Modular tool, method of assembling a tool set, and aircraft

Abstract

The invention provides a modular tool for manufacturing a multi-spar torsion box having different web heights, the modular tool comprising: a core module having a hollow beam geometry comprising a first base and a second base opposite the first base and two walls extending between the first and second bases; at least one spacer module configured to couple with the core module, wherein the web height of a multi-spar torsion box is defined by the coupling between the core module and at least one spacer module. The invention also provides a method for assembling a tool set for manufacturing a multi-spar torsion box and an aircraft comprising a multi-spar torsion box manufactured by the method.

Description

TECHNICAL FIELD

[0001] The present invention is in the field of aircraft structures and, more specifically, in the field of modular tools for manufacturing multi-spar torsion boxes. BACKGROUND

[0002] In the aircraft industry, manufacturers of modern civil passenger aircraft often offer operators the possibility to enlarge or reduce the passenger capacity of a successful product, since, for example, airlines can desire to adjust and optimize the passenger capacity or the baggage capacity for specific routes. The A320 family is a clear example of such an aircraft family, ranging from the shortened A318 to the lengthened A321. Each of these aircraft is designed to meet and guarantee specific mission and performance requirements. From an economic and manufacturing standpoint, the manufacturer therefore usually builds components with a high degree of commonality in order to be able to offer a wider range of possible configurations of the aircraft family to the operators.

[0003] That is, the different models of a given aircraft family share many components, such as fuselage sections, cockpit, wings, tail, etc. In the specific example of aircraft structural components, the size of the tail (VTP: vertical tail and HTP: horizontal tail) is usually designed to meet the critical requirements of the shortest member of the family.

[0004] While this is entirely reasonable in terms of commonality of components for the entire aircraft family, it also means that, due to the additional weight and drag, the mid- and lengthened versions (longer fuselage) of the family members must carry oversized tails and incur a corresponding penalty in terms of performance for the airline.

[0005] In addition, this concept design includes providing a common structure for implementation in different members of an aircraft family having a range of aircraft sizes, resulting in further drawbacks in terms of recurring costs for the aircraft manufacturer due to unnecessary material and labor hours.

[0006] Recently, some modular approaches have been developed for different aircraft surface structures and components, such as lift surfaces, in which some parts of such components are kept, thus keeping the same size for all members of the aircraft family. An example of a modular approach is disclosed in EP 3421352 A1, in which a torsion box is modified by increasing the web height of the front and rear spars, while keeping the common upper and lower covers. The addition of different front and rear edges enables the modification of the planform of the lift surface and thus allows the customization of the size of the lift surface to comply with the size requirements of a specific member of the aircraft family.

[0007] However, the current tooling concept for manufacturing said different parts of aircraft structures and components, such as torsion boxes, includes elements with fixed dimensions, such as base plates, shims, c-shaped cores, etc.

[0008] In particular, one of the different parts manufactured using a fixed size tool is a "multi-spar torsion box". This element is understood as a component for an aircraft structure, whose main elements are the front spar, the rear spar, the intermediate spar, the upper cover and the lower cover, and, if necessary, also the ribs located next to the load introduction areas. Moreover, the multi-spar torsion box can comprise a plurality of stringers, which are longitudinal stiffening elements configured for supporting a portion of the load introduction areas located between the spars, in order to prevent buckling and / or bending under compression or shear loads.

[0009] In particular, the concept for a multi-spar torsion box is known from EP 2153979 A1, wherein an integrated multi-spar torsion box structure of a composite material for an aircraft and a method for manufacturing an integrated multi-spar torsion box structure of a composite material are disclosed.

[0010] Correspondingly, in case of any dimensional change in any component part, such as the torsion box web height, new tool elements, such as c-shaped cores, should be manufactured to meet the dimensional requirements. SUMMARY

[0011] The present invention provides a solution to the above-mentioned problems by means of the modular tool for manufacturing a multi-spar torsion box of the present invention and the method for assembling a tool set for manufacturing a multi-spar torsion box of the present invention.

[0012] In this document, the term "composite material" or "composite laminate" will be understood as any type of material, such as CFRP (Carbon Fiber Reinforced Polymer), which comprises two or more physically distinguishable parts and mechanically separable, which two or more parts cannot be dissolved with each other.

[0013] The term "multi-spar torsion box web height" or "multi-spar torsion box height" is to be understood as the distance between the upper skin, the lower skin or cover of the multi-spar torsion box.

[0014] In a first inventive aspect, the present invention provides a modular tool for manufacturing a multi-spar torsion box having different web heights, the modular tool comprising:

[0015] a core module having a hollow beam geometry comprising a first base and a second base opposite to the first base and two walls extending between the first base and the second base, and

[0016] at least one spacer module configured to be coupled with the core module,

[0017] The web height of the multi-wing beam anti-torsion box is defined by the connection between the core module and at least one spacer module.

