Joining component

Abstract

A component is provided that is configured to engage with another component in a preselected relative orientation. The other component has an interface surface, and the component is configured to contact the interface surface when engaged with the other component. The component includes: a surface disposed on a side of the component that is intended to face the interface surface when the component is engaged; a plurality of recesses formed in the surface; and a plurality of spacer elements. Each recess has a preselected orientation relative to the component, the preselected orientation being selected according to the preselected relative orientation. Each spacer element includes a contact surface that is configured to contact the interface surface when the component is engaged. Each spacer element is disposed in one of the recesses such that the orientation of a given contact surface is defined by the orientation of the corresponding recess.

Description

Technical Field

[0001] The present invention relates to a component configured to be joined to other components, an assembly of such components joined to other components, an aircraft including such components, and a method of joining components. Background Art

[0002] Most conventional aircraft mount engines to wings via engine mounting pylons. For commercial airliners, there is a trend towards higher bypass ratio engines, which have a larger diameter than lower bypass ratio engines. To accommodate the large diameter engines while maintaining sufficient clearance between the engines and the ground, it is desirable to minimize the vertical distance between the top of the engine and the lower surface of the wing.

[0003] To minimize the vertical distance between the top of the engine and the lower surface of the wing, it is desirable to attach the engine mounting pylon directly to the wing. However, due to the shape of the airfoil, the lower surface of the wing is curved, while the upper surface of the engine mounting pylon is typically substantially flat (planar). Thus, the upper surface of the engine mounting pylon will only abut the lower surface of the wing in a relatively small area. To enable the pylon and the wing to be fastened together and for effective load transfer therebetween, it is therefore desirable to provide some interface component to fill the gap between the upper surface of the pylon and the lower surface of the wing - at least in the locations where fasteners joining the pylon and the wing are present. Summary of the Invention

[0004] A first aspect of the present invention provides a component configured to be joined to another component in a preselected relative orientation of the component and the other component. The other component has an interface surface, and the component is configured to contact the interface surface when joined to the other component. The component includes: a surface provided on a side of the component intended to face the interface surface when the component is joined to the other component; a plurality of recesses formed in the surface; and a plurality of spacer elements. Each recess has a preselected orientation relative to the component, the preselected orientation being selected according to the preselected relative orientation of the component and the other component. Each spacer element includes a contact surface configured to contact the interface surface when the component is joined to the other component. Each spacer element is disposed in one of the recesses such that the orientation of a given contact surface is defined by the orientation of the corresponding recess.

[0005] Optionally, the curvature of the surface is different from the curvature of the interface surface. Optionally, the surface is curved and the interface surface is substantially flat.

[0006] Optionally, the shape of each spacer element matches the shape of the recess in which the spacer element is provided. Optionally, each recess and each spacer element are cylindrical.

[0007] Optionally, all the recesses have substantially the same diameter.

[0008] Optionally, all the recesses have the same orientation with respect to the component.

[0009] Optionally, there is an interference fit between each spacer element and the recess in which the spacer element is provided.

[0010] Optionally, the fastener holes extend through at least one spacer element in a direction substantially perpendicular to the contact surface.

[0011] Optionally, each recess includes a counterbore.

[0012] A second aspect of the present invention provides a component. The component includes: a first structure that defines a reference plane of the component; and a second structure that is fixedly attached to the first structure such that the second structure has a preselected orientation with respect to the reference plane. The first structure includes a first surface, and the second structure includes a second surface. The first surface includes a plurality of sockets that extend into the first surface at a predefined angle with respect to the reference plane. Each socket contains an interface member that has a first end in contact with the base of the socket and a second end in contact with the second surface.

[0013] Optionally, the second end of each interface member includes an interface surface in contact with the second surface, and the orientation of each interface surface is set by the orientation of the corresponding socket.

[0014] Optionally, the first structure is fixedly attached to the second structure by at least one fastener, and the fastener extends through one of the interface members.

[0015] Optionally, the fastener includes a tension bolt.

[0016] Optionally, the component further includes a third structure that is attached to the second structure such that the first structure is between the third structure and the second structure. Optionally, the first structure includes a plate that has another surface opposite the first surface, and the another surface is configured to match the surface of the third structure facing the first structure.

[0017] Optionally, the third structure is included in a first aircraft structure, and the second structure is included in a second aircraft structure. Optionally, the first aircraft structure is a wing, and the second aircraft structure is an engine mounting pylon.

[0018] A third aspect of the present invention provides an aircraft that includes the component of the first aspect or the component of the second aspect.

