Aircraft Light Kinematic Coupling for Optical Alignment
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Solution Overview
Problem
Existing aircraft lights with LEDs and optical elements arranged on support boards often suffer from mechanical instability and inaccuracies in light output, which can lead to unsatisfactory performance in terms of mechanical stability and light accuracy.
Innovation Solution
The use of a kinematic coupling fixture to achieve a highly accurate relative placement of the optical element with respect to the light source, ensuring a robust mechanical setup and precise light output. This fixture constrains six degrees of freedom of the optical element, allowing for a well-defined singular position and reliable mechanical fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mounting methods (e.g., pins, adhesives) are used to attach optical elements to support boards, then the assembly process is simple, but the positioning accuracy and mechanical stability are insufficient
Solution Approach 1:
The mounting structure is segmented into multiple independent features: locating pins for positioning, countersunk holes for mechanical attachment, and recesses for optical alignment. This segmentation allows each feature to independently contribute to positioning accuracy without complicating the overall assembly process
Solution Approach 2:
The optical element itself serves as the mounting structure through its integrated features: the recess in the optical element receives the locating pin, while the protrusion engages with the countersunk hole. This self-service approach eliminates separate mounting components while achieving both simple assembly and high positioning accuracy
2Manufacturing precision
If optical elements are mounted with loose tolerances to simplify assembly, then the manufacturing cost decreases, but the light output accuracy deteriorates
Solution Approach 1:
The optical element features local quality variations: a recessed area for precise locating pin engagement and a protruding area for countersunk hole attachment. These localized features concentrate manufacturing precision where needed while maintaining ease of assembly through the overall simple structure
Solution Approach 2:
The positioning and mounting functions are merged into a single integrated feature set on the optical element. The recess and protrusion simultaneously provide both precise positioning and mechanical attachment, eliminating the need for separate tolerance-compensation mechanisms
3Stability of the object's composition
If multiple separate components are used to mount optical elements, then the mechanical stability improves, but the assembly time and complexity increase
Solution Approach 1:
Multiple mounting functions (locating, securing, aligning) are merged into a single integrated feature set on the optical element. The recess and protrusion work together as one unified mounting mechanism, providing mechanical stability while enabling rapid single-step assembly
Solution Approach 2:
The optical element is pre-formed with integrated mounting features (recess and protrusion) during its manufacturing process. This preliminary action ensures mechanical stability is built-in from the start, eliminating the need for additional assembly steps that would reduce productivity
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E~1F
AI summary
An aircraft light (2) includes a support board (4); a light source (6), arranged on the support board (4); an optical element (8; 8'; 12; 14), arranged over the light source (6); and a kinematic coupling fixture (20), establishing a fixed position of the optical element (8; 8'; 12; 14) with respect to the support board (4).