Aircraft Control Surface Integrated Composite Box Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current manufacturing methods for aircraft control surfaces involve multiple components and complex assembly processes, leading to increased costs, complexity, and longer lead times, while also being prone to corrosion and fatigue.
Innovation Solution
A manufacturing method that integrates the upper skin, lower skin, and ribs into a single composite preform using a one-shot curing process, forming a unified body with reduced parts and components, and further integrating the spar and fittings as one-piece elements, allowing for mechanical joining and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components are used for upper skin, lower skin, and ribs, then ease of manufacture is improved, but device complexity increases and assembly time increases
Solution Approach 1:
The patent merges the upper skin, lower skin, and ribs into a single integrated box structure made from one composite preform. This consolidation eliminates the need for separate manufacturing and assembly of these components, directly reducing device complexity while maintaining ease of manufacture through the unified molding process.
Solution Approach 2:
The integrated box structure serves multiple functions simultaneously: it provides the upper skin, lower skin, and ribs as a single unit, and can also incorporate fittings and other elements. This multi-functionality reduces the number of separate parts needed, addressing both ease of manufacture and device complexity.
2Ease of repair
If multiple separate components are assembled, then ease of repair is improved, but assembly time increases and productivity decreases
Solution Approach 1:
By combining upper skin, lower skin, and ribs into a single integrated box, the patent reduces assembly time and increases productivity. The unified structure eliminates multiple assembly steps while maintaining ease of repair through modular replacement of the entire box assembly if needed.
3Adaptability or versatility
If traditional manufacturing methods are used, then adaptability is improved, but loss of time increases due to complex assembly processes
Solution Approach 1:
The patent applies preliminary action by pre-shaping the composite layers into a complete box structure before final curing. This pre-forming allows the integrated structure to be ready for installation without requiring time-consuming assembly operations, thus reducing loss of time while maintaining adaptability through the modular nature of the preformed units.
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 approach results in a control surface that is corrosion and fatigue-free, low-cost, low-weight, and high-strength, with reduced assembly times and improved serviceability, enabling cost savings and streamlined production.
Implementation Method 1
applying heat and pressure to the plurality of elements following the assembling, thereby at least generally simultaneously to join the elements together and to cure at least some of the layers of composite materials
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Manufacturing method of a control surface of an aircraft, the control surface comprising: - an upper skin (1), - a lower skin (2), - ribs (3) joining the upper skin (1) and the lower skin (2) and located along a chordwise direction of the control surface. The manufacturing method comprises the steps of: - providing a single composite preform comprising the upper skin (1), the lower skin (2) and the ribs (3), and - curing said single composite preform such that an integrated box (10) comprising the upper skin (1), the lower skin (2) and the ribs (3) is formed.