[0019] A fourth aspect of the present invention provides a method of joining a first component to a second component in a predetermined relative position and orientation of the first and second components. The method includes:

[0020] - providing a first component having a first surface;

[0021] - providing a second component having a second surface;

[0022] - forming a plurality of recesses in the first surface such that each recess is oriented relative to the first component based on a desired relative orientation of the first and second components when joined;

[0023] - providing a plurality of spacer elements, each spacer element being configured to be received in one of the recesses and each spacer element having a contact surface configured to contact the second surface when the second component is joined to the first component;

[0024] - inserting the spacer elements into each of the recesses;

[0025] - arranging the second component on the spacer elements such that the contact surfaces of the spacer elements contact the second surface and the first and second components are in the desired relative position and orientation; and

[0026] - connecting the first component to the second component.

[0027] Optionally, the first component and the plurality of spacer elements together include a component according to the first aspect.

[0028] Optionally, the performance of the method causes the formation of an assembly according to the second aspect. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0030] Figure 1 is a schematic cross-sectional view through an example component according to the present invention;

[0031] Figure 2 is a schematic perspective view of an example spacer element of a component according to the present invention;

[0032] Figure 3 is a schematic cross-sectional view through an example assembly according to the present invention;

[0033] Figure 4a is a perspective view of an example component according to the present invention at a first stage during the assembly of the component;

[0034] Figure 4b is Figure 4a a perspective view of the example component at a second stage during the assembly of the component;

[0035] Figure 5 is a perspective view of an exemplary aircraft including components according to the present invention; and

[0036] Figure 6 is a flow chart of an exemplary method according to the present invention. DETAILED DESCRIPTION

[0037] The examples described below relate to components, each of which is configured to engage with another component in a preselected relative orientation of the component and the other component. Each other component to which an example component is configured to engage has an interface surface. Each example component is configured to contact the interface surface when engaged with another component. Each example component includes: a surface disposed on a side of the component that is intended to face the interface surface when the component is engaged with another component; a plurality of recesses formed in the surface; and a plurality of spacer elements, each of the spacer elements being disposed in one of the recesses. Each recess has a preselected orientation relative to the component, and the preselected orientation is selected according to the preselected relative orientation of the component and the other component. Each spacer element includes a contact surface that is configured to contact the interface surface when engaging the component with the other component, and the orientation of a given contact surface is defined by the orientation of the corresponding recess.

[0038] The terms "preselected" and "predetermined" used throughout this specification are intended to indicate that parameter values are set based on considerations that are not necessarily related to the specific details of the particular components or structures being joined. For example, preselected values or predetermined values are not intended to be capable of being changed in view of manufacturing tolerances, but rather should be regarded as constraints that must be met despite such tolerances.

[0039] Components according to the present invention may be included, for example, in a joint between an aircraft wing and an aircraft engine pylon. The engine pylon may typically be attached to the wing box by a forward connection and a rearward connection. Exemplary components according to the present invention may be particularly suitable for use in the forward connection between the engine pylon and the wing box. The forward connection between the engine pylon and the wing box supports the weight of the pylon and transfers thrust from the engine to the wing.

[0040] As discussed above, the surfaces of the wing and the engine mounting pylon that are adjacent to each other at the joint between the wing and the pylon typically have different curvatures - the wing is curved while the top of the pylon is typically flat. Nevertheless, the relative orientation of the wing and the pylon must be carefully controlled within strict tolerances to ensure proper operation of the aircraft. It is known to solve this problem by providing one or more interface plates between the wing and the pylon that are shaped to exactly match the lower surface of the wing and the upper surface of the pylon. Such interface plates set the relative orientation of the wing and the pylon by precisely filling the gap between the wing and the pylon, where the shape of the gap depends on the desired relative orientation of the wing and the pylon.

[0041] To ensure good performance of the joint over a reasonable period of time, the surfaces of the one or more interface plates must be carefully controlled to closely match the surfaces they are intended to contact and be precisely oriented to produce the desired relative orientation of the pylon and the wing. Therefore, the forming of the interface plates must be carried out with a high degree of precision. For these reasons, creating such interface plates is time-consuming and can be difficult if the material needs to be highly wear-resistant (which is often the case for wing-pylon joints or any other joint that must transmit high loads during operation). Due to the stacking of manufacturing tolerances, the final shape of the lower surface of the wing cannot be determined until a late stage in the construction of the wing. For this reason, known interface plates are typically machined in place after the wing construction is substantially complete. To create a surface on the interface plate that exactly matches the upper surface of the pylon, a milling machine that is controllable in six degrees of freedom is required. Such machines are large and expensive, and their use greatly increases the cost and difficulty of the aircraft manufacturing process.

