Static Probe Fastening with Adjustable Shims for Flush Aircraft Skin Fit
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Solution Overview
Problem
The existing fastening systems for static probes on aircraft struggle to achieve a flush fit with the aircraft skin after painting, due to irregularities in the paint layer, which can affect air turbulence measurements and measurement accuracy.
Innovation Solution
A decentralized alignment system using a plate with alignment elements, a backplate, peelable shims, and alignment devices that allow for fine adjustment of the static probe's position relative to the aircraft skin, ensuring a flush fit even with uneven paint layers, featuring external or internal threads, splints, and additional fastening means for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fixed fastening system is used to couple the static probe to the aircraft skin, then the installation process is simple and quick, but the ability to achieve a flush fit after painting is compromised due to paint layer irregularities
Solution Approach 1:
The fastening system incorporates adjustable alignment elements that allow dynamic repositioning of the plate relative to the aircraft skin. This enables the system to adapt to paint layer irregularities while maintaining a flush fit, transforming a static fixed fastening into a dynamically adjustable one.
Solution Approach 2:
Alignment elements serve as intermediaries between the plate and the aircraft skin, providing a mechanism to compensate for surface irregularities. These elements allow independent adjustment of the plate's position to achieve optimal alignment with the aircraft skin edge despite paint layer variations.
2Manufacturing precision
If alignment is performed before painting, then the initial installation is precise, but paint layer irregularities cause misalignment after painting
Solution Approach 1:
The fastening system is pre-assembled with the static probe and plate in a test bench environment to achieve precise initial alignment. This preliminary alignment is then transferred to the aircraft during installation, ensuring both precision and reliability after painting.
Solution Approach 2:
The adjustable alignment elements provide a feedback mechanism that allows verification and correction of alignment after painting. The system can be checked and adjusted post-painting to ensure the plate edge remains flush with the aircraft skin despite paint layer irregularities.
3Manufacturing precision
If large-area tolerance compensation layers are used to achieve accurate form combination, then the flush fit is improved, but the complexity of the fastening system increases
Solution Approach 1:
Instead of using a single large-area tolerance compensation layer, the system divides the compensation function into multiple discrete alignment elements. Each element can be independently adjusted, providing the necessary complexity reduction while maintaining form combination accuracy.
Solution Approach 2:
The alignment elements allow for parameter changes in the position and orientation of the plate relative to the aircraft skin. By adjusting these parameters, the system achieves accurate form combination without requiring complex compensation layers, simplifying the overall fastening system.
Data Source
AI summary
A probe fastening system has a plate having at least one coupling-on recess and having at least one alignment element, which is arranged in the outer region of the plate, a backplate which has a fastening device for the fastening of a static probe and at least one recess which corresponds with the alignment element, at least one peelable shim which corresponds with the alignment element and which is arranged between the plate and the backplate, at least one alignment device which corresponds with the alignment element, and a coupling-on element which defines a cavity and which is designed for isobarically coupling the static probe onto the coupling-on recess.