Method for assembling an airfoil structure, kit of parts for forming an airfoil structure, and airfoil structure

Abstract

The invention relates to a method for assembling an airfoil structure, a kit of parts for forming an airfoil structure, and an airfoil structure. A torsion box has first and second mounting features. A fixed leading edge or trailing edge structure has third and fourth mounting features. The first and third mounting features each have fastener holes before the leading edge or trailing edge structure is aligned with the torsion box, and the second and fourth mounting features do not have fastener holes for joining the torsion box to the leading edge or trailing edge structure. The method includes aligning the leading edge or trailing edge structure with the torsion box to align the fastener holes of the first and third mounting features, drilling holes through the second and fourth mounting features to form fastener holes in the second and fourth mounting features while the leading edge or trailing edge structure is aligned with the torsion box, and installing fasteners through the fastener holes of the first and third mounting features and installing fasteners through the fastener holes of the second and fourth mounting features to join the leading edge or trailing edge structure to the torsion box.

Description

Technical Field

[0001] The present invention relates to a set of components for forming an airfoil structure, an airfoil structure, and a method for assembling an airfoil structure. Background Technology

[0002] Airfoil structures are found in various aircraft and spacecraft. An airfoil typically includes a torsion box structure, which comprises one or more longitudinal spars, multiple transverse ribs, and is enclosed by structural coverings. A fixed leading edge (FLE) structure and / or a fixed trailing edge (FTE) structure can be attached to the torsion box structure. The assembly of the FLE, FTE, and torsion box forms the airfoil shape.

[0003] When applied to aircraft wings and stabilizers, anti-torsion boxes are often referred to as "wing boxes." Wing box structures commonly used in commercial airliners typically include a front spar, a rear spar, an upper wing cover (skin) extending between the front and rear spars, and a lower wing cover (skin) extending between the front and rear spars. One or more wing box ribs may also be included between the spars and the cover. Each of the front and rear spars can be configured with a C-shaped or Z-shaped cross-section in cross-section, where the upper and lower flanges extend from a vertical web. The upper and lower wing covers can be attached to the flanges of the front and rear spars. The wing's FTE and FLE structures, such as the leading edge having a D-shaped nose in cross-section, can be supported by mating strips attached to the overhanging edges of the upper and lower covers.

[0004] The modularity of components and major parts allows for more assembly of these components upstream of and before the final assembly line (FAL). This means less time is spent assembling these components in the FAL, which in turn allows for a more streamlined, efficient, faster, and smaller footprint.

[0005] However, the FTE and FLE structures currently require a significant amount of time to assemble and subsequently install onto the aircraft wing because very little assembly of the FLE and FTE structures can be completed in advance. Furthermore, since all systems within the system require installation via the FLE and FTE structures, very little work can be done on the FLE and FTE structures at the FAL (e.g., due to limitations imposed by parallel drilling at other locations on the wing).

[0006] The purpose of this invention is to provide a solution to this problem. Summary of the Invention

[0007] A first aspect of the invention provides an assembly for forming an airfoil structure, the assembly comprising: a torsion box having a first mounting feature and a second mounting feature; and a fixed leading or trailing edge structure attachable to the torsion box, the leading or trailing edge structure having a third mounting feature and a fourth mounting feature, wherein the first mounting feature and the third mounting feature each have a fastener hole before the leading or trailing edge structure is aligned with the torsion box, and the fastener holes of the first mounting feature and the third mounting feature are configured to receive fasteners for engaging the torsion box to the fixed leading or trailing edge structure, and wherein the second mounting feature and the fourth mounting feature do not have fastener holes for engaging the torsion box to the fixed leading or trailing edge structure before the leading or trailing edge structure is aligned with the torsion box.

[0008] Preferably, at least one of the first mounting feature and the third mounting feature includes an adjustable fastener hole for adjusting the position and / or orientation of the fastener hole relative to the first mounting feature or the third mounting feature.

[0009] Preferably, the adjustable fastener hole includes an eccentric bushing.

[0010] Preferably, when the front or rear edge structure is aligned with the anti-torsion box, the second and fourth mounting features are provided with aligned fastener holes configured to receive fasteners for engaging the anti-torsion box to the fixed front or rear edge structure.

[0011] Preferably, the fastener holes of the first mounting feature and the third mounting feature have hole axes that extend generally along the span direction of the airfoil structure.

