Adjustable Annular Washer Assembly for Precise Aircraft Alignment
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Solution Overview
Problem
Existing washer devices for aircraft assembly are complex to manufacture, difficult to align, and lack sufficient mechanical strength, while compensating for tolerance stacks requires time-consuming selection and installation of washers of varying thicknesses.
Innovation Solution
A washer device with two annular components featuring surface regions of different levels and radial projections/notches that allow for precise adjustment of effective thickness, ensuring stability and alignment through angular positioning, optionally using magnetic materials for assembly assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adjustable thickness washers are used to compensate for tolerance stacks, then assembly precision is improved, but device complexity increases due to locking mechanisms
Solution Approach 1:
The washer device allows dynamic adjustment of thickness by rotating one annular component relative to the other, enabling the effective thickness to change continuously between minimum and maximum values. This dynamic mechanism eliminates the need for multiple fixed-thickness washers and complex locking systems, as the adjustable nature provides inherent stability through its geometric design.
Solution Approach 2:
The washer is divided into two separate annular components with engaging faces, allowing independent rotation and adjustment. This segmentation enables the thickness adjustment function while simplifying the overall structure, as each component can be manufactured with standard tolerances rather than requiring a single complex integrated part.
2Manufacturing precision
If steps of different heights are used to create adjustable washers, then assembly precision is improved, but ease of manufacture deteriorates due to manufacturing accuracy requirements
Solution Approach 1:
Instead of manufacturing complex static steps of different heights, the invention uses two simple annular components where rotation dynamically creates the variable thickness effect. The engaging faces require only basic cylindrical geometry, which is much easier to manufacture with standard tolerances compared to precision multi-level steps.
Solution Approach 2:
The effective thickness parameter is changed by rotating one component relative to the other, rather than manufacturing different thickness variants. This parameter change through motion simplifies manufacturing, as the components are made with uniform geometry that is easier to produce accurately.
3Manufacturing precision
If adjustable washer components are used, then assembly precision is improved, but ease of operation deteriorates due to alignment difficulty
Solution Approach 1:
The engaging faces are designed with asymmetric features (such as keys, splines, or cam profiles) that guide the rotation and automatically align the components. This asymmetric design ensures that the components can only be assembled in the correct orientation, eliminating alignment difficulties while maintaining the ability to rotate for thickness adjustment.
Solution Approach 2:
The engaging faces are designed to self-align during assembly through their geometric constraints. As the components are brought together, the asymmetric features automatically guide them into the correct rotational position without requiring external alignment tools or operator skill, making the device easy to operate.
4Device complexity
If small bearing surfaces are used in washer design, then device complexity is reduced, but strength deteriorates for aircraft applications
Solution Approach 1:
One annular component is nested within or alongside the other, with both components contributing to the load-bearing capacity. The engaging faces are designed with sufficient surface area to distribute loads across both components, providing the mechanical strength required for aircraft applications while maintaining a compact and simple overall structure.
Solution Approach 2:
The washer device uses two separate annular components made from strong materials suitable for aircraft applications. The combination of these components, with their engaging faces designed for load distribution, creates a composite structure that achieves the required mechanical strength without increasing complexity.
Data Source
AI summary
A washer device is disclosed including two annular components each having a main face arranged to contact the main face of the other component. Each main face has surface regions of different levels along an axis of the component, such as a step and/or a helical ramp. Relative rotation of one component with respect to the other about their common axis alters the effective thickness of the washer device. The washer device 1 further includes at least one radial projection on one of the annular components arranged to engage with a corresponding notch on the other annular component such that the annular components may be oriented in predetermined angular positions corresponding to different predetermined effective thicknesses of the washer device.