Integral Triangular Fuselage Frame Element
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Solution Overview
Problem
The assembly of aircraft fuselage frame elements is time-consuming and costly due to the large number of fasteners required, particularly at the cross member/frame junctions, where high forces are transmitted, leading to increased manufacturing costs and complexity, especially in large aircraft designs.
Innovation Solution
The integration of a single, machined or composite material frame element that combines a cross member, frame section, and strut into a single, integral triangular part with constant height, reducing the need for multiple fasteners and simplifying the design by distributing forces more evenly, thus allowing for a more straightforward assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple fasteners are used to join cross member and frame at junctions with high forces, then the structural strength and force transmission capability are improved, but the assembly time and manufacturing complexity increase significantly
Solution Approach 1:
The patent merges the cross member and frame into a single integrated component that forms an integral triangle structure. This eliminates the need for separate fasteners to join these components, as they are already unified into one piece. The integration directly reduces assembly time while maintaining the structural strength needed for force transmission, as the unified geometry inherently provides the necessary mechanical properties.
2Strength
If the height of frames and cross members is increased locally to accommodate fasteners, then the force transmission capability is improved, but the manufacturing cost and part complexity increase
Solution Approach 1:
By combining the cross member and frame into a single integrated triangular structure, the patent eliminates the need for variable height adjustments and local geometric modifications that would be required to accommodate fasteners. The unified geometry maintains constant height throughout, simplifying manufacturing while the integrated design inherently provides the necessary force transmission capabilities without requiring increased local dimensions.
3Ease of manufacture
If multiple separate parts are used to form the fuselage frame structure, then the manufacturing flexibility and material selection are improved, but the overall mass and assembly complexity increase
Solution Approach 1:
The patent integrates multiple frame components into a single monolithic triangular structure. This reduction in the number of parts directly decreases the overall mass, as there is no additional weight from fasteners, joinery, or assembly hardware. The integrated design maintains manufacturing flexibility through modern fabrication techniques such as additive manufacturing or precision machining, which can produce complex geometries from single-piece configurations.
4Adaptability or versatility
If traditional separate components are assembled with fasteners, then the design adaptability and repairability are improved, but the assembly cost and time increase
Solution Approach 1:
The integrated triangular structure eliminates the need for fastener installation, directly improving assembly productivity by reducing the number of assembly operations required. The design maintains adaptability through the use of standardized integration methods and modular attachment points that allow for configuration changes without requiring disassembly and reassembly of multiple components. The unified geometry provides inherent structural adaptability while significantly reducing assembly time and cost.
Data Source
AI summary
An aircraft fuselage frame assembly includes a first lower frame element having a cross member and a curved fuselage tub frame. A second upper frame element of the assembly has a cross member and a curved upper frame segment. A third frame element of the assembly is made of a cross member section, floor strut section and frame section. The third frame element is formed as a single, integral triangle element having a hypotenuse that is curved to adopt a curvature of the aircraft fuselage and joining portions at angle areas of the triangle. A lower frame link is joined to the first upper frame and at a first angle area of the triangle element; an upper frame link is joined to the second upper frame and at a second angle area of the triangle element; and a floor cross member is joined at a third angle area of the triangle element.