Ground based aircraft wing and nacelle mockup design for training
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2023-03-24
- Publication Date
- 2026-03-16
AI Technical Summary
Existing aircraft training mockups often employ scrap aircraft sections that require significant modifications and are too heavy for practical training, lacking a mobile support structure for a cantilevered configuration and using real aircraft wings is impractical due to weight and complexity.
A ground-based wing mock-up station with a primary and secondary support structure, using lighter materials like aluminum and polyurethane foam, and a payload pylon mockup to simulate aircraft wings, allowing easy repositioning and supporting weight loads similar to actual aircraft components.
Provides a practical and cost-effective training environment that mimics real aircraft components, reducing structural complexity and weight while enabling maintenance personnel to practice with realistic weight loads.
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Abstract
Description
Technical Field
[0001] The present disclosure relates generally to aircraft, and more particularly to a physical ground-based wing mockup for training ground personnel.
Background Art
[0002] Aircraft maintenance personnel are often trained using physical mockup stations of an aircraft or a selected section of an aircraft. Such mockups allow maintenance personnel to become familiar with the components of the aircraft on which they will be working after training. The mockup also provides experience working within the space constraints associated with the aircraft or section of the aircraft in question and around obstacles. For example, it includes wings and engine nacelles. Often, training mockups employ sections of scrapped aircraft that require significant modification to be used as training simulators.
[0003] Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the above problems and other possible problems.
Summary of the Invention
[0004] An exemplary embodiment provides a ground-based wing mockup station. The mockup station includes a primary support structure detachably coupled to the floor, and a wing mockup coupled to the primary support structure. A secondary support structure configured to suspend the wing mockup above the floor from the primary support structure. A mockup of a payload pylon is coupled to the wing mockup. In that case, the mockup of the payload pylon is configured to hold an apparatus. The primary support structure, the secondary support structure, the wing mockup, and the mockup of the payload pylon are configured to support at least an equal weight as the apparatus.
[0005] Another exemplary embodiment provides a mock-up training station for an aircraft wing. The training station comprises a support structure having steel beams configured to be detachably connected to the floor. The mock-up of the aircraft wing is coupled to the support structure and suspended above the floor. The mock-up of the aircraft wing comprises an aluminum central wing section, an aluminum trailing edge subassembly, and a laminated ABS plastic leading edge subassembly. A polyurethane foam nacelle pylon mock-up is coupled to the aircraft wing mock-up, and a polyurethane foam nacelle mock-up is coupled to the nacelle pylon mock-up. An aluminum payload pylon mock-up is coupled to the aircraft wing mock-up and configured to hold the device. In this case, the support structure, the aircraft wing mock-up, and the payload pylon mock-up are configured to hold a weight load of at least equal to the device.
[0006] Another exemplary embodiment provides a mock-up station for the wing of an aircraft on the ground. The mock-up station comprises a support structure configured to be detachably coupled to the floor. A mock-up of the wing of an aircraft being produced is coupled to the support structure and suspended above the floor. The wing mock-up comprises parts made of lighter material than the corresponding parts of the wing of the aircraft being produced. The parts including the wing mock-up are a subset of the corresponding parts of the wing of the aircraft being produced. A mock-up of a nacelle pylon is coupled to the wing mock-up, and a mock-up of a nacelle is attached to the nacelle pylon mock-up. In this case, the engine nacelle mock-up is made of lighter material than the actual nacelle. A mock-up of a payload pylon is coupled to the wing mock-up. The payload pylon mock-up is configured to hold specific equipment. In this case, the support structure, the wing mock-up, and the payload pylon mock-up are configured to hold a weight load at least equal to that of the specific equipment.
[0007] These characteristics and functions may be realized independently in various embodiments of this disclosure, or they may be combined in yet another embodiment, which can be understood in further detail in relation to the following description and drawings.