[0042] The component according to the present invention seeks to solve these problems and thus enable a more time- and cost-saving process for joining two components in a preselected relative orientation. The component according to the present invention is particularly suitable for use in high-load joints such as the joint between an aircraft engine mounting pylon and an aircraft wing. The recesses and spacer elements included in the component according to the present invention enable the relative orientation of the two components to be set very precisely while only requiring simple machining operations to be performed during the joining process.

[0043] Each recess may have, for example, a simple geometric shape that is easy to create, such as a cylindrical hole. The depth and / or orientation of such a hole can be precisely set using relatively simple assembly tools, depending on the preselected relative orientation of the components and / or depending on the length of the spacer element to be inserted into the hole. Then, when such a cylindrical spacer element is inserted into the hole, the contact surface of the spacer element is oriented at an angle depending on the orientation of the hole, and the contact surface of the spacer element protrudes a certain distance from the surface of the component, which distance depends on the depth of the hole. The contact surfaces of the spacer elements thus jointly provide a precisely controlled surface against which another component can abut.

[0044] Figure 1 is a cross-sectional view through a particular example component 10 according to the present invention. The component 10 is configured to engage with another component 11 in a preselected relative orientation of the component 10 and the other component 11. In Figure 1 is shown another component 11 (indicated by a dashed line to indicate that it does not form part of the claimed invention) in such a position that the component 10 and the other component 11 are in the preselected relative orientation. The other component 11 has an interface surface 111. In this particular example, the interface surface 111 is substantially flat, although this need not be the case in other examples. The component 10 and the other component 11 can be any components that are desired to engage in a preselected relative orientation. In some examples, the component 10 and the other component 11 are aircraft components. The component 10 can be, for example, a component of an aircraft wing, and the other component 11 can be a component of an aircraft engine mounting pylon. The component 10 can be an interface component (such as an interface plate) for facilitating the engagement of another component with yet another component.

[0045] The component 10 is configured to contact the interface surface 111 of the other component 11 when the component 10 engages with the other component 11. In particular, the component includes a plurality of spacer elements 13a to 13c, each of the spacer elements 13a to 13c including a contact surface 131a to 131c. As can be seen from Figure 1 it can be seen that each of the contact surfaces 131a to 131c contacts the interface surface 111 when the component 10 engages with the other component 11. Each of the contact surfaces 131a to 131c is shaped to match the interface surface 111 such that each of the contact surfaces 131a to 131c contacts the interface surface 111 over the entire area of the interface surface 111 when the component 10 and the other component 11 are engaged. Thus, in Figure 1In the example, each contact surface 131a to 131c is substantially flat. Load transfer between the component 10 and another component 11 occurs over the entire area of the contact surfaces 131a to 131c, and thus the areas of the contact surfaces 131a to 131c can be customized according to the load associated with a particular application. In the example shown, all the spacer components 13a to 13c have the same configuration and are substantially identical to each other.

[0046] The component 10 has a surface 101, which is provided on a side of the component 10 that is intended to face the interface surface 111 when the component 10 is joined to another component 11. The surface 101 may have a different curvature from the interface surface 111. In some examples, the surface 101 may be curved while the interface surface 111 is substantially flat. The surface 101 has a plurality of recesses 12a to 12c formed therein. Each of the recesses 12a to 12c has a preselected orientation relative to the component 10, which is selected according to the preselected relative orientation of the component 10 and another component 11. The recesses 12a to 12c may be in the form of cylindrical holes.

[0047] The component 10 has a nominal plane A, and another component 11 has a nominal plane B. For simplicity of illustration, in the example shown, it may be assumed that the planes A and B extend perpendicular to the plane of the page over the entire area of the planes A and B. Thus, the planes A and B are parallel to each other in the plane perpendicular to the page. Therefore, Figure 1 the orientations of the planes A and B of will be discussed only in two dimensions (i.e., the dimensions of the printed page). However, it should be understood that for at least some real-world applications, the orientations of the component 10 and another component 11 will need to be defined using three dimensions. That is, the planes A and B may not be parallel in the plane of the page or in the plane perpendicular to the page.

[0048] In the example shown, along the preselected relative orientation, the planes A and B are not parallel. In contrast, the plane A is at a preselected angle θ relative to the plane B. Each of the recesses 12a to 12c has a nominal axis Z. In the example shown, each of the recesses 12a to 12c has a substantially flat base, and the axis Z is perpendicular to the base. Each of the recesses 12a to 12c is oriented such that the axis Z is at an angle α relative to the plane A, where α = 90 - θ. Thus, the bases of the recesses 12a to 12c are not parallel to the surface 101. In some examples, the plane A may be a reference plane. In such examples, the plane A may correspond to the reference plane of an aircraft that includes (or is intended to include) the component 10.