[0012] Preferably, the anti-torsion box includes a spar, and the first mounting feature and the second mounting feature each include a fitting fixedly attached to the web portion of the spar and extending outwardly from the web portion of the spar.

[0013] Preferably, the fixed leading or trailing edge structure includes an outer skin, wherein the outer skin is configured such that when the fixed leading or trailing edge structure is attached to the anti-torsion box, the outer skin and the aerodynamic cover of the anti-torsion box form a substantially smooth upper aerodynamic surface of the airfoil structure.

[0014] Preferably, the first and third mounting features are closer to the lower aerodynamic surface of the airfoil structure than the second and fourth mounting features.

[0015] Preferably, the outer skin has an opening configured to allow access to the first to fourth mounting features through the opening, and also includes a cover panel configured to close the opening, wherein the cover panel and the outer skin form a substantially smooth aerodynamic surface when the cover panel closes the opening.

[0016] Preferably, the fixed leading or trailing edge structure includes one or more systems for actuating a movable device included in or capable of being mounted to the airfoil structure, and / or electrical, hydraulic and / or aerodynamic systems.

[0017] Preferably, one or more systems are installed in a fixed leading or trailing edge structure after the fastener holes have been provided in the second and fourth mounting features, and preferably after the fastener holes have been cleaned.

[0018] Preferably, the fixed leading or trailing edge structure has a modular design.

[0019] Preferably, the anti-torsion box includes another pair or more pairs of first mounting features and second mounting features, and the fixed leading or trailing edge structure further includes another pair or more pairs of third mounting features and fourth mounting features, wherein the pairs of first mounting features and second mounting features are spaced apart along the spanwise direction of the anti-torsion box according to a predetermined arrangement corresponding to the arrangement of the pairs of third mounting features and fourth mounting features on the fixed leading or trailing edge structure.

[0020] Another aspect of the invention provides an airfoil structure formed from a set of components of the first aspect.

[0021] Another aspect of the present invention provides a method for assembling an airfoil structure, the method comprising: providing an anti-torsion box including a first mounting feature and a second mounting feature; providing a fixed leading edge or trailing edge structure having a third mounting feature and a fourth mounting feature, wherein the first mounting feature and the third mounting feature each have fastener holes before aligning the leading edge or trailing edge structure with the anti-torsion box, and wherein the second mounting feature and the fourth mounting feature do not have fastener holes for engaging the anti-torsion box to the fixed leading edge or trailing edge structure before aligning the leading edge or trailing edge structure with the anti-torsion box; aligning the fixed leading edge or trailing edge structure with the anti-torsion box to align the fastener holes of the first mounting feature and the third mounting feature; drilling through the second mounting feature and the fourth mounting feature to form fastener holes in the second mounting feature and the fourth mounting feature when the fixed leading edge or trailing edge structure is aligned with the anti-torsion box; installing fasteners through the fastener holes of the first mounting feature and the third mounting feature, and installing fasteners through the fastener holes of the second mounting feature and the fourth mounting feature to engage the fixed leading edge or trailing edge structure to the anti-torsion box.

[0022] Preferably, the method further includes adjusting the position and / or orientation of the fastener holes in the first mounting feature and / or the third mounting feature.

[0023] Preferably, during the alignment, drilling, and fastener installation steps, the anti-torsion box is supported by a first clamp, and the fixed front or rear edge structure is supported by a second clamp.

[0024] Preferably, the fixed leading or trailing edge structure has a modular design, and the module includes, during the alignment and drilling steps: a portion of the fixed leading or trailing edge structure without an outer skin, or a complete structure of the fixed leading or trailing edge structure with an outer skin, or a complete structure of the fixed leading or trailing edge structure equipped with one or more systems and / or electrical, hydraulic and / or aerodynamic systems for actuating movable devices included in or capable of being mounted to the airfoil structure.

[0025] Preferably, the method further includes performing the method on a plurality of modules spaced apart along the spanwise direction of the anti-torsion box.

[0026] Preferably, the method further includes cleaning the fastener holes in the second and fourth mounting features before engaging the fixed leading or trailing edge structure to the anti-torsion box.