[0018] Therefore, by defining the desired web height, the present invention provides a modular tool for manufacturing multi-spar torsion boxes of different sizes, thereby allowing for dimensional optimization of the multi-spar torsion boxes to meet the dimensional requirements of specific aircraft structures for a particular aircraft family.

[0019] Advantageously, the modular tooling according to the invention provides an industrial process for manufacturing multi-spar torsion boxes with great flexibility, as it allows for the optimization of multi-spar torsion box dimensions for a given member of an aircraft family using shared tooling elements.

[0020] Equally advantageous is the flexibility to customize the dimensions of different multi-spar torsion boxes, which are part of the aircraft structure, thus improving the performance of the aircraft structure described in specific members of the aircraft family, as weight and drag can be appropriately optimized. Consequently, the overall performance of the aircraft is also improved.

[0021] Modular tools allow for minimizing associated modification costs (e.g., avoiding the use of entirely new toolkits for multi-spar torsion boxes of different sizes).

[0022] Furthermore, the modular tooling approach used in manufacturing the multi-spar torsion box reduces the number of specific tools and fixtures, thus minimizing potential non-repetitive costs.

[0023] In this sense, in addition to minimizing non-repetitive costs, this reduction in the number of specific tools and fixtures also allows for a reduction in repetitive costs associated with management and maintenance operations (cleaning, moving, etc.).

[0024] Furthermore, the modular tools according to the invention allow for the reduction of dedicated workshops required for storing the large number of tools needed to manufacture different multi-spar torsion boxes with high productivity, based on current manufacturing solutions in the prior art, and also minimize the investment required to start new programs.

[0025] Advantageously, regarding the application field of the invention, the provided tools and methods are particularly concerned with the field of manufacturing "multi-wing beam anti-torsion boxes" in a "one-feed method".

[0026] Regarding the "one-time feeding method," it will be understood as a process in which the final configuration of a multi-wing torsion box is obtained by separating new composite materials set on different tooling elements in a single curing process.

[0027] The modular tool according to the invention may include one or more spacer modules. In embodiments in which the modular tool includes more than one spacer module, the spacer modules may have different configurations.

[0028] In particular embodiments, the first base and / or the second base and / or the at least one wall of the core module comprises a first fastening means, and the at least one spacer module comprises a second fastening means configured to match with the first fastening means, thereby fixing the core module to the spacer module.

[0029] In particular embodiments, one of the first and second fastening means comprises at least one pin complementary to at least one hole arranged on the other of the first and second fastening means, such that the at least one pin is configured to engage with the at least one hole.

[0030] Thus, the complementary fastening means implemented in the contact surfaces between the core module and the spacer module, in the form of one or several pins and holes, allow to removably fix the modules between them, which improves the consistency and stability of the coupling.

[0031] Advantageously, the coupling between the modules is ensured to prevent undesired relative movements. Also advantageously, the coupling or stacking process has an improved precision, since the matching between the pins and holes helps to guide the coupling between the modules, resulting in an easier and faster positioning process.

[0032] In embodiments, both contact surfaces are provided with complementary pins and holes drilled using a NC machine, to achieve tight coupling tolerances.

[0033] In particular embodiments, the at least one spacer module comprises a hollow beam geometry comprising a first base and a second base opposite to the first base, and two walls extending between the first and second bases, and the core module and the spacer module are configured to be stacked one on top of the other, such that a base of one of the core module and the spacer module is supported on a base of the other of the core module and the spacer module, so that the stack has a hollow beam geometry comprising:

[0034] - two opposite bases, one base corresponding to the base of the core module and the other base corresponding to the base of the spacer module, and

[0035] - two outer walls defined by the walls of the core module and the walls of the spacer module.

[0036] In embodiments, the hollow beam geometry of the modules is shaped in the form of a closed cell. Advantageously, all the modules have a vacuum tightness.

[0037] In an embodiment, the first base and / or the second base of the core module comprises first fastening means and the first base and / or the second base of the spacer module comprises second fastening means configured to match the first fastening means, thereby fixing one base of the core module to one base of the spacer module.

[0038] In a particular embodiment, at least one spacer module is a plate-shaped structure. A spacer module having a shape according to this embodiment has a flat surface and a substantially constant thickness. This results in easier handling operations (such as handling, cleaning or drilling processes) and provides great flexibility and reduced complexity of the manufacturing process.

[0039] In a particular embodiment, the core module comprises a first core module member and a second core module member configured to be coupled to each other, wherein the first core module member comprises a first base and two walls extending from the first base, the second core module member comprises a second base and two walls extending from the second base, wherein the first wall of the first core module member is configured for abutting the first wall of the second core module member along at least a portion of the length of each wall, each of the other walls of the first core module member and of the second core module member comprises a distal end configured for coupling with at least one spacer module, and wherein the spacer module is configured for being interposed between the distal ends of the first core module member and of the second core module member.

