Falcon Star Mobile Crane
Robotics &
Automation Engineering
The mobile crane could make only relatively coarse positioning adjustments. This made aligning the wing's bolt holes with those on the fuselage a tedious process that involved a great deal of time and, sometimes, the use of brute force. Damage can occur if a mechanic attempts to force the bolts into their respective holes when the holes are not properly aligned. Because the wing attachment fittings are fracture-critical parts, it is important to minimize the possibility of damage to the inside of the bolt holes during installation.
Moreover, when the leading edge flap assembly was left installed on the wing during attachment, the flap's weight caused the wing to tilt, contributing to misalignment of the bolt holes. Sometimes the mechanics literally hang on the wing tip to create proper alignment. Overall, using a crane and sling for wing installation was a time-consuming and potentially damage-inducing process.
Time was another critical factor because a fast-drying sealant must be applied to the wing root prior to installation. Once the sealant is applied, the wing must be installed within two hours. If that time frame is not met, the sealant must be removed and the process repeated. According to an Air Force estimate, this occurred approximately 25 percent of the time with the current process. Additionally, the cost of a crane and operator added to the overall cost of wing installation and removal, and workflow often was impeded by the need to wait for a crane to become available.
Related Terminology
Falcon Star • aircraft assembly • wing assembly • wing lift • wing transport • automation engineering • F16 wing maintenance • removal and installation • U.S. Air Force
