Wing Flap Torque Member Integration for Weight Reduction
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Solution Overview
Problem
Aircraft wing flap systems face challenges with heavy and complex torque members that increase weight, cost, and complexity, particularly in dual torque tube designs, which affect structural and load-bearing performance.
Innovation Solution
The wing flap design incorporates a torque member formed by extension members coupled to the flap body, which reduces weight and complexity by integrating with the upper and lower skins and spars, allowing for a non-circular cross-sectional shape that matches the flap body's profile, thereby optimizing structural integrity and aerodynamic characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional circular torque tube is used, then structural integrity is maintained, but weight and device complexity increase
Solution Approach 1:
The torque member is divided into multiple discrete components including extension members, coupling members, and skin members that can be assembled separately. This segmentation allows each component to be optimized independently for weight while maintaining overall structural integrity through their interconnected configuration.
Solution Approach 2:
The torque member transitions from a traditional symmetric circular cross-section to an asymmetric configuration that integrates with the airfoil's upper and lower skins. This asymmetric design eliminates unnecessary material while maintaining structural strength by aligning the torque member's geometry with the actual load paths and aerodynamic shape of the wing flap.
2Force
If a heavy torque tube is used, then load-bearing performance is improved, but device complexity and cost increase
Solution Approach 1:
The torque member is merged with the upper and lower skins of the wing flap to form an integrated structure. The extension members couple these skins together, creating a unified load-bearing assembly that eliminates separate torque tube components and their associated complex couplings, thereby reducing device complexity while maintaining load-bearing performance.
Solution Approach 2:
The torque member structure serves multiple functions simultaneously: it provides torque transmission, acts as structural reinforcement for the skin, and integrates with the aerodynamic shape of the wing flap. This multi-functionality eliminates the need for separate components, reducing overall device complexity while maintaining necessary load-bearing capabilities.
3Reliability
If a dual torque tube design is used, then reliability is improved, but weight and cost increase significantly
Solution Approach 1:
The dual torque tube reliability requirement is achieved through segmented components (extension members, coupling members, skin members) where each segment can be independently optimized for weight. The modular nature allows for redundant load paths without requiring a complete dual-tube structure, thereby maintaining failsafe performance while significantly reducing weight.
Solution Approach 2:
The torque member utilizes composite construction combining different materials and structural elements (skins, extension members, coupling members) to achieve the necessary reliability and failsafe performance. This composite approach allows for weight optimization in each material selection while maintaining the structural integrity and redundancy required for dual torque tube performance.
Data Source
AI summary
A wing flap includes a flap body. The flap body includes an upper skin, a lower skin opposite the upper skin, and a plurality of spars that extend between the upper skin and the lower skin. The wing flap also includes a torque member that is coupled to the flap body. A portion of the torque member is contiguous with at least one of the upper skin and the lower skin.