[0049] The depth of each of the recesses 12a to 12c is selected according to a preselected relative orientation of the component 10 and another component 11. In the example shown, since the surface 101 is not parallel to the interface surface 111, each of the recesses 12a to 12c has a different depth. In particular, the leftmost recess 12a has the smallest depth, the rightmost recess 12c has the largest depth, and the central recess 12b has an intermediate depth. The exact values of the depths are selected such that the contact surfaces 131a to 131c are coplanar with each other. Alternatively, coplanar contact surfaces can be achieved by providing recesses of equal depth and spacer elements of varying height. For some applications, it may be advantageous to use standard spacer elements and customize the depth of the recesses; while for other applications, it may be advantageous to standardize the depth of the recesses and customize the height of the spacer elements.

[0050] Each of the spacer elements 13a to 13c is disposed in one of the recesses 12a to 12c. The shape of each of the spacer elements 13a to 13c matches the shape of the recess in which it is disposed. Thus, the orientation of a given one of the contact surfaces 131a to 131c is defined by the orientation of the corresponding recess 12a to 12c (the corresponding recess being the recess in which the spacer element including the given contact surface is received). In the example where the contact surfaces 131a to 131c are substantially flat, each of the contact surfaces 131a to 131c is parallel to the interface surface 111. Thus, the axis Z of each of the recesses 12a to 12c is at right angles to the nominal plane B of the other component 11. Each of the spacer elements 13a to 13c can be held in its corresponding recess by any suitable means. For example, the spacer elements 13a to 13c can be press-fitted into the recesses 12a to 12c. It should be understood that after the other component 11 has been joined to the component 10, the spacer elements 13a to 13c are held in the recesses 12a to 12c by the other component 11. Thus, only the holding means is required to maintain the spacer elements 13a to 13c in the recesses before and during the joining process.

[0051] In Figure 2A specific example spacer element 23 is shown in a manner separated from the component including the spacer element 23. The spacer element 23 can be any one of the spacer elements 13a to 13c. The spacer element 23 is cylindrical and is thus configured to be disposed in a cylindrical recess (such as a hole). The spacer element 23 has a diameter D and a height h. The diameter D is substantially equal to the diameter of the recess in which the spacer element 23 is intended to be received. In some examples, the diameter D is selected such that the spacer element 23 is press-fitted in the recess in which it is intended to be received. The height h of the spacer element 23 can have a standard value (i.e., all the spacer elements included in a given component 10 have the same height h, and h does not necessarily depend on the specific features of the component 10). However, as mentioned above, the present invention does not exclude the example in which the height h of each spacer component is customized according to its specific position on the component 10 and / or the specific features of the component 10).

[0052] Depending on the specific application, the spacer element 23 can be formed of any suitable material. Suitable materials include stainless steel and titanium. For high-load and / or safety-critical joints, it may be advantageous to form the spacer element 23 of a wear-resistant material. For aerospace applications, it may be advantageous to form the spacer element 23 of a relatively lightweight material. The spacer element 23 can be formed of a material different from the rest of the first component in which it is intended to be included. In particular, the spacer element 23 can be stronger and / or more wear-resistant than the body of the first component in which it is intended to be included.

[0053] Figure 3 An example assembly 3 according to the present invention is shown. The assembly 3 includes a first structure 30 and a second structure 31 fixedly attached to the first structure 30. The first structure 30 can be a component according to the present invention, such as Figure 1 component 10. The second structure 31 can be another component according to the present invention, such as Figure 1 another component 11. The first structure 30 includes a first surface 301, and the second structure 31 includes a second surface 311. The first surface 301 is curved and convex, and the second surface 311 is substantially flat. The first structure 30 defines a reference plane of the assembly, and the second structure 31 has a preselected orientation relative to this reference plane.

[0054] The illustrated example assembly 3 also includes a third structure 35. Other examples are envisioned in which the third structure 35 is absent. Unless otherwise explicitly stated, the following discussion applies equally to such two-structure assemblies. The third structure 35 is attached to the second structure 31 such that the first structure 30 is between the third structure 35 and the second structure 31. In Figure 3In the example of , the first structure 30 includes a plate having another surface 302 opposite to the first surface 301. The plate is an interface plate for facilitating the engagement of the second structure 31 to the first structure 30. The another surface 302 is configured to match the surface of the third structure 35 facing the first structure 30. For example, the another surface 302 may contact the surface of the third structure 35 over substantially the entire area of the another surface 302. It is expected that the first surface 301 will generally not match the second surface 311 because creating these surfaces to match would be difficult and time-consuming and becomes unnecessary by providing the interface components 33a to 33d.