[0040] According to this embodiment, the core module is split into two core module members which are adapted to move with respect to each other in order to couple with the spacer module interposed between the two core module members. A set of different predetermined positions can be provided, which allows to define a plurality of heights for producing a set of multi-spar torsional boxes.

[0041] On one side, the spacer module comprises an outer shape provided with geometrical elements, such as flat ridges or wedge-shaped protrusions, in its peripheral surface, which are configured to abut and / or match the distal end portions of the two respective walls of each core module member, whereby the spacer module couples with each core module.

[0042] On the other side, the wall of each core module member which is not intended to be connected with the spacer module is configured to have a length greater than the wall intended to be connected with the spacer module.

[0043] In this sense, the longer walls are configured to be mechanically connected between them, so that they can slide with respect to each other. In particular, when the spacer module is provided to be coupled with the core module members in different positions, the defined web height of the coupling thereby changes, the walls sliding with respect to each other to adapt the new configuration.

[0044] In particular embodiments, the distal end configured to couple with the at least one spacer module each comprises a protrusion, and wherein the spacer module has a z-shaped body configured to engage with the protrusion.

[0045] In embodiments, the wall of the core module member intended to be connected with the spacer module comprises first fastening means, and the spacer module comprises second fastening means configured to match the first fastening means, thereby fixing the wall of the core module member to the spacer module.

[0046] In particular embodiments, the modular tool for manufacturing a multi-spar torsion box having different web heights further comprises a joint sealing device located at the interface between the distal end of the core module member and the spacer module, the joint sealing device being configured for providing the joint interface with air tightness.

[0047] Advantageously, the joint interface is provided with air tightness to avoid any vacuum leakage that could generate defects in the composite material, such as porosity, during the curing process.

[0048] In particular embodiments, the joint sealing device comprises a rubber sealant.

[0049] In particular embodiments, the joint sealing device comprises at least one encapsulated anchor nut.

[0050] Advantageously, the joint provided with the joint sealing device generates a precise sealed joint produced in a simple and quick manner.

[0051] In particular embodiments, the at least one spacer module is configured for wrapping the core module such that the spacer module adheres to the first base and to the second base and to the wall of the core module.

[0052] In embodiments, the spacer module is provided on the core module by an additive layer manufacturing process.

[0053] Advantageously, the modular tool is provided with a tight and continuous control of the height defined by the coupling between the core module and the at least one spacer module.

[0054] In particular embodiments, the spacer module configured for wrapping the core module is a composite laminate.

[0055] In particular embodiments, the core module is made of aluminum.

[0056] In a second inventive aspect, the application provides a method for assembling a kit of tools for manufacturing a multi-spar torsion box, the method comprising the steps of:

[0057] - providing a modular tool for manufacturing a multi-spar torsion box according to embodiments of the first inventive aspect,

[0058] - defining a web height of a multi-spar torsion box to be manufactured, and

[0059] - coupling the core module and at least one spacer module for providing the modular tool with the defined web height of the multi-spar torsion box.

[0060] In particular embodiments, the method for assembling a tool set for manufacturing a multi-spar torsion box further comprises the steps of:

[0061] - providing at least one additional modular tool for manufacturing a multi-spar torsion box according to embodiments of the first inventive aspect,

[0062] - defining a chord of a multi-spar torsion box to be manufactured,

[0063] - coupling at least one additional core module and at least one additional spacer module for providing the additional modular tool with the defined web height of the multi-spar torsion box,

[0064] - arranging the core module coupled to at least one spacer module and the at least one additional core module coupled to an additional spacer module to provide an arrangement with the defined chord.

[0065] In another inventive aspect, the present invention provides a method for manufacturing a torsion box, the method comprising the steps of the method for assembling a tool set according to the second inventive aspect, and further comprising:

[0066] - providing a composite material at least partially covering the coupled core module and spacer module,

[0067] - providing a composite material at least partially covering the coupled at least one additional core module and at least one additional spacer module, and

[0068] - providing a composite material on the upper and lower base of the assembled modular tool so as to define an upper and lower skin of the multi-spar torsion box.

[0069] In a third inventive aspect, the present invention provides an aircraft comprising a multi-spar torsion box manufactured by the method according to the second inventive aspect.

[0070] All features described in the present specification (including the claims, the description and the drawings) can be combined in any combination, except combinations where at least some of the constituent features are mutually exclusive. BRIEF DESCRIPTION OF DRAWINGS

[0071] These and other characteristics and advantages of the present application will become apparent from the detailed description, the claims and the accompanying drawings, which are given by way of non-limiting example only, and in which

[0072] Figure 1 This figure shows a tool for manufacturing a single-configuration multi-spar torsion box previously used in the aircraft industry.

