Adjustable Actuator Mold for Composite Fuselage Stringers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing aircraft fuselage shells with large opening angles face challenges such as stringer undercuts, complex geometry, and inefficient production processes, particularly in handling and positioning of auxiliary materials and stringers during the laminating and gluing process.
Innovation Solution
A device featuring longitudinally adjustable actuators and a flexible mold surface with interconnected mold grooves or channels, allowing for precise positioning and adjustment of stringers, and enabling the separation of setup from the laminating and gluing process, thus simplifying the production of strongly curved fuselage shells with large opening angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a grid of support walls and modular profiles is used to form the fuselage shell with stringers, then the structural strength and stiffness are improved, but the device complexity and manufacturing complexity increase due to the need for precise positioning and assembly of multiple components
Solution Approach 1:
The fuselage shell is divided into modular sections with individual support walls and stringer profiles that can be independently positioned and assembled. Each modular profile can be separately adjusted and secured, allowing for simplified assembly while maintaining overall structural integrity.
2Ease of operation
If the opening angle of the fuselage shell is increased to improve accessibility and assembly ease, then the ease of operation is improved, but stringer undercuts and positioning difficulties occur during the laminating and gluing process
Solution Approach 1:
The support walls and modular profiles are designed with adjustable and movable characteristics, allowing the structure to adapt its geometry during the laminating process. This dynamic adjustment capability enables precise stringer positioning even when the fuselage shell has large opening angles, preventing undercuts and ensuring manufacturing precision.
3Manufacturing precision
If auxiliary materials and stringers are positioned during the laminating and gluing process, then the manufacturing precision is improved, but the production time increases due to the complex handling and positioning operations
Solution Approach 1:
Stringers and auxiliary materials are pre-positioned on the modular profiles and support walls before the laminating and gluing process begins. This preliminary positioning ensures precise placement is achieved without requiring complex adjustments during production, thereby maintaining manufacturing precision while reducing overall production time.
4Manufacturing precision
If a rigid mold surface is used to maintain shape accuracy, then the manufacturing precision is improved, but the adaptability to different fuselage configurations and large opening angles is reduced
Solution Approach 1:
The mold surface is designed with adjustable and flexible characteristics, allowing it to adapt to different fuselage configurations and large opening angles while maintaining shape accuracy. The modular nature of the support structure enables reconfiguration for various production requirements without sacrificing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for efficient, reproducible series production of fuselage shells with large opening angles by eliminating undercuts and enabling precise positioning of stringers, reducing production time, and simplifying the manufacturing process, while ensuring accurate alignment and minimizing over-pressing risks.
Implementation Method 1
a vacuum-tight seal is created between the vacuum skin and the LKV. The superstructure is then evacuated on the LKV side
Implementation Method 2
several longitudinally adjustable actuators extending radially outwards being attached to the assembly surface
Implementation Method 3
fiber material and resin are introduced and cured there in various processes
Data Source
Figure 1~2
Figure 3~4c
Figure 4d~4h
AI summary
The invention relates to a device and method for producing a fuselage shell (16) formed from of composite fibre material for an aircraft, said fuselage shell being provided for reinforcement with several stringers (14) which are arranged at a distance from one other. The device according to the invention comprises a base frame (1) having several supporting walls (2) of different length for forming a convex mounting surface (3) for the fuselage shell (16) to be produced, wherein several longitudinally adjustable actuators (4) which extend radially outwards are fixed on the mounting surface (3) and moulding channels (6) for receiving the stringers (14) are fixed to the distal ends thereof. Said moulding channels are connected to one another via flexible intermediate elements (7) and/or further channels (6) thereby forming a vacuum-proof closed moulding surface (8).