Automated Wing Skin Assembly with Integrated Drilling and Collar Swaging
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Solution Overview
Problem
The manual processes of drilling fastener holes and installing collars in aircraft wing assembly are labor-intensive, prone to misalignment, and result in worker fatigue and part damage, with additional steps required for deburring and realignment, leading to increased process time and labor content.
Innovation Solution
An automated system comprising a mobile automated collar installation system (MACIS) with autonomous guided vehicles and end effectors that press skin panels against underlying structures, drill holes, insert fasteners, and automatically install and swage collars, utilizing interactive force feedback systems to control clamping forces and ensure precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual drilling and collar installation processes are used, then workers can perform the operations with basic tools, but the process requires high labor content and results in worker fatigue and part damage
Solution Approach 1:
The patent replaces manual mechanical drilling and collar installation operations with an automated robotic system that uses computer-controlled positioning and automated fastener installation equipment, eliminating the need for workers to manually drill holes and install collars while maintaining manufacturing capability
Solution Approach 2:
The automated system performs self-positioning and self-alignment through computer vision and automated guidance systems, allowing the equipment to automatically locate fastener positions and maintain proper alignment without human intervention, thereby reducing labor content while preserving operational simplicity
2Ease of operation
If manual drilling is performed without clamp-up, then workers can access the work area easily, but misalignment occurs and hole damage results during fastener insertion
Solution Approach 1:
The automated system performs preliminary positioning and alignment of the skin panel to the underlying structure before drilling operations begin, using computer-controlled positioning systems to ensure precise alignment is established in advance, preventing misalignment during subsequent fastener insertion
Solution Approach 2:
The patent replaces manual positioning operations with automated computer-controlled positioning systems that use sensors and guidance equipment to maintain precise alignment throughout the drilling and fastener installation process, eliminating the alignment problems associated with manual operations
3Object-generated harmful factors
If skin panels are separated from the underlying structure after drilling, then chips can be removed from the interface, but additional process time is required and realignment becomes difficult
Solution Approach 1:
The automated system incorporates integrated chip removal capabilities that operate simultaneously with or immediately following drilling operations, using automated vacuum systems or air blasts to clear chips from the interface without requiring panel separation, thereby maintaining continuous process flow and eliminating realignment requirements
Solution Approach 2:
The patent maintains continuous operation by performing chip removal as an integrated step within the automated drilling and fastener installation sequence, rather than requiring interruption and separation of the panel, thus keeping the manufacturing process continuous and eliminating time losses associated with separation and realignment
4Ease of operation
If collar installation is performed manually from below the wing, then workers can access fastener locations, but the work is fatiguing and prone to part damage and worker injuries
Solution Approach 1:
The patent replaces manual collar installation operations with an automated robotic system that installs collars from the same side as the drilling operation, using computer-controlled positioning and automated collar feeding mechanisms, thereby eliminating worker exposure to fatiguing overhead work and reducing the risk of part damage and worker injuries
Solution Approach 2:
The automated system performs multiple functions including drilling, fastener insertion, and collar installation using the same robotic platform and positioning system, allowing the equipment to access fastener locations from a single position and perform all operations without requiring worker intervention, thus improving reliability and safety
Data Source
AI summary
In one embodiment, a system includes a first end effector configured to press a selected area of an aircraft wing skin panel against a corresponding area of an underlying wing support structure with a downward force, drill a hole within the selected area, the hole extending through the skin panel and the support structure, and insert an elongated shaft of a fastener into the hole. The system includes a mechanism configured to locate the first end effector relative to the selected area. The system can further include a second end effector configured to press the corresponding area of the support structure against the selected area of the skin panel with an upward force that is opposite in direction to the downward force, and a mechanism configured to locate the second end effector relative to the corresponding area of the support structure.