[0008] Novel features that may be considered characteristics of exemplary embodiments are specified in the accompanying claims. However, exemplary embodiments, preferred modes of use, further purposes, and their characteristics will be best understood by reading the following detailed description of exemplary embodiments of this disclosure with reference to the accompanying drawings. [Brief explanation of the drawing]
[0009] [Figure 1] A block diagram is drawn showing a mock-up station for a main wing according to one exemplary embodiment. [Figure 2] A perspective view is drawn showing a ground-based mock-up station for a wing according to an exemplary embodiment. [Figure 3] A reverse perspective view of the primary and secondary support structures of a wing mock-up station according to an exemplary embodiment is shown. [Figure 4] A diagram is drawn showing the central wing section according to one exemplary embodiment. [Figure 5] A diagram is drawn showing a leading edge subassembly according to an exemplary embodiment. [Figure 6] A diagram is drawn showing a trailing edge subassembly of a main wing according to an exemplary embodiment. [Figure 7] A mockup of a nacelle pylon and an exploded view of a mockup of a nacelle according to an exemplary embodiment are shown. [Figure 8] A diagram is drawn showing a flap track assembly according to an exemplary embodiment. [Modes for carrying out the invention]
[0010] The exemplary embodiments recognize and consider one or more different considerations. The exemplary embodiments recognize and consider that aircraft training mockups often employ sections of scrapped aircraft, such as wings or engine nacelles. The designs of existing aircraft wings are complex and expensive for use in training and require significant structural modifications to be installed on a training floor.
[0011] The exemplary embodiments also recognize and consider the complexity of the support structure design when using actual aircraft wings for training. Therefore, actual / scrap aircraft wings are heavy and cannot be used as is for training.
[0012] The exemplary embodiments also recognize and consider that the heavier structures of actual aircraft required for flight loads are impractical and unnecessary for use in ground training environments.
[0013] Multiple exemplary embodiments also recognize and consider that there are currently no readily available mobile support structures for mounting aircraft wings in a cantilever configuration.
[0014] Multiple exemplary embodiments provide a mock-up aircraft wing training station that replicates the wings and payload pylons of an actual aircraft. The mock-up is configured to be fixed to the floor of the facility with removable anchor bolts. Thus, the mock-up can be easily repositioned. The mock-up employs additively manufactured (3D printed) plastic or polyurethane foam to maintain the appearance of an actual aircraft wing while reducing structural complexity and weight.
[0015] Figure 1 shows a block diagram illustrating a wing mock-up station according to an exemplary embodiment. The wing mock-up station 100 includes a primary support structure 102 and a secondary support structure 110 that suspend the wing mock-up 118 above the floor 144 of the facility.
[0016] The primary support structure 102 comprises a pair of upright steel beams 104 and a horizontal steel beam 106. Removable anchor bolts 108 connect the upright steel beams 104 to the floor 144 of the facility.
[0017] The secondary support structure 110 comprises several steel tension ropes 112 that suspend the wing mockup 118 from the primary support structure 102 and connect the primary support structure 102 to the floor 144 of the facility. The steel tension ropes 112 may be equipped with turnbuckles 114 at their proximal ends and are secured at their distal ends to the wing mockup 118 and the floor 144 of the facility by D-shackles 116.
[0018] The wing mockup 118 comprises a central wing section 120, a trailing edge subassembly 124, and a leading edge subassembly 126. The central wing section 120 may comprise several modules 122. Similarly, the leading edge subassembly 126 may comprise several pieces made of additively manufactured (3D printed) plastic. The wing mockup 118 also comprises several flap track assemblies 130. Clevis mounts 132 connect the horizontal steel beam 106 to the wing mockup 118.
[0019] The wing mock-up station 100 also includes a nacelle pylon mock-up 136 connected to the wing mock-up 118. The nacelle pylon mock-up 136 may comprise several laminated plastic and / or polyurethane foam pieces 138. A nacelle mock-up 140 may be made of polyurethane foam, attached to the nacelle pylon mock-up 136, and supported by steel ground supports 142.
