Angled Pin and Socket Rod Connection for Aircraft Structures
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Solution Overview
Problem
There is a need for connectors that can securely connect elongated structural members with minimal relative movement, which is not effectively addressed by conventional connectors.
Innovation Solution
The proposed solution involves a rod connection system with angled pin and socket connectors made from Scalmalloy™, using an additive manufacturing process, where the connectors are designed to provide mechanical stability and ease of assembly, featuring a left-handed and right-handed thread combination and a knurled surface for enhanced grip, allowing for efficient load transfer and weight reduction in structural aircraft components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional connectors are used to connect elongated structural members, then the connection can be achieved, but significant relative movement between members is required and the assembly is complex
Solution Approach 1:
The connector is divided into two distinct parts: an angled pin connector with pins protruding from one end, and an angled socket connector with corresponding tubes at the other end. This segmentation allows each part to have specialized geometry optimized for its function, with pins fitting into matching sockets to create the connection
Solution Approach 2:
Instead of using traditional threaded or bayonet connectors that require rotational movement, this invention inverts the approach by using straight pins that fit into sockets with minimal movement. The connection is achieved by inserting pins into sockets rather than threading or rotating components, fundamentally changing the connection mechanism
2Strength
If conventional beams with web and flanges are used, then structural strength is achieved, but weight is increased
Solution Approach 1:
The beam structure is segmented into parallel longitudinal support bars connected by cutter-milled struts, eliminating the need for a continuous web. This segmentation reduces material usage while maintaining structural integrity through the distributed support bar configuration
Solution Approach 2:
Material is placed only where structurally necessary - in the longitudinal support bars and at the connection points with cutter-milled struts. The spaces between support bars are left empty, providing local material distribution optimized for strength-to-weight ratio rather than uniform material distribution
3Ease of manufacture
If additive manufacturing is used for structural components, then weight reduction and manufacturing flexibility are achieved, but manufacturing precision challenges arise
Solution Approach 1:
The angled pin connector and angled socket connector are merged into a single integrally formed component through additive manufacturing. This eliminates the need for separate manufacturing and assembly of connector parts, ensuring precise geometric relationships between pins and sockets while leveraging the flexibility of additive manufacturing
Data Source
AI summary
A rod connection system includes a first structural member having an angled pin connector integrally formed at an end portion of the first structural member with angled pins being spaced apart from and protruding parallel to an end face of the first structural member. The rod connection system further includes a second structural member having an angled socket connector integrally formed at an end portion of the second structural member with angled tubes as sockets for the angled pins of the first structural member. The angled tubes are spaced apart from and protruding parallel to an end face of the second structural member.