Composite Access Assembly Integration in Aircraft Wing Torsion Boxes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing procedures for aircraft wing torsion boxes with access assemblies to surge tanks are inefficient, requiring separate installation of access assemblies during assembly, which increases time and costs.
Innovation Solution
A manufacturing procedure for composite parts with integrated access assemblies, where common laminates of composite material are used to create a cover and housing panel simultaneously, with additional plies and a dummy to maintain aerodynamic continuity, allowing for the simultaneous curing and assembly of the lower skin with the access assembly without material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the lower skin is manufactured leaving a recess around the venting hole for further installation of access assembly, then the access assembly can be installed, but it requires additional installation operation that increases time and costs
Solution Approach 1:
The access assembly is merged with the lower skin by integrating the housing panel into the same composite structure. The housing panel is manufactured as part of the lower skin using the same autoclave curing process, eliminating separate installation operations and reducing manufacturing time and costs.
Solution Approach 2:
The housing panel for the access assembly is prepared in advance as an integrated part of the lower skin manufacturing process. The recess is pre-formed during the composite layup and curing process, so the access assembly components are ready for final integration without requiring separate installation operations.
2Loss of substance
If separate manufacturing of cover and housing panel is used, then material can be precisely allocated, but material waste occurs in prior art methods
Solution Approach 1:
The common laminate is segmented into cover laminates and housing panel laminates by cutting along the perimeter of the cover. This allows precise allocation of material to each component from a single optimized laminate structure, minimizing material waste while maintaining design flexibility.
Solution Approach 2:
The manufacturing approach changes from separate discrete manufacturing to integrated composite manufacturing. By using a single autoclave curing process for both the lower skin and housing panel, material utilization is optimized and waste is reduced while the complexity is managed through process integration.
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 procedure reduces manufacturing time and costs by integrating the access assembly into the lower skin of the aircraft wing, ensuring efficient production and maintaining aerodynamic continuity, while allowing for the incorporation of metallic layers for protection.
Implementation Method 1
providing common laminates of a composite material for said cover and said housing panel in an uncured state
Data Source
AI summary
Procedure for the manufacture of a composite part (13) of a closed compartment, said part (13) having an access assembly to said compartment through an opening (11) in said part (13), said access assembly comprising a cover (27) for said opening (11) and a housing panel (25) for said cover (27), comprising steps of: a) providing common laminates (31, 31′, 31″) of a composite material for said cover (27) and said housing panel (25) in an uncured state; b) cutting said common laminates (31, 31′, 31″) by the perimeter foreseen for said cover (27) and separating the cover laminates (33, 33′, 33″) and the housing panel laminates (35, 35′, 35″); c) manufacturing separately, on the one side, the cover (27) using said cover laminates (31, 31′, 31″) and, on the other side, the part (13) together with said housing panel (25) using said housing panel laminates (35, 35′, 35″).