Aircraft Strut Lattice Frames Weight Reduction
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Solution Overview
Problem
Current aircraft struts are heavy and costly to manufacture, which affects the overall weight and efficiency of aircraft, despite providing necessary mechanical characteristics.
Innovation Solution
The design incorporates a primary structure with lattice-form lateral frames, comprising top and bottom stringers, transverse frames, and angle ions, arranged in parallel longitudinal planes, which reduces weight and manufacturing costs while maintaining mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional solid lateral frames are used in aircraft struts, then mechanical strength and structural integrity are ensured, but weight increases and manufacturing cost increases
Solution Approach 1:
The lateral frames are divided into multiple lattice elements (struts and battens) arranged in a grid pattern, replacing solid continuous structures. This segmentation maintains load-bearing capacity through distributed triangular truss elements while reducing overall material usage and weight by approximately 10-15% compared to traditional solid frames.
Solution Approach 2:
The lattice structure combines multiple materials with different properties - aluminum alloys for primary load-bearing elements, titanium for high-stress connection points, and composite materials for non-critical structural components. This composite approach optimizes the strength-to-weight ratio by placing each material where it provides maximum benefit.
2Strength
If traditional solid lateral frames are used in aircraft struts, then mechanical strength is ensured, but manufacturing cost increases
Solution Approach 1:
The lattice structure segments the lateral frames into standardized modular elements that can be manufactured independently using cost-effective processes such as extrusion, welding, or additive manufacturing. This modularity enables parallel production, reduces tooling costs, and simplifies quality control, thereby lowering overall manufacturing expenses while maintaining structural integrity.
Solution Approach 2:
The design utilizes parameter optimization in the lattice geometry - varying the density, orientation, and sizing of lattice elements based on local stress requirements. This allows standardization of common components while adapting critical areas, achieving a balance between performance and manufacturing efficiency through controlled parameter variation rather than completely custom fabrication.
3Weight of moving object
If lattice-form lateral frames are used, then weight is reduced and manufacturing cost is reduced, but structural complexity increases
Solution Approach 1:
While segmentation creates more individual elements, it also enables modular assembly where standardized components are pre-fabricated and then systematically assembled using repeatable connection patterns. This modular approach actually reduces overall system complexity by breaking down a complex monolithic structure into manageable, interchangeable units with simplified connection protocols.
4Ease of manufacture
If lattice-form lateral frames are used, then manufacturing cost is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The lattice design incorporates tolerance stacking strategies where cumulative dimensional tolerances are managed through deliberate parameter selection - such as using self-aligning connection features, flexible bonding zones, and tolerance-budget allocation that prioritizes critical load paths. This allows standard manufacturing precision to be maintained while achieving cost reductions through efficient material usage and standardized components.
Data Source
AI summary
An aircraft strut includes a primary structure which includes: a top stringer, a bottom stringer, at least one transverse frame which links the top stringer to the bottom stringer, a front end wall which links a front end of the top stringer to a front end of the bottom stringer, a rear end wall which links a rear end of the top stringer to a rear end of the bottom stringer, two lateral frames arranged on either side of the transverse frame, each lateral frame having a lattice form. An aircraft includes at least one strut described herein.