Pre-stressed Sinusoidal Structures Assembly via Adaptive Extruder
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Solution Overview
Problem
Current methods of additive manufacturing and automated assembly systems fail to introduce stress into structures during formation, limiting control over stress profiles and the development of structures with flexural properties, which are essential for enhancing mechanical performance and resilience, particularly in aerospace applications.
Innovation Solution
The Adaptive Sinusoidal Extruder Mechanism (A-SEM) incrementally shapes and connects sinusoidal shaped members to form pre-stressed structures with stored elastic potential energy, using support members to maintain the sinusoidal shape and control the distribution of internal stress, allowing for the formation of flexural members with specific elastic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated assembly systems are used to form structures from discrete parts, then assembly efficiency and productivity are improved, but the ability to introduce and control stress during formation is lost
Solution Approach 1:
The patent applies preliminary action by pre-stressing the sinusoidal members before final assembly. The members are formed with predetermined stress states and elastic potential energy, then assembled into the final structure. This allows stress control to be built into the components themselves during manufacturing, while the automated assembly process simply connects these pre-stressed components, maintaining both productivity and stress control.
2Strength
If pre-stressed sinusoidal structures are formed from discrete parts, then flexural properties and mechanical performance are improved, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the final structure into discrete sinusoidal members that are formed and pre-stressed independently, then assembled together. Each member can be manufactured separately with controlled stress states, and the modular assembly process connects these segments into the complete structure. This segmentation enables flexural performance through pre-stressing while managing complexity through modular construction.
Solution Approach 2:
The patent applies parameter changes by varying the geometric parameters (amplitude, wavelength, cross-section) and material properties of the sinusoidal members to achieve desired flexural characteristics. By controlling parameters such as the degree of pre-stressing, member dimensions, and material elastic properties, the system achieves tailored flexural performance without requiring overly complex assembly mechanisms.
3Reliability
If elastic potential energy is stored in sinusoidal members during assembly, then structural resilience and energy absorption are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-stressing the sinusoidal members during their formation process before final assembly. The elastic potential energy is stored in the members themselves as they are shaped into sinusoidal forms with controlled stress distributions. This preliminary stress introduction ensures that when the members are assembled into the final structure, the pre-stressed state is already established, improving resilience while allowing tolerance in the final assembly process.
Data Source
AI summary
A mechanical system that assembles or deploys pre-stressed structures. The assembly or deployment process outputs and elastically deforms material to form flexural members having a sinusoidal shape and stored potential energy. The sinusoidal shaped members are oriented and deployed with support members as they take shape. Sinusoidal shaped members are formed from a series of contiguous flexures; each flexure's properties may be engineered using a simulation technique. Each flexure is formed from a region of a sinusoidal member's length that begins and ends at antinodes. During assembly or deployment support members are positioned at antinodes maintaining the flexures' shapes and the assembly's pre-stressed state. By controlling the forces applied to and position of each flexure formed during assembly, the distribution of potential energy within the assembly and its secondary shape can be engineered. Elastic potential energy may be harvested from the material forming the flexural members.