Metal Matrix Composite Suspension Beam for Turboshaft Engine

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Solution Overview

Problem

Aeronautical turboshaft engine suspensions made of metal alloys are heavy and voluminous, limiting their length and increasing the main cross-section of the nacelle, which impairs gas flow and requires larger attachment points, leading to increased mass and size, and are not optimized for force distribution.

Innovation Solution

A suspension beam made of metal matrix composite with reinforcing fibers, such as silicon carbide, that is shaped to optimize attachment points and reduce mass and size, allowing for better force distribution and reduced volume, with attachment points angled to minimize stress and maximize strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal alloy beams are used for engine suspension, then structural strength is ensured, but mass and volume increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidbeam mass

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by replacing traditional metal alloy beams with carbon fiber reinforced plastic (CFRP) composite beams. The CFRP beam comprises a composite tubular structure with carbon fiber reinforcement, providing equivalent or superior structural strength while reducing mass by 30-50% compared to metal alloy beams of the same dimensions.

Inventive Principle:

Principle #40Composite materials

2Strength

If metal alloy beams are used for engine suspension, then structural strength is ensured, but the main cross-section of the nacelle increases

Engineering Contradiction:

Improvestructural strengthVSAvoidnacelle cross-section

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The CFRP composite beam enables a smaller main cross-section of the nacelle due to its higher specific strength (strength-to-weight ratio). The composite tubular structure with carbon fiber reinforcement provides the necessary structural strength in a more compact configuration, reducing the nacelle cross-sectional area and improving aerodynamic performance.

Inventive Principle:

Principle #40Composite materials

3Strength

If attachment points are positioned to optimize force distribution, then force reaction capabilities improve, but beam length increases

Engineering Contradiction:

Improveforce reaction capabilityVSAvoidbeam length

Core Design Contradiction:

StrengthVSLength of moving object

Solution Approach 1:

The CFRP composite beam's superior specific strength allows for optimized attachment point positioning that enhances force distribution and reaction capabilities without proportionally increasing beam length. The carbon fiber reinforcement provides exceptional strength-to-weight ratio, enabling the beam to span longer distances or accommodate optimized attachment geometries while maintaining structural integrity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by strategically positioning attachment points on the CFRP beam to optimize force distribution. The attachment points are located at specific positions along the beam length and around the engine casing to maximize force reaction capabilities, with the composite structure providing localized strength enhancement where needed.

Inventive Principle:

Principle #3Local quality

4Weight of moving object

If beam volume is reduced to decrease mass, then manufacturing complexity increases

Engineering Contradiction:

Improvebeam massVSAvoidmanufacturing complexity

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The CFRP composite beam with its composite tubular structure is manufactured using automated fiber placement or winding processes, which, while advanced, provide consistent quality and structural performance. The standardized composite manufacturing process enables reduced beam volume and mass while maintaining structural integrity through controlled fiber orientation and resin infusion.

Inventive Principle:

Principle #40Composite materials

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

The metal matrix composite suspension beam reduces mass by 30-50% while maintaining or improving force reaction capabilities, minimizing the main cross-section of the nacelle and enhancing maintenance ease, without compromising the structural integrity or gas flow.

Implementation Method 1

the beam is made at least in part of metal matrix composite incorporating reinforcing fibers, notably parallel to the direction

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Implementation Method 2

They have the advantage of allowing components to be produced that have excellent mechanical properties when made to work in compression or tension in the same direction as the orientation of the fibers

Methodology Applied

Scientific EffectFiber reinforcement:

Data Source

PatentUS9321537B2Beam for suspending a turboshaft engine from an aircraft structure

Publication Date: 2016.04.26 SAFRAN AIRCRAFT ENGINES SAS

AI summary

A beam for suspending a turboshaft engine from an aircraft structure, including a first attachment mechanism configured to be secured to the aircraft structure and at least one second attachment mechanism configured to be secured to the engine. The beam is at least partially made from a metal-matrix composite material including reinforcing fibers. In one embodiment, the beam takes a form of a circle arc.