Segmented Composite Filler Fabrication for Aircraft Wings
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Solution Overview
Problem
The challenge lies in fabricating long filler segments for composite stringers and other structural components, which requires significant space and labor due to the need for long dies and handling of lengthy filler pieces.
Innovation Solution
The solution involves forming radius filler segments in multiple mold channels of a compact die, such as a rotary die, and then arranging and curing these segments to create a unitary filler structure, thereby reducing the need for long dies and simplifying the fabrication process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a long die is used to extrude filler pieces of the necessary length, then the filler length requirement is met, but the factory space occupied by the die increases significantly
Solution Approach 1:
The filler is divided into multiple segments that are extruded separately using a compact die. Each segment is then joined to form the complete long filler piece, eliminating the need for a single long die while achieving the required filler length.
Solution Approach 2:
The solution transitions from extruding a single continuous long filler in one dimension to producing multiple shorter segments that are subsequently assembled. This dimensional change in the manufacturing approach allows using a compact die while still achieving long filler pieces through assembly.
2Length of moving object
If the length of filler piece increases, then the filler can span longer stringer lengths, but the number of people needed to handle the filler piece increases
Solution Approach 1:
The filler is segmented into multiple manageable pieces that can be easily handled and positioned. These segments are then joined in place to form the complete long filler, reducing handling complexity while achieving the required length.
Solution Approach 2:
The filler segments are prepared in advance as short, easy-to-handle pieces. These pre-prepared segments are then assembled in the final position, combining the benefits of preliminary preparation with the need for long filler pieces.
3Length of moving object
If assisted lift tools are used to extract fabricated filler pieces, then long filler pieces can be handled, but production flow issues arise and valuable space is consumed in storage and manufacturing
Solution Approach 1:
By segmenting the filler into shorter pieces, the need for complex assisted lift tools is eliminated. The segments can be easily extracted and handled using simple tools, improving production flow and reducing the need for specialized equipment and storage space.
Data Source
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AI summary
A method for fabricating a composite wing structural component for an aircraft is described. The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.