Multi-Segment Composite Spar Fabrication via Segmentation
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Solution Overview
Problem
The fabrication of aircraft spars from composite materials is complex and costly due to their large dimensions and complex curvatures, which increases the complexity and expense of equipment needed for layup, consolidation, hardening, and assembly.
Innovation Solution
The method involves forming spars from multiple structurally integrated segments via co-curing, co-bonding, or fastener installation, where each segment has a simpler curvature, reducing the complexity of equipment needed for fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If spars are fabricated as single-piece composite structures, then structural strength is improved, but equipment complexity and fabrication cost increase
Solution Approach 1:
The spar is divided into multiple segments that can be fabricated separately using simpler equipment, then joined together to form the complete spar structure. This segmentation allows each segment to be manufactured with less complex equipment while maintaining the overall structural strength through proper joining methods.
2Strength
If spars are fabricated as single-piece composite structures, then structural strength is improved, but fabrication time increases
Solution Approach 1:
By dividing the spar into segments, each segment can be fabricated simultaneously in parallel, significantly reducing total fabrication time compared to producing a single-piece spar. The segments are then joined together to create the complete spar structure.
Solution Approach 2:
Spar segments can be pre-fabricated and prepared in advance, allowing for overlapping operations and more efficient use of fabrication resources. This preliminary action enables better scheduling and reduces the overall fabrication time for the complete spar.
3Shape
If spars with complex curvatures are fabricated, then aerodynamic performance is improved, but equipment complexity increases
Solution Approach 1:
The spar is divided into segments, each with simpler curvatures that can be formed using less complex equipment. The complex overall curvature of the spar is achieved through the combination and arrangement of these simpler-segment curvatures, rather than requiring complex equipment to form the entire length at once.
4Strength
If large-dimension spar fabrication is performed, then structural strength is improved, but fabrication cost increases
Solution Approach 1:
By segmenting the spar into smaller pieces, each segment can be fabricated using less expensive equipment and with lower material costs. The joining of segments provides cost-effective assembly compared to fabricating a single large spar, while maintaining the required structural strength through proper joint design and construction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the size and complexity of fabrication equipment, decreases fabrication time, and lowers costs, while also simplifying the assembly process of aircraft wings.
Implementation Method 1
a splice doubler bonded to the first spar segment and the second spar segment
Implementation Method 2
hardening the preforms to form the spar segments
Data Source
AI summary
Systems and methods are provided for fabricating multiple segment spars for an aircraft. In one example the method includes fabricating preforms of fiber reinforced material for spar segments, hardening the preforms to form the spar segments, and bonding the spar segments together to form a completed spar detail. In addition to bonding, other examples include co-curing and fastening the spar segments. In additional examples, the spar segments include kinks or sub-kinks as described.