Aircraft Primary Support Strut Box Structure
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Solution Overview
Problem
The manufacturing of primary support struts for aircraft power plants is complex and can be enhanced for optimization of aircraft architecture, with existing structures requiring numerous ribs that occupy space and increase production costs.
Innovation Solution
A primary support strut structure comprising two half-shells assembled to form a box structure, reducing the number of ribs and allowing space for other functions, with the option of cellular side walls and a tongue for reinforcement, enabling adaptable mechanical characteristics and simplified production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional box structure with numerous ribs is used, then structural strength and rigidity are improved, but manufacturing complexity and production cost increase
Solution Approach 1:
The box structure is segmented into two independent half-shells that can be manufactured separately using automated molding processes. This segmentation allows each half-shell to be produced with consistent structural integrity while enabling automated manufacturing, thereby reducing production complexity and cost while maintaining the required structural strength when the half-shells are assembled together.
Solution Approach 2:
The invention changes the manufacturing parameter from traditional rib-by-rib assembly to molded half-shell fabrication. By changing how the structure is produced rather than how it is designed, the patent achieves both high strength and low manufacturing complexity through process innovation.
2Stability of the object's composition
If numerous ribs are installed in the primary structure, then structural rigidity is improved, but available space for other functions is reduced
Solution Approach 1:
The molded half-shell structure integrates rigidity-enhancing features directly into the shell walls during fabrication, eliminating the need for numerous internal ribs. This segmentation approach allows the structural reinforcement to be built into the half-shells themselves, preserving internal space for conduits and other components.
Solution Approach 2:
Instead of adding ribs in the internal volume, the patent enhances rigidity by thickening and reinforcing the half-shell walls themselves (moving the reinforcement to the boundary dimension). This dimensional shift maintains internal space while achieving the required structural rigidity.
3Reliability
If traditional assembly methods with multiple ribs are used, then structural integrity is maintained, but production cycle time increases
Solution Approach 1:
The box structure is divided into two half-shells that can be manufactured independently using automated molding processes. This segmentation enables parallel production of both half-shells simultaneously, significantly reducing production cycle time while maintaining structural integrity through consistent molded fabrication.
Solution Approach 2:
The half-shells are pre-formed using automated molding processes that ensure structural integrity is built into each component during fabrication. This preliminary action of pre-forming the half-shells with integrated reinforcement eliminates the need for time-consuming post-assembly rib installation, thereby reducing production cycle time while maintaining reliability.
Data Source
AI summary
A primary support strut structure and a method of manufacturing thereof for an aircraft power plant is disclosed having a first half-shell including a first free edge, and a second half-shell having a second free edge. The first half-shell and the second half-shell are assembled together by joining the first free edge and the second free edge so as to form a box-shaped structure. The two half-shell construction results in very rigid box structure, and a reduced number of ribs in the primary structure.