System and method for repairing aircraft structures
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Solution Overview
Problem
Conventional repair methods for aircraft structures introduce aerodynamic penalties, such as increased drag and reduced lift, due to the application of external patches, which compromise operational efficiency and regulatory compliance, especially in structures without internal access.
Innovation Solution
A system comprising a divided internal frame with U-shaped portions and straps, secured by blind fasteners, is installed within the aircraft structure to repair damage without disrupting aerodynamics, using a skin insert for additional support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If external patches are applied to repair aircraft structures, then structural integrity is restored, but aerodynamic performance deteriorates due to increased drag and reduced lift
Solution Approach 1:
The frame is divided into two separate portions that can be independently positioned and attached to the internal structure. This segmentation allows the repair components to be installed from the interior without external patches, restoring structural integrity while maintaining aerodynamic smoothness.
Solution Approach 2:
The repair solution transitions from a two-dimensional external patch applied to the skin surface to a three-dimensional internal frame structure. By moving the repair mechanism into the third dimension (internal space), the solution eliminates aerodynamic penalties while providing structural reinforcement.
2Object-affected harmful factors
If internal frame installation is attempted in structures without internal access, then aerodynamic integrity is maintained, but installation complexity increases due to lack of access
Solution Approach 1:
The frame is segmented into two portions that can be separately maneuvered through the skin cutout and positioned on the internal side. This segmentation reduces installation complexity by allowing each portion to be handled independently through limited access openings.
Solution Approach 2:
The skin cutout serves as an intermediary access point that enables installation of internal components without requiring full internal access. The cutout allows the frame portions and straps to be introduced and positioned from the exterior while remaining hidden internally.
3Strength
If a continuous frame is installed internally, then structural reinforcement is maximized, but installation difficulty increases due to inability to maneuver single piece
Solution Approach 1:
The continuous frame is divided into two portions that can be separately installed through the skin cutout. After both portions are positioned on the internal side, they are connected using straps to form a continuous reinforced structure, combining installation ease with structural strength.
Solution Approach 2:
The frame structure transitions from a static continuous piece to a dynamic assembly of two portions connected by straps. This allows the frame to be maneuvered into position in segments and then assembled internally, making installation feasible while maintaining structural integrity.
Data Source
AI summary
A system for repairing aircraft structures comprises a frame that is divided into two portions, and one or more straps that attach both portions of the frame to each other. A method of repairing includes the step of making a cutout in the skin of the structure to be repaired; dividing the frame into two portions; placing the two portions of the frame on the internal side of the skin through the cutout; and attaching the two portions of the frame to each other by one or more straps.