Aircraft Wing Panel Assembly Line With NDI And Indexing
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Solution Overview
Problem
Current aircraft wing fabrication and assembly processes face delays due to uneven work completion rates and require extensive setup and inspection times, particularly with automated optical inspection techniques being time-consuming and expensive.
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 Non-Destructive Inspection (NDI) and other 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, causing delays
Solution Approach 1:
The assembly process is segmented into discrete workstations arranged in a linear sequence, with each workstation performing specific tasks on specific portions of the wing assembly. This allows parallel processing of different components simultaneously, eliminating the bottleneck where the entire assembly must wait at each cell.
Solution Approach 2:
The system transitions from static cell-based assembly to a dynamic assembly line where the wing assembly moves continuously through multiple workstations. This dynamic approach allows work to proceed on multiple sections simultaneously while maintaining coordination through the moving assembly structure.
2Measurement precision
If automated optical inspection techniques and probes are used to inspect position of parts, then measurement accuracy can be achieved, but the inspection process becomes time-consuming and expensive
Solution Approach 1:
Indexing features are formed into components during the initial fabrication process, establishing precise reference points before assembly. This preliminary action eliminates the need for time-consuming post-assembly inspection, as the indexing features inherently define component positions with the required precision.
Solution Approach 2:
The system uses indexing features that replicate precise positional information from the fabrication stage through assembly. Instead of measuring and verifying positions with expensive optical equipment, the indexing features serve as permanent copies of the desired positional data, enabling quick verification through simple feature recognition.
3Ease of manufacture
If components are moved between cells for fabrication and assembly, then work can be performed at specialized stations, but each movement requires setup time that reduces efficiency
Solution Approach 1:
Multiple specialized workstations are merged into a single continuous assembly line structure. This integration allows components to be worked on at specialized stations without requiring repeated setup and teardown between separate cells, as all specialized work occurs in sequence within one unified system.
Solution Approach 2:
The assembly line structure serves multiple functions simultaneously: it provides specialized work capabilities at each station, maintains precise positioning through indexing features, enables continuous movement, and coordinates parallel operations. This multi-functionality eliminates the need for separate specialized cells.
Data Source
AI summary
Systems and methods are provided for inspecting a wing panel. Some methods include advancing a wing panel through a Non-Destructive Inspection (NDI) station, and inspecting the wing panel with inspection heads at the NDI station. The wing panel may be suspended beneath a strongback during inspection and/or advancement, such as by using vacuum couplers and/or adjustable-length pogos of the strongback, and suspending may include enforcing a contour to the wing panel using the vacuum couplers and/or pogos. Other methods include receiving a wing panel at an NDI station and inspecting a portion thereof during movement through the NDI station. Some systems include a track, a strongback to suspend a wing panel beneath it and to advance along the track, and an NDI station disposed at the track to inspect the wing panel while suspended.