Airframe Panel Joining via Simultaneous Edge Machining
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Solution Overview
Problem
Current methods for joining airframe and fuselage structures in aircraft and spacecraft are inefficient and lack automation, leading to potential corrosion, fatigue, and increased production time, while requiring specialized tools for repair.
Innovation Solution
A method involving machining of panel edges to form congruent joining surfaces, followed by alignment and fusion using techniques like laser beam welding or friction stir welding, with optional incorporation of metal strips or connector pins, to create strong and lightweight joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fastening methods (rivets, welding) are used to join panel modules, then structural strength is achieved, but production time increases and automation is limited
Solution Approach 1:
The patent combines multiple joining operations (machining of both panel edges and formation of joining surfaces) into a single simultaneous operation. The cutting tool machines both panel edges at the same time, merging what would traditionally be separate sequential operations into one unified process, thereby doubling the effective production rate without compromising joint strength
Solution Approach 2:
The patent performs preliminary machining of panel edges to create precise joining surfaces before the actual joining process. By pre-forming the surfaces with exact geometry and fit during the simultaneous cutting operation, the subsequent joining process becomes faster and more automated, as the panels are already prepared for optimal alignment and connection
2Manufacturing precision
If multiple sequential machining operations are performed on panel edges, then joining precision is improved, but production time increases
Solution Approach 1:
The patent merges the machining of both panel edges into a single simultaneous operation using a cutting tool that processes both panels at once. This maintains manufacturing precision by ensuring both edges are machined to the same tolerance standards while eliminating the time required for sequential operations and repositioning
Solution Approach 2:
The simultaneous cutting operation ensures continuous useful action by machining both panel edges without interruption or repositioning. The cutting tool continuously removes material from both panels in a single uninterrupted motion, eliminating idle time between operations while maintaining precise dimensional control through continuous tool engagement
3Strength
If conventional joining methods are used, then structural integrity is achieved, but corrosion resistance and fatigue life are compromised
Solution Approach 1:
The patent extracts or eliminates traditional fastening elements (rivets, welds) from the joining process by creating precision-machined joining surfaces that enable direct mechanical coupling or alternative joining methods. This removal of corrosive fastening materials eliminates the primary sources of corrosion and stress concentration that lead to fatigue failure, while maintaining structural integrity through the precision-fit joint design
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
This method enhances production efficiency, reduces material waste, and provides a fail-safe structure with improved corrosion resistance and reduced risk of fatigue, enabling faster and more automated panel joining with simpler repair solutions.
Implementation Method 1
joining techniques like laser beam welding
Implementation Method 2
friction stir welding
Data Source
AI summary
A method of joining two panels of an airframe or fuselage structure of an aircraft or spacecraft, including: preparing an edge region of a first panel to form a first joining surface; preparing an edge region of a second panel to form a second joining surface; aligning the panels with one another such that the joining surfaces abut or interface one another forming a joint area; and joining the panels at the joining surfaces in the joint area. In an embodiment, the preparing steps include machining, and cutting, the edge regions of the first and second panels in a single operation to form the first and second joining surfaces substantially simultaneously. In another embodiment, the first and second joining surfaces are substantially planar and extend at an oblique angle with respect to a primary plane or surface of the respective first and second panels.