Balanced Rotor Blade Core With 3D-Printed Weight Distribution
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Solution Overview
Problem
Conventional methods for balancing rotor blades in rotary wing aircraft are time-consuming due to variations in weight distribution and moments, requiring individual checking and adhesive application to achieve target criteria.
Innovation Solution
A method involving additive manufacturing to create a core panel with varying properties across the span, chord, and thickness, using an algorithm to determine the core's configuration based on sub-component weights and stresses, eliminating the need for adhesive by achieving balanced weight distribution and moments through precise core design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional procedures are used to balance rotor blades by individually checking and applying adhesive, then the target weight distribution and moments can be achieved, but the process is time-consuming
Solution Approach 1:
The core is designed and manufactured with predetermined weight distribution and moments before assembly. The algorithm calculates the exact core configuration needed to achieve target balancing criteria, and the core is fabricated to match these specifications in advance, eliminating the need for time-consuming post-assembly adhesive application
Solution Approach 2:
The invention changes the physical parameters of the core (density, shape, volume distribution) to directly achieve the desired weight distribution and moments. By varying the core's density and geometry according to algorithmic calculations, the blade achieves precise balancing without requiring adhesive modification
2Ease of manufacture
If rotor blades are manufactured using multiple components, then assembly flexibility is improved, but weight variation between blades increases requiring individual balancing
Solution Approach 1:
The core is designed with spatially varying density and properties throughout its volume, with different regions having different characteristics to achieve precise weight distribution. This local variation in core quality compensates for component weight variations and achieves consistent blade balancing
3Manufacturing precision
If adhesive is applied to achieve target weight distribution, then balancing criteria can be met, but the process complexity and time increase
Solution Approach 1:
The invention extracts the balancing function from the adhesive application process and transfers it to the core design and manufacturing process. By incorporating the balancing function directly into the core's physical properties, the complex adhesive application step is eliminated
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 significantly reduces the time required for balancing rotor blades by optimizing core design, ensuring balanced weight distribution and moments without the need for adhesive, thereby enhancing operational efficiency and reducing vibration.
Implementation Method 1
the core is fabricated via an additive manufacturing process
Data Source
AI summary
A method of forming a balanced rotor blade assembly includes measuring a weight of a plurality of sub-components of the rotor blade assembly excluding a core. A configuration of a core of the rotor blade assembly is determined. In combination, the core and the plurality of sub-components achieve a target weight distribution and moment. The core is then fabricated and assembled with the plurality of sub-components to form a rotor blade sub-assembly.