse and expand using its own integrated systems. This eliminates the need for external specialized disassembly equipment, as the mandrel performs its own assembly and disassembly operations through built-in actuators controlled during the removal process
3Adaptability or versatility
If a segmented mandrel is used, then the mandrel can be reassembled for future use, but the labor and time required increase
Solution Approach 1:
The mandrel segments are pre-configured with alignment features, pre-attached fastening mechanisms, and pre-positioned sealing elements. This preliminary preparation allows for rapid reassembly after removal, as segments can be quickly reconnected without requiring complex alignment or custom fabrication, significantly reducing the time penalty for mandrel reuse
Solution Approach 2:
The mandrel employs dynamic expansion mechanisms that automatically return segments to their operational configuration upon reassembly. Hydraulic or mechanical spring systems pre-loaded during assembly automatically expand the mandrel to its operational shape, eliminating time-consuming manual adjustment and positioning operations during reassembly
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
This method reduces complexity and labor, enabling efficient decoupling of the fuselage from the mandrel while maintaining the mandrel's integrity, thus decreasing costs and improving process efficiency.
Implementation Method 1
operating a vacuum source to engage the vacuum suction cups of the plurality of actuators with the first tubular structure
Data Source
AI summary
In an example, a system is disclosed. The system comprises a one-piece mandrel, a fuselage coupled to the one-piece mandrel, and a strongback apparatus positioned on the fuselage. The strongback apparatus comprises an arcuate central body comprising a front end, a rear end, and a plurality of elongated members that connect the front end to the rear end, and actuators mounted to the plurality of elongated members. The actuators are configured to move in a radially outward direction from extended positions to retracted positions and comprise (i) proximal ends mounted to the plurality of elongated members and (ii) distal ends having vacuum suction cups. In the extended positions, the vacuum suction cups engage the fuselage on which the strongback apparatus is positioned. As the actuators moves from the extended positions to the retracted positions, the vacuum suction cups pull the fuselage away from the one-piece mandrel.