Aircraft Structural Assembly with Rotating Connectors for CAD Interfaces
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Solution Overview
Problem
Aircraft manufacturing is complex and costly due to the need for precise control of outer and inner mould lines (OML and IML) and aerodynamic considerations, which often requires extensive machining to compensate for manufacturing tolerances, increasing mass, complexity, and tooling costs.
Innovation Solution
A structural assembly for aircraft featuring a frame structure with rotationally movable connecting elements that allow for quick adjustment of skins to achieve CAD nominal interfaces without post-processing machining, using a frame structure that can also serve as a load-bearing and thermodynamic component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining processes are used to control CAD nominal interfaces, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The connecting elements are pre-configured with rotational adjustment capability during assembly, allowing tolerance compensation to be performed before final skin attachment. This preliminary adjustment action eliminates the need for subsequent complex machining operations to achieve CAD nominal interfaces.
Solution Approach 2:
The connecting elements enable continuous parameter adjustment through rotation about the longitudinal axis, allowing the skin position and orientation to be tuned to achieve precise CAD nominal interfaces. This parametric adjustment replaces discrete machining operations.
2Manufacturing precision
If traditional machining processes are used to control CAD nominal interfaces, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The rotational adjustment mechanism is incorporated into the connecting elements during the assembly phase, enabling precision control to be achieved before skin attachment. This eliminates costly post-assembly machining operations and reduces tooling requirements.
Solution Approach 2:
The patent replaces complex mechanical machining systems with a simpler rotational adjustment mechanism. The connecting elements can be rotated about the longitudinal axis to achieve precise positioning, substituting expensive CNC machining with a more economical adjustment process.
3Manufacturing precision
If additional material is used to allow for machining away geometry, then manufacturing precision is improved, but weight increases
Solution Approach 1:
The connecting elements are designed with rotational adjustment capability that allows precise positioning to be achieved during assembly without requiring excess material to be machined away later. The skin and connecting elements can be positioned accurately in their initial configuration.
Solution Approach 2:
The patent extracts the tolerance compensation function from the material geometry itself and relocates it to the adjustable connecting elements. Instead of machining away material to achieve precision, the adjustment mechanism is separated out and used to achieve the desired interface geometry.
Data Source
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AI summary
A structural assembly for an aircraft comprises: a frame structure comprising a plurality of structural members each having a longitudinal axis; at least one skin arranged on the frame structure; and at least one connecting element. The at least one connecting element comprises: a first portion configured to conformably interface with at least a portion of the at least one skin; and a second portion configured to rotationally receive at least a portion of one of said structural members, such that said connecting element is rotationally movable relative to said structural member about the longitudinal axis thereof. A method of manufacturing a structural component for an aircraft comprises providing said structural assembly; arranging the at least one connecting element on said structural member; rotationally adjusting the at least one connecting element relative to said structural member; arranging the at least one skin on the first portion of the at least one connecting element; attaching the at least one connecting element to said structural member; and attaching the at least one skin on the first portion of the at least one connecting element.