Single-Piece Thermoplastic Reference Probe for Aircraft Assembly Jigs
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Solution Overview
Problem
Existing reference probes for aircraft structures are costly and time-consuming to produce due to the use of multiple materials and complex assembly processes, leading to reliability issues and potential errors in assembly operations, as they often require different production steps, expensive machining operations, and various connection methods, which can be compromised by thermal expansion differences and frequent reuse of damaged probes.
Innovation Solution
A single-piece reference probe made of thermoplastic material, featuring a constraint pin with a knob and pin design that allows for standardized gap generation and easy assembly, eliminating the need for multiple production steps and complex connections, using injection-moulding for production, and enabling quick replacement if damaged.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple materials and complex assembly processes are used for reference probes, then the precision and reliability of the probe can be maintained, but the production time and costs increase significantly
Solution Approach 1:
The patent combines multiple previously separate components (constraint pin, reference support, adjustment mechanisms) into a single integrated reference probe body made from one piece of material. This merging eliminates the need for complex assembly of multiple materials while maintaining the functional precision required for aircraft structure assembly reference points.
Solution Approach 2:
The single-piece reference probe design integrates multiple functions into one component: it provides constraint positioning, reference measurement surfaces, and adjustment capabilities all within a single monolithic structure. This multi-functionality reduces the number of parts and assembly steps while preserving all necessary measurement and positioning functions.
2Adaptability or versatility
If multiple materials are used for probe components, then the functional requirements can be met, but the cost for production systems and materials increases
Solution Approach 1:
The patent employs a homogeneous material structure throughout the entire reference probe, using a single material type for all components that were previously made from different materials. This homogeneity simplifies the manufacturing process, reduces material costs, and eliminates the need for complex multi-material production systems while still meeting all functional requirements through appropriate material selection and design.
3Manufacturing precision
If traditional machining operations are used for probe production, then the precision can be achieved, but the production time and costs increase
Solution Approach 1:
The patent transitions from traditional subtractive machining processes to additive manufacturing or direct forming processes for producing the reference probe. This parameter change in the manufacturing method allows the single-piece complex geometry to be produced more quickly and cost-effectively while maintaining the required precision through process control and design optimization.
4Ease of operation
If different connection methods are used for probe components, then the assembly can be completed, but the production time and device complexity increase
Solution Approach 1:
By merging all connection functions and assembly features into a single monolithic structure, the patent eliminates the need for separate connection members, fasteners, and joining operations. The integrated design inherently provides all necessary connections and constraints without requiring additional assembly steps or connection devices.
Data Source
Figure 1~4
AI summary
A reference probe for assembly jigs for aircraft structures, comprising a constraint pin (1), for being inserted into holes purposely provided on the assembly jig for aircraft structures and a reference support (2), associated to said pin, for generating a gap between the parts of the aircraft structure, during assemblage, of a known and standardized amount.