Variable-Depth Seat Track Flanges for Aircraft Weight Reduction
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Solution Overview
Problem
Conventional aircraft seat tracks are excessively heavy due to uniform flange thickness, resulting in significant weight loss and revenue impact, and require extensive machining for optimized designs, which is inefficient.
Innovation Solution
A seat track assembly with variable-depth track flanges and a base flange, where the center flange segment is thicker than the end segments, reducing overall weight while maintaining load-bearing capacity, fabricated using titanium and featuring lightening apertures and notches for reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional extrusion method is used for seat track fabrication, then manufacturing efficiency is improved, but the ability to achieve optimized variable thickness geometry is worsened
Solution Approach 1:
The seat track is divided into multiple segments including end segments and a center segment, each with different thickness requirements. The track flanges are segmented into first track flanges at the ends and a second track flange at the center, allowing each segment to be optimized independently for its specific load requirements while maintaining manufacturing efficiency.
Solution Approach 2:
Different portions of the seat track are given different thicknesses based on local load requirements. The center segment has increased thickness to handle higher loads at the middle of the track, while the end segments maintain standard thickness. This local quality optimization reduces overall weight while maintaining structural integrity where needed.
2Ease of manufacture
If uniform thickness is used for track flanges, then manufacturing simplicity is improved, but load distribution efficiency is worsened
Solution Approach 1:
The track flanges transition from uniform thickness to variable thickness, with the center portion having greater thickness than the end portions. This local quality change optimizes load distribution by providing additional material strength where loads are greatest (at the center) while reducing material usage at the ends where loads are lower.
Solution Approach 2:
The thickness parameter of the track flanges is changed along the length of the seat track. The center segment has a greater thickness parameter than the end segments, creating a variable thickness profile that optimizes structural performance for load bearing while reducing overall weight compared to uniform thickness design.
3Stability of the object's composition
If thicker track flanges are used to overcome load instability, then structural stability is improved, but weight is worsened
Solution Approach 1:
Instead of uniformly thickening all track flanges, the invention applies increased thickness locally only at the center segment where loads are greatest. This provides the necessary structural stability at critical load points while avoiding the excessive weight that would result from uniform thickening of the entire track structure.
Solution Approach 2:
The track flanges are segmented into end segments with standard thickness and a center segment with increased thickness. This segmentation allows the structure to achieve necessary stability at load-critical areas without the penalty of increased weight throughout the entire structure.
4Shape
If extensive machining is applied to achieve optimized geometry, then geometric optimization is improved, but manufacturing complexity is worsened
Solution Approach 1:
The optimized geometry is achieved through segmentation into standard end segments and an enhanced center segment, rather than through extensive machining of a monolithic structure. This segmentation allows the optimized shape to be achieved through more straightforward manufacturing processes.
Solution Approach 2:
Geometric optimization is applied locally at the center segment rather than requiring extensive machining of the entire structure. The center portion receives the enhanced thickness and geometric optimization where it is most needed, while the end segments maintain standard geometry, reducing overall manufacturing complexity.
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
The design achieves a weight reduction of approximately 400 lbs compared to conventional tracks, enhancing stability under high loads without the need for extensive machining, thereby reducing material costs and weight.
Implementation Method 1
welding a base flange to the track flanges of the seat track
Data Source
AI summary
A seat track assembly is disclosed. An illustrative embodiment of the seat track assembly includes a seat track having an elongated track plate and a pair of generally elongated, parallel, spaced-apart track flanges extending from the track plate. Each of the track flanges is variable in depth. A method of fabricating a seat track assembly is also disclosed.