Segmented Torque Member for Aircraft Wing Flap Weight Reduction
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Solution Overview
Problem
Aircraft wing flap systems face challenges with heavy and complex torque members that increase weight, cost, and complexity, particularly in dual torque tube designs, which affect structural performance and aerodynamic characteristics.
Innovation Solution
The wing flap system incorporates a torque member formed by extension members coupled to the inboard rib of the flap body, using composite materials to reduce weight and complexity, with a design that matches the cross-sectional shape of the flap body, allowing for optimized placement and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional circular torque tube is used, then structural strength is improved, but weight and device complexity increase
Solution Approach 1:
The torque member is divided into multiple discrete components: a torque tube and multiple torque arms. This segmentation allows each component to be optimized independently for strength and weight, replacing the traditional single heavy circular tube with a lighter composite structure that achieves the same structural performance.
Solution Approach 2:
The invention uses a composite structure combining a torque tube with multiple torque arms arranged radially around it. This composite configuration provides enhanced structural strength and load distribution while reducing overall weight compared to a solid circular torque tube, as the arms can be strategically positioned to carry specific loads.
2Reliability
If a dual torque tube design is used, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The failsafe capability is achieved through segmentation into multiple independent torque arms rather than using a dual torque tube design. Each arm can independently carry load, and if one arm fails, the others maintain structural integrity and functionality, providing failsafe operation without the complexity of nested dual tubes.
Solution Approach 2:
The torque arms are designed with rotational freedom around the torque tube, allowing dynamic adaptation to load conditions. This dynamic configuration enables the structure to automatically redistribute loads among multiple arms, providing inherent failsafe capability without requiring complex mechanical redundancy systems.
3Strength
If a heavy torque tube is used, then structural integrity is improved, but manufacturing cost increases
Solution Approach 1:
Segmenting the torque member into a central tube and multiple attachable arms simplifies manufacturing. Each component can be produced separately using standard fabrication processes, then assembled through straightforward attachment methods, reducing both manufacturing complexity and cost compared to producing a single heavy integrated torque tube.
Solution Approach 2:
The design allows flexible adjustment of torque arm parameters such as number of arms, arm spacing, and arm dimensions to match specific load requirements. This parametric flexibility enables optimization of structural integrity while minimizing material usage and manufacturing cost, avoiding the need for oversized heavy tubes.
Data Source
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AI summary
A wing flap (100) includes a flap body (164). The flap body (164) includes an upper skin (102), a lower skin (104) opposite the upper skin (102), and a plurality of spars (106) that extend between the upper skin (102) and the lower skin (104). The wing flap (100) also includes a torque member (108) that is coupled to the flap body (164). A portion of the torque member (108) is contiguous with at least one of the upper skin (102) and the lower skin (104).