Jet Engine Air Intake U-Shaped Lip Assembly
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Solution Overview
Problem
The conventional assembly method for aircraft jet engine air intakes is time-consuming and heavy due to the numerous elements and steps required for attachment, necessitating a more efficient assembly process.
Innovation Solution
An assembly method that uses a single U-shaped lip element, produced through additive manufacturing, which integrates the acoustic and outside panels with reduced steps by providing a chassis for initial placement, attaching flanges and a collar, measuring geometric data, and manufacturing the lip as a single element using 3D printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lip is constructed from numerous attached elements, then the structural integrity and functionality are maintained, but the installation time increases and additional weight is added
Solution Approach 1:
The patent merges multiple lip elements into a single integrated lip component that performs all necessary functions (acoustic sealing, structural support, and aerodynamic shaping) without requiring assembly of separate parts, thereby eliminating installation time while maintaining structural integrity through monolithic construction
2Reliability
If the lip is constructed from numerous attached elements, then the functional requirements are met, but the weight increases due to attachment elements
Solution Approach 1:
The patent combines multiple functional elements into a single lip structure, eliminating the weight of attachment elements (screws, bolts, welds) while maintaining all necessary functions through integrated design, resulting in weight reduction without compromising functionality
3Ease of manufacture
If conventional assembly methods are used with multiple elements, then the air intake can be assembled, but the number of assembly steps increases
Solution Approach 1:
The patent reduces assembly complexity by providing the lip as a single pre-manufactured component that requires only one installation step, eliminating the multiple assembly operations needed for attaching separate lip elements while maintaining ease of manufacture through simplified installation procedures
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 significantly reduces assembly steps and weight by integrating the lip as a single element, improving handling and integration, while allowing for efficient production using advanced manufacturing techniques like 3D printing.
Implementation Method 1
a manufacturing step in which a U-shaped lip is produced as a single element on the basis of the geometric data so taken, wherein the manufacturing step comprises additive manufacturing
Data Source
AI summary
An assembly method for an air intake of a jet engine of an aircraft, comprising providing an acoustic panel, an outside panel, flanges and a collar, arranging a rear edge of the acoustic panel on an assembly chassis. The flanges and the collar are attached at the rear edge of the acoustic panel. A rear edge of the outside panel is attached to the attached collar. A first set of geometric data of a front edge of the acoustic panel is measured and a second set of geometric data of a front edge of the outside panel is measured. A U-shaped lip as a single element is produced based on the two sets of geometric data. An inside leg of the lip is attached to the front edge of the acoustic panel and an outside leg of the lip is attached to the front edge of the outside panel.