Aircraft airframe assembly

• US 10,179,662 B2
• Filed: 04/21/2015
• Issued: 01/15/2019
• Est. Priority Date: 04/24/2014
• Status: Active Grant

• Current Assignee: BAE Systems Plc
• Original Assignee: BAE Systems Plc
• Inventors: Bickerstaff, John
• Primary Examiner(s): Rampuria, Satish
• Application Number:
  US15/304,674
• Publication Number:
  US 20170045876A1
• Time in Patent Office: 1,365 Days
• Field of Search: 700 95-129
• CPC Class Codes: B64F 5/10 Manufacturing or assembling aircraft, e.g. jigs therefor
• CPC Class Codes: G05B 19/402 characterised by control arrangements for positioning, e.g. centring a tool relative to a hole in the workpiece, additional detection means to correct position G05B19/19 takes precedence
• CPC Class Codes: G05B 19/4099 Surface or curve machining, making 3D objects, e.g. desktop manufacturing
• CPC Class Codes: G05B 19/41805 characterised by assembly
• CPC Class Codes: G05B 2219/35025 Design and manufacture jig
• CPC Class Codes: G05B 2219/37221 Probe fixture to know datum points
• CPC Class Codes: G05B 2219/45055 Assembly
• CPC Class Codes: G05B 2219/49007 Making, forming 3-D object, model, surface
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

An assembly process for assembling at least part of an aircraft airframe, the assembly process comprising: providing a first assembly including a first part of the airframe and a first reference structure attached thereto; providing a second assembly including a second part of the aircraft airframe and a second reference structure attached thereto; receiving, by a first receptacle, the first reference structure; receiving, by a second receptacle, the second reference structure; moving, by an actuation device, the receptacles into a predetermined configuration, thereby moving the first part of the aircraft airframe and the second part of the aircraft airframe into a predetermined configuration; and performing an assembly operation on the airframe parts to fixedly attach together the first part of the aircraft airframe and the second part of the aircraft airframe, thereby producing the part of the aircraft airframe.

Claims

1. An assembly process for assembling at least part of an aircraft airframe, the assembly process comprising:

providing a first assembly, the first assembly including a first part of the aircraft airframe and a first reference structure attached to the first part of the aircraft airframe, the first part of the aircraft airframe having a predetermined position and orientation with respect to the first reference structure, the first reference structure comprising a first plurality of key protrusions;

providing a second assembly, the second assembly including a second part of the aircraft airframe and a second reference structure attached to the second part of the aircraft airframe, the second part of the aircraft airframe having a predetermined position and orientation with respect to the second reference structure, the second reference structure comprising a second plurality of key protrusions;

locating each of the first plurality of key protrusions in a respective key hole of a first receptacle attaching the first reference structure to the first receptacle;

locating each of the second plurality of key protrusions in a respective key hole of a second receptacle, attaching the second reference structure to the second receptacle;

moving, by an actuation device, the first and second receptacles into a predetermined configuration for the receptacles, thereby moving the first part of the aircraft airframe and the second part of the aircraft airframe into a predetermined configuration for the airframe parts;

while the first part of the aircraft airframe and the second part of the aircraft airframe are in the predetermined configuration for the airframe parts, performing an assembly operation on the airframe parts to fixedly attach together the first part of the aircraft airframe and the second part of the aircraft airframe, producing the at least part of an aircraft airframe; and

wherein;

each key protrusion comprises a fastener head at a distal end of that key protrusion and a shank portion connecting the fastener head of that key protrusion to the reference frame, the fastener heads having a first diameter, the shank portions having a second diameter, the second diameter being less than the first diameter; and

each key hole comprises a first portion having a having a diameter greater than or equal to the first diameter, and a second portion having a diameter greater than or equal to the second diameter and less than the first diameter.

2. The method according to claim 1, wherein the at least part of an aircraft airframe is an aircraft aft fuselage, the first part of the aircraft airframe being a first side portion of the aircraft aft fuselage, and the second part of the aircraft airframe being a second side portion of the aircraft aft fuselage.

3. The method according to claim 1, wherein the at least part of an aircraft airframe is for attachment to a further part of the aircraft airframe, and providing the first assembly comprises:

providing a plurality of components of the first part of the aircraft airframe;

for each component of the first part of the aircraft airframe, determining a position and orientation of that component relative to the further part of the aircraft airframe that that component would have if the at least part of the aircraft airframe was attached to the further part of the aircraft airframe;

providing the first reference structure, the first reference structure being representative of the further part of the aircraft airframe;

arranging the components of the first part of an aircraft airframe such that the position and orientation of each of said components relative to the first reference structure is the same as the determined position and orientation relative to the further part of the aircraft airframe that that component would have if the at least part of the aircraft airframe was attached to the further part of the aircraft airframe; and

thereafter, attaching together the components of the first part of the aircraft airframe such that the relative positions and orientations of those components are maintained.

