Propagation analysis of variation for fuselage structures in multi-station aircraft assembly

Abstract

Purpose This paper aims to present a modeling and analysis approach for multi-station aircraft assembly to predict assembly variation. The variation accumulated in the assembly process will influence the dimensional accuracy and fatigue life of airframes. However, in digital large aircraft assembly, variation propagation analysis and modeling are still unresolved issues. Design/methodology/approach Based on an elastic structure model and variation model of multistage assembly in one station, the propagation of key characteristics, assembly reference and measurement errors are introduced. Moreover, the reposition and posture coordination are considered as major aspects. The reposition of assembly objects in a different assembly station is described using transformation and blocking of coefficient matrix in finite element equation. The posture coordination of the objects is described using homogeneous matrix multiplication. Then, the variation propagation model and analysis of large aircraft assembly are established using a discrete system diagram. Findings This modeling and analysis approach for multi-station aircraft assembly reveals the basic rule of variation propagation between adjacent assembly stations and can be used to predict assembly variation or potential dimension problems at a preliminary assembly phase. Practical implications The modeling and analysis approaches have been used in a transport aircraft project, and the calculated results were shown to be a good prediction of variation in the actual assembly. Originality/value Although certain simplifications and assumptions have been imposed, the proposed method provides a better understanding of the multi-station assembly process and creates an analytical foundation for further work on variation control and tolerance optimization.