Fuel Control Structure Layout for Additive Manufacturing Weight Reduction
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Solution Overview
Problem
Conventional design methods for fuel control devices in aircraft are constrained by traditional manufacturing processes, limiting design optimization and extending product development cycles, while the need for lightweight, high-performance components is urgent.
Innovation Solution
An optimization method for fuel control device structure using additive manufacturing, involving basic arrangement analysis, flow channel and envelope structure optimization, and iterative design using finite element tools, to achieve a lightweight and functional design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional casting and machining processes are used for fuel control device manufacturing, then manufacturing precision and structural strength can be ensured, but device weight increases and design optimization is constrained
Solution Approach 1:
The patent changes the manufacturing process parameter from conventional casting and machining to additive manufacturing technology. This fundamental parameter change enables the fuel control device to achieve weight reduction while maintaining manufacturing feasibility, as additive manufacturing allows for complex lightweight structures that cannot be produced by traditional methods
Solution Approach 2:
The patent segments the fuel control device into modular components including valve body, valve core, actuator, and flow control elements. This segmentation allows each component to be optimized independently for weight reduction while maintaining overall structural integrity and functional requirements
2Productivity
If traditional design thinking and manufacturing constraints are applied, then manufacturing feasibility is maintained, but product development cycle extends and design optimization space is limited
Solution Approach 1:
The patent applies preliminary action by performing comprehensive arrangement analysis and structural optimization during the design phase before manufacturing. This includes determining optimal component layouts, flow channel configurations, and structural reinforcements in advance, which enables rapid prototyping and iteration without manufacturing constraints limiting design exploration
Solution Approach 2:
The patent transitions from two-dimensional conventional manufacturing constraints to three-dimensional additive manufacturing capabilities. This dimensional change allows complex spatial structures, internal flow channels, and integrated components to be designed and manufactured directly, dramatically expanding design optimization space and reducing development iterations
3Adaptability or versatility
If additive manufacturing is used for fuel control device production, then design flexibility and rapid prototyping are achieved, but manufacturing precision and structural strength may be compromised
Solution Approach 1:
The patent applies local quality by implementing region-specific structural optimizations within the additive manufactured fuel control device. Different areas of the device have tailored wall thicknesses, reinforcement patterns, and material densities according to local stress distributions and functional requirements, ensuring high precision and strength where needed while maintaining design flexibility in other areas
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
The method reduces the fuel control device weight by 38% and shortens the development cycle through flexible design and rapid prototyping, while maintaining structural integrity and functionality.
Implementation Method 1
selective laser melting (SLM) is currently the most widely used metal additive manufacturing technology. The technology uses metal powder as raw material and laser as heat source, by reducing the dimension of three-dimensional parts to two-dimensional plane and processing them layer by layer
Data Source
AI summary
An optimization method for a fuel control device structure based on additive manufacturing includes: performing a basic arrangement analysis and a selection of the fuel control device structure; performing an arrangement design of a basic component/interface feature structure according to the basic configuration structure; performing an optimization design for a flow channel structure on the basis of determining structural features of all cores, components and interfaces; performing the optimization design for an outer envelope structure on the basis of the flow channel structure; and checking a calculation and optimizing an iterative design of the fuel control device structure through a finite element tool, and determining a structural scheme of the optimal fuel control device. The optimization method gives full play to the technological advantages of additive manufacturing and determines the optimal structural arrangement and flow channel design scheme to meet the product requirements through pure forward design ideas.