Integral Triangle Region Structure for Fastener-Free Fuselage Assembly
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Solution Overview
Problem
The assembly of triangle regions in aircraft fuselages is ergonomically unfavorable due to restricted access and complex component connections, particularly for Z-struts located below the intermediate floor, which are difficult to install and require multiple components.
Innovation Solution
A method involving an integral board with deformable edges is used to create internal and external flanges, forming a triangle region without separate components, allowing for simplified assembly and integration into the fuselage structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional separate components (Z-struts, transverse spars, floor beams) are used to form the triangle region, then the structural integrity and load-bearing capacity are maintained, but the assembly complexity increases and ergonomics deteriorate due to restricted access below the intermediate floor
Solution Approach 1:
The patent combines multiple separate structural components (Z-strut, transverse spar, floor beam, and triangle region elements) into a single integral fuselage structural component formed from one continuous board of former material. This merging eliminates the need for separate assembly operations in the difficult-to-access triangle region below the intermediate floor, directly improving assembly ergonomics while reducing the total number of components.
Solution Approach 2:
The integral board is designed to perform multiple functions simultaneously: it forms the former structure, creates the triangle region geometry, provides the intermediate floor support, and incorporates reinforcement flanges for load-bearing. This multi-functionality consolidates what would traditionally require multiple separate components, reducing assembly complexity while maintaining structural integrity.
2Productivity
If multiple separate components are assembled to form the triangle region, then the structural strength and reinforcement are achieved, but the assembly time and production efficiency decrease
Solution Approach 1:
By forming the entire triangle region structure from a single integral board, the patent eliminates multiple assembly operations including fastening Z-struts to transverse spars and floor beams. This single-component approach dramatically increases assembly speed and reduces production time, as the entire structure can be installed as one piece rather than assembling multiple separate components in the confined space below the intermediate floor.
3Ease of manufacture
If traditional assembly methods with multiple components and fasteners are used, then the structural reinforcement is achieved, but the manufacturing complexity and production cost increase
Solution Approach 1:
The integral board design maintains structural reinforcement by incorporating deformation flanges that extend from the board edges, creating rigid connections equivalent to traditional multi-component assemblies. However, this is achieved through a single manufacturing process (board formation and deformation) rather than assembling multiple reinforced components with fasteners, significantly simplifying production and reducing manufacturing complexity while preserving the necessary structural strength.
4Device complexity
If separate Z-struts and floor beams are installed in the triangle region, then the load-bearing capacity is maintained, but the number of fasteners and connection points increases
Solution Approach 1:
The integral board structure eliminates the need for multiple fasteners by creating a continuous load-path through the single-piece construction. The deformation flanges formed from the board edges provide inherent connection points that maintain load-bearing capacity without requiring additional fasteners to join separate Z-struts and floor beams. This reduces the number of fasteners to zero for the triangle region assembly while preserving the necessary structural strength.
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
This method reduces assembly complexity, eliminates the need for fasteners, and enables faster, more efficient production of fuselage structural components with enhanced reinforcement, reducing overall build time and cost.
Implementation Method 1
deforming at least one internal edge of the board that forms the opening to an internal flange, and deforming at least one external edge of the board to an external flange
Data Source
AI summary
A method for producing a fuselage structural component for a triangle region of an aircraft by: providing an integral board of a former material, wherein the board has an opening; and deforming at least one internal edge of the board that forms the opening to an internal flange; and deforming at least one external edge of the board to an external flange. Adjacent to the opening, the integral and deformed board forms in each case a former portion, a floor beam and a vertical support. Also a fuselage structural component and an aircraft with the fuselage structural component.