Aircraft Leading Edge Assembly for Low-Disturbance Surface Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing aircraft leading edges result in significant gaps and offsets between the outer surfaces of the leading edge and the wing surfaces, leading to aerodynamic disturbances and reduced laminar flow.
Innovation Solution
A manufacturing method that involves pressing the outer wall of the leading edge against a shaping surface with a magnetic or suction system to align it with a theoretical outer surface, using adhesive to compensate for gaps, and assembling the structure with the outer wall while maintaining alignment during adhesive setting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional assembly methods are used to connect the structure and outer wall, then assembly simplicity is maintained, but significant gaps and offsets occur between the leading edge and wing surfaces, causing aerodynamic disturbances
Solution Approach 1:
The outer wall is pre-shaped against a shaping surface before assembly to achieve the correct aerodynamic profile. This preliminary shaping ensures that when the outer wall is subsequently connected to the structure, the alignment with wing surfaces is already optimized, reducing gaps and offsets without requiring complex adjustment mechanisms during assembly
Solution Approach 2:
A shaping surface acts as an intermediary tool during the assembly process. The outer wall is pressed against this shaping surface to achieve precise geometric alignment before final connection to the structure. The shaping surface serves as a reference that transfers the correct aerodynamic profile to the outer wall, ensuring proper alignment with wing surfaces
2Manufacturing precision
If reduced tolerance intervals are applied to transverse and longitudinal reinforcements, then assembly precision is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of requiring tight tolerances throughout the entire reinforcement structure, the invention applies localized precision only where aerodynamic performance is critical - specifically at the outer wall interface with wing surfaces. The shaping surface ensures precise alignment at this critical location, while other parts of the reinforcements can maintain standard manufacturing tolerances, simplifying overall manufacturing
3Ease of operation
If offsets between leading edge outer surfaces and wing surfaces are allowed, then assembly ease is maintained, but aerodynamic performance deteriorates due to disturbed laminar flow
Solution Approach 1:
The invention replaces complex mechanical alignment systems with a magnetic field-based positioning system. Magnets embedded in the structure automatically attract and position the outer wall with high precision during assembly, eliminating the need for manual measurement and adjustment while achieving the required alignment precision to minimize aerodynamic disturbances
Solution Approach 2:
The invention changes the physical state or properties of materials to achieve better alignment. For example, using materials with specific magnetic properties allows for automatic positioning through magnetic attraction, or using adhesives with extended setting times allows for alignment adjustments during the bonding process, thereby achieving precise alignment without complicating the assembly procedure
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
Reduces gaps between the leading edge and wing surfaces, minimizing aerodynamic disturbances and enhancing laminar flow, while reducing assembly costs and allowing for greater dimensional tolerances.
Implementation Method 1
during the assembly step, the outer wall being held pressed by a magnetic system against a shaping surface
Implementation Method 2
the structure and the outer wall are connected by gluing using an adhesive having a setting time, the outer wall being kept pressed against the shaping surface during the setting time of the adhesive
Data Source
Figure 1~3
Figure 4~6
Figure 7~10
AI summary
The invention relates to a method for manufacturing a leading edge comprising a structure (46) and at least one outer wall (38). The manufacturing method includes a step of assembling the structure (46) and an assembly step for joining the structure (46) and the outer wall (38), during which the outer wall (38) is held against a conforming surface (50) having a profile identical to a theoretical outer surface configured to limit aerodynamic disturbances. This manufacturing method improves the aerodynamic performance of the resulting leading edge and the aircraft's airfoil incorporating it.