Extruded Control Surface Structure for Impact-Resistant UAV Wings
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Solution Overview
Problem
Current methods for manufacturing flight control surfaces for unmanned aerial vehicles (UAVs) are either labor-intensive, result in heavy and thick parts, or are prone to damage due to the use of molded foam wings, which are susceptible to denting and require frequent replacement.
Innovation Solution
The development of an extruded control surface with a channel, knuckle, leading and trailing voids, and separators, along with clips and cuffs, made from UV-resistant plastic or polycarbonate-ABS, which allows for lightweight, inexpensive, and structurally strong control surfaces that can pivot and absorb impact, protecting the wings during take-off and landing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molded foam wings are used for UAVs, then the wings are lightweight and easy to manufacture, but they are susceptible to denting and require frequent replacement
Solution Approach 1:
The wing assembly is segmented into multiple components: the molded foam wing structure and separate extruded control surfaces. This segmentation allows the foam wing to maintain its lightweight and easy manufacturing advantages while the extruded control surfaces provide the necessary structural protection and durability, resolving the contradiction between ease of manufacture and resistance to damage.
Solution Approach 2:
The solution employs composite construction by combining molded foam material for the wing structure with extruded plastic control surfaces. This composite approach leverages the advantages of each material: the foam provides lightweight structure while the extruded plastic components provide durability and damage resistance, thereby resolving the contradiction between ease of manufacture and reliability.
2Ease of manufacture
If traditional manufacturing methods (lay-up or injection molding) are used for control surfaces, then the control surfaces can be manufactured, but they result in thicker and heavier parts
Solution Approach 1:
The invention changes the manufacturing parameter from traditional lay-up or injection molding methods to extrusion process. This parameter change enables the production of control surfaces with optimized wall thickness and reduced material usage, resulting in lighter control surfaces while maintaining structural integrity and manufacturability.
3Ease of manufacture
If traditional manufacturing methods are used for control surfaces, then the control surfaces can be constructed, but the process requires manual labor and is labor-intensive
Solution Approach 1:
The invention changes the manufacturing parameter from labor-intensive lay-up or injection molding processes to an extrusion process. This parameter change enables continuous production of control surfaces with consistent quality, reducing manual labor requirements and significantly improving manufacturing efficiency and productivity.
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 solution reduces the weight and complexity of control surfaces, enhances structural integrity, and allows for easy replacement of damaged components, minimizing repair costs and extending the operational life of UAVs by acting as disposable wing protectors.
Implementation Method 1
where the knuckle deforms to accept the pin
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Systems, devices, and methods for an extruded wing protection and control surface (126) comprising: a channel (206) proximate a leading edge (202) of the control surface, a knuckle (210) disposed about the channel, a leading void (212), a trailing void (214), and a separator (216) dividing the leading void and the trailing void; and a plurality of notches (200) disposed in the extruded control surface proximate the leading edge of the control surface.