Honeycomb Tip Core Assembly for Rotor Blade Structural Rigidity
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Solution Overview
Problem
Conventional rotor blades with anhedral tip sections in rotary-wing aircraft face increased manufacturing complexity and cost due to the need for numerous components to manage high stresses and strains from aerodynamic forces, which complicates the manufacturing process and increases costs.
Innovation Solution
A rotor blade design featuring a core member with a spar member and a tip core assembly made of honeycombed material, which is mounted to the spar member and provides structural rigidity while minimizing manufacturing complexity and cost by forming the anhedral tip section, thereby reducing the risk of delamination and manufacturing failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional anhedral tip sections are used to enhance rotor blade performance, then hover performance and lift capabilities are improved, but the number of components increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the tip section structure into a single integrated core member that combines the functions of multiple conventional components. The core member includes a spar, shear web, and tip section structure all as one piece, eliminating the need for separate components to carry aerodynamic loads.
Solution Approach 2:
The patent uses composite material construction for the core member, combining different materials to achieve the required strength and stiffness while reducing the number of discrete components. The honeycombed material provides structural rigidity with reduced weight and component count.
2Strength
If conventional anhedral tip sections are used to enhance rotor blade performance, then hover performance and lift capabilities are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The tip section is integrated into the core member as a single structure, eliminating the need to manufacture and assemble multiple separate components. This reduces manufacturing steps, assembly operations, and associated costs.
Solution Approach 2:
The core member is designed with segmented functional zones (spar region, shear web region, tip section) that can be manufactured separately and then joined, allowing for specialized manufacturing processes for each zone while still achieving overall simplification.
3Strength
If numerous components are used to carry aerodynamic loads, then structural integrity is maintained, but manufacturing difficulty increases
Solution Approach 1:
The core member is designed as an integrated structure where the spar, shear web, and tip section work together as a unified load-carrying system, maintaining structural integrity while eliminating the need for multiple separate components.
Solution Approach 2:
The use of composite materials and honeycombed structures allows the core member to achieve high strength-to-weight ratio and structural integrity with a single monolithic or minimally segmented construction, reducing manufacturing difficulty.
Data Source
AI summary
A rotor blade for a rotary-wing aircraft includes a core member having a first end that extends to a second end, and a spar member positioned about the core member. The spar member includes a first end section that extends to a second end section. A tip core assembly is mounted at the second end section of the spar member. The tip core assembly is formed from a honeycombed material. The rotor blade also includes a rotor blade skin mounted about the spar member and the tip core assembly.