[0027] Preferably, the method includes assembling a kit of components according to the first aspect. Attached Figure Description

[0028] Embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

[0029] Figure 1 A schematic plan view of the aircraft is shown;

[0030] Figure 2 A schematic plan view of the aircraft's wings is shown;

[0031] Figure 3 A partial perspective view of the front wing spars of the wing's anti-torsion box is shown;

[0032] Figure 4 A partial side view of the anti-torsion box is shown;

[0033] Figure 5 A side view of the anti-torsion box with mounting features having adjustable fastener holes is shown;

[0034] Figure 6 A side view of part of the anti-torsion box and the leading edge structure before they are joined together is shown;

[0035] Figure 7 A side view of part of the anti-torsion box and leading edge structure during engagement is shown;

[0036] Figure 8 A side view of part of the anti-torsion box and leading edge structure during engagement is shown;

[0037] Figure 9 A side view showing a portion of the anti-torsion box joined to the leading edge structure is shown;

[0038] Figure 10A , Figure 10B and Figure 10C Various forms of leading edge structures are shown; and

[0039] Figure 11 A side view of a portion of the anti-torsion box used for engagement with the trailing edge structure of an aircraft wing is shown. Detailed Implementation

[0040] Figure 1 The aircraft 10 is shown. The aircraft 10 has a fuselage 11 and fixed wings 12 on the starboard and port sides. Each wing 12 is equipped with an engine 13. The aircraft also includes a tail (or tail assembly) which includes horizontal stabilizers 14 on the starboard and port sides and vertical stabilizers 15.

[0041] exist Figure 1 In the embodiment illustrated, aircraft 10 is a typical jet passenger aircraft, but the present invention is applicable to various types of fixed-wing aircraft, including commercial, military, passenger, cargo, jet, propeller, and general aviation fixed-wing aircraft, which have any number of engines 13 attached to the wing 12 or fuselage 11.

[0042] Figure 2 A schematic diagram of the anti-torsion box assembly 20 of the starboard wing 12 is shown. The port wing is structurally similar, therefore only the starboard wing is described herein.

[0043] The wing 12 has a cantilever structure whose length extends from the wing root 16 to the wingtip 17 in the spanwise direction, wherein the wing root 16 is connected to the aircraft fuselage 11. Figure 1 As shown, wing 12 has a leading edge 18 and a trailing edge 19. The leading edge 18 is located at the leading end of wing 12, and the trailing edge 19 is located at the trailing end of wing 12. Wing 12 includes a torsion box assembly 20, as well as leading edge and trailing edge assemblies (…). Figure 3 (As shown in the image).

[0044] The leading edge assembly and trailing edge assembly may include one or more control surfaces (e.g., slats, flaps, ailerons, etc.) for controlling the movement of the aircraft 10 about its longitudinal axis and / or lateral axis.

[0045] like Figure 2As shown, the wing 12 has a spanwise axis (X) extending from the wing root 16 to the wing tip 17, a chordwise axis (Y) extending from the leading edge 18 to the trailing edge 19, and a thickness axis (Z) extending in a direction perpendicular to the chordwise axis (Y) and the spanwise axis (X). Figure 4 (As shown in the image).

[0046] The anti-torsion box assembly 20 forms a structural assembly and includes: a front spar 21 and a rear spar 22 extending in the spanwise direction between the wing root 16 and the wingtip 17; a rib 23 extending in the chordwise direction between the front spar 21 and the rear spar 22; an upper airfoil cover and a lower airfoil cover 24 located on the upper and lower sides of the anti-torsion box assembly 20; and a stringer 30 to which the upper airfoil cover and the lower airfoil cover 24 are mounted. It should be understood that the upper airfoil cover and the lower airfoil cover 24 define the outermost aerodynamic surface of the anti-torsion box assembly 20.

[0047] Each of the front wing 21 and the rear wing 22 can be formed as a C-shaped or Z-shaped section in which the upper flange 25 and the lower flange 26 extend from the upright web 27, and the upper skin and the lower skin 24 of the anti-torsion box assembly 20 are respectively attached to the flanges 25 and 26 of the front wing 21 and the rear wing 22.

[0048] Figure 3 A partial perspective view of the front wing spars 21 is shown; and Figure 4 The front wing spar 21 is shown as part of the torsional rigid box assembly 20. Figure 4 The diagram shows only the front portion of the anti-torsion box, which is supported by the anti-torsion box clamp 170. The anti-torsion box assembly 20 has a first mounting feature 30 and a third mounting feature 32. The first mounting feature 30 and the third mounting feature 32 are rigidly connected to the anti-torsion box assembly 20 and are used to engage the anti-torsion box assembly 20 to a fixed leading edge (FLE) structure. The first mounting feature 30 and the second mounting feature 32 are positioned such that they are in the same vertical plane.

