Track-Aligned Trim Tool Assembly for Precise Fuselage Edge Machining
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Solution Overview
Problem
The manual trim process in aircraft fuselage assembly is time-consuming, prone to errors, and ergonomically stressful, as it relies on manual hand grinding, which affects the accuracy and efficiency of joining fuselage segments.
Innovation Solution
A flexible track assembly with vacuum grippers and indexing carts is used to align and secure a tool cart with a trim saw, allowing precise machining along a defined process line, reducing manual labor and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual hand grinding is used for trim process, then workers can perform the work flexibly, but the process becomes time-consuming and prone to errors
Solution Approach 1:
The patent replaces the manual mechanical grinding system with an automated computer-controlled machining system. The CNC-controlled trim saw automatically executes pre-programmed cutting paths, eliminating manual hand grinding operations while maintaining precision and enabling parallel processing of multiple segments, thus resolving the contradiction between operational flexibility and manufacturing time.
Solution Approach 2:
The patent implements preliminary programming of the trim paths and machining parameters before actual production. By pre-defining the cutting trajectories and processing parameters for different fuselage segments, the system eliminates setup time during manufacturing and enables rapid execution of trim operations, thereby improving productivity while maintaining operational precision.
2Device complexity
If manual hand grinding is used for trim process, then equipment complexity is reduced, but accuracy and reliability deteriorate
Solution Approach 1:
The patent replaces simple manual tools with sophisticated computer-controlled machining equipment. The CNC system incorporates precise positioning mechanisms, programmable cutting paths, and automated control systems that dramatically improve trim accuracy and consistency, resolving the contradiction between equipment simplicity and manufacturing precision.
Solution Approach 2:
The patent implements feedback mechanisms through computer-controlled systems that monitor and adjust machining parameters in real-time. The system uses sensors and control algorithms to maintain precise cutting paths and compensate for variations, ensuring high accuracy and reliability while managing the complexity through systematic control.
3Device complexity
If manual hand grinding is used for trim process, then equipment cost is reduced, but ergonomic stress on workers increases
Solution Approach 1:
The patent replaces manual labor-intensive operations with automated machining systems. This substitution eliminates ergonomic stress on workers by removing the need for manual hand grinding, while the automated system handles all physically demanding tasks, resolving the contradiction between equipment cost and worker welfare.
Solution Approach 2:
The patent implements self-service automation where the machining system performs all trim operations autonomously without human physical intervention. The automated equipment handles positioning, cutting, and finishing tasks, completely eliminating ergonomic stress on workers while the system manages its own operation through computer control.
4Manufacturing precision
If automated tool cart with indexing carts is used, then manufacturing precision and productivity improve, but device complexity increases
Solution Approach 1:
The patent divides the automated machining system into modular components: indexing carts, tool carts, and track segments. Each module performs specific functions and can be independently controlled or replaced, managing overall system complexity while maintaining high precision through coordinated operation of segmented components.
Solution Approach 2:
The patent designs the indexing carts and tool carts with multi-functional capabilities. The same cart infrastructure supports multiple tools and can accommodate different machining operations, reducing the need for separate dedicated systems and managing complexity through universal, adaptable components.
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 solution significantly reduces manufacturing time, improves accuracy, and decreases ergonomic stress by automating the trim process, ensuring precise mating of fuselage segments during assembly.
Implementation Method 1
a flexible track assembly is mounted to an outer surface of the fuselage segment near the end of the fuselage segment. The flexible track assembly includes a track and a plurality of vacuum grippers that attach to the outer surface of the fuselage.
Data Source
AI summary
During an assembly process for an aircraft, segments of the fuselage are fabricated separately prior to joining the segments together to form the complete fuselage. In order to ensure that abutting ends of the segments mate together correctly, a machining process is performed along the edges of the segments at their ends. A trim-tool assembly includes an indexing cart mounted to a track secured to a surface of the workpiece, where a setting on the indexing cart varies a distance between a centerline of the track and an edge of a workpiece. The trim-tool assembly further includes a tool cart mounted to the track and translatable along the track. The tool cart includes a process tool that performs a machining process on the workpiece at a fixed distance from the centerline of the track.