Braced Aircraft Wheel Bar Structure for Lighter Brake Disk Drive
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Solution Overview
Problem
Existing aircraft wheels with integrated braking bars contribute significantly to the overall weight, which is a critical issue for reducing emissions and meeting environmental standards, while maintaining mechanical strength.
Innovation Solution
A braked aircraft wheel bar design featuring a rectilinear body with wings connected by a core and brace elements, optimized for weight reduction without compromising mechanical strength, fabricated using additive manufacturing with Inconel® alloy powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional solid bars with constant H-shaped cross-section are used, then mechanical strength is sufficient to withstand braking stresses, but weight is excessive and contributes to higher emissions
Solution Approach 1:
The bar is divided into multiple segments along its length, with each segment having a different cross-sectional area. The cross-section varies from a larger H-shape at the ends (where strength is needed for mounting and stress resistance) to a reduced cross-section in the intermediate portion (where weight reduction is prioritized). This segmentation allows optimization of material distribution to achieve both weight reduction and sufficient mechanical strength.
Solution Approach 2:
Different portions of the bar are given different cross-sectional properties tailored to their specific functional requirements. The end portions maintain larger cross-sections for mounting and stress resistance, while the intermediate portion has a reduced cross-section for weight reduction. This local differentiation of quality optimizes the overall design by applying material only where structurally necessary.
2Temperature
If titanium wedges are added to position bars and limit heat transfer, then positioning accuracy and heat isolation improve, but assembly complexity and number of components increase
Solution Approach 1:
The positioning and heat isolation functions previously performed by separate titanium wedges are merged into the bar structure itself. The bar is designed with built-in features that provide both precise positioning on the rotor disk and thermal isolation from the rim, eliminating the need for separate wedge components while maintaining or improving the thermal and positional performance.
Solution Approach 2:
The bar is designed to perform multiple functions simultaneously: it provides structural strength for withstanding braking stresses, precise positioning on the rotor disk, and thermal isolation from the rim. By integrating these functions into a single component, the design reduces the total number of parts while improving overall system efficiency.
3Reliability
If seven to eleven bars are used per wheel depending on wheel size, then braking performance is sufficient, but total weight of the wheel-brake assembly becomes significant
Solution Approach 1:
The bar is divided into multiple segments along its length, with each segment having a different cross-sectional area. The cross-section varies from a larger H-shape at the ends (where strength is needed for mounting and stress resistance) to a reduced cross-section in the intermediate portion (where weight reduction is prioritized). This segmentation allows optimization of material distribution to achieve both weight reduction and sufficient mechanical strength.
Solution Approach 2:
Different portions of the bar are given different cross-sectional properties tailored to their specific functional requirements. The end portions maintain larger cross-sections for mounting and stress resistance, while the intermediate portion has a reduced cross-section for weight reduction. This local differentiation of quality optimizes the overall design by applying material only where structurally necessary.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new design achieves a weight savings of 15-20% with improved mechanical strength and reduced heat transfer to the rim, enhancing the efficiency and environmental performance of aircraft wheels.
Implementation Method 1
additive fabrication operation makes use of laser beam melting on a bed of powder
Implementation Method 2
Controlled pressure applied to the stack of disks gives rise to friction between the facing disks, and thus to a braking torque that slows down the rotation of the wheel
Data Source
AI summary
The invention relates to a bar (10) for a braked aircraft wheel (103), the bar being for fitting to a rim (104) of the wheel in order to drive rotor brake disks (106b) in rotation. The bar comprises a substantially rectilinear body (11) having at least one segment (14) including two wings (15) connected together by a core (16) and intended to co-operate with the rotor disks. At least one brace element (17) connects a free edge of each of the wings to a central portion of the core.