Wing-to-Fuselage Hole Mapping for Faster Aircraft Assembly
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Solution Overview
Problem
The current process of joining an aircraft wing to its fuselage is time-consuming due to the need to duplicate the hole pattern on the Centre Wing Box, which delays downstream operations and requires a technician to enter the narrow wing box for pilot hole drilling.
Innovation Solution
A process using laser trackers and templates to map the wing root and fuselage surfaces, allowing for the precise duplication of the hole pattern on the fuselage without physically aligning the components, enabling upstream hole pattern creation and improved dynamic symmetry for optimal flight performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the hole pattern is duplicated on the CWB by drilling pilot holes from inside the wing root, then the hole pattern can be accurately transferred, but the process becomes time-consuming and delays downstream operations
Solution Approach 1:
The patent applies preliminary action by performing the hole pattern duplication on the CWB before the wing root is physically aligned with it. Laser trackers are used to map the wing root's hole pattern coordinates, and these coordinates are used to drill pilot holes on the CWB in advance. This eliminates the need to wait for physical alignment before duplicating the hole pattern, thereby accelerating the assembly process while maintaining accuracy.
Solution Approach 2:
The patent replaces the mechanical alignment and manual drilling process with a laser-based measurement and drilling system. Laser trackers capture the spatial coordinates of the wing root's hole pattern, and this data is used to guide the drilling of pilot holes on the CWB. This substitution of mechanical processes with optical measurement and automated drilling significantly reduces assembly time while preserving manufacturing precision.
2Manufacturing precision
If a technician enters the narrow wing box to provide pilot holes, then the hole pattern can be duplicated, but the operation becomes complex and time-consuming
Solution Approach 1:
The patent introduces laser trackers as an intermediary between the wing root and the CWB. Instead of requiring a technician to physically enter the narrow wing box and manually drill pilot holes, the laser tracker captures the spatial coordinates of the hole pattern on the wing root and transfers this information to the CWB. This intermediary measurement system eliminates the need for complex manual operations in confined spaces while maintaining duplication accuracy.
3Manufacturing precision
If the wing root is positioned with respect to the CWB for hole pattern duplication, then accurate hole alignment is achieved, but the process holds up downstream operations
Solution Approach 1:
The patent applies preliminary action by using laser trackers to capture the hole pattern coordinates on the wing root before physical positioning with the CWB. The captured coordinates are then used to drill pilot holes on the CWB in advance. This allows the hole pattern duplication to be completed before the wing root is actually aligned with the CWB, eliminating the time delay that would otherwise occur while waiting for physical positioning.
Solution Approach 2:
The patent uses laser trackers to create a digital copy of the hole pattern coordinates from the wing root. This digital copy is then used to guide the drilling of pilot holes on the CWB without requiring the physical presence of the wing root during the drilling operation. This copying approach decouples the hole pattern duplication from the physical alignment process, thereby reducing assembly delays while maintaining accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces assembly time, eliminates the need for physical alignment, and ensures precise hole placement, enhancing production efficiency and aircraft performance by allowing hole pattern duplication outside the critical assembly path and accounting for actual component characteristics.
Implementation Method 1
A process using laser trackers and templates to map the wing root and fuselage surfaces
Data Source
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AI summary
The invention relates to a process of joining a wing to an aircraft fuselage comprising the steps of: mapping the wing root (11) of the wing (10), mapping the centre-wing-box (CWB) of the aircraft fuselage, determining the position to provide the hole pattern on the CWB, providing the holes on the CWB, and attaching the wing root (11) to the CWB. Primary and secondary templates with corresponding hole patterns may be used in combination with targets and laser trackers to implement the process. The hole pattern (17) of the wing root (11) can therefore be duplicated on the CWB at a position such that when the wings (10) are joined to the fuselage, the aircraft will have optimum flight performance and dynamic symmetry. The invention thereby provides a predictive fit, based on virtual representation and analysis, and advantageously permits the hole pattern (17) to be provided without requiring the CWB and wing root (11) to be brought together.