Spacer Element Joining for Curved Wing-Pylon Interfaces
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Solution Overview
Problem
Conventional methods for joining aircraft engine mounting pylons to wings face challenges due to the mismatch in curvature between the flat pylon and curved wing surfaces, requiring complex and costly interface plates to ensure precise orientation and effective load transmission, which are time-consuming and difficult to manufacture.
Innovation Solution
The use of components with recesses and spacer elements that are designed to fit together in a preselected orientation, allowing for precise alignment and load distribution without the need for complex machining, using cylindrical recesses and spacer elements that match the shape and orientation of the interface surfaces, enabling efficient and cost-effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flat pylon surface is attached directly to a curved wing surface, then the attachment area is reduced, but manufacturing complexity is also reduced
Solution Approach 1:
The patent introduces interface components (spacer elements) as intermediaries between the flat pylon surface and the curved wing surface. These spacer elements have curved outer surfaces that conform to the wing's aerofoil shape, enabling effective load transmission across the interface while maintaining the simplicity of the flat pylon structure.
Solution Approach 2:
The interface components are designed with varying local geometries - the outer surface curvature matches the local wing curvature at each attachment location, while the inner surface provides a flat mounting interface for the pylon. This local adaptation of geometry allows the rigid pylon to attach effectively to the curved wing without requiring the entire pylon structure to be curved.
2Strength
If complex interface plates are used to match curved surfaces, then load transmission is improved, but manufacturing time and cost increase
Solution Approach 1:
The interface structure is segmented into multiple discrete spacer elements rather than using a single complex interface plate. Each spacer element is a simple cylindrical or conical component that can be manufactured independently using standard machining processes, significantly reducing manufacturing complexity and time while collectively providing the necessary load transmission capability.
Solution Approach 2:
The spacer elements are designed to be self-aligning and self-positioning through their geometric features (cylindrical shapes, tapered sections, and interference fit characteristics). This eliminates the need for complex alignment procedures and custom machining operations during assembly, reducing both manufacturing time and operational complexity.
3Length of moving object
If the pylon is attached closer to the wing to minimize vertical distance, then engine clearance is improved, but the curvature mismatch between surfaces worsens
Solution Approach 1:
The spacer elements serve as mediators that bridge the geometric gap between the flat pylon and curved wing surfaces. By positioning these adaptable interface components at the attachment interface, the design can achieve minimal vertical distance between the engine and wing while the spacer elements locally conform to the wing's curvature, eliminating the need for larger clearance distances.
Data Source
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Figure 3~4b
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AI summary
There is provided a component (10) which is configured to be joined to a further component (11) in a preselected relative orientation. The further component (11) has an interface surface (111) and the component (10) is configured to contact the interface surface (111) when joined to the further component. The component (10) comprises: a surface disposed on a side of the component intended to face the interface surface when the components are joined, a plurality of recesses (12a) formed in the surface, and a plurality of spacer elements (13a). Each recess (13a) has a preselected orientation relative to the component (10), the preselected orientation being selected in dependence on the preselected relative orientation. Each spacer element (13a) comprises a contact surface configured to contact the interface surface (111) when the components are joined. Each spacer element (13a) is disposed in one of the recesses (12a) such that the orientation of a given contact surface is defined by the orientation of the corresponding recess.