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Quick Assembly Process
This is an aggressive master schedule for the 18-month
production of a full-scale, 500-ft Dynalifter Freighter prototype.
This is possible because of the simplified design of the
Dynalifter, and the use of “commercially off the shelf” systems
and parts.
Also, there now exists a unique process for building
Dynalifters more quickly (and safely). Historical Zeppelins were
built entirely in a fully enclosed building. It was necessary to
have massive scaffolding systems in place which resulted in
dangerously high work conditions.
The “two half” (upper and lower) system was developed
for Dynalifters in order to negate the need for a fully-enclosed
hanger and unusually high work conditions. This process was
perfected during the building of the reduced-scale prototype. Many
of the components for each half can be provided as sub assemblies,
and shipped just-in-time for installation at many assembly
locations.
The upper hull, neutral beam, and towers with rigging will be
assembled first. Helium cells will be installed and sealed at the
top. Inexpensive nitrogen or CO2 will fill the cells for
initially, as these gasses can be easily filtered out when helium
is introduced later in the process. These cells will provide an
all-weather roof for the assembly below (Appendix L: New
Production Facilities).
Once the upper hull is completed, it will be lifted by its
towers and supported by scaffolding. The placement of the control
bridge (cockpit), cargo bays will be at a very low level making
assembly easier. Nose and tail section then will be attached, the
helium cells installed, and the preassembled wings and canards
will be fitted. Avionics, APU’s, and all engines will then be
attached and tested. The entire hull will be lifted once more and
landing gear will be installed.
Using this
inexpensive facility and production method, production can be
quickly scaled up to accommodate mass production.
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