[0055] The first surface 301 includes a plurality of sockets 32a to 32d extending into the first surface 301. Each socket is at a predefined angle relative to a reference plane. That is, each socket can be considered to have an axis, and the axis is at a predefined angle relative to the reference plane. The axis of the socket may correspond to the axis of the tool (such as a drill or a boring machine) used to create the socket during the process of creating the socket. Each of the sockets 32a to 32d has a base, which is substantially flat in the example shown. Each of the sockets 32a to 32d may have Figure 1 substantially the same features as the recesses 12a to 12c of .

[0056] Each of the sockets 32a to 32d contains an interface component 33a to 33d. Each of the interface components 33a to 33d has a first end in contact with the base of the socket in which it is contained and a second end in contact with the second surface 311. Each of the interface components 33a to 33d may have Figure 1 substantially the same features as the interface components 13a to 13c of . The interface components 33a to 33d do not all have equal dimensions. In contrast, each of the interface components 33a to 33d has the same diameter, but the outermost interface components 33a, 33d have a relatively large first height, while the innermost interface components 33b, 33c have a relatively small second height. However, the first height and the second height are still standard values that are not customized according to the specific configuration of the first component 30. In contrast, Figure 1 as in the example of , considering the different heights of the interface components 33a to 33d, the depth of the recesses 32a to 32c is selected to ensure that the surfaces of the second ends of the interface components 33a to 33d are coplanar. The surfaces of the second ends of the interface components 33a to 33d contact the second component 31 (and are thus connected to the second component 31), and can therefore be considered interface surfaces. The orientation of each interface surface is set by the orientation of the corresponding socket, Figure 1 in substantially the same way as the orientation of the contact surfaces 131a to 131c of is set by the orientation of the recesses 12a to 12c.

[0057] The third structure 35 is fixedly attached to the second structure 31 by a plurality of fasteners 34a to 34d. The fasteners 34a to 34d extend through each of the first structure 30, the second structure 31, and the third structure 35. In an example where there is no third structure 35, the fasteners 34a to 34d fixedly attach the first structure 30 to the second structure 31. Each of the fasteners 34a to 34d extends through a different one of the interface members 33a to 33d. The fasteners 34a to 34d are configured to resist separation of the first structure 30, the second structure 31, and the third structure 35. The fasteners 34a to 34d may include, for example, tension bolts.

[0058] Components having Figure 3 the general configuration shown can find application anywhere where it is desired to join two structures in a precisely controlled relative orientation. Such applications can involve joining a planar structure to a curved structure (as Figure 3 shown), or can involve joining two planar structures (as Figure 1 shown). Such components can be particularly advantageous when it is difficult or impossible to precisely control the exact configuration of the surface (i.e., the surface in which the socket or recess is formed) on the first structure. In some examples, the third structure can be included in an aircraft wing, and the second structure can be included in an aircraft engine mounting pylon.

[0059] Now a process of forming a component according to the present invention will be described with reference to Figure 4a and Figure 4b . Figure 4a and Figure 4b show example components 40 according to the present invention at two different stages during the process of forming the component 40. The component 40 is an interface plate that is configured to be disposed between two aircraft structures (not shown) as part of a joint connecting the aircraft structures. In particular, the interface plate 40 is configured to be disposed between the wing and the pylon when the aircraft engine mounting pylon is connected to the aircraft wing. The upper surface (not visible) of the interface plate 40 is shaped to match the lower surface of the aircraft wing. The interface plate 40 is configured to be attached to the lower surface of the wing by a plurality of fasteners 47.

[0060] The lower surface 401 of the interface plate 40 is configured to face the upper (interface) surface of the engine mounting pylon when the engine mounting pylon is connected to the wing. The lower surface 401 of the interface plate 40 is not configured to exactly match the upper (interface) surface of the pylon. Unless otherwise explicitly stated, the elements of the interface plate 40 can have the same features as the corresponding elements of the example component 10 or the example first structure 30 described above.

[0061] The lower surface 401 of the interface plate 40 includes four recesses 42a to 42d. Figure 4aThe interface plate 40 is shown after the recesses 42a to 42d have been formed but before the spacer elements 43a to 43d are inserted into the recesses 42a to 42d. Each of the recesses 42a to 42d is positioned coaxially with a fastener hole extending through the interface plate 40. These fastener holes are configured to receive tension bolts for fastening the engine mounting hanger to the wing. Each of the recesses 42a to 42d is formed as a counterbore around one of the tension bolt fastener holes. Thus, each recess is substantially cylindrical with a substantially flat base. Such a counterbore can be created relatively easily using a drill bit controllable in only 3 degrees of freedom. In contrast, the formation of prior art custom interface plates requires a cutting machine or milling machine controllable in 6 degrees of freedom.

