Adjustable Payload Enclosure for Rotor Blade
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Solution Overview
Problem
Existing methods for installing enclosures within rotor blades face challenges such as fatigue-induced stresses, difficulty in sizing bondlines and fasteners due to complex tip designs, and increased weight or restricted inspection with removable tips or co-bonded enclosures, which require adhesive bonds or threaded fasteners.
Innovation Solution
An adjustable payload enclosure comprising multiple elements with angled surfaces that utilize natural centrifugal forces during rotor operation to remain in place without adhesives or fasteners, featuring a unitized design with flanges that engage the rotor blade's peripheral edge, allowing for easy installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If enclosures are held in place using fasteners or adhesive bondlines, then the enclosure is securely attached to the wing interior, but fatigue is induced in the bondlines or fastener threads during flight
Solution Approach 1:
The patent replaces mechanical attachment systems (fasteners and adhesive bondlines) with a form-fitting mechanical interference system. The enclosure features angled outer surfaces that mate with complementary angled inner surfaces of the cavity, creating a wedge-like interference fit that secures the enclosure without fasteners or adhesives, thereby eliminating fatigue in connection elements.
Solution Approach 2:
The enclosure is divided into multiple segments (first enclosure segment, second enclosure segment, third enclosure segment) that can be separately inserted and assembled within the cavity. Each segment has angled outer surfaces that engage with the cavity walls, allowing modular assembly and distribution of mechanical loads without requiring continuous bondlines or fasteners.
2Ease of operation
If enclosures are moved inboard on the rotor blade, then access and installation is improved, but the enclosure is farther from the rotor blade tips reducing balancing effectiveness
Solution Approach 1:
The patent employs a dynamic insertion system where the enclosure segments are assembled inboard within the rotor blade cavity and then retrieved outward toward the tip region. This allows the enclosure to be installed in an accessible inboard location while ultimately positioned near the rotor blade tip for optimal balancing effectiveness, combining ease of installation with operational performance.
3Stability of the object's composition
If enclosures are co-bonded with composite rotor blade, then the enclosure is integrated into the blade structure, but pressure application during cure is restricted affecting laminate quality
Solution Approach 1:
The patent segments the enclosure into multiple separate pieces that are inserted and assembled within the rotor blade cavity after blade manufacturing. This eliminates the need for co-bonding the entire enclosure during blade curing, allowing proper pressure application and laminate quality while still achieving structural integration through the form-fitting interference system of the segmented enclosure components.
4Ease of operation
If removable tips are used to access enclosure, then the enclosure can be easily accessed, but the blade weight increases and cost increases
Solution Approach 1:
The patent creates a universal access system where the same inboard cavity opening used for initial enclosure installation also serves for future maintenance and inspection. The enclosure segments can be disassembled and removed through this existing opening without requiring additional removable tips, achieving easy accessibility while avoiding the weight and cost penalties of removable tip designs.
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
The enclosure is securely held in place by natural forces, eliminating the need for adhesives or fasteners, reducing manufacturing and inspection costs, and enabling simple assembly and repeated access for maintenance or inspection.
Implementation Method 1
The shape of the enclosure allows the natural forces applied by the rotor during operation to trap the enclosure
Data Source
Figure 1
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Figure 3
AI summary
An enclosure (100) for carrying an adjustable payload (150). The enclosure (100) is beneficially used on a rotorcraft blade or other similar structure. The enclosure (100) has a first element (104, 106) having a first flange (124, 126) and an upper element (102). The first element (104, 106) has an upper surface (170) which has a first angle (160) with respect to a lower surface of the first flange (124, 126) in a direction extending from an inboard direction to an outboard direction. The upper element (102) has a lower surface (172) which has a second angle (158) with respect to an upper surface (114) of said upper element (102) in a direction extending from an inboard direction to an outboard direction, the lower surface (172) being in contact with the upper surface (170) of said first element (104, 106), the second angle (158) being in a direction which is opposite to the direction of said first angle (160). The first element (104, 106) and the upper element (102) define a cavity for holding a payload (150).