[0073] Figure 2 This figure shows a schematic representation of the modular principle of a multi-spar torsion box with different web heights produced by a tool according to the present application.

[0074] Figure 3 This figure shows a schematic representation of two different configurations of a modular tool according to an embodiment of the present application, each configuration defining a different web height for manufacturing a multi-spar torsion box.

[0075] Figure 4 This figure shows two different configurations of a modular tool set according to an embodiment of the present application, each configuration defining a different web height for manufacturing a multi-spar torsion box.

[0076] Figure 5 This figure shows a modular tool according to an embodiment of the present application, in which two core module components and one spacer module are coupled, defining a web height for manufacturing a multi-spar torsion box.

[0077] Figure 6 This figure shows two different configurations of the joint between a z-shaped spacer module and the protrusions of the distal ends of two core module components according to an embodiment of the present application.

[0078] Figure 7 This figure shows a schematic representation of two different configurations of a modular tool according to an embodiment of the present application, each configuration defining a different web height for manufacturing a multi-spar torsion box.

[0079] Figure 8 This figure shows a modular tool comprising several configurations of the coupling between core modules and spacer modules, arranged in combination for manufacturing a multi-spar torsion box.

[0080] Figure 9 This figure shows an aircraft comprising a multi-spar torsion box manufactured according to an embodiment of the present application. DETAILED DESCRIPTION

[0081] Figure 1A top view of an example of a tool solution currently used in the aircraft industry and of a multi-spar torsion box 100 is schematically shown. In particular, the tool 101 comprises several fixed-height cores 102 for manufacturing a single-configuration multi-spar torsion box 100. The tool 101 shown is used to produce a multi-spar torsion box 100 by means of a hot forming process.

[0082] The tool 101 comprises a base plate 103 which performs the function of supporting and transporting the remaining elements which are part of the tool 101 for applying the thermodynamic process to the multi-spar torsion box 100 made of composite material, while ensuring that the restrictive structural and dimensional tolerances are met.

[0083] Along a portion of the outer surface of the core 102, different layers of composite material are provided, so as to obtain the desired distribution of the composite material which will undergo the curing process. In particular, in the Figure 1 core 102, the composite material is distributed according to a C-shaped pattern, so that the core 102 can be distributed according to the alternation of the orientation of the C-shaped pattern, for producing the spars 100.1 by joining two walls completely covered by the composite material; and for producing several stringers or reinforcing elements 100.2 by joining walls which are only partially covered by the composite material.

[0084] In this sense, several cores 102 are shown assembled with new composite laminates which are stacked in order to provide the structure with its final shape before the curing process, in order to build the complete multi-spar torsion box 100. Furthermore, external shims are used to ensure the aerodynamic tolerances.

[0085] With regard to the fixed-height cores 102 used in the prior art, as Figure 1 shown, they are built by welding two C-shaped aluminium beams and are assembled and coordinated between them by means of longitudinal bars 105 having a stadium shape.

[0086] With this tool 101, it is possible to manufacture a multi-spar torsion box 100 which combines the skin 100.3, 100.4, the stringers 101.2 and the spars 101.1. Since each core 102 has a predetermined fixed shape, in the event of any variation in the height of the multi-spar torsion box 100, a new core 102 should be implemented to produce the required structure.

[0087] Figure 2The principles of the application are illustrated schematically using a set of modular lifting surfaces as an example. In this particular example, the multi-spar torsion box 100 is modified only by changing the web height of the front and rear spars 101.11, 101.12, while keeping the common upper skin 100.3 and lower skin 100.4. Different front and rear leading edges 106, 107 are then added to enable modification of the lifting surface planform shape, and thus allow customizing the size of the lifting surface to comply with the size requirements of a particular member of the aircraft family.

[0088] It is important to note that, Figure 2 The schematic representation is only conceptual and does not take into account the implicit increase in relative thickness (t / c, thickness to chord ratio). It is assumed that the different multi-spar torsion boxes 100 with different heights corresponding to each embodiment compensate for the increased load due to the increased web height of the longer LE / TE chord.

[0089] Furthermore, for simplicity, Figure 2 The increase in the trailing edge chord is not shown.

[0090] Figure 3 Schematic representations of front views showing two different configurations of the modular tool 10 for manufacturing multi-spar torsion boxes 100 with different web heights z1, z2 according to embodiments of the application are shown.

[0091] In particular, the left drawing shows a core module 11 coupled to a spacer module 12A, and the right drawing shows the same core module 11 coupled to a larger spacer module 12A', thus allowing the production of higher multi-spar torsion boxes 100 for different structures of the family of aircraft 1000.