[0020] The mock-up 134 of the payload pylon is also connected to the mock-up 118 of the main wing. The mock-up 134 of the payload pylon may be configured to support certain types of equipment, such as a sensor package, an external fuel tank, a propulsion system, and other things that may be attached to the main wing of an aircraft simulated by the mock-up 118 of the main wing. The mock-up 134 of the payload pylon can be used by ground maintenance personnel to practice attaching and detaching equipment to the main wing.
[0021] Figure 2 depicts a perspective view showing a ground-based mock-up station for a main wing according to an exemplary embodiment. Figure 3 depicts a perspective view from the back of the primary and secondary support structures of the main wing mock-up station. The main wing mock-up station 200 is an exemplary embodiment of the main wing mock-up station 100 of Figure 1.
[0022] The main wing mock-up station 200 includes a primary support structure removably coupled to the floor 232 of the facility and a main wing mock-up 214 coupled to the primary support structure. The primary support structure includes two upright steel beams 202 and a horizontal steel beam 204 connecting the upright steel beams. The upright steel beams 202 are fixed to the floor 232 of the facility by removable anchor bolts passing through the base plates 206 of the upright steel beams 202. A third upright steel beam 238 may also support the center of the horizontal beam 204 (most clearly shown in Figure 3). The upright steel beams 202, 238 and the horizontal steel beam 204 may be further supported by a truss 240.
[0023] The secondary support structure suspends the main wing mock-up 214 above the floor 232 of the facility from the primary support structure. The secondary support structure includes several steel tension ropes 208 that connect the upright steel beams 202 to the main wing mock-up 214 and connect the upright steel beams 202 and the horizontal steel beam 204 to the floor 232 of the facility.
[0024] The wing mockup 214 simulates the wing of a production aircraft, but includes parts made of lighter materials than the corresponding parts of the production aircraft's wing. The parts including the wing mockup 214 may be a subset of the corresponding parts of the production aircraft's wing, thereby making the wing mockup 214 simpler and lighter than the corresponding actual production wing simulated by the mockup. The wing mockup 214 may include a central wing section 226 made of aluminum, a trailing edge subassembly 218 made of aluminum, and a leading edge subassembly 220 made of acrylonitrile butadiene styrene (ABS) plastic. Several double shear clevis fittings 216 may connect the proximal end of the wing mockup 214 to a horizontal steel beam 204. The wing mockup 214 further includes several flap track assemblies 222, which may be made of aluminum. The wing mock-up 214 may also include an outer skin air vehicle presentation (AVR) 224.
[0025] A mock-up 236 of a payload pylon, configured to hold the equipment, is coupled to a mock-up 214 of a wing. The mock-up 236 of the payload pylon may be made of machined aluminum and may be configured to hold certain pieces of equipment, such as sensor packages and external fuel tanks, allowing ground personnel to practice loading and unloading the payload pylon mock-up 236. The primary support structure, secondary support structure, mock-up 214 of the wing, and mock-up 236 of the payload pylon are configured to support a weight at least equal to the equipment. Thus, ground personnel training at the mock-up station 200 can practice working with a weight load approximately equal to the load that may need to be attached to or removed from the corresponding payload pylon on the wing of an actual aircraft.
[0026] The wing mock-up station further comprises a nacelle pylon mock-up 228 coupled to the wing mock-up 214, and a nacelle mock-up 230 coupled to the nacelle pylon mock-up 228. The nacelle mock-up 230 may be made from polyurethane (PU) foam. The nacelle pylon mock-up 228 may comprise a combination of polyurethane foam components and 3D printed plastic components (e.g., ABS) (see Figure 7). A steel ground support structure 234 may be positioned beneath the nacelle mock-up 230.
[0027] The flap track assembly 222 and the nacelle mockup 230 may be positioned according to aircraft coordinates to simulate a training environment of an actual aircraft and to provide necessary obstacles that ground personnel may encounter while working on an actual production aircraft.
[0028] Figure 4 illustrates a central wing section according to an exemplary embodiment. Figure 4 provides a more detailed view of the central wing section 226 of Figure 2.
