Aircraft Wing Assembly Line with Contour Enforcement Shuttle
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Solution Overview
Problem
Current aircraft wing fabrication and assembly processes face inefficiencies due to delays when components are completed at different rates, requiring extensive setup and inspection times, and involve costly automated optical inspection techniques.
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 and a shuttle with adjustable-length pogos to enforce a contour and facilitate the installation of structural components, reducing the need for frequent cell changes and minimizing setup time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are fabricated and assembled in predefined cells on a factory floor, then reliability is maintained, but productivity decreases due to delays when work at a specific portion is completed more slowly than expected
Solution Approach 1:
The wing assembly process is divided into multiple discrete work stations (first work station for rib installation, second work station for spar installation, third work station for panel installation) that can operate independently and simultaneously on different portions of the wing, eliminating the bottleneck where the entire assembly must wait for any single operation to complete
Solution Approach 2:
The assembly line enables continuous movement of the wing through multiple work stations without stopping the overall process. While one portion of the wing is being worked on at a station, other portions can be processed at different stations simultaneously, maintaining continuous productive action throughout the system
2Adaptability or versatility
If components are moved between cells for fabrication work, then manufacturing flexibility is achieved, but loss of time increases due to frequent moves and setup time
Solution Approach 1:
Multiple work stations are merged into a single integrated assembly line where the wing moves sequentially through each station without being physically moved between separate cells. This combines the functions of multiple cells into one continuous process, eliminating transport time and setup time between cells while maintaining manufacturing flexibility
Solution Approach 2:
A conveyor system acts as an intermediary mechanism that transports the wing between work stations within the same assembly line, eliminating the need for frequent cell changes and reducing setup time while maintaining the ability to perform different operations at each station
3Manufacturing precision
If automated optical inspection techniques and probes are used to inspect position of parts, then manufacturing precision is improved, but loss of time increases due to time-consuming inspection processes
Solution Approach 1:
Indexing features are formed into the wing panel during the initial fabrication process at the first work station, establishing precise reference points before subsequent assembly operations. This preliminary action eliminates the need for time-consuming inspection processes later, as the indexing features provide built-in positional accuracy for rib, spar, and panel installation
Data Source
AI summary
Systems and methods are provided for installing ribs and/or spars to a wing panel while a contour is enforced. Methods include suspending a wing panel beneath a shuttle that enforces the contour, advancing the wing panel through work stations via the shuttle, and installing a rib or a spar (or another wing panel) at a work station, while the contour is enforced. Other methods include locating a wing panel beneath a shuttle, coupling adjustable-length pogos to the wing panel at locations distinct from those corresponding with an installation location, e.g. for a rib or a spar, and controlling the length of the pogos to enforce a contour to the wing panel. Some systems include a track, work stations disposed along the track, and a shuttle to advance along the track and convey a wing panel to each of the work stations while enforcing a contour onto the wing panel.