Variable-Depth Seat Track Assembly for Lightweight Load Matching
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Solution Overview
Problem
Conventional aircraft seat tracks are heavy due to uniform cross-sectional geometry and require extensive machining for optimized designs, leading to instability and increased material costs, as they are typically extruded with constant thickness flanges to handle varying internal loads.
Innovation Solution
A seat track assembly with a Pi-Box design featuring variable depth track flanges and an enclosed section, allowing for optimized cross-sectional geometry matching internal loads and reducing instability, fabricated using a method involving a base flange and welded track flanges, potentially made from titanium with lightening apertures and notches for weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional extrusion processes are used to manufacture seat tracks, then manufacturing simplicity is maintained, but the seat track weight increases and load optimization is limited due to uniform cross-sectional geometry
Solution Approach 1:
The seat track is divided into multiple segments or sections along its length, with each section having a different cross-sectional geometry optimized for its specific loading conditions. This allows variable height and thickness profiles without requiring complete redesign of the entire track, reducing overall weight while maintaining manufacturability through modular fabrication approaches
Solution Approach 2:
The cross-sectional geometry of the seat track is locally optimized at different positions along its length. Sections experiencing higher loads have increased height and material thickness, while low-load sections have reduced dimensions. This local variation in geometry reduces unnecessary material usage and weight while maintaining structural integrity where needed
2Stability of the object's composition
If open I or Pi cross section designs are used, then manufacturing simplicity is maintained, but instability-related failures occur requiring excess material
Solution Approach 1:
The seat track design merges the traditional open I or Pi section with an additional flange or closure element to create a closed-box cross-sectional geometry. This closed section combines the structural advantages of both open and closed sections, providing high torsional and bending stiffness with reduced material usage, thereby improving stability without requiring excessive material
Solution Approach 2:
The seat track employs a composite cross-sectional design that integrates different geometric features (open sections where appropriate, closed-box sections where stability is critical) within a single structural element. This composite approach allows optimization of material distribution to achieve maximum stability with minimum material quantity
3Weight of moving object
If uniform thickness flanges are used in extruded tracks, then manufacturing ease is maintained, but load distribution optimization is prevented leading to increased weight
Solution Approach 1:
The seat track design incorporates variable thickness flanges that adapt to the dynamic loading conditions at different positions along the track. The flange thickness varies continuously or in steps to match the internal load distribution, with thicker sections at high-load areas and thinner sections at low-load areas, optimizing weight while maintaining load-bearing capacity
Solution Approach 2:
The cross-sectional parameters of the seat track, including flange thickness, height, and width, are varied along the length of the track to match the internal load distribution. This parameter optimization allows the structure to use minimum material while adequately resisting the varying loads, directly reducing weight without sacrificing strength
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
The solution results in a lighter seat track assembly that effectively withstands weight dynamics with enhanced stability and reduced material usage, optimizing load distribution and minimizing weight while maintaining structural integrity.
Implementation Method 1
welding a base flange to the track flanges of the seat track
Data Source
AI summary
A seat track assembly an illustrative embodiment of the seat track assembly includes a seat track having an elongated track plate and a pair of generally elongated, parallel, spaced-apart track flanges extending from the track plate. Each of the track flanges is variable in depth. A method of fabricating a seat track assembly is also disclosed.