[0029] As shown in this embodiment, the central wing section 226 may comprise several modules 402, 404, and 406 that are combined together to form the central wing section. Depending on the wing of a particular production aircraft being simulated by the mock-up station, more or fewer modules may be used.
[0030] Also, more clearly shown in Figure 4 is a double shear clevis attachment 216 that connects the main wing mockup 214 to the horizontal steel beam 204 of the primary support structure. The clevis attachment 216 may hold the double shear steel lugs from the spar on the horizontal steel beam 204.
[0031] Figure 5 illustrates a leading edge subassembly according to an exemplary embodiment. Figure 5 provides a more detailed view of the leading edge subassembly 220 shown in Figure 2.
[0032] In this embodiment, the leading edge subassembly 220 comprises several pieces 502 that are additively manufactured using ABS plastic. The pieces 502 may be stacked on top of each other, allowing them to slide on each other during structural deflection caused by loading and unloading the wing mockup 214.
[0033] Figure 6 illustrates a trailing edge subassembly of the main wing according to an exemplary embodiment. Figure 6 shows a more detailed view of the trailing edge subassembly 218 in Figure 2.
[0034] Figure 7 shows exploded views of a mock-up of a nacelle pylon and a mock-up of a nacelle according to an exemplary embodiment. Figure 7 shows more detailed views of the mock-up of the nacelle pylon 228 and the mock-up of the nacelle 230 from Figure 2.
[0035] In this embodiment, the nacelle pylon mockup 228 comprises a pylon hood 702 made from polyurethane foam and a pylon rear section 704 made from 3D printed ABS plastic.
[0036] The nacelle mock-up 230 comprises the main engine body 706 and the aft engine section 708, both of which are made of polyurethane foam. Metal tubes 710 provide stability for the main engine body 706 on a steel ground support structure 234.
[0037] Figure 8 illustrates a flap track assembly according to an exemplary embodiment. Figure 8 shows a more detailed view of the flap track assembly 222 of Figure 2.
[0038] In this embodiment, the flap track assembly comprises five pieces 802, 804, 806, 808, and 810. More or fewer pieces may be used depending on the main wing of the aircraft being produced and simulated by the mock-up station.
[0039] In this specification, "connected to" a first component means that the first component can be connected to the second component directly or indirectly. That is, additional components may be interposed between the first and second components. If one or more additional components exist between these two components, the first component is considered to be indirectly connected to the second component. If the first component is directly connected to the second component, there are no additional components between these two components.
[0040] As used herein, the phrase “several” means one or more. When used with an enumerated list of items, the expression “at least one of” means that one or more combinations of the enumerated items may be used, and that only one of each enumerated item may be required. In other words, “at least one of” means that any combination of items, and several items, may be used from the enumerated list, but not all of the enumerated items are necessarily required. An item may be a specific object, article, or category.
[0041] For example, though not limited, “at least one of item A, item B, and item C” may include “item A,” “item A and item B,” or “item C.” This example may also include “item A, item B, and item C,” or “item B and item C.” Any combination of these items may, of course, also exist. In an exemplary embodiment, “at least one of ~” may, though not limited, be “two item A, one item B, and ten item C,” “four item B and seven item C,” or any other suitable combination.
[0042] The various block diagrams of the embodiments shown illustrate the structure, function, and operation of several possible embodiments of the apparatus and method in an exemplary embodiment. In this regard, each block in the block diagram may represent at least one of a module, segment, or function.
[0043] Furthermore, this disclosure includes embodiments as defined below.
[0044] Article 1. A ground-based mock-up station (100) for the main wing, A primary support structure (102) detachably connected to the floor (144), A mock-up of the main wing (118) connected to the primary support structure, A secondary support structure (110) configured to suspend the main wing mockup from the primary support structure onto the floor, and A mockup (134) of a payload pylon coupled to the mockup of the main wing, comprising a mockup of a payload pylon configured to hold a device, A wing mockup station comprising the primary support structure, the secondary support structure, the wing mockup, and the payload pylon mockup, configured to support a weight at least equal to that of the device.
