Aircraft Wing Rib Assembly Line with Indexed Robotic Shim Installation
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Solution Overview
Problem
Current aircraft wing fabrication and assembly processes face inefficiencies due to delays when components are completed at different rates, requiring extensive setup and inspection times, and involve costly automated optical inspection techniques.
Innovation Solution
Implementing an assembly line system where wing panels are moved in pulses or continuously, with discrete work stations performing tasks along the line, utilizing indexing features formed during manufacturing to align components precisely, and integrating Non-Destructive Inspection (NDI) and other processes to reduce movement and setup times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are fabricated and assembled in predefined cells on a factory floor, then reliability of fabrication processes is maintained, but productivity is reduced due to delays when work is completed more slowly than expected and extensive setup times for each cell movement
Solution Approach 1:
The assembly process is segmented into discrete work stations arranged in a sequence along an assembly line. Each work station performs a specific task on a portion of the wing panel, allowing parallel processing and eliminating the need to wait for complete assembly at single locations. This segmentation enables continuous flow and improves productivity while maintaining quality through specialized stations.
Solution Approach 2:
The system transitions from static predefined cells to a dynamic assembly line where the wing panel moves continuously through multiple work stations. The panel can be advanced to the next station once current work is complete, allowing flexible pacing and eliminating idle time. This dynamic approach resolves the contradiction by enabling both reliable process execution and high productivity.
2Manufacturing precision
If automated optical inspection techniques and probes are used to inspect position of parts, then manufacturing precision is improved, but loss of time increases due to time-consuming inspection processes
Solution Approach 1:
Indexing features are formed into the wing panel during the initial manufacturing process, before the panel reaches inspection or assembly stages. This preliminary action embeds reference information that enables rapid identification and positioning later in the process, eliminating the need for time-consuming optical inspection while maintaining precision through pre-established geometric references.
Solution Approach 2:
The system replaces complex automated optical inspection systems with simpler mechanical indexing features. The indexing features provide inherent positional information that can be read by basic mechanical sensors or encoders, substituting expensive and time-consuming optical measurement systems with faster, more reliable mechanical reference systems.
3Adaptability or versatility
If frequent moves between cells are performed, then adaptability of the fabrication process is improved, but loss of time increases due to substantial setup time required for each movement
Solution Approach 1:
The assembly line uses universal indexing features and standardized work station interfaces that can accommodate different wing panel configurations and assembly tasks. This universality allows the system to adapt to various production requirements without requiring physical reconfiguration or setup time, as the same infrastructure serves multiple functions and product variants.
Data Source
AI summary
Systems, methods, and apparatus are provided for assembling a wing. Methods include coupling a robot arm to a bracket on a rib held against a wing panel, and operating the coupled robot arm to install shims between the rib and wing panel. Some methods further include mounting (e.g. detachably) the bracket, such as by aligning it with indexing features at the rib. In some methods, the bracket enforces a contour to the rib. Systems include a carriage coupled to a rib, and a robot arm extending therefrom that is operable to perform work (e.g. inspection, installing shims and/or fasteners, etc.) at an interface between the rib and a wing panel. Apparatus includes a robot arm dimensioned for placement at an interface between a rib and a wing panel, with the robot arm including an end effector to perform work upon the interface (e.g. inspection, installing shims and/or fasteners, etc.).