Composite Panel Insert Skirt for Stable Automated Mounting
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Solution Overview
Problem
Automated mounting of inserts in composite panels used in aviation is challenging due to the panels' unique mechanical behavior, specific material requirements, and the influence of cover sheets, which affects the mechanical response and stability of inserts, leading to difficulties in accurate positioning and efficient production.
Innovation Solution
The insert design features a base with an outer skirt and fixation means, such as thickenings or recesses, that interact with the panel to provide initial and long-term stability, combined with an adhesive agent to secure the insert during curing, and a working head system for efficient mounting, including an adhesive dispenser and magazine for insert storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an insert is mounted in a composite panel using conventional methods, then the insert can be installed, but the panel's cover sheets may be damaged or discolored due to adhesive contact, and positioning accuracy is difficult to achieve
Solution Approach 1:
The insert is divided into functionally distinct parts: a mounting portion that interfaces with the cover sheet and a receiving portion that interfaces with the adhesive. This segmentation allows the mounting portion to be optimized for precise positioning and cover sheet protection, while the receiving portion handles the adhesive bonding function, thereby resolving the contradiction between positioning accuracy and panel appearance damage.
Solution Approach 2:
The mounting portion acts as an intermediary element between the adhesive and the cover sheet. It provides a dedicated interface that prevents direct contact between the adhesive and the cover sheet, thereby protecting the panel appearance while still enabling secure bonding through the adhesive to the insert's receiving portion.
2Productivity
If multiple inserts are mounted manually in composite panels, then each insert can be positioned, but the production efficiency is low and positioning consistency is difficult to maintain
Solution Approach 1:
The insert design incorporates universal features including standardized mounting portions, alignment features, and a modular structure that can be used across different panel types and insert locations. This universality enables the development of automated mounting systems that can handle multiple inserts consistently, thereby improving both productivity and positioning consistency.
Solution Approach 2:
The insert includes specific geometric parameters such as the shape and dimensions of the mounting portion, alignment features, and recess geometry that can be optimized for automated handling. These parameter changes enable robotic pick-and-place operations and adhesive dispensing systems to achieve high-speed, consistent positioning of multiple inserts, resolving the contradiction between productivity and positioning consistency.
3Ease of manufacture
If the insert structure is simplified for easy manufacturing, then production cost decreases, but the insert stability in the panel is reduced
Solution Approach 1:
The insert is segmented into two main portions: a simple mounting portion for easy manufacturing and assembly, and a receiving portion designed for stable adhesive bonding. This segmentation allows each portion to be optimized independently - the mounting portion can be manufactured simply while the receiving portion provides the necessary stability through its geometric design for adhesive retention.
Solution Approach 2:
The insert utilizes composite geometric structures combining different features (mounting portion with alignment features, receiving portion with retention geometry) that together provide both ease of manufacture and high stability. The composite design allows simple manufacturing processes while achieving reliable panel insertion stability through the integrated features.
Data Source
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AI summary
The invention is directed to an insert (100) that comprises a base (110) and an outer skirt (120) which extends from the base (110), thereby forming a chamber (101). The outer skirt (120) is provided with a first inner skirt surface (123) and a first outer skirt surface (124). According to the present invention at least one fixation means (180) is arranged at the first outer ski rt surface (124) and configured to interact with a (panel 200) when inserted in an opening (212) of the panel (200) in order to increase initial insert stability.