Coupon FEM Modeling for Accurate Global Structure Testing
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Solution Overview
Problem
Existing methods for testing structural components require significant resources and time due to the lack of a suitable coupon or apparatus analogue, leading to inefficient and costly testing of larger structures.
Innovation Solution
The development of methods and apparatuses for generating a coupon finite element model (FEM) and determining the difference between global-element and coupon-element outputs, allowing for the evaluation of structural durability and damage performance, particularly in aircraft coatings, by iteratively refining the coupon FEM until it accurately represents the global FEM within a specified threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical testing of larger structures is conducted to demonstrate sufficient capability, then testing accuracy and reliability are improved, but resource expenditure and time consumption increase significantly
Solution Approach 1:
The patent segments the global structure into a coupon model that represents only the critical local region of interest. This segmentation allows testing to focus on the specific area needing validation rather than the entire structure, reducing time and resource requirements while maintaining testing accuracy for the critical region.
Solution Approach 2:
The patent creates a coupon model that serves as a simplified copy or representation of the critical portion of the global structure. This coupon model replicates the essential mechanical behavior and boundary conditions of the local region, enabling accurate testing without requiring the full global structure, thus reducing time consumption while preserving testing reliability.
2Reliability
If physical testing of larger structures is conducted to demonstrate sufficient capability, then testing accuracy and reliability are improved, but resource expenditure increases significantly
Solution Approach 1:
The patent segments the global structure into a coupon model representing only the critical local region. This segmentation reduces the amount of physical material, equipment, and resources required for testing while maintaining accuracy for the critical region of interest.
Solution Approach 2:
The patent creates a coupon model as a simplified physical or computational copy of the critical structure portion. This coupon requires fewer resources to test while preserving the essential mechanical behavior needed for accurate assessment of the critical region.
3Productivity
If a coupon model is created to represent a global structure, then resource expenditure and time consumption are reduced, but modeling complexity and computational requirements increase
Solution Approach 1:
The patent applies local quality by creating a coupon model with detailed representation only in the critical local region of interest, while using simplified representations elsewhere. This approach reduces overall modeling complexity while maintaining high fidelity where it matters most, improving testing efficiency without excessive computational burden.
Solution Approach 2:
The patent utilizes parameter changes by adjusting boundary conditions, material properties, and geometric parameters in the coupon model to accurately represent the global structure's behavior. This allows the simplified coupon model to capture essential mechanics without requiring full global structure complexity, balancing productivity and modeling complexity.
4Measurement precision
If the coupon FEM is refined to accurately represent the global FEM, then modeling accuracy is improved, but computational requirements and complexity increase
Solution Approach 1:
The patent applies local quality by refining the coupon FEM mesh and parameters only in the critical local region where high accuracy is needed, while using coarser representations in non-critical areas. This reduces overall computational complexity while maintaining high modeling accuracy where it matters most.
Solution Approach 2:
The patent applies partial action by refining the coupon FEM to the extent necessary to achieve adequate accuracy for the critical region, rather than excessively refining the entire model. This balances modeling accuracy with computational complexity by applying refinement only where needed.
Data Source
AI summary
Methods comprising generating a coupon finite element model (FEM) comprising coupon elements. Examples of the methods further comprise determining a difference between a global-element output of global elements of a global FEM and a coupon-element output of the coupon elements of the coupon FEM. Examples of the global-element output and the coupon-element output comprise one or more of a physical characteristic, dimension, and displacement. An apparatus comprising non-volatile memory, instructions stored on the non-volatile memory, and a processor configured to execute the instructions. Examples of the instructions include generating a coupon FEM comprising coupon elements and determining a difference between a global-element output of global elements of a global FEM and a coupon-element output of the coupon elements of the coupon FEM.