Rotor Blade Spar Structure for Multi-Model Manufacturing
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Solution Overview
Problem
Manufacturing different rotor blades for various rotary wing aircraft models requires expensive custom tooling and machinery, occupying valuable factory space.
Innovation Solution
A rotor blade design with a spar having a substantially constant inboard height and thickness, allowing for trimming or extension to accommodate different aircraft models, and a root seal positioned outboard to facilitate easy adaptation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom tooling and machinery are used for each rotor blade model, then manufacturing precision and blade-specific performance are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The spar is designed with a standardized constant height section that serves as a universal interface for multiple aircraft models. This single spar design can be adapted to different blade lengths and configurations without requiring custom tooling for each model, thereby reducing device complexity while maintaining manufacturing precision through consistent dimensional controls.
Solution Approach 2:
The spar is divided into distinct functional sections: a constant height inboard portion that provides standardized mounting interfaces, and variable outboard portions that can be trimmed or extended. This segmentation allows the same spar to be configured for different aircraft models by modifying only the non-critical outboard sections, rather than requiring custom tooling for the entire blade.
2Ease of manufacture
If custom tooling is manufactured for each aircraft model, then ease of manufacture for specific models is improved, but loss of substance and manufacturing cost increase
Solution Approach 1:
A single spar design with standardized constant height dimensions serves multiple aircraft models, eliminating the need to manufacture custom tooling for each model. The same spar can be trimmed or extended to fit different configurations, reducing material waste associated with producing discarded custom tooling while maintaining ease of manufacture through standardized processes.
3Ease of manufacture
If factory space is occupied by custom machinery for each model, then manufacturing capability for specific models is improved, but productivity and space utilization worsen
Solution Approach 1:
The standardized spar design enables a single manufacturing setup to produce blades for multiple aircraft models by varying only the outboard length through trimming or extension. This eliminates the need for separate manufacturing lines for each model, improving factory space utilization and overall productivity while maintaining the capability to manufacture model-specific blades.
Data Source
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Figure 3A~3C
AI summary
A method of modifying a rotor blade is provided for a rotor blade including a spar having an inboard portion with a substantially constant overall height, the inboard portion further including a top layer having a substantially constant first thickness and a bottom layer having a substantially constant second thickness. The method includes removing a root portion of the inboard portion to thereby modify the rotor blade and installing a cuff configured to couple to the rotor blade to an aircraft.