[0045] Article 2. A mockup of a nacelle pylon (136) attached to the mockup of the main wing, and The wing mock-up station described in Clause 1 further comprises a mock-up of a nacelle (140) coupled to the mock-up of the nacelle pylon.
[0046] Article 3. The mock-ups of the nacelle pylons and the nacelles are made of polyurethane foam, as described in Clause 2, for the wing mock-up station.
[0047] Article 4. The mockup of the nacelle pylon is a wing mockup station as described in Clause 2, comprising several layered pieces (138).
[0048] Article 5. The wing mock-up station according to Clause 2 further comprises a steel ground support structure (142) positioned below the nacelle mock-up.
[0049] Article 6. The aforementioned primary support structure is Two upright steel beams (104), and A mock-up station for the main wing as described in Clause 1, comprising horizontal steel beams (106) connecting the aforementioned upright steel beams.
[0050] Article 7. The wing mock-up station as described in Clause 6, wherein the upright steel beam is fixed to the floor by removable anchor bolts (108).
[0051] Article 8. The wing mock-up station according to Clause 6, wherein the secondary support structure comprises several steel tension ropes (112) that connect the upright steel beams to the wing mock-up and the upright steel beams and the horizontal steel beams to the floor.
[0052] Article 9. The aforementioned wing mockup is The central wing section (120) is made of aluminum. A trailing edge subassembly (124) made of aluminum, Leading edge subassembly (128) made of ABS plastic, and A wing mock-up station according to Clause 6, comprising several double shear clevis attachments (132) for connecting the proximal end of the wing mock-up to the horizontal steel beam.
[0053] Article 10. The leading-edge subassembly comprises several additively fabricated pieces (128) of the wing mock-up station as described in Clause 9.
[0054] Article 11. The wing mockup station described in Clause 9 further comprises several flap track assemblies (130) made of aluminum.
[0055] Article 12. The mockup of the payload pylon is made of machined aluminum, as described in Clause 1, for the wing mockup station.
[0056] Article 13. A mock-up training station (100) for the main wing of an aircraft, A support structure (102) comprising a steel beam configured to be detachably connected to the floor (144), A mock-up of an aircraft wing (118) coupled to the support structure and suspended above the floor, comprising an aluminum central wing section (120), an aluminum trailing edge subassembly (124), and an ABS plastic leading edge subassembly (126), A mockup of a polyurethane foam nacelle pylon attached to a mockup of the main wing of the aforementioned aircraft (136), A mockup (140) of a polyurethane foam nacelle attached to the mockup of the nacelle pylon, and The aircraft comprises a mockup (134) of an aluminum payload pylon, which is coupled to a mockup of the aircraft's wing and configured to hold a device. An aircraft wing mock-up training station, wherein the support structure, the mock-up of the aircraft wing, and the mock-up of the payload pylon are configured to hold a weight load at least equal to that of the device.
[0057] Article 14. The aforementioned support structure is Two upright steel beams (104) fixed to the floor by removable anchor bolts (108), and A mock-up training station for the main wing of an aircraft as described in Clause 13, comprising horizontal steel beams (106) connecting the aforementioned upright steel beams.
[0058] Article 15. A training station for a mock-up of an aircraft wing according to Clause 14, further comprising several steel tension ropes (112) for connecting the upright steel beams to the mock-up of the wing, and for connecting the upright steel beams and the horizontal steel beams to the floor.
[0059] Article 16. The mock-up of the main wing of the aforementioned aircraft is Several flap track assemblies (130) made of aluminum, and A mock-up training station for an aircraft wing according to Clause 14, further comprising several double-shear clevis attachments (132) for connecting the proximal end of the mock-up of the wing to the horizontal steel beam.
[0060] Article 17. The leading edge subassembly comprises several additively manufactured pieces (128) of the mock-up training station for the main wing of an aircraft as described in Clause 13.