4. The method according to claim 3, wherein the step of attaching together the components of the first part of the aircraft airframe is performed such that the relative position and orientation of each of the components of the first part of the aircraft airframe and the first reference structure is maintained.

5. The method according to claim 3, wherein the further part of the aircraft airframe is at least part of an aircraft fore fuselage.

6. The method according to claim 3, wherein each component of the first part of the aircraft airframe is selected from a group of airframe components consisting of frames, longerons, keels, and beams.

7. The method according to claim 3, wherein:

the step of arranging the components of the first part of an aircraft airframe comprises producing an assembly tool, the assembly tool including the first reference structure, and mounting the components of the first part of an aircraft airframe on the assembly tool; and

after the components of the first part of the aircraft airframe have been attached together, the first part of the aircraft airframe and first reference structure attached thereto are removed from the assembly tool, thereby providing the first assembly.

8. The method according to claim 7, wherein the step of producing the assembly tool comprises:

for each component of the first part of the aircraft airframe, using the determined position and orientation of that component relative to the further part of the aircraft airframe, determining one or more positions and orientations relative to the further part of the aircraft airframe at which that component is to be supported;

providing a jig frame;

attaching, to the jig frame, the first reference structure;

providing a plurality of pickup devices, each pickup device having a receiving element for receiving a component; and

securing each pickup device to the jig frame such that a position and orientation relative to the first reference structure of each receiving element is the same as a respective determined position and orientation relative to the further part of the aircraft airframe at which a component is to be supported.

9. The method according to claim 3, wherein providing the second assembly comprises:

providing a plurality of components of the second part of the aircraft airframe;

for each component of the second part of the aircraft airframe, determining a position and orientation of that component relative to the further part of the aircraft airframe that that component would have if the at least part of the aircraft airframe was attached to the further part of the aircraft airframe;

providing the second reference structure, the second reference structure being representative of the further part of the aircraft airframe;

arranging the components of the second part of an aircraft airframe such that the position and orientation of each of said components relative to the second reference structure is the same as the determined position and orientation relative to the further part of the aircraft airframe that that component would have if the at least part of the aircraft airframe was attached to the further part of the aircraft airframe; and

thereafter, attaching together the components of the second part of the aircraft airframe such that the relative positions and orientations of those components are maintained.

10. The method according to claim 9 wherein the step of attaching together the components of the second part of the aircraft airframe is performed such that the relative position and orientation of each of the components of the second part of the aircraft airframe and the second reference structure is maintained.

11. At least part of an aircraft airframe having been produced using the method according to claim 1.

12. At least part of an aircraft airframe according to claim 11, wherein the at least part of the aircraft airframe is an aircraft aft fuselage.

13. Apparatus for assembling at least part of an aircraft airframe, the apparatus comprising:

a first receptacle comprising a first plurality of key holes, each of the first plurality of key holes configured to receive a respective key protrusion of a first reference structure of a first assembly, the first assembly including a first part of the aircraft airframe and the first reference structure attached to the first part of the aircraft airframe, the first part of the aircraft airframe having a predetermined position and orientation with respect to the first reference frame;

a second receptacle comprising a second plurality of key holes, each of the second plurality of key holes configured to receive a respective key protrusion of a second reference structure of a second assembly, the second assembly including a second part of the aircraft airframe and the second reference structure attached to the second part of the aircraft airframe, the second part of the aircraft airframe having a predetermined position and orientation with respect to the second reference frame;

an actuation device operatively coupled to the first and second receptacles and configured to move the first and second receptacles into a predetermined configuration for the receptacles, moving the first part of the aircraft airframe and the second part of the aircraft airframe into a predetermined configuration for the airframe parts; and

wherein;

each key protrusion comprises a fastener head at a distal end of that key protrusion and a shank portion connecting the fastener head of that key protrusion to the reference frame, the fastener heads having a first diameter, the shank portions having a second diameter, the second diameter being less than the first diameter; and

each key hole comprises a first portion having a having a diameter greater than or equal to the first diameter, and a second portion having a diameter greater than or equal to the second diameter and less than the first diameter.

14. The apparatus according to claim 13, wherein the at least part of an aircraft airframe is an aircraft aft fuselage, the first part of the aircraft airframe being a first side portion of the aircraft aft fuselage, and the second part of the aircraft airframe being a second side portion of the aircraft aft fuselage.