Corrugated Aircraft Rib Structure With Discontinuous Caps
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Solution Overview
Problem
Aircraft design faces challenges in achieving optimal stiffness and weight balance, leading to issues with buckling and increased manufacturing complexity, particularly in rib structures, which affect the structural integrity and efficiency of aircraft.
Innovation Solution
The implementation of single-part and multi-part corrugated rib designs with discontinuous caps and tooled surfaces to simplify manufacturing, reduce part count, and minimize assembly tolerance buildup, while maintaining structural soundness and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional multi-part rib structures with continuous caps are used, then structural integrity is improved, but manufacturing complexity and assembly tolerance buildup increase
Solution Approach 1:
The rib structure is divided into multiple discrete ribs rather than using continuous complex geometry. Each rib can be manufactured separately using simplified processes, reducing manufacturing complexity while maintaining structural integrity through the distributed rib configuration.
Solution Approach 2:
The continuous cap structure is removed entirely from the design. Instead of having continuous caps that require complex manufacturing and precise assembly, the design uses discrete ribs without continuous caps, eliminating the associated manufacturing complexity and tolerance buildup issues.
2Strength
If traditional rib structures with complex geometric patterns are used, then structural soundness is improved, but weight increases
Solution Approach 1:
Instead of using complex geometric patterns throughout the entire structure, the design applies ribs only where structurally necessary. The discrete rib configuration provides local reinforcement where needed while leaving other areas lighter, achieving structural soundness without excessive weight.
Solution Approach 2:
Complex geometric patterns are discarded in favor of simpler discrete rib structures. The design recovers structural effectiveness by strategically positioning simpler rib elements, achieving the same structural soundness with reduced weight compared to complex continuous patterns.
3Strength
If multi-part assemblies with continuous caps are used, then structural integrity is improved, but assembly tolerance buildup increases
Solution Approach 1:
The structure is segmented into discrete ribs that can be manufactured and assembled independently. This segmentation reduces the cumulative tolerance buildup that would occur in continuous multi-part assemblies, as each rib is a separate, simpler component with fewer tolerance accumulation points.
Solution Approach 2:
The continuous cap assembly is removed from the design, eliminating the complex multi-part joints and connections that cause tolerance buildup. The discrete rib structure requires simpler connections, reducing assembly tolerance issues while maintaining structural integrity.
Data Source
AI summary
One embodiment includes a rib structure to be used, for example, in any number of aerospace applications, the rib structure, comprising a first piece having a first curvature in a first plane; and a second piece having a second curvature in a second plane that is different from the first plane. The first piece and the second piece are bonded together to form the rib structure. In certain embodiments, the first piece further comprises a plurality of discontinuous flanges to interface with a plurality of skin surfaces. In other examples, the first piece includes an aft spar interface for bonding to a surface. In some implementations, the first piece includes a forward spar interface for bonding to a surface. Manufacturing of the airframe/aircraft parts, panels, and rib components can include any suitable composites, alloys, titanium, aluminum, artificial materials, sheet metal, etc.