Rotor Blade Tip Fastener Hole Alignment From Spar Reference Openings
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Solution Overview
Problem
The complex and time-consuming process of re-establishing machined features in replacement rotor blade tip sections of rotary-wing aircraft, particularly the regeneration of fastener holes, poses a challenge in maintaining design intent and structural integrity.
Innovation Solution
A system comprising multiple fixtures, including a fastener check fixture, a fastener drill fixture, and a fastener countersink alignment fixture, is used to accurately position and form fastener holes and countersinks in the replacement tip section, aligning with existing features in the rotor blade spar, thereby simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex machinery and manual methods are used to locate and form fastener holes in replacement tip sections, then positioning accuracy can be achieved, but the process becomes time-consuming and complex
Solution Approach 1:
The patent applies preliminary action by pre-positioning fixtures and alignment tools on the rotor blade spar before the fastener hole formation process. The fixtures are mounted on weight cup openings that already exist in the spar, establishing precise reference points in advance. This preliminary setup eliminates the need for complex measurements and positioning during the actual fastener hole formation, significantly reducing process time while maintaining accuracy.
Solution Approach 2:
The patent uses fixtures as intermediary devices that bridge the gap between the existing spar features and the new tip section. These fixtures include alignment pins, bushings, and positioning mechanisms that transfer the precise location information from the spar's weight cup openings to the replacement tip section. The intermediaries simplify the complex positioning task by providing direct physical references rather than requiring complex calculation and measurement procedures.
2Manufacturing precision
If multiple fixtures and alignment tools are used to regenerate fastener holes, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing fixtures that serve multiple functions within a single integrated system. The fixtures can be mounted on existing weight cup openings and simultaneously perform alignment, positioning, and reference establishment functions. The same fixture system can be used for different fastener holes and potentially for different tip section replacements, reducing the need for multiple specialized tools and simplifying the overall device complexity.
Solution Approach 2:
The patent uses copying by replicating the precise geometric relationships and positioning features from the original spar to the replacement tip section. The fixtures copy the location and orientation of weight cup openings and fastener hole patterns, ensuring that the regenerated features match the original design intent. This copying approach simplifies the process by using direct physical replication rather than complex measurement and reconstruction procedures.
3Adaptability or versatility
If traditional methods are used to re-establish machined features, then flexibility is maintained, but reliability of feature regeneration decreases
Solution Approach 1:
The patent applies self-service by designing a system where the existing spar features (weight cup openings, existing fastener holes) automatically provide the reference information needed for accurate feature regeneration. The fixtures utilize these existing features to self-align and self-position, eliminating the need for external measurement and calculation procedures. This self-referencing approach increases reliability by using the existing geometry itself as the source of truth, rather than relying on manual measurements that can introduce errors.
Data Source
AI summary
A system for regenerating fastener holes in a replacement tip section of a rotor blade includes a first fixture, a second fixture, and a third fixture positionable adjacent a tip section of the rotor blade. The first fixture is used to verify a position of an opening formed in the spar. The second fixture includes a removable bushing having a drillable opening. The drillable opening is aligned with the at least one opening formed in the spar and defines at least one hole to be formed in the replacement tip section. The third fixture includes a countersink opening. The countersink opening is aligned with the at least one hole to be formed in the replacement tip section and the at least one opening formed in the spar to define a countersink feature to be formed in the at least one hole.