[0061] Article 18. The mock-up of the nacelle pylon is a mock-up training station for the main wing of an aircraft as described in Clause 13, comprising several layered pieces (138).
[0062] Article 19. A mock-up training station for the wing of an aircraft as described in Clause 13, further comprising a steel ground support structure (142) positioned below the mock-up of the nacelle.
[0063] Article 20. A mock-up station (100) for the main wing of an aircraft on the ground, A support structure (102) configured to be detachably connected to the floor (144), A mockup (118) of a wing of an aircraft in production, coupled to the support structure and suspended above the floor, wherein the wing mockup comprises parts made of a lighter material than the corresponding parts of the wing of the aircraft in production, and the parts including the wing mockup are a subset of the corresponding parts of the wing of the aircraft in production, A mockup of a nacelle pylon (136) attached to the aforementioned mockup of the main wing, A mockup of a nacelle (140) attached to the mockup of the nacelle pylon, the mockup of a nacelle made of a lighter material than the actual nacelle, and A mockup (134) of a payload pylon coupled to the mockup of the main wing, comprising a mockup of a payload pylon configured to hold specific equipment, A ground-based mock-up station for the wings of an aircraft, wherein the support structure, the wing mock-up, and the payload pylon mock-up are configured to hold a weight load at least equal to that of the specific equipment.
[0064] The descriptions of various exemplary embodiments are presented for illustrative and explanatory purposes only and are not intended to be exhaustive or limit to the embodiments disclosed. Many modifications and variations will be obvious to those skilled in the art. Furthermore, various exemplary embodiments may offer different features compared to other exemplary embodiments. One or more selected embodiments have been chosen and described to best illustrate the principles and practical applications of the embodiments and to enable those skilled in the art to understand that the disclosure of various embodiments, including various modifications, is suitable for specific intended uses.
Claims
1. A ground-based mock-up station (100) for the main wing, A primary support structure (102) that is detachably connected to the floor (144), A mock-up of the main wing (118) connected to the primary support structure, A secondary support structure (110) is configured to suspend the main wing mockup from the primary support structure onto the floor, and A mockup (134) of a payload pylon coupled to the mockup of the main wing, comprising a mockup of a payload pylon configured to hold a device, A wing mockup station comprising the primary support structure, the secondary support structure, the wing mockup, and the payload pylon mockup, configured to support a weight at least equal to that of the device.
2. A mockup of a nacelle pylon (136) attached to the mockup of the main wing, and The wing mock-up station according to claim 1, further comprising a mock-up of a nacelle (140) coupled to the mock-up of the nacelle pylon.
3. The wing mockup station according to claim 2, wherein the mockups of the nacelle pylon and the nacelle are made of polyurethane foam.
4. The wing mock-up station according to claim 2 or 3, wherein the mock-up of the nacelle pylon comprises several laminated pieces (138).
5. The wing mock-up station according to claim 2, further comprising a steel ground support structure (142) positioned below the nacelle mock-up.
6. The aforementioned primary support structure is Two upright steel beams (104), and The main wing mock-up station according to claim 1, further comprising a horizontal steel beam (106) connecting the aforementioned upright steel beams.
7. The wing mock-up station according to claim 6, wherein the upright steel beam is fixed to the floor by removable anchor bolts (108).
8. The wing mock-up station according to claim 6, wherein the secondary support structure comprises several steel tension ropes (112) that connect the upright steel beams to the wing mock-up and the upright steel beams and the horizontal steel beams to the floor.
9. The aforementioned wing mockup is The central wing section (120) is made of aluminum. A trailing edge subassembly (124) made of aluminum. Leading edge subassembly (128) made of ABS plastic, and The wing mock-up station according to claim 6, further comprising several double shear clevis mounting fixtures (132) for connecting the proximal end of the wing mock-up to the horizontal steel beam.
10. The wing mock-up station according to claim 9, wherein the leading edge subassembly comprises several additively manufactured pieces (128).
11. The wing mockup station according to claim 9, further comprising several flap track assemblies (130) made of aluminum.