The HOLO concept provides a new solution for the next generation of aerospace assembly. Based on the existing angle tool provided by Atlas Copco for the aerospace assembly, HOLO can be installed on all angle tools without obstacles.
The main benefits are to help the operators to see hidden areas when working in the wing box and help to decrease fatigue during assembly. Based on the field trip to Airbus in Hamburg, how to protect aircraft material while also protecting the staff is a very big design opportunity for the future of aerospace assembly. HOLO is a solution with two different devices, the inception device and the display, both working together to offer the operator better guidance with AR technology and more precious control of the workflow.
Smarter guidance of operation with AR technology, less fatigue, and more efficiency are what HOLO offers for its stakeholder, Atlas Copco.
Design Problem & Opportunity
Mock-up Testing Conclusion
How It Works
"Next Generation Aerospace Assembly" was the project to collaborate closely with the Atlas Copco in exploring the future in an industry of aerospace assembly and getting new insights via addressing relevant problems and design opportunities.
During the Hamburg period, all activities were concentrated in the process of aerospace assembly. The mechanical engineering expert at Airbus explained the importance and process of fasteners in the aerospace assembly in detail. Here I focused on the assembly flow of the aircraft wing.
In my opinion, the most interesting thing is how to protect aircraft material while also protecting the staff. There is no doubt that all the terrible and difficult problems are all out, especially when assembling inside the wing.
From the insights of the field trip, Atlas Copco will focus on smarter tool connections, less HW, more precise control of workflow and better operator guidance in the future.
The structure of the aircraft wing is rather special and complex compared to other parts of the airplane. In large passenger aircraft, a large number of ribs and stringers divide the wing box into a lot of small boxes. In general, the operator enters the inside of the wing and tightens all the structurally connected parts before the skin panel is attached during the wing box assembly process.
1. non-ergonomic postures in the cramped space lead to neck and waist pain.
2. The distance between the two ribs is too narrow for operators to move easily.
3. The operator needs a mattress to kneel or lie down to work for the bottom nuts or fasteners.
"How might we help the operators to see the hidden areas and help to decrease their fatigue during assembly?"
The HOLO concept contains two types of equipment, the inception device HOLO-i which is Mounted and used Atlas Copco angle tools' battery and the display HOLO-D which is fixed on the operator's arm.
HOLO-i helps the operator to see the invisible parts, with equipment that can replace the operator's eyes to quickly and easily observe hidden parts, such as miniature cameras, fiberscopes, etc.
HOLO-D is a compact and portable display that helps and guides the operator to quickly find the target to reduce the fatigue caused by working in narrow spaces. It shows real-time video with AR technology.
1. Quick Detachable and Mounting
HOLO-i mount fits well on the angle tool's neck and head. After assembling it onto the angle tool HOLO-i is fixed by rotating the closure.
2. Dual Fiberscopes
The two fiberscopes are placed on both sides of the angle tool head. The fiberscope is only 1 mm in diameter so that the mount has minimal influence on the movement of the angle tool in narrow spaces.
3. A Versatile Mount for the right viewing angle
HOLO-D has a high-quality design and a flexible mounting method. The operator can attach it to the arm with a wrist strap and adjust the viewing angle of the screen and eyes by rotating the screen, the product itself or the wrist strap to see the intuitive live video.
4. Adjustable Viewing Angle
In order to allow the operator to see the information more clearly, the screen can always be kept perpendicular to the eye angle via rotating.
5. Augmented Reality Guidance
After turning HOLO-D and connecting it with HOLO-i via Wi-Fi or Bluetooth, HOLO-D adds graphics through AR technology to guide the operator to match the nut-runner to the nut. The red cross indicates the two fiberscopes.
6. Mirror Function
HOLO-D will show the opposite direction of movement when the head of the angle tool points to the operator. The image is automatically adjusted to the same direction of movement by the mirror function.
HOLO is a very realistic and practical solution that can be put into production and use immediately based on AtlasCopco existing tool family. With a smarter connection between different types of tools, HOLO can give the operator more precious control of aerospace assembly and better guidance with friendly user experience.
Feel free to watch more about design generations and mock-up testing in detail on my website.