Aircraft Assembly with Shear Keys and Clearance Rods
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Solution Overview
Problem
The existing method of assembling aircraft components with coaxial through holes is time-consuming and requires repeated machining, leading to increased weight and potential compatibility issues with nearby equipment.
Innovation Solution
The assembly comprises first and second components with inner faces and through holes, and a connection element with a rod that ensures traction/compression force transmission. Additionally, first and second plates with bumps are interposed between the components to transmit shear forces independently of the rod, allowing the through holes to be produced independently before assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the through holes are made coaxial and of the same diameter before assembly, then the connection element can be properly installed, but the assembly process becomes time-consuming and requires repeated machining
Solution Approach 1:
The patent divides the force transmission function into two independent systems: the rod transmits only traction/compression forces through clearance holes, while separate shear keys transmit shear forces. This segmentation allows the through holes to be drilled independently without requiring coaxiality, thereby reducing assembly time and eliminating repeated machining operations.
Solution Approach 2:
The patent introduces shear keys as intermediary elements that transmit shear forces between the two components. These shear keys work in conjunction with the rod to achieve complete force transmission, while allowing the through holes to be non-coaxial. The shear keys act as mediators that enable independent hole positioning.
2Manufacturing precision
If the through holes are remachined upon each reassembly to ensure coaxiality, then the connection element can be reinstalled, but the hole diameter increases and requires a larger rod, increasing weight
Solution Approach 1:
By segmenting the force transmission into independent traction/compression (rod) and shear (shear keys) components, the patent eliminates the need for repeated machining of through holes during reassembly. The clearance holes can be reused without remachining, maintaining their original diameter and allowing the same rod to be reused, thus avoiding weight increase.
Solution Approach 2:
The shear keys are pre-installed in the components before assembly, establishing the shear force transmission path in advance. This preliminary action allows the through holes to be positioned independently without requiring subsequent remachining for coaxiality, enabling direct reassembly with the same connection elements.
3Ease of operation
If the rod diameter is increased to accommodate enlarged through holes, then the connection element can be reinstalled, but the weight on board increases
Solution Approach 1:
The patent segments the force transmission functions so that the rod handles only traction/compression forces while shear keys handle shear forces. This allows the rod to maintain its original diameter in clearance holes that do not require remachining, enabling reassembly with the same rod and avoiding weight increase.
Solution Approach 2:
The patent changes the functional parameters of the connection system by separating force transmission modes. The rod operates with clearance (not tight fit) and transmits only axial forces, while shear keys provide shear force transmission. This parameter change allows reuse of the same rod diameter without enlargement, maintaining weight efficiency during reassembly.
Data Source
AI summary
An assembly comprising at least first and second components, at least one connection element comprising a rod configured to ensure uptake of the traction/compression forces between the first and second components, and at least one pair of first and second contact surfaces provided respectively with first and second bumps and rigidly secured respectively to the first and second components, the first and second bumps having complementary shapes configured to nest in one another and ensure transmission of the shear forces between the first and second components. Also, an aircraft comprising at least one such assembly.