Generic Repair Component Analysis for Composite Structures
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Solution Overview
Problem
Existing methods for repairing composite structures, such as aircraft fuselages, are time-consuming, labor-intensive, and require extensive engineering analysis, especially for large area repairs, due to the complexity of bonding techniques and the need for multiple specialized tools and experts.
Innovation Solution
A computer-implemented method for analyzing a repair for a structure by identifying component parts with common material properties and geometric constraints, determining a generic repair component, redistributing loads using a loads redistribution model, and performing an analysis to determine the margin of safety for the generic repair component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If bonding techniques are used for small area repairs, then the repair can be performed on localized areas, but the plies are built up beyond normal skin thickness altering the cross sectional profile
Solution Approach 1:
The invention changes the geometric parameters of the repair component by providing templates with varying radii of curvature that match the original skin profile. This allows the repair component to conform to the skin's cross-sectional shape rather than altering it, resolving the contradiction between ease of repair and shape preservation
Solution Approach 2:
The invention applies local quality by creating repair components with specific geometric properties tailored to different locations on the skin. Each template is designed with radius of curvature values matched to the local skin geometry at specific stations, allowing localized repairs that preserve the original cross-sectional profile
2Ease of manufacture
If bonding techniques are used for repairs, then repairs can be performed on composite structures, but the variations are difficult to control on a repeatable basis
Solution Approach 1:
The invention applies preliminary action by pre-calculating and pre-defining the geometric parameters (radii of curvature) of repair components before manufacturing. The templates are designed in advance with precise geometric constraints that ensure repeatable manufacturing, eliminating variations that occur with traditional bonding techniques
Solution Approach 2:
The invention creates universal repair components that can be applied to multiple locations on the skin. The templates with defined geometric constraints serve as standardized repair solutions that can be repeatably manufactured and applied across different repair sites, improving both ease of manufacture and manufacturing precision
3Ease of repair
If large area repairs are performed by cutting away sections and replacing interior stringers and frame members, then larger damaged areas can be repaired, but extensive engineering analysis is required to determine the area to be cut out
Solution Approach 1:
The invention applies preliminary action by pre-defining the geometry and dimensions of repair components using templates with specified radii of curvature. This preliminary design work eliminates the need for extensive engineering analysis during actual repair, as the repair component geometry is predetermined based on the skin's original cross-sectional profile
Solution Approach 2:
The invention segments the repair process into template design and component fabrication stages. By separating the geometric definition (templates) from the actual repair execution, the method enables large area repairs without requiring extensive on-site engineering analysis, reducing time loss while maintaining repair capability
4Measurement precision
If engineering analysis is performed for large area repairs, then precise determination of repair area can be achieved, but multiple specialized experts and tools are required
Solution Approach 1:
The invention uses copying by creating template representations of the skin's cross-sectional profile at various stations. These templates capture the essential geometric information needed for precise repair area determination without requiring complex engineering tools or multiple experts, simplifying the analysis process while maintaining accuracy
Data Source
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AI summary
An apparatus is provided for analysis of a repair for a structure by identifying component parts of the structure that have common material properties and geometric constraints, and based thereon determining a generic repair component for the component parts that also have the common material properties and the geometric constraints. A set of loads are extracted from a loads model of the undamaged structure and redistributed in a loads redistribution model at a damaged or defective portion of the component part. The set of redistributed loads indicate loading incurred by the generic repair component under an external load. The apparatus then uses the redistributed loads to perform an analysis to determine a margin of safety of the generic repair component and, in instances in which the margin of safety is positive, outputs the material properties and geometric constraints of the generic repair component to a fabrication system for production thereof.