Automated Wing Box Clamp for One-Way Rib Web Assembly
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Solution Overview
Problem
The assembly of aircraft wing boxes is time-consuming and complicated due to the need for drilling, shimming, and bolting multiple components together, and one-way assembly is not practical without a clamping force, which can lead to inter-laminar burring and disassembly requirements.
Innovation Solution
An automated clamp system with a clamp frame, moveable arms, and a robot end effector connector, equipped with vision and contact normalization systems, that allows for clamping of rib webs to rib posts or feet, enabling one-way assembly by maintaining clamping force during drilling and fastening while minimizing tooling size and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional assembly methods are used without clamping, then assembly process is simpler, but inter-laminar burring occurs and disassembly is required
Solution Approach 1:
The clamp applies clamping force to the rib web and rib post before drilling operations begin, pre-positioning the components in precise alignment. This preliminary clamping action prevents movement during drilling, eliminating inter-laminar burring and ensuring accurate hole formation without requiring subsequent disassembly for corrections.
Solution Approach 2:
The clamp acts as an intermediary device between the drilling tool and the workpiece, maintaining continuous contact and pressure on the rib web and rib post throughout the drilling process. This intermediary clamping force ensures that the components remain perfectly aligned and prevents burring without requiring complex assembly procedures.
2Manufacturing precision
If clamping force is applied to prevent burring, then assembly precision is maintained, but assembly time increases due to disassembly and reassembly
Solution Approach 1:
The clamp maintains continuous clamping force throughout the entire drilling and assembly process, from initial positioning through hole formation to final fastening. This uninterrupted clamping action eliminates the need to release and reapply clamps during disassembly and reassembly operations, maintaining precision while significantly reducing total assembly time.
Solution Approach 2:
The clamp is applied once at the beginning and maintains pressure through all subsequent operations, preventing the need for repeated disassembly and reassembly. This single preliminary clamping action covers the entire assembly sequence, eliminating time-consuming intermediate steps while preserving assembly precision.
3Adaptability or versatility
If large tooling is used to accommodate aircraft component scale, then component coverage is sufficient, but space envelope increases
Solution Approach 1:
The clamp is divided into separate functional modules including independent clamping arms, positioning mechanisms, and drilling fixtures. Each module can be adjusted and reconfigured to accommodate different rib web and rib post sizes and geometries. This segmentation allows the tooling to adapt to various aircraft component scales without requiring a completely different clamp size, reducing the overall space envelope while maintaining adequate coverage.
Solution Approach 2:
The clamp incorporates movable and adjustable components that can dynamically adapt to different component dimensions. The clamping arms and positioning elements can be repositioned along adjustment ranges to match the specific scale and geometry of each aircraft component being assembled, providing versatile coverage without requiring oversized fixed tooling.
Data Source
AI summary
An automated clamp for clamping a rib web to a rib post or rib foot of an aircraft wing box is disclosed including a clamp frame, a first arm and a second arm extending from the base of the clamp frame, the second arm is moveably mounted to the base of the clamp so as to be moveable towards and away from the first arm; a robot end effector connector coupled to the clamp frame. The clamp jaws include a first jaw fixed at a distal end of the first arm, and a second jaw fixed at a distal end of the second arm, the clamp jaws configured to clamp the rib web to the rib post or rib foot. One of the clamp jaws defines a tool module docking aperture configured to receive a tool module for providing access to the rib web and rib post or rib foot clamped between the clamp jaws.