[0049] Before aligning the FLE structure with the anti-torsion box assembly 20 and engaging the FLE structure to the anti-torsion box assembly 20, the first mounting feature 30 has fastener holes 34. In contrast, before aligning the FLE structure with the anti-torsion box assembly 20 and engaging the FLE structure to the anti-torsion box assembly 20, the third mounting feature 32 does not have fastener holes for engaging the anti-torsion box assembly 20 to the FLE structure.

[0050] Figure 5A detailed view of the first mounting feature 30 is shown, wherein the fastener hole 34 is an optional, adjustable fastener hole for adjusting the position and / or orientation of the fastener hole 34 relative to the first mounting feature 30. This adjustment can be provided by an eccentric bushing 36. Rotating the eccentric bushing 36 adjusts the position of the fastener hole 34 in the Z and Y directions of the wing.

[0051] Figure 6 An FLE structure 100 for joining torsion box assembly 20 is shown.

[0052] The FLE assembly 100 (sometimes referred to as the leading-edge "D-shaped nose" assembly) includes a D-shaped nose cover 102 and a plurality of ribs 110. The D-shaped nose cover 102 defines the aerodynamic surface of the FLE assembly 100, and the plurality of ribs 110 are arranged at fixed intervals along the spanwise direction of the FLE assembly 100. It should be understood that, due to... Figure 6 A cross-sectional (or side view) view of the FLE component 100 is depicted, therefore in Figure 6 In the middle, only one of the aforementioned ribs 110 is visible.

[0053] When the FLE structure 100 is attached to the anti-torsion box assembly 20, the D-shaped head cover 102 is positioned substantially flush with the upper airfoil cover 24 of the anti-torsion box assembly 20, such that the D-shaped head cover 102 and the upper airfoil cover 24 together form a smooth aerodynamic surface along the suction side of the aircraft wing 12.

[0054] For example, the D-shaped head cover 102 may include aluminum or a composite material. For example, the rib 110 may include aluminum or a composite material.

[0055] like Figure 6 As shown, when viewed along the wingspan (X-axis), rib 110 is generally D-shaped and includes a body 122 and a pair of second mounting features 124 and a fourth mounting feature 126, which project rearward toward the front spar 21 of the anti-torsion box assembly 20 away from the body 122 in the chord (Y-axis) direction.

[0056] The second mounting feature 124 and the fourth mounting feature 126 are spaced apart in the thickness (Z-axis) direction such that a cavity 128 for receiving one or more aircraft subsystems 150 is defined between the second mounting feature 124 and the fourth mounting feature 126. The second mounting feature 124 and the fourth mounting feature 126 are positioned such that they are located in the same vertical plane.

[0057] One or more aircraft subsystems 150 may be electrical subsystems (e.g., power control systems, signal control systems, etc.), hydraulic subsystems, hot air bleed subsystems, and / or mechanical subsystems (e.g., drive shafts) for actuating one or more control surfaces of the aircraft 10, such as slats (not shown).

[0058] Before aligning the FLE structure 100 with the anti-torsion box assembly 20 and engaging the FLE structure 100 to the anti-torsion box assembly 20, the second mounting feature 124 has fastener holes 132. In contrast, before aligning the FLE structure 100 with the anti-torsion box assembly 20 and engaging the FLE structure 100 to the anti-torsion box assembly 20, the fourth mounting feature 126 does not have fastener holes for engaging the anti-torsion box assembly 20 to the FLE structure.

[0059] The second mounting feature 124 optionally configures the fastener hole 132 as an adjustable fastener hole for adjusting the position and / or orientation of the fastener hole 132 relative to the second mounting feature 124. This adjustment can be provided by an eccentric bushing. Rotating the eccentric bushing adjusts the position of the fastener hole 34 in the Z and Y directions of the wing. The adjustable fastener hole can be compared with the above-mentioned... Figure 5 The fastener holes described are identical. One or both of the fastener hole 34 of the first mounting feature 30 and the fastener hole 132 of the second mounting feature 124 may have adjustable fastener holes.