[0092] Correspondingly, the same modular tool 10 allows providing a set of multi-spar torsion boxes 100 with different web heights, thus customizing the size of the multi-spar torsion boxes 100 to comply with the size requirements of a particular member of the family of aircraft 1000.

[0093] The shown spacer modules 12A, 12A' comprise a hollow beam geometry, with a first flat bottom base 12A.1, 12A.1' substantially parallel to a second flat top base 12A.2, 12A.2' spaced apart from the first flat bottom base 12A.1, 12A.1' by a distance determined by two parallel walls 12A.3, 12A.4; 12A.3', 12A.4' extending substantially perpendicularly between the first flat bottom base 12A.1, 12A.1' and the second flat top base 12A.2, 12A.2'.

[0094] Similarly, the core module 11 comprises a hollow beam geometry having a first flat bottom base 11.1 substantially parallel to a second flat top base 11.2 spaced apart from the first flat bottom base 11.1 by a distance determined by two parallel walls 11.3, 11.4 extending substantially perpendicularly between the first flat bottom base 11.1 and the second flat top base 11.2.

[0095] In the left and right-hand figures, the core module 11 and the spacer modules 12A, 12A’ are stacked, the core module 11 being supported on top of each spacer module 12A, 12A’ so that the first flat bottom base 11.1 of the core module 11 is supported on the second flat top base 12A.2, 12A.2’ of each spacer module 12A, 12A’. The width of the core module 11, i.e. the distance between the walls 11.3, 11.4, is equal to the width of each spacer module 12A, 12A’. The stack 15 of the core module 11 and each spacer module 12A, 12A’ thus has a substantially rectangular geometry comprising two closed cells.

[0096] Figure 4 A front view is shown of two different configurations of the modular tool 10 for manufacturing a multi-spar torsion box 100 having different web heights z1, z2 according to an embodiment of the application.

[0097] In particular, the left-hand figure shows one core module 11 coupled to a spacer module 12A, and the right-hand figure shows the same core module 11 coupled to the same spacer module 12A and also connected to an additional spacer module in the form of a plate-shaped structure 12D for reaching a greater height z2 than the height z1 reached in the absence of the plate-shaped structure 12D, thus allowing the production of higher multi-spar torsion boxes 100 for different structures of the series of aircraft 1000.

[0098] The shared spacer module 12A shown comprises a hollow beam geometry having a first flat bottom base 12A.1 parallel to a second flat top base 12A.2 spaced apart from the first flat bottom base 12A.1 by a distance determined by two parallel walls 12A.3, 12A.4 extending perpendicularly between the first flat bottom base 12A.1 and the second flat top base 12A.2.

[0099] In the left-hand figure, the core module 11 and the spacer module 12A are stacked in the same way as in the right-hand figure, but the plate-shaped structure 12D is not present. Figure 3The core module 11 is stacked in the same way as the embodiment shown. That is, the core module 11 is supported on top of the spacer module 12A so that the first flat bottom base 11.1 of the core module 11 is supported on the second flat top base 12A.2 of the spacer module 12A. Moreover, the width of the core module 11, i.e. the distance between the walls 11.3, 11.4, is equal to the width of the spacer module 12A. Therefore, the stack 15 of core modules 11 and spacer modules 12A has a substantially rectangular geometry, comprising two closed cells.

[0100] However, in the right-hand figure, a plate-shaped structure 12D is interposed between the core module 11 and the spacer module 12A so that the first flat bottom base 11.1 of the core module 11 is supported on the top surface of the plate-shaped structure 12D and the plate-shaped structure 12D is supported on the second flat top base 12A.2 of the spacer module 12A.

[0101] Moreover, both configurations, with and without the interposition of a plate-shaped structure 12D, comprise complementary fastening means for guiding the coupling process and fixing the coupling once it is completed.

[0102] In particular, in the left-hand figure, the core module 11 and the spacer module 12A comprise blind holes drilled in the contact faces 11.1, 12A.2 of the stack using a NC machine tool for achieving tight tolerances and allowing the precise coordination between the two holes so that the pin 13 can penetrate both holes substantially perpendicularly to the two contact surfaces 11.1, 12.2, thus fixing the coupling. In the same way, in the right-hand figure, the plate-shaped structure 12D stacked between the core module 11 and the spacer module 12A is drilled in coordination with the holes of the contact surfaces 11.1, 12A.2 so that a longer pin 13’ can pass through the entire stack 15, thus fixing the stack between the core module 11, the plate-shaped structure 12D and the spacer module 12A.

[0103] Figure 5 A front view of a configuration of a core module 11 according to another embodiment of the present application is shown, coupled to a spacer module 12B of a modular tool 10 for manufacturing a multi-spar torsion box 100, wherein the core module 11 is divided into a first core module member 16 and a second core module member 17.

