Wing Root Hole Transfer for Laser-Aligned Fuselage Assembly
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Solution Overview
Problem
The current process of duplicating the hole pattern on the Center Wing Box (CWB) of an aircraft fuselage for joining the wing is time-consuming and requires manual intervention, causing delays in aircraft assembly and impacting production efficiency.
Innovation Solution
A process involving laser tracking and template mapping to determine the precise position and orientation of the hole pattern on the CWB, allowing for accurate duplication without physically aligning the wing root and CWB, using primary and secondary templates with laser targets to create a 3D representation and alignment for optimal flight performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wing root is physically aligned with the CWB and pilot holes are drilled manually, then the hole pattern can be duplicated accurately, but the assembly process becomes time-consuming and reduces productivity
Solution Approach 1:
The patent replaces the manual mechanical alignment and drilling process with a laser-based measurement and mapping system. Laser trackers capture 3D coordinates of the wing root hole pattern, and a computer processes this data to automatically determine hole positions on the CWB, eliminating the need for physical wing-CWB alignment and manual drilling operations.
Solution Approach 2:
The patent creates a digital copy of the wing root hole pattern through laser scanning and 3D coordinate mapping. Instead of physically transferring the hole pattern through alignment, the system captures the hole pattern data digitally and uses computer processing to replicate it on the CWB, enabling faster and more accurate duplication.
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 system enables self-service by allowing the hole pattern to be mapped and transferred automatically without requiring a technician to physically enter the wing box. The laser tracker and computer system perform the measurement, calculation, and position determination functions that previously required manual intervention, simplifying the operation and reducing complexity.
3Reliability
If the wing is moved away for deburring and cleaning, then quality can be ensured, but the assembly process is delayed
Solution Approach 1:
The patent performs preliminary mapping of the wing root hole pattern using laser tracking before the wing is moved away for deburring and cleaning. By capturing the 3D coordinates early in the process, the system eliminates the need to remap or reposition the wing later, allowing quality checks to proceed without delaying the overall assembly timeline.
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 enables efficient and accurate duplication of the hole pattern on the CWB, reducing assembly time, improving production efficiency, and ensuring dynamic symmetry and optimal flight performance by allowing hole pattern creation upstream in the assembly line, accounting for actual component characteristics and defects.
Implementation Method 1
a first laser tracker to measure a plurality of first 3D coordinates of a plurality of first targets on the wing root; a second laser tracker to measure a plurality of second 3D coordinates of a plurality of second targets on the CWB
Data Source
AI summary
A process of joining a wing to an aircraft fuselage comprising the steps of: mapping the wing root of the wing, mapping the center-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 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 of the wing root can therefore be duplicated on the CWB at a position such that when the wings are joined to the fuselage, the aircraft will have optimum flight performance and dynamic symmetry. A predictive fit is thus provided, based on virtual representation and analysis, and advantageously permits the hole pattern to be provided without requiring the CWB and wing root to be brought together.