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Design and development of jigless assembly process: the case of complex aeronautical systems

The optimization of the aeronautical structures manufacturing is one of the most challenging tasks in development of a new aircraft. Nowadays, aeronautical industries are supporting researches deal with the development of new assembly approaches which aim at increasing efficiency and reducing cost of the processes. The work here presented focused on definition of a Jig-less assembly procedure of the “Integrated Main Landing Gearbox” (ITEM B). The project aims to develop a new generation of Lower Center Fuselage with an innovative landing system integrated in the fuselage itself. The ambition of ITEMB is the creation of a single integrated structure in composite material of the gear bay that reduces assembly costs, optimizing and integrating the entire design, construction and maintenance of the aircraft. The approach here described is based on the integration of different engineering disciplines, as such as the tolerance statistical prediction, the ergonomics, digital human modeling, manufacturing and measurement technologies. In particular, through an appropriate ergonomic analysis, an innovative assembly process of the gear bay was developed and optimized in a virtual environment pointing out the advantages and disadvantages with respect to a traditional assembly cycle. The assembly process is based also on the implementation of the assembly tolerance prediction.