[0104] In particular, the first core module member 16 comprises a first base 16.1, a first wall 16.2 extending from said first base 16.1 and a second wall 16.3; and the second core module member 17 comprises a second base 17.1, a first wall 17.2 extending from said second base 17.1 and a second wall 17.3.

[0105] On one side, the first wall 16.2 of the first core block member 16 is shown abutting the first wall 17.2 of the second core block member 17 along a portion of the length of the first wall of the first core block member and of the first wall of the second core block member. The two first walls 16.2, 17.2 are configured to slide with respect to each other so that, when the spacer block 12B is replaced or set to be coupled with the core block members 16, 17 in a different position, the defined web height z of the coupling changes as a result of the walls 16.2, 17.2 sliding with respect to each other to adapt to the new configuration.

[0106] In this sense, the first walls 16.2, 17.2 are shown to comprise a reduction in thickness along the portion of their length configured for mechanically connecting the other respective first wall 16.2, 17.2. In this way, the length of the portion in contact is maximized so that the two first walls 16.2, 17.2 can slide with respect to each other along a plurality of configurations to define different web heights for the multi-spar torsion box 100 to be manufactured. In particular, when the defined web height of the coupling changes as a result of the replacement or change of position of the spacer block 12B interposed between the two core block members 16, 17, the first walls 16.2, 17.2 slide with respect to each other to adapt to the new configuration while maintaining mechanical contact, thus preventing any vacuum leak from the internal hollow volume.

[0107] On the other side, the spacer block 12B is shown interposed between the distal ends 16.4, 17.4 of the second walls 16.3, 17.3. In this sense, the distal ends 16.4, 17.4 of the two core block members 16, 17 are partially inclinedly sloped towards the joint interface 19.1, 19.2. In a similar way, the spacer block 12B shown has a portion shaped substantially as a trapezoid comprising two sloped surfaces configured for abutting the distal ends 16.4, 17.4 along the joint interface 19.1, 19.2.

[0108] This particular configuration with inclined surfaces in mechanical contact along the joint interface 19.1, 19.2 provides the modular tool 10 with a continuous height adjustment as a result of the potential coupling choices of the core block members 16, 17 and the spacer block 12B along the joint interface 19.1, 19.2.

[0109] Figure 6 It is shown that replacing the spacer block 12B with another spacer block 12B’ having a different height, as shown in the figure, allows to change the defined web height z of the coupling between the two core block members 16, 17. Figure 5Alternative embodiments of the inclined surfaces shown in mechanical contact at the joint interfaces 19.1, 19.2. In particular, this figure shows a particular embodiment of the coupling between the distal end 16.4, 17.4 of the core module members 16, 17 and the spacer module 12B, which is achieved through two rectangular protrusions 16.5, 17.5, which are provided only on a portion of the contact surface of the distal end 16.4, 17.4, since the remaining portion of this surface is configured to match with the spacer module 12B, which in this particular embodiment is in the form of a z-shaped body.

[0110] Therefore, the z-shaped body is configured to match with the protrusions 16.5, 17.5 of each respective distal end 16.4, 17.4, being interposed between these protrusions.

[0111] Furthermore, since ensuring the internal tightness along the composite material curing cycle is necessary to ensure that the cycle is performed under proper conditions, preventing defects such as porosity due to vacuum leaks, the joint interfaces 19.1, 1.2 have been provided with a flat rubber sealant 18.1 interposed between the contact surfaces of both the rectangular protrusions 16.5, 17.5 and the z-shaped body.

[0112] In addition to the addition of the flat rubber sealant 18.1, in order to improve the sealing effect as well as the stability of the coupling, at each joint interface 19.1, 19.2 an encapsulated anchor nut 18.2 as well as a sealing ring are provided.

[0113] Figure 7 A front view showing two different configurations of the modular tool 10 for manufacturing multi-spar torsion boxes 100 with different web heights z1, z2 according to an embodiment of the present application.

[0114] The left figure shows one core module 11 coupled to a spacer module 12C, while the right figure shows the same core module 11 coupled to a larger spacer module 12C', thus allowing the production of higher multi-spar torsion boxes 100 for different structures of the series of aircraft 1000.

[0115] In particular, the spacer modules 12C, 12C' are provided directly on the core module 11 through an additive layer manufacturing process. More particularly, the configuration corresponding to the left figure shows a core module 11 made of aluminum, in which the two opposite bases 11.1, 11.2 and the walls 11.3, 11.4 have been completely surrounded by a composite laminate provided directly on the outer surface of the core module 11, thus wrapping said core module 11 through a weaving technique.

