Aircraft Structure Cover Alignment via Adjustable Spacer
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Solution Overview
Problem
Conventional aircraft wing assembly methods, such as the butt-strap arrangement, are complex, time-consuming, and require drilling holes in composite materials, which weakens them, and struggle to achieve a smooth aerodynamic surface within strict tolerance ranges.
Innovation Solution
The use of a spar with a primary and secondary cover, a bracket, and an adjustable spacer that allows the secondary cover to overlap the primary cover, eliminating the need for butt-strap fasteners and enabling alignment without drilling, thereby simplifying assembly and ensuring a continuous aerodynamic surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If butt-strap fasteners are used to attach covers to spars, then the covers can be securely fastened, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent removes the butt-strap fastening system entirely and replaces it with a direct attachment method where the cover is secured to the spar through simplified fastening points, eliminating the complex multi-component butt-strap assembly while maintaining secure connection
Solution Approach 2:
The cover attachment system is divided into discrete, simplified fastening points distributed along the spar, replacing the continuous butt-strap system with separate, easier-to-install connection elements that reduce assembly complexity
2Reliability
If holes are drilled in composite materials for fastening, then the covers can be securely attached, but the structural integrity of the composite materials is weakened
Solution Approach 1:
The patent eliminates the need to drill holes in composite materials by using a fastening system that attaches to the external surface of the cover without penetrating it, thereby preserving the structural integrity of the composite material while maintaining secure attachment
Solution Approach 2:
The patent introduces an intermediary fastening mechanism that connects the cover to the spar through external attachment points rather than direct drilling, acting as a mediator that secures the cover without compromising the composite material's integrity
3Manufacturing precision
If packers are added between surfaces to achieve alignment, then the aerodynamic surface continuity can be improved, but the assembly process becomes more complex
Solution Approach 1:
The patent incorporates alignment features directly into the mold or manufacturing process of the cover and spar components, pre-establishing the correct geometric relationship between surfaces before assembly, thereby eliminating the need for post-assembly packers and simplifying the assembly process
4Manufacturing precision
If hand fettling is performed during assembly to match surfaces, then the aerodynamic surface continuity can be achieved, but the assembly time increases
Solution Approach 1:
The patent incorporates surface continuity features directly into the manufacturing process, pre-forming the aerodynamic surfaces with precise geometry before assembly, thereby eliminating the need for time-consuming hand fettling operations during assembly while maintaining surface continuity
Solution Approach 2:
The patent designs the cover and spar components with self-aligning geometric features that automatically ensure proper positioning and surface continuity during assembly, eliminating the need for manual fettling operations and reducing assembly time
Data Source
AI summary
An aircraft structure comprising: a spar; a primary cover attached to the spar and extending on a first side of the spar; and a secondary cover positioned on a second side of the spar and partially overlapping an internal surface of the primary cover. A bracket is attached to the spar, and a spacer is provided between the secondary cover and the bracket. The spacer is sized so that the primary and secondary covers together form a substantially continuous external aerodynamic surface. The structure provides an alternative to conventional butt-strap arrangements.