Space Frame Layout for Lightweight Load-Bearing Structures
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Solution Overview
Problem
There is a need for structural components in aircraft that can reduce overall weight while maintaining mechanical stability and effectively handling stress-induced loads, as conventional designs often compromise on weight reduction without ensuring equal structural performance.
Innovation Solution
A computer-implemented method using a two-staged evolutionary route finding algorithm for space frame design, incorporating an adaptive dynamics scheme inspired by the growth patterns of Physarum polycephalum and a growth algorithm mimicking bone growth, to optimize space frame structures for lightweight mechanical stability and efficient load distribution, which are then manufactured using additive manufacturing processes.
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 connected by nodes, replacing the monolithic honeycomb core. This segmentation allows for optimized load paths through each rod while reducing overall material usage, achieving weight reduction of up to 45% while maintaining structural performance
Solution Approach 2:
The patent transitions from a two-dimensional honeycomb pattern to a three-dimensional space frame structure. By adding the third dimension with vertically oriented rods and complex node connections, the structure achieves superior load distribution and mechanical performance with reduced material quantity
2Weight of moving object
If material is reduced to decrease weight, then weight decreases, but mechanical stability deteriorates
Solution Approach 1:
The patent employs computational optimization algorithms that pre-calculate the optimal arrangement of rods and nodes before manufacturing. This preliminary design phase ensures that each rod is positioned and sized to efficiently carry specific loads, achieving mechanical stability with minimized material usage
Solution Approach 2:
The patent replaces conventional mechanical design methods with computational optimization algorithms. These algorithms simulate load paths and iteratively optimize the space frame configuration, ensuring mechanical stability is achieved through mathematically optimal material distribution rather than conservative design margins
3Quantity of substance
If conventional beam designs with webs are used, then structural integrity is ensured, but material consumption increases
Solution Approach 1:
The patent extracts and removes the web component from conventional I-beam designs. By eliminating the web and replacing it with a network of optimized rods connected at nodes, the structure achieves comparable or superior structural integrity with significantly reduced material consumption, as only load-carrying elements are retained
Data Source
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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 a plurality of attachment points and load application points in the design space, creating a starting network of interconnecting lines between each two of the plurality of 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 a plurality of potential space frame designs by selectively 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 performance score of each of the plurality of potential space frame designs with respect to a number of predefined 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.