A zigzag path based joining method for fuselage panels in digital assembly

The purpose of this paper is to design a reasonable joining path and achieve assembly automation for multiple arc-shaped panels. A fuselage panel is primarily composed of skins, stringers, frames and clips. Both inserted and nested structures are adopted in the panels to improve the strength and hermeticity of the fuselage. Due to the complex structures and relationships, it is a challenge to coordinate the arc-shaped panels in the assembly process.

A motion sequence model which achieves arc approximation based on the relative motion of multiple panels is established. The initial position of the panels is obtained by decomposing the computer-aided design model of the panels. Two translation rules, i.e. progressively decreasing translation and limited deformation translation, are applied to determine the moving path of the panels. If a panel is not at its path node, a search algorithm is used to find the nearest path node. Finally, the key algorithms are implemented in an integration system to promote joining automation of multiple panels.

The zigzag path is effective for the joining of multiple panels with complex mating relationships. The automation of the join–separate–rejoin operations is time-saving and safety-assuring. The proposed method is demonstrated in practical engineering and a good efficiency is obtained.

This method has been used in a middle fuselage assembly project. The practical results show that the zigzag path is convenient to be stored and reused, and the synchronous movements of multiple curved panels are precisely realized. Additionally, the posture accuracy of panels is significantly improved, and the operating time is reduced considerably.

This paper gives a solution including path planning and process integration to solve the joining problem of multiple panels. The research will promote the automation of fuselage assembly.