Modular Tooling for Multi-Spar Torsion Box Web Height Adjustment
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Solution Overview
Problem
Aircraft manufacturers face inefficiencies due to common components, such as oversized empennage, which add weight and drag, and require extensive tooling changes for dimension adjustments in multi-spar torsion boxes, leading to increased costs and complexity in manufacturing.
Innovation Solution
Modular tooling system comprising a mandrel module and spacer modules with adjustable web height, allowing for flexible manufacturing of multi-spar torsion boxes with different sizes, optimizing weight and drag performance while minimizing tooling requirements and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If common components are used across aircraft family members, then manufacturing commonality and cost are improved, but component size becomes larger than needed for most models, increasing weight and drag
Solution Approach 1:
The empennage is divided into modular components: a common central section that maintains manufacturing standardization, and adjustable outer sections that can be configured to different sizes for different aircraft models. This segmentation allows the common central section to provide manufacturing commonality while the adjustable outer sections enable weight optimization for each specific aircraft model.
Solution Approach 2:
The empennage configuration is made dynamic through adjustable outer sections that can be modified based on the specific aircraft model requirements. This allows the empennage size to adapt to different fuselage lengths and performance requirements, rather than being fixed at the largest size for all models.
2Adaptability or versatility
If common components are sized for the shortest fuselage model, then component commonality is improved, but the component becomes oversized for longer fuselage models, adding aerodynamic drag
Solution Approach 1:
The empennage is segmented into a common central portion and adjustable outer portions. The common central portion maintains versatility across all aircraft models, while the adjustable outer portions can be trimmed or removed to reduce size for longer fuselage models, thereby reducing aerodynamic drag without sacrificing component commonality.
Solution Approach 2:
Different portions of the empennage have different levels of commonality: the central section maintains identical geometry and manufacturing for all models, while the outer sections allow local variations in size to optimize aerodynamic performance for each specific aircraft model.
3Ease of manufacture
If fixed dimension tooling elements are used for manufacturing, then manufacturing simplicity is improved, but extensive tooling changes are required for dimension adjustments, increasing costs and complexity
Solution Approach 1:
The tooling system is segmented into modular components including a common base plate, adjustable mandrels, and interchangeable positioning elements. This modular tooling allows dimension adjustments by reconfiguring the same tooling elements rather than requiring complete tooling changes, reducing both cost and complexity.
Solution Approach 2:
The tooling elements are made dynamically adjustable through mechanisms such as adjustable mandrels with variable positions, movable positioning fixtures, and reconfigurable support structures. This enables the same tooling to accommodate different empennage dimensions for various aircraft models without requiring extensive tooling changes.
4Ease of manufacture
If oversized empennage components are used across all models, then manufacturing commonality is improved, but material usage and maintenance costs increase
Solution Approach 1:
The empennage is divided into a common central section that uses identical materials and manufacturing processes for all models, and adjustable outer sections where material usage can be optimized for each aircraft model. This reduces overall material consumption while preserving manufacturing commonality in the standardized central portion.
Solution Approach 2:
The empennage dimensions are made variable through adjustable outer sections that can be configured to different sizes based on aircraft model requirements. This parameter adjustment allows material usage to be optimized for each specific model rather than using oversized components for all models.
Data Source
AI summary
Tooling for manufacturing multi-spar torsion boxes with different web heights, the tooling includes a mandrel module having a hollow beam geometry which comprises a first base and a second base opposite to the first base, and two walls extending between said first base and said second base, and at least one spacer module configured for coupling with the mandrel module, wherein the web height of a multi-spar torsion box is defined by the coupling between the mandrel module and at least one spacer module. A method for manufacturing multi-spar torsion boxes with different web heights.