Variable Stringer Positioning Tool for Aviation Assembly
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Solution Overview
Problem
Existing joining tools fail to achieve precise positioning and joining of long profile bodies, such as stringers, to components, particularly in the aviation industry, where deviations can exceed 4 mm for stringers up to 18 m in length, due to limitations in positioning accuracy.
Innovation Solution
A joining tool that includes a docking system for industrial robots, a gripper for handling profile bodies of varying geometries, guide rollers with adjustable positions, and a pressure system for secure attachment, along with an optional activation device for creating a permanent connection, utilizing multiple robots for enhanced precision and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional gripping and joining tools are used to join stringers to components, then the joining process can be automated, but the positioning accuracy deteriorates to deviations of up to 4 mm for stringers 18 m in length
Solution Approach 1:
The guide rollers are designed with adjustable positions along the longitudinal axis of the stringer, allowing the system to adapt dynamically to different stringer lengths and geometries. This dynamic adjustability enables maintaining high positioning accuracy across varying production conditions while preserving full automation.
Solution Approach 2:
The system changes the parameter of guide roller positioning to optimize accuracy for different stringer configurations. By adjusting the location and arrangement of guide rollers along the stringer length, the system compensates for the inherent limitations of automated robotic positioning, achieving sub-millimeter accuracy even for 18 m stringers.
2Device complexity
If the guide rollers are fixed in position, then the device structure is simplified, but the tool cannot adapt to different profile body shapes and geometries
Solution Approach 1:
The guide rollers are mounted on adjustable mechanisms that allow their positions to be modified along the longitudinal axis. This dynamic configuration enables the same tool to handle multiple profile body shapes and geometries without requiring complete tool changes, balancing structural simplicity with operational versatility.
Solution Approach 2:
The adjustable guide roller system provides universal applicability across different profile body types. By enabling position adjustment, a single tool design can serve multiple functions for various stringer geometries, eliminating the need for multiple specialized tools while maintaining adaptability.
3Device complexity
If a single robot is used for positioning and joining, then the device complexity is reduced, but the positioning accuracy and stability deteriorate for long profile bodies
Solution Approach 1:
The joining task is segmented between the robot (for gross positioning and transport) and the guide rollers (for fine positioning and alignment). This segmentation allows each component to specialize: the robot handles the complex task of moving and roughly positioning long stringers, while the guide rollers provide the precise alignment and stability needed for accurate joining, achieving high precision without requiring multiple robots.
Data Source
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AI summary
The tool has a docking port for automatically docking and undocking an industrial robot, and a gripper for optionally gripping, holding or positioning a profile body (8). A pressing device slightly presses the profile body to a component. Guide rollers (5) engage with a rolling surface at sides of the profile body projecting from the component such that the guide rollers are automatically adaptable to different profile body forms. The guide rollers are pivotable about an axis parallel to a longitudinal axis of the profile body.