Composite Fuselage Surface Optimization via Cell Concatenation
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Solution Overview
Problem
The existing design processes for composite-material structures, particularly in the aeronautical sector, face errors and prolonged times when updating solid and fabric models due to the use of multi-cell surfaces as master geometries, which complicates the geometric definition and lengthens the design process.
Innovation Solution
A computer-assisted method that transforms multi-cell surfaces into optimized surfaces with fewer cells by breaking down zones, obtaining basic surfaces, matching and concatenating contiguous surfaces, and using these optimized surfaces as master geometry for designing components, significantly reducing the number of cells and facilitating faster updates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multi-cell surfaces are used as master geometries in the design process, then the aerodynamic calculations can be performed with sufficient precision, but the updating of solid models and fabric models becomes time-consuming and error-prone
Solution Approach 1:
The multi-cell surface is segmented into multiple single-cell surfaces, each representing a distinct zone of the structure. This segmentation allows each zone to be independently modeled and updated, reducing the complexity of global updates while preserving the aerodynamic precision of the original multi-cell representation.
Solution Approach 2:
A software program acts as an intermediary between the aerodynamic calculation stage and the design modeling stage. This software automatically transforms multi-cell surfaces into optimized single-cell surfaces and generates corresponding solid and fabric models, eliminating manual updating operations and reducing errors.
2Manufacturing precision
If multi-cell surfaces are used as master geometries, then detailed aerodynamic zones can be represented, but the complexity of handling and updating models increases significantly
Solution Approach 1:
The structure is divided into distinct single-cell surfaces corresponding to different aerodynamic zones. Each single-cell surface maintains the geometric precision required for its specific zone while being simpler to handle than the complex multi-cell surface, thus reducing model handling complexity.
Solution Approach 2:
The software transforms the geometric parameters of the multi-cell surface into equivalent single-cell surface parameters, preserving the aerodynamic characteristics and geometric accuracy while changing the topological complexity parameter to a simpler single-cell configuration that is easier to manage.
3Measurement precision
If multi-cell surfaces are used for structure design, then aerodynamic zones are accurately defined, but errors occur during model updates when geometry changes
Solution Approach 1:
The software program serves as a reliable intermediary that automatically manages the transformation from multi-cell to single-cell surfaces and generates consistent solid and fabric models. This automation eliminates manual errors during updates and ensures reliability when geometry changes occur.
Solution Approach 2:
The software implements feedback loops that automatically detect geometry changes in the master surface and trigger corresponding updates to solid and fabric models. This ensures that all models remain consistent with the current geometry, preventing errors from propagating through the design process.
Data Source
AI summary
Computer-assisted method for optimizing surfaces of composite-material structures as part of a design process that includes the following stages: a) Providing a multi-cell surface (11) of the structure obtained using aerodynamic calculations; b) Transforming said multi-cell surface (11) into an optimized surface (13) with fewer cells, concatenating contiguous cells and maintaining point and tangent continuity between them; c) Using said optimized surface (13) as geometric master when designing the components of the structure. The method is particularly applicable to the design of structures with a plurality of components and in particular fuselages of aircraft made of composite material. The invention also relates to a computer program for performing the method.