Lightweight Gimbal Joint Structure for Bleed Air Ducting
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Solution Overview
Problem
Existing gimbal joint designs for high temperature and high pressure fluid ducting systems in aerospace applications are heavy due to excessive material usage, which increases the weight of aircraft and spacecraft while compromising flexibility and structural integrity.
Innovation Solution
The development of geometrically and topologically optimized gimbal joint assemblies that minimize material usage by integrating structural features such as struts, trusses, and shear webs, and utilizing additive manufacturing techniques to produce complex designs with reduced weight and friction, allowing for two degrees of angular deflection and enhanced structural compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional solid annular gimbal joint components are used, then structural integrity is sufficient, but weight increases significantly
Solution Approach 1:
The patent applies topology optimization to create a porous or lattice-like internal structure within the gimbal joint components. This replaces solid annular sections with strategically placed material that maintains structural integrity while significantly reducing weight. The optimized geometry creates a framework that distributes stresses efficiently throughout the structure, mimicking the strength-to-weight ratio of porous materials.
Solution Approach 2:
The gimbal joint components are segmented into discrete structural elements rather than using solid continuous material. The topology optimization divides the annular structure into optimized segments or struts that carry specific loads, allowing material to be removed from non-critical areas while maintaining strength in load-bearing regions.
2Weight of moving object
If material is removed to reduce weight, then weight decreases, but friction and wear at contact points increase
Solution Approach 1:
The patent changes the geometric parameters of the contact surfaces and bearing surfaces through topology optimization. By carefully designing the curvature, radius, and geometry of rotating contact points, the optimization reduces contact pressure and distributes wear more evenly. The optimized geometry allows for larger bearing surfaces or more favorable contact angles without increasing overall component size or weight.
3Weight of moving object
If complex optimized geometry is implemented, then weight and friction are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple manufacturing operations or features into a single additive manufacturing process. The complex topology-optimized geometry, which would require multiple machining steps, tool paths, and assemblies using traditional methods, is produced as a single monolithic component through additive manufacturing. This eliminates the need for separate machining operations, assembly steps, and tooling for complex internal geometries.
Solution Approach 2:
The patent changes the manufacturing method from subtractive (machining) to additive manufacturing. This parameter change in the manufacturing process enables the production of complex topology-optimized geometries that would be difficult or impossible to manufacture using traditional subtractive methods. The additive process can directly create internal lattices, hollow sections, and optimized strut configurations without requiring complex tooling or multiple assembly steps.
Data Source
AI summary
A sealed joint assembly for transmitting high temperature and high pressure fluid between adjoining ducts in, for example, an aircraft bleed air system, includes a gimbal ring and two annular clevises. Each clevis includes a pair of axially-extending lobes that each includes a bore hole extending therethrough. The bore holes of the clevis lobes may each align with a respective bore hole formed within the gimbal ring, through which a pin may be inserted to couple the clevises to the gimbal ring. The clevises and gimbal ring may be formed using additive manufacturing, to produce component geometries and topologies that reduce the overall weight of the joint assembly while maintaining or improving its structural integrity. For example, the clevis lobes may include a plurality of gaps, such that the remaining material forms a shear web. The gimbal ring may also include strut or truss networks to enhance structural integrity.