Computational Space Frame Design for Weight Reduction
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Solution Overview
Problem
There is a need for structural aircraft components that reduce overall weight while maintaining mechanical stability and effectively handling stress-induced loads, as conventional designs often require excessive material.
Innovation Solution
A computer-implemented method for space frame design that constructs a load stress map, defines attachment and load application points, generates potential space frame designs by culling interconnecting lines based on load stress, and evaluates performance using optimization parameters, incorporating an adaptive dynamics scheme and growth algorithm to optimize for low weight and high mechanical stability, with the resulting design manufactured using additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional honeycomb core sandwich structures are used, then structural stability is maintained, but weight is excessive
Solution Approach 1:
The space frame structure is divided into multiple individual rods or tubes arranged in a geometric pattern, rather than using a solid honeycomb core. This segmentation allows material to be placed only where structurally necessary, reducing overall weight while maintaining strength through the distributed geometric configuration
Solution Approach 2:
The patent applies different material properties or cross-sectional characteristics to different rods within the space frame based on their specific load requirements. Each rod can be optimized locally for its function, allowing the overall structure to achieve high strength-to-weight ratio by concentrating material where most needed
2Strength
If more material is used to ensure mechanical stability, then strength is improved, but weight increases
Solution Approach 1:
The patent employs iterative computational optimization that dynamically adjusts the configuration, thickness, and material distribution of space frame members based on simulated load conditions. This dynamic optimization process continues until the minimum weight configuration achieving required mechanical stability is found
Solution Approach 2:
The invention systematically varies critical parameters such as rod diameter, wall thickness, node connectivity, and material composition to find the optimal combination that minimizes weight while satisfying mechanical stability constraints. Parametric modeling allows efficient exploration of the design space
3Loss of substance
If conventional design methods are used, then manufacturing simplicity is maintained, but material efficiency decreases
Solution Approach 1:
The patent performs comprehensive structural optimization and design finalization through computational methods before the actual manufacturing process. This preliminary digital prototyping and simulation eliminates the need for iterative physical prototyping, reducing material waste while providing precise manufacturing instructions for fabrication
Data Source
AI summary
A computer-implemented method for space frame design involves constructing a load stress map in a geometrical boundary representation of a design space, defining attachment points and load application points in the design space, creating a starting network of interconnecting lines between each two of the attachment points and load application points in the design space, assigning load application factors to each line of the starting network of interconnecting lines based on values of the load stress map, generating potential space frame designs by culling different subsets of lines of the starting network of interconnecting lines for each potential space frame design according to variable culling parameters, evaluating the potential space frame designs with respect to optimization parameters, combining the culling parameters for the potential space frame designs the performance score of which is above a predefined performance threshold, and iterating the steps of generating potential space frame designs and evaluating the potential space frame designs on the basis of the combined culling parameters.