[0116] Therefore, the lengths of the walls 11.3 and 11.4 of the core module 11 and the thickness of the spacer module 12C connected to the core module (caused by the amount of composite material disposed on the core module 11) define the total height z1 corresponding to the web height of the multi-wing torsion box 100 to be manufactured.

[0117] Regarding the configuration corresponding to the right figure, additional composite material has been deposited around the core module 11, thereby achieving a higher height z2 that allows for the production of a higher multi-wing torsion box 100.

[0118] Figure 8 A modular tool 10 according to the invention is shown, comprising several configurations for the connection between a core module 11 and a spacer module 12A of a multi-wing torsion box 100 having different web heights, arranged according to the steps of a method for manufacturing a multi-wing torsion box 100.

[0119] Specifically, distance z1 has been determined as the web height of the multi-wing torsion box 100 to be manufactured. Then, according to Figure 3 In the illustrated embodiment, two core modules 11, 11' are connected to corresponding spacer modules 12A, 12A', which are customized to achieve the determined web height z1. Subsequently, the core modules 11, 11' and the spacer modules 12A, 12A' connected thereto are provided with composite material distributed according to a C-shaped pattern.

[0120] Then, the two core modules 11, 11' connected to the corresponding spacer modules 12A, 12A' have been arranged and coordinated between them by longitudinal bars 24 having an arena shape, such that the two stringers 23 are defined by joining together walls partially covered with composite material. In addition, the first wing beam 20 has been defined by composite material disposed on one of the walls fully covered with composite material.

[0121] In a similar manner, according to Figure 5 In the illustrated embodiment, each core module is divided into two corresponding core module members 16, 17; 16', 17', which are connected to each other. These core modules are then connected to corresponding spacer modules 12B, 12B', which are customized to achieve a defined web height z1. Subsequently, the core module members 16, 17; 16', 17' and the spacer modules 12B, 12B' connected thereto are provided with a composite material distributed according to a C-shaped pattern.

[0122] Then, the core module members 16, 17; 16', 17' coupled to the respective spacer modules 12B, 12B' are arranged and coordinated between them by means of longitudinal bars 25 having a rectangular shape, so as to define two stringers 23 by joining together the walls partially covered with composite material. Moreover, the second spar 22 has been defined by the composite material provided on one of the walls fully covered with composite material.

[0123] Then, the four core modules with the respective spacer modules have been further assembled and coordinated between them so as to define the intermediate spar 21 by joining together the other walls of composite material of each arrangement corresponding to the embodiments of Figure 3 and Figure 5 .

[0124] Then, the composite material has been provided on both the upper base and the lower base of the assembled modular tool 10 to define the upper skin 26 and the lower skin 27 of the multi-spar torsion box 100.

[0125] Figure 9 An aircraft 1000 is shown comprising a multi-spar torsion box 100 manufactured according to the present application.

Claims

1. A modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights, said modular tool (10) comprising: - Core module (11), the core module having a hollow beam geometry, the hollow beam geometry including a first base (11.1) and a second base (11.2) opposite to the first base (11.1), and two walls (11.3, 11.4) extending between the first base (11.1) and the second base (11.2), and - At least one spacer module (12A, 12B, 12C, 12D), said spacer module being configured to be coupled to the core module (11), The web height of the multi-wing torsion box (100) is defined by the connection between the core module (11) and at least one spacer module (12A, 12B, 12C, 12D). Its features are: At least one spacer module (12A) includes a hollow beam geometry comprising a first base (12A.1) and a second base (12A.2) opposite to the first base (12A.1), and two walls (12A.3, 12A.4) extending between the first base (12A.1) and the second base (12A.2), and in... The core module (11) and the spacer module (12A) are configured to stack on top of each other, such that the base of one of the core module (11) and the spacer module (12A) is supported on the base of the other of the core module (11) and the spacer module (12A), thus the stack (15) has a hollow beam geometry, which includes: - Two opposite bases (15.1, 15.2), one base corresponding to the base (11.1, 11.2) of the core module (11), and the other base corresponding to the base (12A.1, 12A.2) of the spacer module (12A), and - Two outer walls, defined by the walls (11.3, 11.4) of the core module (11) and the walls (12A.3, 12A.4) of the spacer module (12A).

2. The modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights according to claim 1, wherein, The first base (11.1) and / or the second base (11.2) and / or at least one wall (11.3, 11.4) of the core module (11) includes a first fastening device, and wherein at least one spacer module (12A, 12D) includes a second fastening device configured to mate with the first fastening device to secure the core module (11) to the spacer module (12A, 12D).

3. The modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights according to claim 2, wherein, One of the first and second fastening devices includes at least one pin (13) that is complementary to at least one hole arranged on the other fastening device in the first and second fastening devices, such that the at least one pin (13) is configured to engage with the at least one hole.

