Wing Panel Shuttle Assembly With Enforced Contour Indexing
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Solution Overview
Problem
Current aircraft wing assembly processes face inefficiencies due to delays when components are completed at different rates, requiring extensive setup and movement between cells, and rely on time-consuming automated inspection techniques.
Innovation Solution
A method and system where a wing panel is suspended beneath a shuttle that enforces a contour, allowing for continuous advancement through an assembly line with indexed work stations, enabling rapid installation of structural components like ribs and spars, and reducing the need for frequent setup and inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are fabricated and assembled in predefined cells on a factory floor, then structural integrity and precision are maintained, but production time increases due to frequent moves and setup between cells
Solution Approach 1:
The assembly line is divided into multiple specialized work stations (tacking cell, riveting cell, splicing cell, side of body cell) that process different portions of the wing assembly simultaneously. This segmentation allows parallel processing of multiple components without requiring frequent moves between cells, maintaining precision while reducing production time.
Solution Approach 2:
The patent transitions from a two-dimensional factory floor layout with discrete cells to a three-dimensional assembly line configuration where components move continuously through overlapping work stations. This dimensional change enables simultaneous operations at different stations, reducing the time required while maintaining assembly precision through controlled movement.
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 substantially
Solution Approach 1:
Indexing features are incorporated into the wing components during the fabrication process itself, before assembly begins. This preliminary action eliminates the need for time-consuming post-fabrication inspection and measurement, as the indexing features provide built-in reference points that ensure proper alignment and positioning during assembly.
Solution Approach 2:
The indexing features on the wing components serve as self-contained reference systems that automatically guide alignment and positioning during assembly. This self-service mechanism eliminates the need for external inspection equipment and probes, reducing both inspection time and cost while maintaining measurement accuracy through precision-machined indexing features.
3Adaptability or versatility
If a component is moved between cells, then work can be performed at different locations, but setup time increases for each movement
Solution Approach 1:
The indexing features are designed with universal compatibility across all work stations along the assembly line. Each work station is equipped with corresponding indexing mechanisms that can accommodate the same indexing features on wing components, eliminating the need for cell-specific setup adjustments and enabling seamless transitions between stations.
Solution Approach 2:
The assembly line is designed with dynamic indexing mechanisms that can automatically adjust to accommodate variations in component dimensions and tolerances. This dynamic capability allows components to move between work stations without manual setup, as the indexing system adapts to each component's specific characteristics while maintaining precise alignment.
Data Source
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AI summary
Systems and methods are provided for installing ribs (572) and/or spars (580) to a wing panel (550) while a contour is enforced. Methods include suspending a wing panel beneath a shuttle (540) that enforces the contour, advancing the wing panel through work stations (520) via the shuttle, and installing a rib or a spar (or another wing panel) at a work station, while the contour is enforced. Other methods include locating a wing panel beneath a shuttle, coupling adjustable-length pogos (545) to the wing panel at locations distinct from those corresponding with an installation location, e.g. for a rib or a spar, and controlling the length of the pogos to enforce a contour to the wing panel. Some systems include a track (510), work stations disposed along the track, and a shuttle to advance along the track and convey a wing panel to each of the work stations while enforcing a contour onto the wing panel.