[0060] In the illustrated embodiment, the first mounting feature 30 and the second mounting feature 124 are engaged together via a hole-to-hole connection. A hole-to-hole connection refers to a connection in which fastener holes are formed in the components before the two (or more) components, in this case the first mounting feature 30 and the second mounting feature 124, have been placed together. In other words, during final assembly, the first mounting feature 30 and the second mounting feature 124 are first placed together and engaged to join the FLE structure 100 to the anti-torsion box assembly 20.

[0061] This is different from the so-called "part-to-part" connection, in which two (or more) parts are placed together, aligned, and then drilled during final assembly.

[0062] Therefore, the use of fastener hole (or hole-to-hole) connection enables the corresponding first mounting feature 30 and second mounting feature 124 to engage during final assembly without the need to drill holes in any component.

[0063] It should be understood that, in the illustrated embodiment, the use of more time-consuming "component-to-component" connections is reserved for "aerodynamically critical" areas, such as the connection between the second mounting feature 32 and the fourth mounting feature 126 adjacent to the upper aerodynamic surface, where the flushness of the upper wing cover 32 with the upper trailing edge of the FLE structure 100 is very important; while lower-level "aerodynamically critical" areas, such as the connection between the first mounting feature 30 and the third mounting feature 124 adjacent to the lower aerodynamic surface, use faster "hole-to-hole" connections.

[0064] In this way, aircraft assembly time can be improved (and thus production throughput) while maintaining excellent tolerance control in the aerodynamically critical areas of the aircraft 10.

[0065] like Figure 7 As shown, the fastener holes 34, 132 provided in the first mounting feature 30 and the third mounting feature 124 extend generally along the wingspan (X-axis) direction and are adjusted until the fastener holes 34, 132 are aligned when the FLE structure 100 and the anti-torsion box 20 are placed together. This adjustment ensures that, especially when the D-shaped nose cover 102 overlaps with the wing cover 24, the vertical (Z-axis) and longitudinal (Y-axis) alignment of the FLE structure 100 and the anti-torsion box 20 is within the strict tolerances required to avoid exceeding the tolerance grade and tolerance clearance.

[0066] Once the FLE structure 100 is properly aligned with the anti-torsion box 20 and the fastener holes 34 of the first mounting feature 30 and 132 of the third mounting feature 124 are adjusted to be coaxially aligned to receive the fastener 136, the fastener 136 (which may preferably be a temporary fastener) is installed, and the second mounting feature 32 and the fourth mounting feature 126 can be drilled.

[0067] The drilling through the overlapping second mounting feature 32 and fourth mounting feature 126 forms a component-to-component connection, achieving high tolerance requirements without relying on the design or manufacturing capabilities of the FLE structure 100 or the anti-torsion box 20.

[0068] After drilling the holes for the component-to-component connection, the fastener holes 34 of the first mounting feature 30 and the fastener holes 132 of the third mounting feature 124 are cleaned or clean-reamed. For this step, the FLE structure 100 and the anti-torsion box 20 can be moved to a misaligned position, or the step can be performed in situ while the components remain aligned. Figure 8As shown, once the fastener holes 34, 132 are ready for fastening, fastener 138 is installed (if necessary, after the component is put back into alignment). If the component is disassembled to clean the fastener holes 34, 132, fastener 136 will need to be removed to allow the component to be disassembled, and then fastener 136 will be reinstalled after the component has been put back into alignment. In this step, the installed fastener 136 will be the final fastener.

[0069] Now, referring to the D-shaped head cover 102, such as Figure 8 As shown, the upper rear edge of the D-shaped head cover 102 is attached to the leading edge of the upper wing-shaped cover 24 via a skin or butt joint 104. Both the upper rear edge of the D-shaped head cover 102 and the leading edge of the upper wing-shaped cover 24 may have interlocking features to form an overlapping area. This interlocking connection can be secured by a vertical (Z-axis) tension fastener, or, if desired, by a shear fastener at a high load point.

