Universal Flap Support Structure Reducing Aircraft Wing Drag
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Solution Overview
Problem
Existing flap support structures for aircraft wings are complex, heavy, and costly, leading to increased manufacturing, assembly, and maintenance times, as well as higher fuel costs due to weight and drag penalties.
Innovation Solution
A modular flap support structure incorporating a universal support structure that forms part of both the drive unit and the support beam, featuring an aerodynamic fairing and a drive unit with a rotatable drive shaft, which reduces parts count and allows for efficient power transfer and easier adjustment of flap kinematic components, while being partially housed within the wing to minimize drag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional flap support structure is used, then the flap can be supported and actuated, but the structure becomes complex and heavy, increasing manufacturing cost, assembly time, and maintenance cost
Solution Approach 1:
The invention combines the drive shaft support function and the aerodynamic fairing support function into a single universal support structure. This merging eliminates the need for separate support components, reducing parts count and simplifying the overall flap support structure while maintaining all necessary functionalities.
Solution Approach 2:
The universal support structure is designed to perform multiple functions: supporting the drive shaft for actuation mechanisms, supporting the aerodynamic fairing for drag reduction, and providing mounting points for both the drive unit and fairing. This multi-functional design reduces complexity while ensuring reliable flap support and actuation.
2Reliability
If a traditional flap support structure is used, then the flap can be supported, but the structure is heavy, leading to increased fuel costs
Solution Approach 1:
By merging multiple support functions into a single universal support structure, the invention eliminates redundant materials and components. This integration significantly reduces the overall weight of the flap support structure compared to traditional designs that use separate support elements for each function.
3Reliability
If a traditional flap support structure is used, then the flap can be supported, but the structure has large sectional area, increasing drag and fuel costs
Solution Approach 1:
The universal support structure integrates the drive shaft support and aerodynamic fairing support into a single streamlined component. This merging allows for an optimized cross-sectional area that minimizes drag while providing all necessary support functions, unlike traditional designs that require multiple separate support elements increasing the overall area.
4Ease of manufacture
If a modular flap support structure is used, then parts count is reduced and assembly is simplified, but the structure must be designed with multi-functional components
Solution Approach 1:
The universal support structure is designed as a multi-functional component that handles drive shaft support, fairing support, and mounting functions. While the individual component design is complex to accommodate multiple functions, this complexity is concentrated in one element, allowing the overall assembly process to be simplified and reducing the total parts count.
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5c
AI summary
A flap support structure (6) for an aircraft wing (3) having a trailing edge flap (5), the flap support structure comprising: a flap support beam (10) including an aerodynamic fairing (17); and a drive unit (13) including a universal support structure (18) which rotatably receives a drive shaft (25) connected to a drive arm (14a) for moving the trailing edge flap, wherein the universal support structure also forms part of the flap support beam and supports the aerodynamic fairing.