Conformal Array Assembly Tooling for Aerodynamic Integration
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Solution Overview
Problem
Conformal arrays require efficient assembly methods to ensure secure integration of radiating elements into structural back skins while maintaining aerodynamic profiles and minimizing conspicuousness, especially in applications like aircraft and vehicles.
Innovation Solution
A system and method utilizing an outer tool and an inner tool with a pneumatic arrangement to deliver adhesive to the edges of open cells in a conformal array, where the outer tool is made of a flexible material like Polytetrafluoroethylene or silicone, and the inner tool is made of metal, facilitating secure bonding and easy removal without separate sealing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid tools are used for adhesive application, then structural stability is improved, but friction and damage to the conformal array increase
Solution Approach 1:
The outer tool is constructed from flexible material (silicone or Polytetrafluoroethylene) that can deform to conform to the curved surfaces of the conformal array cells. This flexibility allows the tool to adapt to the aerodynamic profile without causing friction or damage, while still providing sufficient structural stability for precise adhesive application and tool removal.
2Manufacturing precision
If adhesive is applied manually, then control precision is improved, but assembly time and productivity decrease
Solution Approach 1:
The system combines automated adhesive delivery through the inner tool conduit with the flexible outer tool that provides precise positioning and sealing. This integration allows automated adhesive application with controlled precision while maintaining high assembly speed, eliminating the need for manual adhesive application.
Solution Approach 2:
The flexible outer tool acts as an intermediary between the adhesive delivery system and the conformal array cell. It receives adhesive from the inner tool and distributes it precisely along the cell edges through its flexible walls, ensuring accurate adhesive placement while maintaining high assembly throughput.
3Ease of operation
If the outer tool is made of flexible material, then ease of insertion and removal is improved, but tool strength decreases
Solution Approach 1:
The system uses composite construction where the outer tool is made of flexible material (silicone or Polytetrafluoroethylene) for ease of insertion and removal, while the inner tool provides structural strength and rigidity. The combination of these materials creates a composite system that achieves both flexibility for operation and sufficient strength for adhesive application.
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 method ensures secure and efficient assembly of conformal arrays by minimizing friction and damage, allowing for precise insertion and removal of tools while maintaining aerodynamic profiles and reducing tool wear, thus enhancing the assembly process.
Implementation Method 1
The outer tool is inserted into the open cell and expanded within the open cell to engage and seal against the inner faces
Implementation Method 2
adhesive extending along the edges of the open cell
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Systems and methods according to the present disclosure for assembling conformal arrays utilize an outer tool for insertion into an open cell of a conformal array, an inner tool for insertion into the outer tool, and an adhesive source for delivering adhesive to the edges of the open cell via the inner tool and the outer tool. An assembled conformal array includes adhesive extending along the edges of the open cell.