[0070] In the illustrated embodiment, the D-shaped head cover 102 also includes an access panel 106 (in... Figure 8 (Seen separately from the D-shaped head cover 102), the access panel 106 is located in the portion of the D-shaped head cover 102 near the lower wing cover 24, providing access to the interior of the FLE structure 100 for assembly or ground maintenance personnel. Specifically, during the assembly process of joining the FLE structure 100 to the anti-torsion box assembly 20, the access holes exposed when the access panel 106 is removed allow tools for adjustment, drilling, fastening, and cleaning to be introduced into the area surrounding the first to fourth mounting features 30, 32, 124, 126 to perform the aforementioned adjustment, drilling, cleaning, and fastening operations.

[0071] The FLE structure 100, engaged to the anti-torsion box 20 by fasteners 136 and 138, can take various different forms. Some examples of the FLE structure 100 are shown in... Figure 10A , Figure 10B and Figure 10C As shown in the figure. The FLE structure 100 may include one or more systems for actuating movable devices included in or that may be mounted to the aircraft wing 12, and / or electrical, hydraulic and / or aerodynamic systems.

[0072] The FLE structure 100 can have a modular design. Figure 10A In the first example shown, the FLE structure 100 is a partial FLE structure module 100A that includes multiple ribs 110 but does not have a D-shaped head cover 102. The multiple ribs 110 are attached to a common FLE fixture 140.

[0073] exist Figure 10B In the second example shown, FLE structure 100 is a complete FLE structure module 100B, which includes multiple ribs 110 and D-shaped head covers 102 attached to the ribs 110. FLE structure module 100B is attached to a common FLE fixture 140.

[0074] exist Figure 10C In the third example shown, the FLE structure 100 is a fully equipped FLE structure module 100C, which includes multiple ribs 110 and D-shaped head covers 102 attached to the ribs 110, and one or more systems 160. System 160 can be used to actuate movable devices, such as slats, included in or potentially mounted to the aircraft wing 12. For example, system 160 may include a slat track mechanism. System 160 may also be equipped with, for example, electrical, hydraulic, and / or aerodynamic systems passing through module 100C, which may be independent of actuating the movable device. FLE structure module 100C is attached to a common FLE clamp 140.

[0075] Using any of the FLE modules 100A, 100B, or 100C, they all include a plurality of ribs 110, each of which has a pair of third mounting features 124 and a fourth mounting feature 126, the pair of third mounting features 124 and fourth mounting features 126 being identical to the aforementioned third and fourth mounting features. Figure 3 As shown, the anti-torsion box includes multiple pairs of first mounting features 30 and second mounting features 32. According to a predetermined arrangement corresponding to the arrangement of pairs of third mounting features 124 and fourth mounting features 126 on the respective FLE modules 100, the pairs of first mounting features 124 and second mounting features 126 are spaced apart along the spanwise direction of the anti-torsion box.

[0076] The method for assembling airfoil structures such as aircraft wings will now be described.

[0077] The FLE structure 100, which can be any of the FLE structure modules 100A, 100B, and 100C, is supported by the FLE clamp 140. The FLE structure 100 is placed together with the front wing 21 of the anti-torsion box assembly 20 (which is supported by the anti-torsion box clamp 170) so that the fastener hole 34 of the first mounting feature 30 is aligned with the fastener hole 132 of the third mounting feature 124.

[0078] It should be understood that, alternatively, each rib 110 can be aligned individually with the corresponding first mounting feature 30 on the front spar 21 of the anti-torsion box assembly 20, using a rib tool instead of the FLE clamp 140.

[0079] Once one or more ribs 110 of the FLE structure 100 are aligned with the anti-torsion box assembly 20, and any necessary adjustments have been made to the adjustable fastener holes 34 and / or 132, one or more fasteners 136 can be received in the fastener holes 34 / 132 to secure the ribs 110 to the front wing 21 of the anti-torsion box assembly 20.

[0080] A series of fastener holes are drilled through the second mounting feature 32 and the fourth mounting feature 126 at position X to form a fastener hole 40 in the second mounting feature 32 and the fourth mounting feature 126 at each rib location.

[0081] Each fastener hole 40 extends through a corresponding second mounting feature in the second mounting feature 32 provided in the front wing spar 21, and also extends through a corresponding fourth mounting feature 126 aligned with the second mounting feature 32, such that one or more fasteners 138 can be received within the fastener holes 40 for securing the rib 110 to the front wing spar 21 of the anti-torsion box assembly 20.

