Aircraft Wing Assembly Line With Suspended Panel Rib Installation
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Solution Overview
Problem
Current aircraft wing fabrication and assembly processes face delays due to uneven work completion rates and require significant time for component transportation and setup, leading to inefficiencies and increased costs.
Innovation Solution
The implementation of an assembly line system where large wing components are transported in pulses or continuously, with discrete work stations performing tasks on the components during pauses or movement, utilizing indexing features on the components to facilitate efficient alignment and processing at each station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If components are fabricated and assembled in predefined cells on a factory floor, then work can be performed on components, but delays occur when work completion rates are uneven and setup time is required for each cell
Solution Approach 1:
The assembly process is segmented into discrete work stations arranged in a linear sequence, with each station performing a specific task on the wing panel. The panel itself is segmented into regions that can be worked on simultaneously at different stations, allowing parallel processing and eliminating the need to wait for complete work at one location before moving to the next.
Solution Approach 2:
The system transitions from static predefined cells to a dynamic assembly line where the wing panel moves continuously or in pulses through multiple work stations. This dynamic approach allows the panel to be worked on at multiple locations simultaneously, with work stations adding or removing components as the panel passes, thereby eliminating setup time associated with moving between fixed cells.
2Measurement precision
If automated optical inspection techniques and probes are used to inspect position of parts, then measurement accuracy is improved, but inspection time and cost increase significantly
Solution Approach 1:
Indexing features are incorporated into the wing panel design during the manufacturing phase, establishing a precise reference framework before the component enters the assembly line. These pre-built features eliminate the need for time-consuming post-manufacturing inspection and cataloging, as the panel's position and orientation are inherently defined by its indexing features that interface with the work stations.
Solution Approach 2:
Instead of using complex automated optical inspection systems to determine panel geometry, the patent uses simplified optical sensors that detect the known indexing features. The indexing features serve as a reference copy of the panel's intended geometry, allowing verification through simple feature detection rather than comprehensive surface scanning.
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.