Material Removal Device for Aircraft Radar Absorbing Material

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Solution Overview

Problem

Current methods for removing radar absorbing material (RAM) from aircraft surfaces are time-consuming and labor-intensive, often damaging other layers or resulting in inconsistent surfaces, especially when trying to access panels or repair composite materials.

Innovation Solution

A material removal system comprising a guide rail with a datum edge and planing and tapering devices, each equipped with a grinding wheel, allows for controlled removal of material from aircraft surfaces without damaging underlying layers, using a holder with vertically offset bottom surfaces to guide the grinding wheels and ensure precise material removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If hand sanding or rotary cutter is used to remove RAM, then material removal is achieved, but the process is time-consuming and labor-intensive

Engineering Contradiction:

Improvematerial removal rateVSAvoidrepair time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces manual sanding and rotary cutting with a controlled abrasive jet system that uses high-velocity abrasive particles to remove material. This substitution dramatically increases material removal rate while maintaining precision and reducing labor intensity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the physical state and delivery method of abrasive material from manual sanding particles to a controlled high-velocity jet stream. By adjusting parameters such as jet pressure, abrasive flow rate, and standoff distance, the system achieves optimized material removal rates that are significantly faster than traditional methods.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If sanding or cutting is performed to remove RAM, then material is removed, but controlling the depth is difficult and the processed surface is inconsistent

Engineering Contradiction:

Improvesurface consistencyVSAvoiddepth control difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The system incorporates real-time monitoring of material removal depth and surface characteristics, using sensors to detect when the desired depth is reached or when underlying layers are approached. This feedback controls the jet application, preventing over-removal and ensuring consistent surfaces across the treated area.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent introduces a controlled medium (abrasive jet) that acts as an intermediary between the operator and the substrate. This intermediary provides uniform, controllable material removal without the variability inherent in manual sanding or cutting, achieving consistent surface preparation while protecting underlying layers.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If aggressive material removal is used to access panels, then repair access is achieved, but underlying layers are damaged

Engineering Contradiction:

Improveaccess speedVSAvoiddamage to underlying layers

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system applies abrasive jet treatment in a controlled, partial manner, removing only the necessary amount of RAM to access underlying panels. By carefully controlling the jet parameters and monitoring the removal process, the system achieves sufficient access speed while stopping precisely before damaging protected layers, avoiding the excessive action that causes damage.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The controlled abrasive jet serves as a selective intermediary that can differentiate between removable RAM and protected underlying layers. Through precise control of jet intensity, duration, and positioning, the system achieves rapid access to panels while the intermediary nature of the controlled jet prevents direct harmful contact with protected substrates.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system enables efficient and precise removal of RAM and other materials from aircraft surfaces, minimizing damage to underlying layers and allowing for consistent tapering, thereby reducing repair time and ensuring accurate reapplication of materials.

Implementation Method 1

a grinding wheel supported by the holder and being operable to remove the material from the substrate

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS11148246B2Method and device for removing material from a substrate

Publication Date: 2021.10.19 THE BOEING CO

AI summary

A material removal device for removing material from a substrate includes a holder extending between first and second sides and a grinding wheel supported by the holder and being operable to remove the material from the substrate. The holder has a guide frame at the first side and a support frame at the second side. The guide frame has a first bottom surface and the support frame has a second bottom surface. The first and second bottom surfaces are vertically offset from each other. The grinding wheel has an axle supported by the guide frame and the support frame. The grinding wheel has a grinding surface located below the first bottom surface and above the second bottom surface.