[0062] The diameter of each of the recesses 42a to 42d matches the diameter of the spacer elements 43a to 43d such that one of the spacer elements 43a to 43d can be inserted (by interference fit) into each of the recesses 42a to 42d. The depth and orientation of each of the recesses 42a to 42d are set by a drilling process according to the desired relative orientation of the wing and the engine mounting hanger. For example, a CNC drilling tool can be programmed to create each recess based on measurements of the lower surface 401 of the interface plate 40 and / or the lower surface of the wing, the upper surface of the hanger, and a preselected relative orientation of the wing and the hanger. The depth and orientation of the recesses 42a to 42d can be controlled very precisely using such a drilling process.

[0063] Figure 4b The interface plate 40 is shown at a later stage in the process of forming the interface plate 40. The spacer elements 43a to 43d (shown in black in Figure 4b have been inserted into each of the recesses 42a to 42d. The spacer elements 43a to 43d are cylindrical and have substantially the same characteristics as the exemplary spacer element 23 described above. The spacer elements 43a to 43d are held in the recesses 42a to 42d by an interference fit between each of the spacer elements 43a to 43d and the recess in which it is disposed. The spacer elements 43a to 43d are all substantially identical to each other. The spacer elements 43a to 43d are formed of a material having higher wear resistance than the material forming the body of the interface plate 40. For example, the spacer elements 43a to 43d can be formed of stainless steel while the body of the interface plate 40 can be formed of aluminum.

[0064] Each of the spacer elements 43a to 43d includes a pre-drilled fastener hole coaxial with the spacer element. The diameter of the fastener hole can be larger than the diameter of the stud intended to be inserted through the fastener hole to allow for some tolerance in the angle of the stud. Alternatively, the diameter of the fastener hole can be substantially equal to the diameter of the stud.

[0065] Figure 5 FIG. 500 shows an exemplary aircraft 500 that includes one or more components or assemblies in accordance with the present invention. In particular, the aircraft 500 includes a fuselage 501 and wings 502, and an engine mounting pylon 504 is attached to the wings 502. An engine 503, which may be, for example, an ultra-high bypass ratio (UHBR) engine, is mounted on the engine mounting pylon 504. The engine mounting pylon 504 is tightly coupled to the wings 502. The joint between the engine mounting pylon 504 and the wings 502 includes an exemplary component in accordance with the present invention (e.g., any one of the exemplary components or assemblies 10, 3, 30, 40 described above). The aircraft 500 also includes another wing, another engine mounting pylon, and another engine. The another wing and the another engine mounting pylon may be connected in the same manner as the wings 502 and the pylon 504.

[0066] The aircraft 500 may also include one or more other components or assemblies in accordance with the present invention that can connect aircraft structures other than the pylon and the wings together.

[0067] Figure 6 FIG. 600 is a flow chart showing a method 600 of joining a first component to a second component in a predetermined relative position and orientation of the first component and the second component. The first component may be the first component or the third component according to any of the examples described above. The second component may be the second component according to any of the examples described above. Performing the method may result in forming an assembly in accordance with the present invention, such as the exemplary assembly 3 described above.

[0068] In a first block 601, a first component having a first surface is provided. The first component may be, for example, any one of the exemplary first components or structures 11, 31, 41. In some examples, the first component may be provided as pre-attached to another component, such as the exemplary third structure 35.

[0069] In block 602, a second component having a second surface is provided. The second component may be, for example, any one of the exemplary second components or structures 11, 31.

[0070] In a third block 603, a plurality of recesses are formed in the first surface such that each recess is oriented relative to the first component based on a desired relative orientation of the first component and the second component when joined. The desired relative orientation may include an angle between a first plane associated with the first component and a second plane associated with the second component. The desired relative orientation is a preselected relative orientation of the first component and the second component. In some examples, the plane associated with the first component may correspond to a reference plane of an aircraft that includes the first component.

[0071] Forming the plurality of recesses can include selecting the orientation of each recess. Forming the plurality of recesses can include selecting the depth of each recess. Selecting the orientation and / or depth of each recess can be performed based on configuration data for the first surface and the second surface. Such configuration data can be obtained, for example, by scanning or otherwise measuring the first surface and the second surface. Preferably, such measurements are made with a high level of accuracy. The configuration of the gap between the first surface and the second surface when the first component and the second component are arranged in a desired relative orientation can be determined based on the configuration data for the first surface and the second surface.

