Composite Joint Layout for Electromagnetic Resistance Reduction

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Solution Overview

Problem

The existing design process for aircraft joints is inefficient as it requires iterative testing to meet both structural integrity and electromagnetic effect requirements, leading to repeated redesign and testing cycles until FAA standards are met, which is time-consuming and costly.

Innovation Solution

A method and system that iteratively processes joint parameters and ply stackup to minimize electromagnetic effective resistance, optimizing fastener arrangements and fiber orientations to direct electrical current along a predetermined path, thereby reducing weight and effective resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If iterative testing is performed to meet both structural integrity and electromagnetic effect requirements, then compliance with FAA standards is achieved, but design time and cost increase significantly

Engineering Contradiction:

Improvecompliance with FAA standardsVSAvoiddesign time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by integrating electromagnetic effect analysis into the initial structural design phase rather than performing separate iterative testing. The system calculates electromagnetic effective resistance during the structural design process itself, allowing designers to evaluate both structural integrity and electromagnetic compliance simultaneously from the outset, thereby eliminating repeated testing cycles and reducing design time while maintaining FAA standard compliance

Inventive Principle:

Principle #10Preliminary action

2Reliability

If iterative redesign and retesting is performed to meet electromagnetic effect requirements, then electromagnetic compliance is achieved, but development cost increases

Engineering Contradiction:

Improveelectromagnetic complianceVSAvoiddevelopment cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges structural design and electromagnetic effect analysis into a single integrated process. The system simultaneously evaluates structural integrity and electromagnetic effective resistance using the same structural parameters, allowing designers to optimize both aspects together. This combination eliminates the need for separate iterative redesign and retesting cycles, reducing development costs while achieving electromagnetic compliance

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If structural design is optimized for structural integrity, then structural strength is improved, but electromagnetic effective resistance increases

Engineering Contradiction:

Improvestructural integrityVSAvoidelectromagnetic effective resistance

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent applies parameter changes by using a unified set of structural parameters (fastener location, pitch, diameter, offset, and ply stackup) to control both structural integrity and electromagnetic effective resistance. The system calculates and optimizes these parameters simultaneously to achieve the dual objective of maximizing structural strength while minimizing electromagnetic effective resistance, rather than treating them as separate optimization problems

Inventive Principle:

Principle #35Parameter changes

4Productivity

If separate design processes are used for structural and electromagnetic aspects, then design expertise is specialized, but overall design efficiency decreases

Engineering Contradiction:

Improvedesign efficiencyVSAvoiddesign process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies universality by creating a unified design system that performs both structural analysis and electromagnetic effect evaluation using the same input parameters and design variables. The system integrates multiple functions (structural strength calculation, electromagnetic effective resistance calculation, and optimization) into a single computational framework, eliminating the need for separate design processes and improving overall design efficiency while managing complexity through integration

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 integrates structural and electromagnetic design disciplines, reducing the weight of aircraft structures and minimizing electromagnetic strain energy, allowing for efficient compliance with FAA requirements without repeated testing, thereby streamlining the design process and reducing costs.

Implementation Method 1

optimizing fastener arrangements and fiber orientations to direct electrical current along a predetermined path, thereby reducing weight and effective resistance

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP3124386B1Composite joint optimization

Publication Date: 2021.04.28 THE BOEING CO

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Figure 3A~3B

AI summary

A method including receiving a joint parameter for a joint between at least two composite structural components, a ply stackup for each of the at least two composite structural components and an electromagnetic effect parameter in a controller, iteratively processing with the controller, the joint parameter and the ply stackup and outputting an optimized joint parameter based on at least a convergence of an electromagnetic effect resistance of the joint and the at least two composite structural components, and changing, with the controller, a value of one or more of the joint parameters and the ply stackup during the iterative processing to reach the convergence of the electromagnetic effect resistance.