Aircraft Engine Case Coupling Alignment Mechanism
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Solution Overview
Problem
Aircraft engine case flanges experience stress and cracking due to thermal gradients, leading to premature engine removal and misalignment, which increases bolt manufacturing costs and the risk of human error during assembly.
Innovation Solution
A system for coupling aircraft engine cases using alignment pins and brackets to ensure proper alignment before thread engagement, allowing for torque application to secure the cases together, thereby reducing stress and misalignment risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolts are manufactured to tight tolerances to prevent case clocking, then case alignment reliability is improved, but bolt manufacturing cost increases
Solution Approach 1:
The alignment pin is inserted into the alignment hole in the first case before the bolt is installed. This preliminary alignment action ensures that the second case is properly positioned relative to the first case, preventing clocking during bolt tightening. The alignment pin performs the alignment function that would otherwise require extremely tight bolt tolerances.
2Manufacturing precision
If multiple bolts of different lengths are used in different locations, then case alignment precision is improved, but assembly complexity and human error risk increase
Solution Approach 1:
A single alignment pin with a universal design is used across all case coupling locations. The alignment pin can be inserted into alignment holes in different cases and performs the same alignment function at each location. This eliminates the need for multiple specialized alignment tools or bolts of different lengths, reducing assembly complexity while maintaining precision.
3Reliability
If alignment pins and brackets are used to ensure proper alignment, then assembly reliability is improved, but assembly procedure complexity increases
Solution Approach 1:
The alignment pin and bracket system is designed to be self-aligning. The pin fits into a predetermined alignment hole, and the bracket geometry automatically positions the cases correctly when the pin is inserted and the bracket is secured. This self-aligning mechanism eliminates the need for complex alignment procedures or multiple adjustment steps, reducing procedural complexity while improving reliability.
Data Source
AI summary
A system and method for coupling cases associated with an engine of an aircraft. A first case includes a first plurality of threads. A second case includes a second plurality of threads. A coupler includes a third plurality of threads and a fourth plurality of threads. An interface is configured to align the first case and the second case before the first plurality of threads engage the third plurality of threads or the second plurality of threads engage the fourth plurality of threads.