Seal-Cover Assembly for One-Sided Fuel Tank Fastener Installation
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Solution Overview
Problem
The installation of metallic fasteners in fuel tanks requires access to both sides, making it difficult to secure the containment cap before the fastener is installed, which complicates the process and increases the risk of electrical transmission and sparks during electromagnetic events.
Innovation Solution
A seal-cover assembly that allows the cap to be secured to one side of the structure before the fastener is installed from the other side, using a cap with a recess and an insert to form a cover unit that isolates the fastener and prevents electrical transmission, enabling one-sided installation and improved safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the containment cap is installed after the metallic fastener is secured to the fuel tank, then the fastener can be properly secured to the structure, but the installation process requires access to both sides of the fuel tank which complicates the process and increases installation time
Solution Approach 1:
The cap is pre-installed on the fuel tank before the fastener is inserted. This preliminary action allows the cap to be in place during fastener installation, eliminating the need to access both sides of the tank for fastener securing, thereby reducing installation time while maintaining containment reliability
2Reliability
If the containment cap is installed after the fastener is secured, then the fastener can be properly contained, but the complexity of the installation process increases due to requiring access to both sides
Solution Approach 1:
The cap is installed in advance on the fuel tank before fastener installation. This preliminary placement simplifies the overall installation process by allowing workers to install the fastener through the tank wall without needing to access the other side, reducing procedural complexity while ensuring electrical insulation is maintained
3Ease of operation
If the cap is secured before the fastener is installed, then one-sided installation is enabled simplifying the process, but the cap must be designed with specific features to accommodate subsequent fastener attachment
Solution Approach 1:
The cap is divided into two functional segments: an external portion that interfaces with the fuel tank surface and an internal portion with attachment features for the fastener. This segmentation allows the cap to be pre-installed on one side while providing built-in mechanisms for fastener attachment from the opposite side, simplifying installation without requiring complex additional components
Data Source
AI summary
A seal-cover assembly for a structure including a first side and a second side opposing the first side. The seal-cover assembly includes a cap defining a recess, and an insert fixed to the cap within the recess to form a cover unit. The cover unit is configured to be secured to the first side of the structure. The seal-cover assembly includes a fastener configured to be disposed through the structure from the second side of the structure. The fastener is attached to the cover unit relative to the second side without accessing the first side of the structure. Additionally, an aircraft includes the structure and the seal-cover assembly as discussed above. Furthermore, a method of assembling the seal-cover assembly to the structure includes the cover unit secured to the first side of the structure such that an interior of the cover unit is inaccessible from the first side.