Aircraft Cover Panel Space Frame Weight Reduction
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Solution Overview
Problem
There is a need for structural aircraft components that can be easily retrofitted, offer greater design flexibility, and reduce material weight while maintaining mechanical stability and aesthetic appeal.
Innovation Solution
A cover panel with a space frame structure optimized using a two-staged evolutionary algorithm, combining adaptive dynamics and growth algorithms to minimize material usage, integrated with additive manufacturing for lightweight and adaptable designs, and featuring a fabric panel for protection and customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional honeycomb core sandwich structures are used, then structural strength and stability are maintained, but weight is excessive and material usage is inefficient
Solution Approach 1:
The patent applies topology optimization to fundamentally change the structural parameters from conventional honeycomb sandwich construction to a space frame configuration. This parameter transformation enables achieving equivalent or superior structural strength with significantly reduced weight by optimizing the spatial arrangement and cross-sections of structural members based on actual stress distributions.
Solution Approach 2:
The patent employs composite material construction in the space frame members, combining different materials with complementary properties to achieve optimal strength-to-weight ratio. The composite approach allows tailoring material properties to specific structural requirements, reducing overall weight while maintaining structural integrity.
2Loss of substance
If conventional solid beam structures are used, then structural stability is ensured, but material usage is excessive and weight is increased
Solution Approach 1:
The patent extracts and removes unnecessary material from conventional solid beam structures through topology optimization. By analyzing stress distributions and removing material from low-stress regions while maintaining structural members only where needed, the design achieves minimal material usage while preserving essential structural stability and load-bearing capacity.
Solution Approach 2:
The patent segments the continuous solid beam structure into discrete space frame members arranged in a truss configuration. This segmentation allows each member to be optimized independently for its specific function, reducing overall material usage while maintaining structural stability through the collective action of the segmented members.
3Adaptability or versatility
If standardized structural components are used, then manufacturing is simplified, but design flexibility and customization options are limited
Solution Approach 1:
The patent applies local quality optimization where each space frame member is designed with specific properties tailored to its local structural requirements. The cross-sections, materials, and geometries are locally optimized based on the stress conditions and functional requirements of each specific location, enabling high design flexibility while maintaining manufacturability through standardized connection details.
Data Source
AI summary
A cover panel for a core panel of a structural aircraft component includes a protection cover having an outer shape corresponding to the outer shape of the core panel and including at least one cutout aperture, and at least one fabric panel mounted to the protection cover and covering the at least one cutout aperture.