Integrally Machined Thrust Reverser Arms Reduce Part Count

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Solution Overview

Problem

The manufacturing of thrust reversers for turbofan gas turbine engines is hindered by the need for precise positioning of fittings, which increases manufacturing time and costs due to the requirement of multiple fittings and jigs.

Innovation Solution

A thrust reverser design featuring integrally formed fittings on solid metal side arms, which are machined to include attachment points for actuators and other hardware, allowing for a reduced part count and streamlined assembly process, along with a method of manufacturing that involves machining workpieces to form these arms and assembling them with skins to create a cylindrical jet pipe body.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple separate fittings are installed on thrust reverser arms, then attachment points for actuators are provided, but manufacturing time and costs increase due to precise positioning requirements and jigs

Engineering Contradiction:

Improveattachment points for actuatorsVSAvoidmanufacturing time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent merges the fittings with the thrust reverser arms by integrally forming them as a single piece. This eliminates the need for separate fittings and their associated positioning jigs, thereby reducing manufacturing time and costs while maintaining the attachment function for actuators.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated fittings serve multiple functions: they provide attachment points for actuators, maintain structural integrity of the arm, and eliminate the need for separate positioning jigs. This multi-functionality resolves the contradiction by reducing manufacturing complexity while maintaining adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple separate fittings are installed on thrust reverser arms, then attachment points for actuators are provided, but part count increases

Engineering Contradiction:

Improveattachment points for actuatorsVSAvoidpart count

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple separate components (fittings and arms) into a single integrated component. This reduces the part count and simplifies the assembly process while maintaining the necessary attachment functionality for actuators.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated structure provides multiple functions within a single component, including attachment points for actuators and structural support, thereby reducing the overall part count and device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If jigs are used for fitting installation, then precise positioning is achieved, but manufacturing costs increase

Engineering Contradiction:

Improvefitting positioningVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

By integrating the fittings into the arms as a single piece, the patent eliminates the need for separate positioning jigs. This maintains manufacturing precision through the integrated design while reducing manufacturing costs by removing the jig requirement.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fittings are pre-formed as integral parts of the arms during the arm manufacturing process, eliminating the need for subsequent fitting installation with jigs. This preliminary integration maintains precision while reducing cost.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS8127530B2Thrust reverser for a turbofan gas turbine engine

Publication Date: 2012.03.06 GULFSTREAM AEROSPACE CORP

AI summary

The thrust reverser comprises sections, such as arms and skins, which may be connected along joints to provide a thrust reverser body. A plurality of fittings may be integrally formed on a surface of each arm.