Aircraft Nacelle Panel Assembly Using Electromagnetic Heating
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Solution Overview
Problem
Existing methods for manufacturing structural and/or acoustic panels for aircraft nacelles face challenges such as long manufacturing cycles, inability to modulate temperatures, and difficulty in forming complex shapes, leading to non-uniform mechanical stresses and inefficiencies in assembly processes like brazing and diffusion-welding.
Innovation Solution
A method using electromagnetic radiation, such as infrared or laser radiation, for selective heating of the working skin to assemble it with a metallic cellular structure, allowing for direct and uniform heating, reducing manufacturing time, and incorporating a forming step to conform the skin to the cellular structure under controlled pressure, thereby avoiding mechanical stresses and oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating by electric resistances is used in a vacuum furnace, then the assembly of skins and cellular structure can be achieved, but the manufacturing cycle becomes long and thermal gradients cause non-uniform heating
Solution Approach 1:
The patent replaces the conventional electric resistance heating system with electromagnetic radiation heating (infrared or laser). This substitution allows direct heating of the working skin without heating the entire furnace, significantly reducing the manufacturing cycle time while achieving the necessary brazing or diffusion-welding temperatures
Solution Approach 2:
The electromagnetic radiation heating system applies heat locally and selectively to the working skin rather than heating the entire vacuum furnace uniformly. This localized heating approach eliminates thermal gradients between inner and outer skins, ensuring uniform temperature distribution in the heated zone while reducing overall process time
2Reliability
If conventional heating methods are used, then assembly can be performed, but temperature modulation on parts is impossible and the process lacks precision
Solution Approach 1:
The electromagnetic radiation heating system enables dynamic temperature control by adjusting the radiation source parameters (intensity, duration, position). This allows real-time temperature modulation during the heating process, providing adaptability for different material thicknesses, compositions, and assembly requirements that conventional fixed heating systems cannot achieve
3Shape
If the skin is hot formed under gaseous pressure to conform to complex shapes, then the skin can be shaped, but the cellular structure experiences non-uniform mechanical stresses and local squeezing
Solution Approach 1:
The patent performs the forming operation before the assembly operation, but uses a controlled heating process that maintains uniform temperature distribution during forming. The electromagnetic radiation heats the skin uniformly, allowing it to be formed under pressure without creating the non-uniform thermal conditions that would cause localized squeezing of the cellular structure
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 manufacturing time, prevents non-uniform deformation, and enhances the mechanical properties of the panels by allowing for more precise temperature control and uniform deformation, improving the assembly process and mechanical properties of the panels.
Implementation Method 1
the working skin is heated by electromagnetic radiation so as to assemble the working skin and the cellular structure by brazing or diffusion-welding
Implementation Method 2
this radiation may be a laser radiation
Implementation Method 3
the first volume of the enclosure is placed under gaseous pressure so as to press and hold the working skin against the cellular structure
Implementation Method 4
the assembly is carried out within a vacuum enclosure
Data Source
AI summary
A method and a device for manufacturing a structural and/or acoustic panel for a nacelle of an aircraft propulsion assembly involves heating, by producing electromagnetic radiation, at least one skin of the structural and/or acoustic panel in such a way as to assemble this skin with a cellular structure of the structural and/or acoustic panel, by diffusion brazing or welding. This heating device can also be used to shape the skin to the cellular structure prior to assembly.