Aircraft Wing Rib Box Structure Design for Weight Reduction
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Solution Overview
Problem
Conventional aircraft wing rib manufacturing methods are inefficient and costly, requiring intricate machining and material wastage, with a single central plate design that limits design flexibility and increases weight, while also complicating assembly and maintenance.
Innovation Solution
A rib design featuring a pair of opposing outer skins with internal reinforcement members forming a box structure, using extrusions and friction stir welding to minimize material usage and weight, allowing for efficient manufacturing and flexible optimization based on loading requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional single central plate rib design is used, then manufacturing simplicity is maintained, but weight increases and design flexibility is limited
Solution Approach 1:
The rib structure is segmented into multiple components: a pair of opposing outer skins and internal reinforcement members, replacing the conventional single central plate design. This segmentation allows for optimized material distribution that reduces overall weight while maintaining structural integrity and manufacturing feasibility through modular assembly.
Solution Approach 2:
The invention employs composite construction combining outer skins and internal reinforcement members as distinct structural elements. This composite approach enables each component to be optimized independently for its specific function, achieving weight reduction while preserving the ease of manufacture through standardized joining processes.
2Manufacturing precision
If conventional CNC machining from billet is used, then precise geometry is achieved, but material wastage increases and cost increases
Solution Approach 1:
The outer skins and internal reinforcement members are designed with pre-defined geometries that can be manufactured using near-net-shape processes. This preliminary preparation of components before final assembly reduces the need for extensive post-machining operations, thereby minimizing material wastage while maintaining the required manufacturing precision for rib geometry.
Solution Approach 2:
By segmenting the rib into separable outer skins and reinforcement members, each component can be manufactured independently using optimized processes with lower material wastage. This segmentation eliminates the need to machine the entire rib structure from a single large billet, significantly reducing material loss while achieving precise geometries for each component.
3Device complexity
If conventional single plate rib structure is used, then assembly is simplified, but structural strength is limited
Solution Approach 1:
The rib structure is divided into outer skins and internal reinforcement members that work together to enhance structural strength. This segmentation allows the reinforcement members to be strategically positioned within the box structure formed by the skins, providing targeted strength enhancement without significantly increasing overall structural complexity.
Solution Approach 2:
The composite construction of outer skins combined with internal reinforcement members creates a structurally stronger rib configuration. The interaction between these composite elements provides enhanced load-bearing capacity and structural integrity while maintaining relatively simple assembly procedures through standardized joining methods.
4Quantity of substance
If conventional rib design is used, then material usage is minimized for single plate, but design flexibility for different loading conditions is reduced
Solution Approach 1:
The segmented design with separate outer skins and internal reinforcement members enables independent optimization of each component based on specific loading conditions. This segmentation provides design flexibility to adjust the number, position, and configuration of reinforcement members within the box structure formed by the skins, allowing adaptation to various loading scenarios while controlling material usage.
Solution Approach 2:
The invention applies local quality by allowing the internal reinforcement members to be strategically positioned and configured within the box structure based on local loading requirements. Different sections of the rib can have different reinforcement patterns, providing design flexibility to optimize material usage for specific loading conditions rather than using a uniform structure throughout.
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 box structure rib design reduces material costs and weight, simplifies manufacturing and assembly, and enhances structural strength and maintenance accessibility, while enabling optimized performance for various flight loads and applications.
Implementation Method 1
The reinforcement members may be secured to the opposing skins using conventional techniques such as rivets or the like. However, advantageously, the reinforcement members may be connected to the skins by means of one of friction stir welding, linear friction welding or rotary friction welding.
Data Source
AI summary
A rib can be manufactured comprising two opposing outer skins and a plurality of internal reinforcement members connecting the skins together.