Modular Aircraft Pylon Assembly for Larger Payload Clearance
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Solution Overview
Problem
Conventional pylons in the aviation industry are limited in payload capacity, size, and weight, restricting operational capabilities and interfering with weapons bay door openings, and introduce proximity constraints that complicate payload carriage.
Innovation Solution
A modular pylon assembly with an ambidextrous core module and symmetrical carriage modules that can be reconfigured for left or right side attachment, allowing full opening of weapons bay doors and reducing interference with aircraft operations, while supporting multiple mounting hardpoints and enabling the carriage of diverse payloads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional pylons are used to carry external payloads, then payload attachment is achieved, but payload capacity is limited in size and weight
Solution Approach 1:
The pylon assembly is divided into modular components: a core module containing carriage-attachment elements, a fairing module for aerodynamic coverage, and optional payload modules. This segmentation allows the system to be configured for different payload sizes and weights by assembling appropriate modules, directly addressing the limitation of fixed conventional pylon capacity.
Solution Approach 2:
The core module is designed with multiple sets of carriage-attachment elements that can accommodate various payload types and configurations. The symmetrical design with attachment elements on both inboard and outboard sides enables the same core module to serve multiple functions with different payloads, increasing adaptability while expanding capacity.
2Ease of operation
If conventional pylons are mounted on the aircraft, then payload carriage is enabled, but weapons bay doors cannot fully open
Solution Approach 1:
The fairing module is designed to be movable or adjustable relative to the core module, allowing it to clear the weapons bay door path when needed. This dynamic configuration enables the pylon structure to adapt during door operation, resolving the conflict between maintaining pylon functionality and enabling full door opening.
Solution Approach 2:
The pylon assembly utilizes the outboard side of the aircraft for payload attachment, positioning payloads in a different spatial dimension that does not interfere with the weapons bay door opening path. This dimensional repositioning allows both functions to coexist without interference.
3Adaptability or versatility
If conventional pylons are positioned close to the aircraft structure, then aerodynamic efficiency is maintained, but proximity constraints complicate payload carriage
Solution Approach 1:
The fairing module nests over the core module and payload, providing aerodynamic coverage while allowing the payload to extend outward. This nested configuration maintains aerodynamic efficiency near the aircraft structure while enabling payloads to be positioned outward to avoid proximity constraints with other aircraft components.
Data Source
AI summary
Disclosed herein is a modular pylon assembly for an aircraft. The pylon assembly includes a core module with an inboard side and an outboard side, each equipped with multiple sets of carriage-attachment elements. A forward post assembly and an aft post assembly extend from the core module and are removably mountable to the aircraft. The pylon assembly also includes a carriage module that can be removably attached to either the inboard side or the outboard side of the core module, using a selected set of carriage-attachment elements. Additionally, a suspension rack is mounted to the carriage module to support a payload. The core module is reconfiguration for left side or right side attachment to the aircraft.