Additively Built FODS Clamp for Vibration-Resistant Rail Tube Joints
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Solution Overview
Problem
Fire and overheat detection system (FODS) assemblies in aircraft face failures due to vibrational loading and bending/twisting modes, leading to weld failures between dual element clamp bodies and rail tubes, necessitating the use of costly materials to prevent damage.
Innovation Solution
The method involves additively manufacturing a clamp body onto a rail tube using laser direct metal deposition (LMD), incorporating a locking feature, holders with grooves, and securing grommets with top clamp parts and a locking pin, eliminating the need for traditional welding and allowing the use of less expensive materials like stainless steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding is used to attach clamp bodies to rail tubes, then assembly strength is improved, but material costs increase and weld failures occur under vibrational loading
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system consisting of a clamp body with locking features, grommets, and retaining clips. This substitution eliminates the harmful effects of welding (heat-affected zones, weld cracks) while maintaining secure attachment through mechanical interlocking, thereby improving reliability under vibrational loading without sacrificing joint strength.
Solution Approach 2:
The clamp assembly is divided into separate components: the clamp body, grommets, and retaining clips. This segmentation allows each component to be optimized independently and assembled mechanically without welding, reducing the risk of weld failures while maintaining overall joint strength. The modular design also facilitates easier inspection and replacement of individual components.
2Reliability
If costly materials are used for clamp bodies, then damage prevention is improved, but manufacturing costs increase
Solution Approach 1:
The patent changes the material parameter of the clamp body from expensive materials to cost-effective materials such as aluminum alloys or plastics. This parameter change is compensated by optimizing the mechanical design (locking features, grommets, retaining clips) to ensure adequate strength and damage prevention, thereby reducing manufacturing costs without sacrificing reliability.
Solution Approach 2:
The clamp assembly utilizes composite construction combining different materials: the clamp body (aluminum alloy or plastic), grommets (elastomeric material for vibration damping), and retaining clips (metal for structural support). This composite approach allows each material to be selected for its optimal properties, achieving reliable damage prevention at lower overall cost compared to using expensive materials throughout.
3Strength
If dual element clamps with welding are used, then sensing element constraint is improved, but assembly complexity increases
Solution Approach 1:
The patent merges the functions of multiple components (clamp body, grommets, retaining clips) into an integrated assembly that works together to constrain sensing elements. The locking features of the clamp body combine with the elastomeric grommets and metal retaining clips to provide both mechanical constraint and vibration damping, achieving strong constraint while simplifying the overall assembly process through standardized mechanical fastening rather than welding.
4Productivity
If welds are used to attach clamp bodies, then manufacturing efficiency is improved, but weld cracking occurs under vibrational loading
Solution Approach 1:
The patent replaces the welding process with mechanical fastening using locking features, grommets, and retaining clips. This substitution eliminates the formation of welds that are susceptible to cracking under vibrational loading, thereby improving reliability while maintaining manufacturing efficiency through streamlined assembly of pre-fabricated components.
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 approach enhances joint strength, reduces material costs, eliminates weld cracking, and improves manufacturing efficiency, enabling the use of higher strength materials while reducing weight and assembly time.
Implementation Method 1
The building and the sequential building include laser direct metal deposition (LMD).
Data Source
AI summary
A method of additively manufacturing a fire and overheat detection system (FODS) clamp onto a rail tube is provided. The method includes building a base of a clamp body on the rail tube, sequentially building portions of a locking feature and holders of the clamp body on the base and sequentially building remaining portions of the holders and flanges forming grooves at each of the holders of the clamp body on the base.