Integrated Aircraft Hinge Spar for Precise Alignment

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Solution Overview

Problem

Conventional manufacturing methods for aircraft moveable structure hinges are labor-intensive, costly, and result in high rejection rates, with inconsistent alignment leading to maintenance challenges and increased downtime.

Innovation Solution

A spar structure formed as a single continuous component with integrated hinge lines and brackets, using CNC machining or additive manufacturing, allowing precise alignment and reducing the need for separate parts and complex jigs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional manufacturing methods with multiple components and complex jigs are used, then alignment precision can be achieved through careful assembly, but manufacturing complexity and labor intensity increase significantly

Engineering Contradiction:

Improvehinge alignment precisionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple separate components (brackets, hinges, alignment features) into a single integrated spar structure. The continuous body defines both the attachment brackets and the hinge lines as integral features, eliminating the need for separate manufacturing and assembly operations while ensuring precise alignment through the unified geometry of the single component.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If conventional manufacturing methods with multiple components are used, then flexibility in assembly is maintained, but manufacturing time and labor costs increase

Engineering Contradiction:

Improveassembly flexibilityVSAvoidmanufacturing speed

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

While the spar is a continuous body, the patent segments the functional features (attachment brackets, hinge lines, actuation points) as distinct defined elements within the unified structure. This allows the single component to be manufactured efficiently while maintaining clear functional boundaries that simplify assembly and maintenance operations.

Inventive Principle:

Principle #1Segmentation

3Ease of repair

If conventional manufacturing with separate components is used, then component replacement is possible, but maintenance time and complexity increase due to alignment requirements

Engineering Contradiction:

Improvecomponent replaceabilityVSAvoidmaintenance downtime

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The patent incorporates all alignment features, hinge lines, and attachment geometries directly into the continuous spar structure during manufacturing. This preliminary establishment of precise alignment relationships eliminates the need for complex alignment procedures during maintenance, allowing for rapid replacement of attached components without requiring re-alignment operations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20260042529A1Hinge structure

Publication Date: 2026.02.12 FOKKER AEROSTRUCTURES

AI summary

A spar structure for connecting a moveable component to an aircraft includes a continuous body of material defining a plurality of attachment and actuation brackets. The spar structure includes a pair of continuous hinge lines extending through the body. The spar structure is formed by drilling a pair of elongate bores into a block or billet of material to define the pair of continuous hinge lines and by machining the block or billet of material according to a predetermined machining profile to form the spar structure around the pair of continuous hinge lines.