[0082] Once the corresponding fastener hole 40 has been drilled through the second mounting feature 32 in the front wing spar 21 and also through the corresponding fourth mounting feature 126 of the rib 110, the rib 110 can be disengaged from (or removed from) the front wing spar 21, allowing the corresponding fastener hole 40 to be cleaned in preparation for final assembly. Removing the FLE structure 100 may require removing the fastener 136 (which may be a temporary fastener). The adjustable fastener holes 34 / 132 can also be set to disallow further adjustment at this point. Alternatively, the fastener hole 40 can be cleanly reamed in situ without removing the rib 110 from its alignment with the anti-torsion box assembly 20.

[0083] Alternatively, one or more aircraft subsystems 150 can be installed in the space 128 defined between pairs of fittings 30, 32 disposed on the front wing spars 21. This can be done at any time before the first alignment of the FLE structure 100 with the anti-torsion box 20 and before the final alignment of the FLE structure 100 with the anti-torsion box 20 for final assembly.

[0084] Once the corresponding fastener holes 40 have been cleaned, and optionally once one or more aircraft subsystems have been installed into the space 128 between the corresponding fittings 30, 32 on the front wing spar 21, the rib 110 can be placed back into contact with the front wing spar 21, so that the FLE structure 100 is realigned with the anti-torsion box assembly 20.

[0085] Then, fasteners 136 and 138 are finally installed into one or more fastener holes 34 / 132 and 40 to attach the FLE structure 100 to the front wing spars 21 of the anti-torsion box assembly 20, and thereby secure the FLE structure 100 to the aircraft wing 12.

[0086] By using a combination of part-to-part connections and hole-to-hole connections between the anti-torsion box assembly 20 and the FLE structure 100, this method helps to reduce airfoil assembly time and thus further improves production throughput.

[0087] Although the present invention is described in the above embodiments as relating to joining the FLE structure 100 to the anti-torsion box assembly 20, it is understood that, as Figure 11 As shown, the invention is also applicable to joining the fixed trailing edge (FTE) structure 200 to the anti-torsion box assembly 20.

[0088] Although the invention has been described above in conjunction with the aircraft wing 12, it should be understood that aspects of the invention can also be used to construct other types of airfoil structures, whether for aircraft or for a wider range of non-aerospace applications.

[0089] When the word "or" appears, it will be interpreted as meaning "and / or," meaning that the items mentioned are not necessarily mutually exclusive and can be used in any appropriate combination.

[0090] Although the invention has been described above with reference to one or more preferred embodiments, it should be understood that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims.

Claims

1. A method for assembling an airfoil structure, the method comprising: Provides an anti-torsion box including a first mounting feature and a second mounting feature; A fixed leading or trailing edge structure is provided having a third mounting feature and a fourth mounting feature, wherein the first mounting feature and the third mounting feature each have fastener holes before the leading or trailing edge structure is aligned with the anti-torsion box, and wherein the second mounting feature and the fourth mounting feature do not have fastener holes for engaging the anti-torsion box to the fixed leading or trailing edge structure before the leading or trailing edge structure is aligned with the anti-torsion box; Align the fixed leading or trailing edge structure with the anti-torsion box to align the fastener holes of the first mounting feature and the third mounting feature; When the fixed leading or trailing edge structure is aligned with the anti-torsion box, holes are drilled through the second mounting feature and the fourth mounting feature to form fastener holes in the second mounting feature and the fourth mounting feature; Fasteners are installed through the fastener holes of the first and third mounting features, and fasteners are installed through the fastener holes of the second and fourth mounting features, to engage the fixed leading or trailing edge structure to the anti-torsion box.

2. The method according to claim 1, further comprising adjusting the position and / or orientation of the fastener holes in the first mounting feature and / or the third mounting feature.

3. The method according to claim 1, wherein, During the alignment, drilling, and fastener installation steps, the anti-torsion box is supported by a first clamp, and the fixed leading or trailing edge structure is supported by a second clamp.

4. The method according to claim 3, wherein, The fixed leading or trailing edge structure has a modular design, and the module includes, during the alignment and drilling steps: i) The fixed portion of the leading or trailing edge structure that does not have an outer skin, or ii) A fixed, complete structure with an outer skin, or iii) A complete structure for fixing the leading or trailing edge structure, the complete structure having one or more systems for actuating a movable device included in or capable of being mounted to the airfoil structure, and / or electrical, hydraulic and / or aerodynamic systems.

