Tolerance-Compensating Connection Joint With Ductile Interlayer
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Solution Overview
Problem
Existing methods for connecting components in aircraft assembly, such as drilling for riveting or using additional components like spherical bearings, result in contamination or require excessive materials to compensate for multiple deviations, leading to high costs and weight.
Innovation Solution
A connection system with engagement elements and a ductile material that allows components to be connected in a flexible, lightweight, and stable manner, compensating for deviations in all directions through 5 or 6 degrees of freedom, using engagement elements that are pressed into the ductile material to adjust position and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If drilling for riveting is used to compensate tolerances, then positional deviations can be corrected, but chip contamination occurs which is not allowed in final aircraft assembly
Solution Approach 1:
A ductile intermediary material is introduced between the engagement elements and the component surfaces. This intermediary material deforms plastically under compression to accommodate positional deviations, eliminating the need for drilling operations that generate contaminating chips while maintaining precise connection
2Manufacturing precision
If additional components like spherical bearings or adjuster screws are used to compensate deviations, then positional accuracy can be achieved, but the number of parts increases leading to high costs and weight
Solution Approach 1:
Multiple tolerance compensation functions are merged into a single ductile material layer that deforms plastically to accommodate deviations in multiple directions. This eliminates the need for separate spherical bearings, adjuster screws, and other additional components, significantly reducing the overall weight and part count
3Manufacturing precision
If additional components like spherical bearings or adjuster screws are used to compensate deviations, then positional accuracy can be achieved, but the complexity and cost of the connection system increase
Solution Approach 1:
Multiple tolerance compensation functions are merged into a single ductile material layer that deforms plastically to accommodate deviations in multiple directions. This eliminates the need for separate spherical bearings, adjuster screws, and other additional components, significantly reducing the overall weight and part count
4Adaptability or versatility
If engagement elements are pressed into the ductile material to compensate deviations, then flexibility and tolerance compensation are improved, but the connection strength may be compromised
Solution Approach 1:
The physical state of the intermediary material is changed from rigid to ductile, allowing it to deform plastically under compression. This parameter change enables the material to accommodate engagement elements while maintaining sufficient connection strength, resolving the contradiction between adaptability and strength
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
Enables precise and stable connection of components while compensating for positional deviations, reducing contamination and material usage, and allowing for efficient load transmission.
Implementation Method 1
a ductile material configured for being positioned between the connection surfaces of the first part and of the second part, such that the engagement elements are pressed into the ductile material at required positions when the parts are pressed together
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A connection system comprises at least a first part (11; 31; 41) and at least a second part (14, 15; 32, 33; 43), both comprising a connection surface (16, 19) and being configured to be connected to each other. A plurality of engagement elements (17, 18) is protruding from the connection surface (16, 19) of the first part (11; 31; 41) and from the connection surface (16, 19) of the second part (14, 15; 32, 33; 43). For connecting different components (25, 26), the parts (11, 14, 15; 31, 32, 33; 41, 43) are positioned such that their connection surfaces (16, 19) are facing each other. A ductile material (20) is positioned between the connection surfaces (16, 19) of the parts (11, 14, 15; 31, 32, 33; 41, 43) to be connected to each other. The parts (11, 14, 15; 31, 32, 33; 41, 43) are pressed together, wherein the engagement elements (17, 18) are pressed into the ductile material (20) at required positions, thereby compensating position deviations.