4. The modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights according to claim 1, wherein, At least one spacer module (12D) is a plate-shaped structure.

5. The modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights according to claim 2, wherein, At least one spacer module (12D) is a plate-shaped structure.

6. The modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights according to claim 3, wherein, At least one spacer module (12D) is a plate-shaped structure.

7. A modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights, said modular tool (10) comprising: - Core module (11), the core module having a hollow beam geometry, the hollow beam geometry including a first base (11.1) and a second base (11.2) opposite to the first base (11.1), and two walls (11.3, 11.4) extending between the first base (11.1) and the second base (11.2), and - At least one spacer module (12A, 12B, 12C, 12D), said spacer module being configured to be coupled to the core module (11), The web height of the multi-wing torsion box (100) is defined by the connection between the core module (11) and at least one spacer module (12A, 12B, 12C, 12D). Its features are: The core module (11) includes a first core module component (16) and a second core module component (17) configured to be connected to each other. The first core module component (16) includes a first base (16.1) and two walls (16.2, 16.3) extending from the first base (16.1). The second core module component (17) includes a second base (17.1) and two walls (17.2, 17.3) extending from the second base (17.1). The first wall (16.2) of the first core module member (16) is configured to abut the first wall (17.2) of the second core module member (17) for at least a portion of the length of each wall (16.2, 17.2). Each of the other walls (16.3, 17.3) of the first core module component (16) and the second core module component (17) includes a distal end (16.4, 17.4) configured for engagement with at least one spacer module (12B), and is located in The spacer module (12B) is configured to be inserted between the distal ends (16.4, 17.4) of the first core module member (16) and the second core module member (17).

8. The modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights as described in claim 7, in, The distal ends (16.4, 17.4) configured to connect with the spacer module (12B) each include a protrusion (16.5, 17.5), and The spacer module (12B) has a z-shaped body configured to engage with the protrusions (16.5, 17.5).

9. The modular tool (10) for manufacturing a multi-wing torsion box (100) with different web heights according to claim 8, further comprising a joint sealing device (18) located at the interface (19.1, 19.2) between the distal ends (16.4, 17.4) of the core module members (16, 17) and the spacer module (12B), the joint sealing device (18) being configured to provide airtightness for the joint interface (19.1, 19.2).

10. The modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights according to claim 9, wherein, The joint sealing device (18) includes a rubber sealant (18.1) and / or at least one encapsulated anchor nut (18.2).

11. A modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights, said modular tool (10) comprising: - Core module (11), the core module having a hollow beam geometry, the hollow beam geometry including a first base (11.1) and a second base (11.2) opposite to the first base (11.1), and two walls (11.3, 11.4) extending between the first base (11.1) and the second base (11.2), and - At least one spacer module (12A, 12B, 12C, 12D), said spacer module being configured to be coupled to the core module (11), The web height of the multi-wing torsion box (100) is defined by the connection between the core module (11) and at least one spacer module (12A, 12B, 12C, 12D). At least one spacer module (12C) is configured to enclose the core module (11) such that the spacer module (12C) adheres to the first base and the second base (11.1, 11.2) and to the walls (11.3, 11.4) of the core module (11). Its features are: The spacer module (12C) configured to enclose the core module (11) is a composite laminate.

12. The modular tool (10) for manufacturing a multi-wing beam torsion box (100) with different web heights according to claim 11, wherein, The core module (11) is made of aluminum.

13. A method for assembling a tool kit for manufacturing a multi-wing torsion box (100), the method comprising the steps of: - Provides a modular tool (10) for manufacturing a multi-wing torsion box (100) according to any one of claims 1 to 12, - The web height of the multi-wing torsion box (100) to be manufactured is limited, and - Connect the core module (11) and at least one spacer module (12A, 12B, 12C, 12D) to provide a defined web height for the multi-wing torsion box (100) of the modular tool.

14. The method of assembling a tool kit for manufacturing a multi-wing torsion box (100) according to claim 13, the method further comprising the following steps: - Provide at least one additional modular tool (10') for manufacturing the multi-wing torsion box (100) according to any one of claims 1 to 12, -The chord of the multi-wing torsion box (100) to be manufactured is limited. - Connecting at least one additional core module (11') and at least one additional spacer module (12A', 12B', 12C', 12D') to provide a defined web height of the multi-wing torsion box (100) for the additional modular tool (10'), the core module (11) connected to at least one spacer module (12A, 12B, 12C, 12D) and the at least one additional core module (11') connected to the additional spacer module (12A', 12B', 12C', 12D') are arranged to provide an arrangement having the defined chord.

15. An aircraft (1000) comprising a multi-spar anti-torsion box (100) manufactured by the method according to claim 13 or 14.

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