UAV Assembly H-Frame with Adhesive Shells
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Solution Overview
Problem
Conventional UAV manufacturing processes are inefficient due to difficulties in removing excess outer shell material and thermal expansion issues between the structural frame and outer shell, leading to assembly defects and material fatigue.
Innovation Solution
The assembly of a UAV using a modular H-frame structure with pre-drilled wing spar and boom carriers, where wing and boom shells are attached using adhesive elements, reducing thermal expansion stresses and allowing for interchangeable fuselage components, and pre-testing of subsystems to identify and eliminate defective parts early in the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the outer shell material is sprayed onto the frame and then excess material is cut away, then the UAV takes shape, but the manufacturing process becomes time-consuming and inefficient
Solution Approach 1:
The patent applies preliminary action by pre-forming the outer shell into modular sections with precise geometry before assembly. The shell is divided into multiple pre-shaped sections that are manufactured separately with exact dimensions, eliminating the need for post-assembly cutting and shaping operations. This pre-forming approach maintains accurate UAV shape while dramatically improving manufacturing efficiency.
Solution Approach 2:
The patent segments the outer shell into multiple separate sections that can be manufactured independently and then assembled to form the complete UAV shell. This segmentation allows each section to be pre-formed with precise geometry, avoiding the need to spray and cut a single large piece of material. The modular sections are designed to fit together, maintaining the overall UAV shape while enabling parallel manufacturing of multiple components.
2Ease of manufacture
If the frame and outer shell materials have different coefficients of thermal expansion, then the UAV can use optimal materials for each component, but thermal cycling causes manufacturing defects, frame bending, and material fatigue
Solution Approach 1:
The patent segments the outer shell into multiple separate sections that are attached to the frame at discrete locations rather than as a single continuous piece. This segmentation interrupts the thermal stress transmission path, preventing cumulative thermal cycling effects from causing frame bending or material fatigue. Each shell section can expand and contract independently, reducing the overall thermal stress on the frame structure.
Solution Approach 2:
The patent introduces adhesive elements as intermediary components between the frame and outer shell sections. These adhesive elements act as stress-absorbing intermediaries that accommodate differential thermal expansion between the frame and shell materials. The adhesive layer allows for controlled movement and stress distribution, preventing direct stress transmission that would cause manufacturing defects or structural failure during thermal cycling.
3Adaptability or versatility
If the outer shell is removed to make room for cables, engines, and avionics, then components can be installed, but the process becomes difficult and time-consuming
Solution Approach 1:
The patent segments the outer shell into multiple sections with pre-formed openings and cutouts designed specifically for cable routing, engine mounting, and avionics installation. Each shell section is manufactured with integrated access points and mounting features, eliminating the need for additional removal or modification operations during assembly. Components can be installed directly through these pre-designed openings while maintaining shell integrity.
Solution Approach 2:
The patent applies preliminary action by pre-configuring the outer shell sections with all necessary openings, cutouts, and mounting features before assembly. Cable routes, engine mounts, and avionics access points are all prepared in advance during shell manufacturing. This eliminates the need for time-consuming on-site modifications and allows for rapid component installation during the assembly process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach improves the efficiency and reliability of UAV assembly, reduces material fatigue, and enhances modularity and versatility by minimizing thermal expansion stresses and allowing for early identification and removal of defective components, thus lowering production costs and lead time.
Implementation Method 1
wing and boom shells are attached using adhesive elements
Data Source
AI summary
Systems and methods for assembling Unmanned Autonomous Vehicle (UAV) are disclosed herein. In one embodiment, a method for assembling a UAV includes connecting a wing spar with boom carriers to form an H-frame. The wing spar provides mounting locations for securing horizontal propulsion units, and the boom carriers provide mounting locations for securing vertical propulsion units. The method also includes attaching a fuselage body to the wing spar; attaching a pre-formed wing shell to the H-frame; and attaching pre-formed individual boom shells to their corresponding boom carriers. The H-frame provides structural frame for mounting the wing shell and the boom shells.