[0072] Selecting the orientation and / or depth of each recess can be performed based on the configuration data for the first surface and the second surface in combination with data related to the desired relative orientation of the first component and the second component. Additionally, selecting the depth of each recess can be performed based on the configuration data for the spacer element intended to be inserted into the recess. For example, the depth of a given recess can be selected based on the width of the gap between the first surface and the second surface at the location of the given recess when the first component and the second component are in the desired relative orientation in combination with the height of the spacer element intended to be inserted into the given recess. The recesses are formed to have a shape corresponding to the shape of the spacer element intended to be inserted into the recess. In some examples, the recesses are formed such that such spacer elements will be press-fitted into the recesses.

[0073] Forming the plurality of recesses can include programming an automated tool, such as a CNC drilling machine, to create recesses having the selected orientation and depth. Forming the plurality of recesses can include creating counterbores having the selected orientation and depth. One or more of the recesses can be formed coaxially with a fastener hole already present in the first component. Forming the plurality of recesses can include controlling the cutting or drilling tool with up to three degrees of freedom.

[0074] In the fourth block 604, a plurality of spacer elements are provided. Each spacer element may have the same design as any one of the exemplary spacer elements or spacer members 13a to 13c, 23, 33a to 33d, 43a to 43d. Each spacer element is configured to be received in one of the recesses formed in the block 603. In some examples, each of the plurality of spacer elements is substantially identical to each other. For example, the spacer elements may be supplied as standard parts. In such examples, the formation of the recesses is controlled accordingly. However, other examples are possible where providing the plurality of spacer elements includes creating or modifying one or more of the spacer elements to match the configuration of the corresponding recesses. Each spacer element has a contact surface that is configured to contact a second surface when the second component is joined to the first component. Preferably, each contact surface is configured to contact the second surface over the entire area of the contact surface. In examples where the second surface is substantially flat, each spacer element is provided with a substantially flat contact surface that is generally perpendicular to the axis of the spacer element. However, other examples are possible where the second surface is not substantially flat. In such examples, providing the plurality of spacer elements may include creating or modifying the contact surface on one or more of the spacer elements such that the contact surface contacts the second surface over the entire area of the contact surface.

[0075] In the fifth block 605, the spacer elements are inserted into each recess. Inserting the spacer elements may include pushing the spacer elements into the recesses with sufficient force to overcome the friction between the sidewalls of the spacer elements and the sidewalls of the recesses. In some examples, an adhesive may be applied to one or both of the spacer elements and the recesses before inserting the spacer elements into the recesses. Block 605 may be performed manually or automatically (e.g., by an industrial robot).

[0076] In block 606, the second component is disposed on the spacer elements such that the contact surfaces of the spacer elements contact the second surface and the first and second components are in a desired relative position and orientation. Disposing the second component on the spacer elements may include supporting and moving the second component to a position where the second surface contacts each of the contact surfaces of the spacer elements. Additionally, disposing the second component on the spacer elements may include aligning the fastener holes (or the locations intended to create fastener holes) of the second component with the fastener holes (or the locations intended to create fastener holes) of the spacer members.

[0077] Due to the configuration of the recesses and the spacer elements, when the second component contacts each of the contact surfaces of the spacer elements, the second component and the first component will necessarily be in the desired orientation. This is because, as described above, the orientation of the contact surfaces relative to the nominal plane of the first component has been set during the process of creating the recesses. Thus, during the placement of the second component on the spacer elements, only the translational position of the second component relative to the first component needs to be precisely controlled. The execution of block 606 can be implemented in any suitable manner, for example, using a fixture, an industrial robot, or manually. During the execution of block 606, the first component can be held in a fixed position and orientation, for example, using a fixture or any other suitable assembly device.

[0078] In block 607, the first component is connected to the second component. This connection can be performed using any suitable known technique. For example, connecting the first component to the second component can include fastening the first component to the second component. Such fastening can include installing one or more fasteners through holes extending through the first component and the second component. In some examples, one or more such fasteners can additionally extend through the spacer elements. In some examples, the fasteners can extend through each spacer element. In an example where the first component is attached to another component such as the exemplary third structure 35, the fasteners can additionally extend through the other component. At least some portions of the fastener holes can be pre-drilled before the components of the assembly are brought together in the desired final configuration in block 607. After the components of the assembly are brought together in the desired final configuration, some portions of the fastener holes can be drilled as part of the execution of block 607.

[0079] Although the present invention has been described above with reference to one or more preferred examples or embodiments, it should be understood that various changes or modifications can be made without departing from the scope of the present invention as defined by the appended claims. For example, although the present invention has been mainly described with reference to aircraft applications, the present invention can be equivalently applied to any other vehicle or structure in which it is desired to join two (or more) components in a preselected relative orientation.

