Modular Airframe Cells with Nested Structural Profiles
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Solution Overview
Problem
Conventional airframe manufacturing methodologies lack reconfiguration capabilities to adapt to mission-specific operational requirements, limiting flexibility and efficiency in assembly and customization.
Innovation Solution
The development of an airframe composed of modular cells with structural and non-structural profiles that can be assembled and reconfigured, allowing for the insertion and removal of components such as propulsors, fuel tanks, and electronics, enabling flexible configuration and modular assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional monocoque or semi-monocoque manufacturing methodologies are used, then structural integrity is maintained, but reconfiguration capability according to mission-specific operational requirements is lost
Solution Approach 1:
The airframe is divided into multiple modular cells that can be independently manufactured and then assembled. Each cell contains structural profiles with internal passageways that can receive and secure additional components. This segmentation enables reconfiguration by allowing different combinations of cells and components to be assembled according to mission requirements, while maintaining structural integrity through standardized connection interfaces.
2Ease of manufacture
If modular cells with passageways are used, then reconfiguration and assembly flexibility are improved, but manufacturing complexity increases
Solution Approach 1:
The design features nested structural profiles where one profile is received within the passageway of another profile. This nesting arrangement allows components to be securely housed within the modular cell structure while maintaining a compact overall form. The nested configuration simplifies assembly by providing built-in mounting positions and reduces the need for additional fastening hardware, thereby improving ease of manufacture despite the modular complexity.
3Productivity
If automated manufacturing processes are implemented, then productivity and quality are improved, but initial device complexity increases
Solution Approach 1:
The modular cells and structural profiles are pre-manufactured with standardized features, including pre-formed passageways and connection interfaces, before final assembly. This preliminary manufacturing of standardized components enables automated production processes to be implemented efficiently, as the components require minimal customization during final assembly. The pre-prepared modular units can be manufactured in advance using automated composite material processing, thereby improving productivity while the standardized nature of the components actually reduces overall process complexity.
Data Source
AI summary
An airframe or a part thereof 3, for example a skin assembly or a profile such as a structural profile, comprises: a wall W having an aperture A therethrough, wherein the wall W provides a frame F surrounding, at least in part, the aperture A; a panel P conforming with the aperture A; and wherein the airframe or the part 3 thereof is configurable in: a first configuration, wherein the panel P and the frame F are mutually spaced apart; and a second configuration, wherein the panel P is received in the frame F and wherein the frame F resists movement of the panel P in two or three mutually orthogonal directions.