Aircraft Wing Panel Assembly Line With In-Motion NDI Inspection
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Solution Overview
Problem
Current aircraft wing fabrication and assembly processes are inefficient due to delays caused by uneven work rates among components, excessive setup times, and the need for precise positioning and scanning, which result in significant non-value-added time and costs.
Innovation Solution
Implementing an assembly line system where wing panels are moved in pulses or continuously, with discrete work stations performing tasks along the way, utilizing indexing features formed during manufacturing to align components precisely and reduce the need for repeated scanning and setup, and employing non-destructive inspection and automated systems for real-time monitoring and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are fabricated and assembled in predefined cells on a factory floor, then structural precision and quality control are maintained, but production time increases due to frequent moves between cells and setup time
Solution Approach 1:
The fabrication process is segmented into discrete work stations arranged in an assembly line configuration, where each station performs a specific task on wing panels. This allows continuous flow of components through the manufacturing process without requiring complete moves between cells, reducing setup time while maintaining precision through specialized equipment at each station.
Solution Approach 2:
The system transitions from static predefined cells to a dynamic assembly line where wing panels move continuously or in pulses through multiple work stations. This dynamic approach allows simultaneous work on multiple sections of the wing panel by different stations, reducing overall production time while maintaining quality control through standardized processes at each station.
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 formed into the wing panels during the initial manufacturing process, establishing precise reference points before the components enter the assembly line. This preliminary action eliminates the need for time-consuming post-manufacturing scanning and positioning, as the indexing features provide immediate, accurate alignment references at each work station.
Solution Approach 2:
Instead of using complex automated optical inspection systems to determine component positions, the patent uses simplified indexing features that replicate the necessary alignment information. These indexing features serve as physical copies of the precise positioning data, allowing quick and accurate alignment without expensive scanning equipment.
3Manufacturing precision
If a wing panel takes longer than expected to be laid-up or fastened, then work quality may improve, but the entire wing assembly remains at the cell until all work is completed, reducing productivity
Solution Approach 1:
The wing assembly process is divided into multiple independent work stations, each handling specific tasks on different sections of the wing panel. This segmentation allows parallel processing where multiple stations work simultaneously on different portions of the same panel, preventing bottlenecks and maintaining high throughput even when individual tasks take varying amounts of time.
Solution Approach 2:
The assembly line maintains continuous motion of wing panels through the manufacturing process, with panels moving from one work station to the next without interruption. This continuous flow ensures that productivity is not halted by delays at any single station, as other stations continue their operations simultaneously, maintaining overall assembly throughput.
Data Source
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AI summary
Systems and methods are provided for inspecting a wing panel (550). Some methods include advancing a wing panel through a Non-Destructive Inspection (NDI) station (524), and inspecting the wing panel with inspection heads (624) at the NDI station. The wing panel may be suspended beneath a strongback (540) during inspection and/or advancement, such as by using vacuum couplers (548) and/or adjustable-length pogos (545) 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 (510), 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.