Inflatable Bladder Bore Alignment Without Surface Wear
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Solution Overview
Problem
The challenge of aligning bores in large mechanical components, such as aircraft components, is time-consuming and costly, especially as component sizes increase, and existing methods like tapered alignment pins can wear down surfaces during alignment.
Innovation Solution
An inflatable bladder system with a layered structure, including an elastomeric layer, a friction-reducing layer, and a pressurized fluid source, is used to align bores by expanding within the bores to align them without surface wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tapered alignment pins are thrust into misaligned bores to effect alignment, then alignment is achieved, but the thrusting process is time consuming and wears off the surface finish on the components
Solution Approach 1:
The patent uses an inflatable bladder aligned with the bore that is inflated with fluid pressure to push the workpiece against the fixture, replacing the traditional mechanical thrusting process with a pneumatic/hydraulic system that achieves alignment without time-consuming manual operations
Solution Approach 2:
The invention replaces the mechanical thrusting process with a fluid pressure system. The inflatable bladder uses fluid pressure to generate the aligning force, substituting the mechanical hammering/thrusting action with a controlled fluid pressure application that is both faster and less damaging to surfaces
2Manufacturing precision
If tapered alignment pins are thrust into misaligned bores to effect alignment, then alignment is achieved, but the surface finish on the components is worn off
Solution Approach 1:
The inflatable bladder uses fluid pressure to generate aligning forces, replacing direct mechanical contact and thrusting that causes surface wear. The fluid pressure acts through the bladder material, distributing forces evenly and avoiding concentrated mechanical contact that damages surfaces
Solution Approach 2:
The inflatable bladder acts as an intermediary between the fixture and the workpiece. Instead of direct mechanical contact between alignment pins and the workpiece surface, the bladder mediates the force transmission, protecting the workpiece surface from direct mechanical contact and associated wear
3Strength
If mechanical fasteners are used to connect large aircraft components, then secure connection is achieved, but alignment of bores becomes more difficult and expensive as component size increases
Solution Approach 1:
The inflatable bladder alignment system provides a scalable solution for large components by using fluid pressure to generate sufficient aligning forces regardless of component size. The system can be adjusted by controlling fluid pressure, making it adaptable to various component sizes without increasing operational difficulty
Solution Approach 2:
The alignment system is dynamic and adjustable through fluid pressure control. The inflatable bladder can be inflated to different pressure levels to accommodate different component sizes and alignment requirements, providing a flexible solution that adapts to varying operational conditions rather than requiring different fixed alignment methods for different sizes
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 inflatable bladder system efficiently aligns bores with reduced friction and surface wear, facilitating faster and more cost-effective assembly of large mechanical components, such as aircraft parts, by using pressurized fluid to expand and engage with the components.
Implementation Method 1
pressurizing the inflatable bladder with a fluid to cause the inflatable bladder to expand into engagement with the first member and the second member
Implementation Method 2
an elastomeric layer defining an interior surface of the body
Implementation Method 3
a friction-reducing layer defining an exterior surface of the body
Data Source
AI summary
A bladder assembly including an inflatable bladder having an elongated body defining an internal volume, the body being formed as a layered structure that includes an elastomeric layer defining an interior surface of the body, a friction-reducing layer defining an exterior surface of the body, and a jacketing layer positioned between the elastomeric layer and the friction-reducing layer, and a pressurized fluid source in selective fluid communication with the internal volume of the body.