Aircraft Wall Component with Flush Joint Element
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in aircraft fuselage manufacturing lies in achieving a dimensionally accurate external geometry for composite fiber materials without weakening the material, while also simplifying the manufacturing and assembly processes, as existing methods either require elaborate tools or lead to fiber interruptions and aerodynamic issues.
Innovation Solution
A wall component design featuring a double-shell structure with set-back connecting regions and a one-piece joint element that fits into a depression, allowing for a flush outer surface and reducing material stress, along with oblique ramps for precise alignment and a pultrusion-manufactured joint element that supports interior structures without additional mountings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite fiber materials are used for aircraft fuselage, then weight is reduced and specific strength is improved, but manufacturing complexity and cost increase due to elaborate tools and time-consuming processes
Solution Approach 1:
The fuselage is divided into multiple wall elements that can be manufactured separately using simpler tools and then assembled together. This segmentation allows each component to be produced with less complex equipment while maintaining the overall structural integrity and weight benefits of composite fiber materials.
Solution Approach 2:
Wall elements are pre-assembled into wall components with connecting regions prepared in advance. This preliminary assembly allows for quality control and alignment adjustments to be made before final installation, reducing the need for complex adjustment tools during final assembly.
2Strength
If composite fiber materials are used, then strength-to-weight ratio is improved, but manufacturing time increases due to time-consuming processes
Solution Approach 1:
The fuselage manufacturing is divided into parallel processes where multiple wall elements can be manufactured simultaneously. This segmentation of the manufacturing process reduces total production time while maintaining the high specific strength properties of composite fiber materials.
Solution Approach 2:
Connecting regions are prepared and pre-assembled during the manufacturing process, allowing for quality control and alignment adjustments before final assembly. This preliminary preparation reduces rework time and accelerates the overall manufacturing process.
3Ease of manufacture
If conventional joining methods are used for wall elements, then connection is achieved, but aerodynamic surface quality deteriorates due to protrusions and depressions
Solution Approach 1:
The connecting regions are designed with local geometric features (set-backs and complementary shapes) that allow for precise mating of wall elements. This local quality optimization ensures that the joint areas blend smoothly with the overall aerodynamic surface, eliminating protrusions and depressions.
Solution Approach 2:
The connecting regions utilize asymmetric set-backs where one wall element's connecting region is positioned differently relative to its outer surface compared to the other wall element. This asymmetric design allows for precise alignment and creates a flush joint that maintains aerodynamic surface quality.
4Strength
If connecting regions are positioned at edge regions set back from outer surfaces, then material stress is reduced and alignment is improved, but manufacturing precision requirements increase
Solution Approach 1:
The connecting regions incorporate specific geometric features such as set-backs and complementary shapes that provide self-alignment capabilities. These local geometric qualities guide the assembly process and reduce the impact of manufacturing tolerances, making it easier to achieve precise alignment.
Solution Approach 2:
The connecting regions act as intermediary elements between the wall elements' outer surfaces and their structural cores. These intermediate connecting regions with their specific geometric features facilitate precise alignment and stress distribution without requiring extremely high manufacturing precision across the entire component.
Data Source
AI summary
The present disclosure relates to a wall component for an aircraft for forming an outer wall comprising at least one first wall element, at least one second wall element and at least one connecting device for connecting the first wall element to the second wall element. On wall regions that are to be directed towards each other, the first and the second wall element comprise connecting regions. Furthermore, a joint element is provided, which comprises a joint region with a joint region surface that is to be arranged towards the outside of the aircraft, wherein the joint region is designed to be received with a matching fit into a recess formed by the connecting regions of the wall elements, and wherein the joint region surface, when the joint element is inserted, is flush with the outer surfaces of the wall elements.