Aircraft Crown Integration Panel With Self-Aligning Attachments
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Solution Overview
Problem
Existing secondary support structures for aircraft crown portions are costly, labor-intensive to install, and inefficiently utilize variable configurations, leading to increased weight and complexity, with challenges in aligning ceiling panels and accommodating build tolerances.
Innovation Solution
A support system comprising a crown integration panel with a honeycomb and sheet metal structure, dual-bracketed support system, and self-aligning attachments that allow for easier installation, alignment, and adaptation to aircraft deflections, featuring a crown raceway support and adjustable fittings to simplify the attachment process and reduce manual adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a lattice structure is used to support equipment and furnishings, then stable and variable configurations are provided, but the structure becomes expensive, heavy, and difficult to install
Solution Approach 1:
The support system is divided into modular units (cross members, longitudinal members, and equipment supports) that can be independently configured and assembled. This segmentation allows the structure to provide variable configurations while using smaller, lighter components rather than a heavy continuous lattice.
Solution Approach 2:
The cross members and longitudinal members serve multiple functions: they provide structural support, enable variable equipment positioning, and facilitate installation from the aircraft exterior. This multi-functionality eliminates the need for separate heavy lattice structures for each purpose.
2Adaptability or versatility
If a lattice structure is used to support equipment and furnishings, then stable and variable configurations are provided, but the installation process becomes time consuming and labor intensive
Solution Approach 1:
Equipment is attached to the equipment supports before installation into the aircraft. This preliminary assembly allows installation personnel to work efficiently from the aircraft exterior without the congestion and time consumption of working inside the cabin during final installation.
Solution Approach 2:
Instead of installing the support structure first and then attaching equipment inside the aircraft, the system is designed to be assembled with equipment attached from the exterior, inverting the traditional installation sequence and dramatically reducing installation time.
3Ease of manufacture
If conventional sheet metal construction is used for support trays and panels, then ease of manufacture and assembly is provided, but larger scale panels require progressively more stiffening elements which increases cost and weight
Solution Approach 1:
The support system uses composite construction combining aluminum extrusions for the framework and honeycomb panels for equipment supports. This composite approach provides the strength and stiffness of heavy sheet metal structures without the weight, eliminating the need for additional stiffening elements.
4Weight of stationary object
If composite honeycomb panels are used for larger support panels, then weight reduction is achieved, but specialized hardware is required and electrical conductivity is lost
Solution Approach 1:
The system merges the advantages of composite honeycomb panels (weight reduction) with aluminum extrusions (electrical conductivity and standardized hardware). The aluminum framework provides grounding paths and uses conventional fasteners, while honeycomb panels are used only for lightweight equipment mounting surfaces.
Solution Approach 2:
The aluminum extrusion framework serves multiple functions: structural support, electrical grounding, and providing standardized attachment points with conventional hardware. This eliminates the need for specialized composite hardware while maintaining weight advantages.
5Strength
If existing secondary structures are used to attach ceiling panels, then support is provided, but the attachment and alignment process becomes difficult and time consuming
Solution Approach 1:
The cross members are designed with integrated features that automatically align and position ceiling panels during installation. The panels self-align to the cross member positions without requiring repetitive measurement, adjustment, and repositioning, dramatically reducing installation time while maintaining support strength.
Data Source
Figure 1
Figure 2A~2B
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AI summary
A support system for a crown area of an aircraft and a corresponding method is disclosed. The support system includes a crown integration panel (CIP). The CIP is configured to provide a mounting surface for a plurality of aircraft equipment and to provide an electrical ground for at least one of the aircraft equipment of the plurality of aircraft equipment. The system further includes a first attachment and a second attachment attached to the CIP. The first attachment and the second attachment are configured to attach to an airframe of the aircraft. The system further includes a crown raceway support (CRS) having a first end and a second end, where the first end is attached to a first end of the CIP and the second end is configured to attach to an outboard rail of the aircraft.