Thrust Reverser Cascade Strip Assembly Manufacturing
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Solution Overview
Problem
The manufacturing of thrust reverser cascades for jet engines is labor-intensive and costly due to complex shapes, leading to compromised aerodynamic performance and increased weight, which necessitates longer cascades and additional installation challenges, resulting in higher re-certification and testing costs.
Innovation Solution
A method involving strip assemblies with strong back members and vane members that are secured to the nacelle, using thermoplastic resin and resin transfer molding processes to simplify the cascade geometry while maintaining aerodynamic performance, reducing labor and costs by employing a three-sided configuration instead of four-sided molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If compression mold thermoplastic manufacturing process is used, then labor intensity is reduced, but aerodynamic performance is compromised due to simplified geometry
Solution Approach 1:
The cascade is divided into multiple modular components including vanes, strong backs, and intercostal elements that can be manufactured separately using compression molding, then assembled to form the complete aerodynamic structure. This allows simplified manufacturing of individual parts while maintaining the complex overall geometry needed for aerodynamic performance
Solution Approach 2:
Multiple cascade components are combined through assembly to create the complete aerodynamic surface. The intercostal elements connect vanes and strong backs to form a unified structure that achieves both manufacturing simplicity and aerodynamic effectiveness
2Shape
If four-sided mold configuration is used, then complete cascade geometry can be achieved, but installation and removal procedures become complicated
Solution Approach 1:
The cascade assembly process is segmented into multiple steps where components are attached sequentially to the nacelle. This allows the complex four-sided geometry to be achieved through staged installation rather than requiring complete assembly in a single complex mold operation
Solution Approach 2:
The cascade structure utilizes three-dimensional spatial arrangement of vanes and strong backs that extend in multiple directions from the nacelle surface. This multi-dimensional configuration allows complex aerodynamic geometry while maintaining relatively simple attachment procedures at each stage
3Ease of manufacture
If aerodynamic lines are simplified, then manufacturing cost is reduced, but reverse thruster aerodynamic performance is penalized
Solution Approach 1:
The aerodynamic surface is segmented into discrete vanes and intercostal elements that can be manufactured using cost-effective compression molding processes. Each component has simplified geometry for manufacturing, but the collective arrangement maintains the required aerodynamic performance
Solution Approach 2:
The design optimizes geometric parameters of individual components such as vane angles, curvatures, and spacing to achieve the desired aerodynamic performance while maintaining manufacturing simplicity. Parameters are tuned to balance manufacturing ease with aerodynamic effectiveness
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 approach streamlines the manufacturing and assembly of thrust reverser cascades, reducing labor and costs while maintaining necessary aerodynamic performance, thereby minimizing re-certification and installation challenges.
Implementation Method 1
compression mold thermoplastic manufacturing processes
Implementation Method 2
resin transfer molding processes
Data Source
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AI summary
A method for manufacturing a cascade for a thrust reverser for a jet engine includes forming a strip assembly. The strip assembly includes a strong back member which includes a length. The strip assembly includes a plurality of first vane members which extend from a first side of the strong back member in a first direction nonparallel relative to the length of strong back member wherein the plurality of the first vane members are spaced apart from one another along the length of the strong back member.