Bladder Bond Fixture for Rotor Blade Hole Pattern Concentricity

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Solution Overview

Problem

The challenge in rotary-wing aircraft rotor blades is maintaining concentricity of the hole pattern when replacing components, as the original and replacement parts may have slightly varying hole positions due to manufacturing tolerances, requiring precise alignment and bonding techniques to ensure proper fitment and structural integrity.

Innovation Solution

A bond assembly featuring a fixture with movable sections and a bladder assembly that applies controlled pressure and heat to secure the rotor blade, utilizing a heater and caul plate to ensure uniform bonding across the laminate, allowing for precise alignment and bonding of replacement components with existing rotor blades.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the hole pattern is formed in both the component and the rotor blade simultaneously during initial manufacturing, then alignment between the component and rotor blade is achieved, but over time the component wears and needs replacing, making it difficult to maintain concentricity of the hole pattern with the existing blade hole pattern

Engineering Contradiction:
Improvehole pattern concentricityVSAvoidcomponent replacement alignment
Core Design Contradiction:
Manufacturing precisionVSEase of repair

Solution Approach 1:

The patent applies preliminary action by creating a template from the original component that captures the precise hole pattern geometry before the component wears or is replaced. This template serves as a reusable reference that preserves the original concentricity relationships, allowing replacement components to be accurately aligned without requiring the original component to still be in service. The template is created by projecting the hole pattern onto a durable surface, establishing the geometric relationships in advance for future use during maintenance operations.

Inventive Principle:
Principle #10Preliminary action

2Ease of repair

If a replacement component is bonded to the rotor blade, then the component is restored to service, but the hole positions may vary due to manufacturing tolerances, compromising structural integrity and performance

Engineering Contradiction:
Improvecomponent replacementVSAvoidstructural integrity
Core Design Contradiction:
Ease of repairVSReliability

Solution Approach 1:

The patent applies copying by creating a physical template that replicates the exact hole pattern geometry of the original component. This template serves as a master copy that can be used repeatedly to transfer the precise hole positions to replacement components. By copying the geometric relationships rather than relying on direct measurement or alignment during each replacement operation, the system ensures that hole pattern concentricity and positioning accuracy are maintained across multiple replacement cycles, thereby preserving structural integrity and reliable performance.

Inventive Principle:
Principle #26Copying

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 solution ensures accurate and reliable bonding of replacement components to the rotor blade, maintaining concentricity and structural integrity, even after wear and tear, by applying controlled heat and pressure, thus addressing the issue of varying hole patterns and ensuring consistent performance.

Implementation Method 1

A bladder assembly is mounted to at least one of the first section and the second section. The bladder assembly is configured to apply controlled, localized pressure and heat to a component receivable between the first section and the second section.

Methodology Applied
Scientific EffectHydraulic Pressing: Hydraulic Press

Implementation Method 2

The bladder assembly includes a heater.

Methodology Applied
Scientific EffectThermal Heating: Heating

Implementation Method 3

the first section and the second section are coupled by at least one threaded fastener and rotation of the at least one threaded fastener about an axis causes the first section to move relative to the second section.

Methodology Applied
Scientific EffectMechanical Fastening: Screw

Data Source

PatentUS11511499B2Bond fixture for root end laminate or rotor blade
Publication Date: 2022.11.29 SIKORSKY AIRCRAFT CORP
  • US11511499B2 patent drawing
  • US11511499B2 patent drawing
  • US11511499B2 patent drawing

AI summary

A bond assembly includes a fixture having a first section movably coupled to a second section. The first section and the second section are disposed opposite one another. A bladder assembly is mounted to at least one of the first section and the second section. The bladder assembly is configured to apply controlled, localized pressure and heat to a component receivable between the first section and the second section.