5. The method of claim 4, further comprising performing the method on a plurality of modules spaced apart along the spanwise direction of the anti-torsion box.

6. The method according to any one of claims 1 to 5, further comprising cleaning the fastener holes in the second mounting feature and the fourth mounting feature before engaging the fixed leading or trailing edge structure to the anti-torsion box.

7. A set of components for forming an airfoil structure, the set of components comprising: An anti-torsion box, the anti-torsion box having a first mounting feature and a second mounting feature, and A fixed leading or trailing edge structure, said leading or trailing edge structure being attachable to the anti-torsion box, said leading or trailing edge structure having a third mounting feature and a fourth mounting feature. Specifically, before aligning the leading or trailing edge structure with the anti-torsion box, the first mounting feature and the third mounting feature each have fastener holes, and the fastener holes of the first mounting feature and the third mounting feature are configured to receive fasteners for engaging the anti-torsion box to the fixed leading or trailing edge structure. Wherein, before aligning the leading or trailing edge structure with the anti-torsion box, the second mounting feature and the fourth mounting feature do not have fastener holes for engaging the anti-torsion box to the fixed leading or trailing edge structure.

8. The complete set of components according to claim 7, wherein, At least one of the first mounting feature and the third mounting feature includes an adjustable fastener hole for adjusting the position and / or orientation of the fastener hole relative to the first mounting feature or the third mounting feature.

9. The complete set of components according to claim 8, wherein, The adjustable fastener hole includes an eccentric bushing.

10. The assembly according to any one of claims 7 to 9, wherein, When the leading or trailing edge structure is aligned with the anti-torsion box, aligned fastener holes are provided for the second mounting feature and the fourth mounting feature, the aligned fastener holes being configured to receive fasteners for engaging the anti-torsion box to the fixed leading or trailing edge structure.

11. The assembly according to any one of claims 7 to 9, wherein, The fastener holes of the first mounting feature and the third mounting feature have hole axes that extend generally along the span direction of the airfoil structure.

12. The assembly according to any one of claims 7 to 9, wherein, The anti-torsion box includes a wing beam, and the first mounting feature and the second mounting feature each include a fitting fixedly attached to and extending outward from the web portion of the wing beam.

13. The assembly according to any one of claims 7 to 9, wherein, The fixed leading or trailing edge structure includes an outer skin, wherein the outer skin is configured such that when the fixed leading or trailing edge structure is attached to the anti-torsion box, the outer skin and the aerodynamic cover of the anti-torsion box form a substantially smooth upper aerodynamic surface of the airfoil structure, and Preferably, the first mounting feature and the third mounting feature are closer to the lower aerodynamic surface of the airfoil structure than the second mounting feature and the fourth mounting feature.

14. The complete set of components according to claim 7, wherein, The outer skin has an opening configured to allow access to the first to the fourth mounting features through the opening, and further includes a cover panel configured to close the opening, wherein the cover panel and the outer skin form a substantially smooth aerodynamic surface when the cover panel closes the opening.

15. The assembly according to any one of claims 7 to 9, wherein, The fixed leading or trailing edge structure includes one or more systems and / or electrical, hydraulic and / or aerodynamic systems for actuating a movable device included in or capable of being mounted to the airfoil structure.

16. The complete set of components according to claim 10, wherein, The fixed leading or trailing edge structure includes one or more systems and / or electrical, hydraulic and / or aerodynamic systems for actuating a movable device included in or capable of being mounted to the airfoil structure, and wherein the one or more systems are mounted in the fixed leading or trailing edge structure after fastener holes have been provided for the second mounting feature and the fourth mounting feature, and preferably after the fastener holes have been cleaned.

17. The assembly according to any one of claims 7 to 9, wherein, The fixed leading or trailing edge structure has a modular design.

18. The assembly according to any one of claims 7 to 9, wherein, The anti-torsion box includes another pair or more pairs of first mounting features and second mounting features, and the fixed leading or trailing edge structure also includes another pair or more pairs of third mounting features and fourth mounting features, wherein the pairs of first mounting features and second mounting features are spaced apart along the anti-torsion box in the spanwise direction according to a predetermined arrangement corresponding to the arrangement of the pairs of third mounting features and fourth mounting features on the fixed leading or trailing edge structure.

19. An airfoil structure formed from a set of components according to any one of claims 7 to 18.

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