[0080] Where the term "or" is used in the previous description, unless otherwise explicitly stated, the term should be understood to mean "and / or".

Claims

1. A component for joining, which is configured to join to another component in a preselected relative orientation of the component and the other component, wherein, the other component has an interface surface, and the component is configured to contact the interface surface when joined to the other component; the component comprises: a first surface provided on a side of the component intended to face the interface surface when the component is joined to the other component; a plurality of recesses formed in the first surface, wherein each recess has the form of a hole with a predetermined depth and an inner surface and has a preselected orientation relative to the component, and the preselected orientation and the predetermined depth are selected according to the preselected relative orientation of the component and the other component; and a plurality of spacer elements, each spacer element including an outer surface and a contact surface, the outer surface being configured to contact the inner surface of the recess, the contact surface being configured to contact the interface surface when the component is joined to the other component, and each spacer element being disposed in one of the recesses such that the orientation of a given contact surface is defined by the orientation of the corresponding recess.

2. The component for joining according to claim 1, wherein, the curvature of the first surface is different from the curvature of the interface surface.

3. The component for joining according to claim 2, wherein, the first surface is curved and the interface surface is flat.

4. The component according to any one of the preceding claims, wherein, the shape of each spacer element matches the shape of the recess in which the spacer element is provided.

5. The component for joining according to claim 4, wherein, each recess and each spacer element are cylindrical.

6. The component for joining according to claim 5, wherein, all the recesses have the same diameter.

7. The component for joining according to any one of claims 1 to 3, wherein, all the recesses have the same orientation relative to the component.

8. The component for joining according to any one of claims 1 to 3, wherein, there is an interference fit between each spacer element and the recess in which the spacer element is provided.

9. The component for joining according to any one of claims 1 to 3, wherein, fastening holes extend through at least one spacer element in a direction perpendicular to the contact surface.

10. The component for joining according to any one of claims 1 to 3, wherein, each recess includes a counterbore.

11. A joining assembly, comprising: a first structure that defines a reference plane of the assembly, the first structure including a first surface; and a second structure fixedly attached to the first structure such that the second structure has a preselected orientation relative to the reference plane, the second structure including a second surface; Wherein, the first surface includes a plurality of sockets, the plurality of sockets extend into the first surface at a predefined angle relative to the reference plane, each socket has an inner surface and is formed as a hole with a predetermined depth, each socket contains an interface member, the interface member has an outer surface configured to contact the inner surface of the socket and has a first end in contact with the base of the socket and a second end in contact with the second surface.

12. The assembly for joining according to claim 11, wherein, the second end of each interface member includes an interface surface in contact with the second surface, and wherein the orientation of each interface surface is set by the orientation of the corresponding socket.

13. The assembly for joining according to claim 11 or 12, wherein, the first structure is fixedly attached to the second structure by at least one fastener, and wherein the fastener extends through one of the interface members.

14. The assembly for joining according to claim 13, wherein, the fastener includes a tension bolt.

15. The assembly for joining according to claim 11 or 12, further comprising a third structure attached to the second structure such that the first structure is between the third structure and the second structure, wherein, the first structure includes a plate having another surface opposite to the first surface, and the another surface is configured to match the surface of the third structure facing the first structure.

16. The assembly for joining according to claim 15, wherein, the third structure is included in a first aircraft structure, and the second structure is included in a second aircraft structure.

17. The assembly for joining according to claim 16, wherein, the first aircraft structure is a wing, and the second aircraft structure is an engine mounting pylon.

18. An aircraft comprising a joining component according to any one of claims 1 to 3 or a joining assembly according to any one of claims 11 to 12.

19. A method of joining a first component to a second component in a predetermined relative position and orientation of the first component and the second component, the method comprising: providing a first component having a first surface; providing a second component having a second surface; forming a plurality of recesses in the first surface such that each recess has the form of a hole and an inner surface, and each recess is oriented relative to the first component based on the desired relative orientation of the first component and the second component when joined; providing a plurality of spacer elements, each spacer element having an outer surface configured to contact the inner surface of the recess and configured to be received in one of the recesses, and each spacer element having a contact surface configured to contact the second surface when the second component is joined to the first component; inserting the spacer elements into each recess; Arrange the second component on the spacer element such that the contact surface of the spacer element contacts the second surface and the first component and the second component are in a desired relative position and orientation; and Connect the first component to the second component.

20. The method according to claim 19, wherein, The first component and the plurality of spacer elements together form a component for joining according to any one of claims 1 to 3.

21. The method according to claim 19, wherein, The component for joining according to any one of claims 1 to 3 is joined to the second component using the method.

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