Aircraft Wing Assembly Line with Indexed Panel Positioning
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Solution Overview
Problem
Current aircraft wing fabrication and assembly processes face delays due to uneven work completion rates and inefficiencies in component transportation and inspection, leading to significant non-value-added time and setup costs.
Innovation Solution
Implementing an assembly line system where large components like wing panels are moved in pulses or continuously, with discrete work stations performing tasks along the line, utilizing indexing features formed into the components for precise positioning and alignment, and integrating transportation with assembly processes to reduce movement and setup times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are fabricated and assembled in predefined cells on a factory floor, then work can be performed on each component, but the entire assembly must wait at each cell until all work is completed, leading to delays
Solution Approach 1:
The assembly process is segmented into multiple workstations arranged in sequence, with each workstation performing specific tasks on different portions of the wing assembly simultaneously. This allows parallel processing of multiple components across different stations, eliminating the sequential waiting time inherent in cell-based fabrication.
Solution Approach 2:
The patent transitions from a two-dimensional cell-based layout to a one-dimensional assembly line configuration, enabling components to move continuously through multiple workstations. This spatial reorganization allows simultaneous operations at different stations along the line, improving throughput without compromising manufacturing capability.
2Adaptability or versatility
If components are moved between cells for different work tasks, then multiple operations can be performed, but frequent moves require setup time and cataloging time that is not value-added
Solution Approach 1:
Indexing features are pre-formed into the wing panels during initial fabrication, eliminating the need for time-consuming cataloging and setup procedures when components arrive at workstations. This preliminary action ensures that components are immediately ready for assembly operations upon arrival at the line.
Solution Approach 2:
The wing panels themselves provide the indexing features needed for positioning and alignment at workstations, rather than requiring external measurement and cataloging systems. This self-service approach eliminates non-value-added time by making the components self-sufficient for precise positioning.
3Measurement precision
If automated optical inspection techniques and probes are used to inspect position of parts, then inspection accuracy is improved, but the process becomes time-consuming and expensive
Solution Approach 1:
Indexing features are incorporated into the wing panel design during initial fabrication, providing built-in reference points for positioning and alignment. This preliminary incorporation of measurement references eliminates the need for separate, time-consuming optical inspection processes while maintaining high precision.
Solution Approach 2:
The patent replaces complex optical inspection systems with simple mechanical indexing features that provide inherent positioning accuracy. This substitution eliminates expensive and time-consuming optical measurement processes while achieving the same or better precision through mechanical means.
Data Source
AI summary
Systems and methods are provided for assembling a wing. Methods include suspending an upper wing panel of an aircraft beneath a shuttle, translating a rib to a position it, and placing the rib into contact with, then affixing the rib to, the upper wing panel, while suspended. Some methods include installing ribs and spars to the upper wing panel, and joining a lower wing panel to the ribs and spars, while the upper wing panel is suspended. Some methods involve joining ribs to spars (e.g., all, or some) to produce a support structure that is then affixed to the upper wing panel. Systems include a shuttle that suspends an upper wing panel, and a cart that includes supports to hold a rib, a chassis to translate the rib to a position beneath the upper wing panel, and a lifting apparatus to lift the rib into contact with the upper wing panel.