Monolithic Engine Support Structure for Modular Aerial Vehicle Assembly
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Solution Overview
Problem
Existing aerial vehicle designs with gas turbine engines and vehicle bodies lack efficient integration and modular support structures, leading to complexity and high manufacturing and assembly costs.
Innovation Solution
An integrated monolithic structure that combines the gas turbine engine and vehicle body with a support structure, formed as a single unitary body using additive manufacturing, allowing for simplified assembly and reduced part count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate engine support structure and vehicle body sections are used, then assembly flexibility is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines the engine support structure and vehicle body sections into a single integrated monolithic component formed by additive manufacturing. This merging eliminates the need for separate parts and their associated assembly operations, directly reducing manufacturing cost and structural complexity while maintaining functional requirements.
2Ease of repair
If multiple separate components are used for engine mounting, then ease of repair is improved, but device complexity and part count increase
Solution Approach 1:
The integrated monolithic component incorporates internal segmentation with hollow cavities that can house bearing assemblies and other maintenanceable elements. This allows the overall structure to be single-piece (reducing part count) while maintaining internal functional segmentation for ease of repair and maintenance access.
Solution Approach 2:
The design nests bearing assemblies and other components within hollow cavities of the monolithic structure. This nesting approach eliminates the need for separate mounting brackets and fasteners, reducing the overall part count while maintaining the ability to access and service internal components.
3Productivity
If traditional manufacturing methods are used for support structures, then manufacturing precision is maintained, but productivity and assembly time decrease
Solution Approach 1:
The patent employs additive manufacturing technology which fundamentally changes the manufacturing parameters from traditional subtractive or formative methods. This enables the direct fabrication of complex monolithic geometries with high precision features, including internal cavities and mounting interfaces, in a single manufacturing process that inherently ensures structural accuracy while eliminating multi-step assembly operations.
Data Source
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AI summary
An assembly (20) for an aerial vehicle includes a vehicle body (24), a gas turbine engine (22) and a support structure (26). The vehicle body (24) includes a body section (111). The gas turbine engine (22) includes a stationary structure (66). The gas turbine engine (22) is housed within the vehicle body (24). The support structure (26) extends between and is connected to the body section (111) and the stationary structure (66). The support structure (26) supports the gas turbine engine (22) within the vehicle body (24). The body section (111), the stationary structure (66) and the support structure (26) are included in a monolithic body (70).