Trailing Edge Assembly Using Blind Fasteners for Lightweight Aerostructures
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Solution Overview
Problem
Existing aerodynamic structures face challenges in economically fabricating and weight-efficiently designing the trailing edge region, which requires a balance of structural efficiency, durability, strength, and accessibility in a limited space.
Innovation Solution
The aerodynamic structure comprises a first skin region and a second skin region angled relative to each other, defining a gap where a trailing edge structure is positioned. This structure is interconnected using a plurality of blind fasteners, allowing for efficient assembly and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fabrication methods are used for the trailing edge region, then structural strength can be maintained, but manufacturing cost increases and weight is not optimized
Solution Approach 1:
The trailing edge structure is divided into multiple discrete components including a trailing edge beam, skin panels, and fastener systems. This segmentation allows for independent manufacturing of each component using optimized processes, reducing overall manufacturing cost while maintaining structural integrity and minimizing weight through precise material placement.
2Strength
If the trailing edge region is designed for structural efficiency, then strength is improved, but fabrication complexity and cost increase
Solution Approach 1:
The trailing edge beam incorporates self-aligning features and self-locating geometries that automatically position skin panels and fasteners during assembly. This self-service design reduces the need for complex jigs, fixtures, and skilled labor, thereby lowering fabrication complexity and cost while ensuring consistent structural strength.
3Weight of moving object
If the trailing edge region is compacted to save weight, then weight is reduced, but accessibility for assembly and maintenance becomes difficult
Solution Approach 1:
The trailing edge structure employs a nested arrangement where skin panels are positioned over the trailing edge beam, and fasteners are inserted from the exterior to secure the assembly. This nested configuration achieves weight reduction through compact material usage while maintaining exterior accessibility for assembly and maintenance operations.
4Reliability
If durable materials and construction methods are used in the trailing edge region, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The structure utilizes parameter optimization in material selection and fastener design to achieve the required durability at reduced cost. By carefully selecting material grades, fastener types, and connection parameters, the design achieves reliable performance without the need for expensive over-engineering, balancing durability with manufacturing economy.
Data Source
AI summary
Aerodynamic structures and methods of forming aerodynamic structures are disclosed herein. The aerodynamic structures include a first skin region that includes a first skin edge and a second skin region that includes a second skin edge. The first skin region and the second skin region are angled relative to one another and define a gap between the first skin edge and the second skin edge. The aerodynamic structures also include a trailing edge structure that extends within the gap and between the first skin edge and the second skin edge. The aerodynamic structures further include a plurality of blind fasteners. A first subset of the plurality of blind fasteners operatively interconnects the first skin region and the trailing edge structure. A second subset of the plurality of blind fasteners operatively interconnects the second skin region and the trailing edge structure. The methods include methods of forming the aerodynamic structures.