Modular Airframe Cells with Nested Profiles for Reconfiguration

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Solution Overview

Problem

Conventional airframe manufacturing methodologies lack reconfiguration capabilities to adapt to mission-specific operational requirements, limiting their flexibility and efficiency.

Innovation Solution

The development of an airframe composed of modular cells with interchangeable profiles, allowing for the assembly and reconfiguration of airframes according to specific needs, where a first structural profile encloses a passageway to receive a second profile, enabling the integration of various components such as propulsors, fuel tanks, and electronics, facilitating flexible configuration and in-field reconfiguration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional monocoque or semi-monocoque manufacturing methodologies are used, then structural integrity is maintained, but reconfiguration capability is lost

Engineering Contradiction:

Improvereconfiguration capabilityVSAvoidairframe structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The airframe is divided into multiple modular cells that can be independently manufactured and then assembled. Each cell contains profiles that can receive other profiles, enabling the airframe to be segmented into reusable modules that maintain structural integrity while allowing reconfiguration for different mission requirements.

Inventive Principle:

Principle #1Segmentation

2Productivity

If conventional airframe manufacturing is used, then manufacturing process is simple, but production flexibility for high-variety low-volume production is reduced

Engineering Contradiction:

Improvemanufacturing speedVSAvoidproduction flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

Standard modular cells are pre-manufactured and stocked before final airframe assembly. This preliminary production of standardized modules enables rapid assembly of different airframe configurations on demand, significantly improving manufacturing speed for high-variety low-volume production while maintaining production flexibility.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If modular cells with passageways are used, then reconfiguration capability is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvereconfiguration capabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The modular cells are designed with universal features including standardized passageways that can receive different profile types and standardized coupling mechanisms. This universality allows the same cell design to serve multiple functions and configurations, reducing overall manufacturing complexity despite the added reconfiguration capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11738850B2Airframe and method for assembling an airframe

Publication Date: 2023.08.29 BAE SYSTEMS PLC

AI summary

An airframe 1 or part thereof comprises a set of modular cells 10, including a first cell 10A comprising a set of profiles 100 including: a first structural profile 100A, having a first length L1 and enclosing a first volume V1 providing a first passageway P1; and a second profile 100B, having a second length L2 and enclosing a second volume V2, wherein the first passageway P1 is arranged to receive the second profile 100B therein.