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A Lightweight Cargo Roller

IP.com Disclosure Number: IPCOM000243420D
Publication Date: 2015-Sep-21
Document File: 3 page(s) / 120K

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The IP.com Prior Art Database

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10681: IP.COM

Abstract

Abstract A Lightweight Cargo Roller In this publication we were busy with a light-weight part design achieved by numerical topology and sizing optimization. The roller might be e.g. produced by additive manufacturing (AM) technology. A general topology design assuming unified loads is known. The proposed cargo roller unit design is specifically designed regarding to specific aircraft requirements and loading conditions. The optimized cargo roller unit design provides an option for weight saving and reduction of recurring costs to the existing cargo roller. The geometry is optimized according to its loading conditions, mass and additive manufacturability.

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Page 01 of 3

A Lightweight Cargo Roller

The following concerns a light-weight part design achieved by numerical topology and sizing optimization. The roller might be finally produced by additive manufacturing (AM) technology.

A general topology design assuming unified loads is known. The proposed cargo roller unit design is specifically designed regarding to specific aircraft requirements and loading conditions.

The optimized cargo roller unit design provides an option for weight saving and reduction of recurring costs to the existing cargo roller. The geometry is optimized according to its loading conditions, mass and additive manufacturability.

Design not optimized for manufacturability. Additional supporting structure causes higher recurring costs (fly-to-buy ratio, manufacturing time) and surface porosity

According to AM Design principles no additional supporting structure is needed for α < 40° overhang

The proposed part designs cover an open body and closed surface variant for optimum load introduction according to the bearing position and fixed outer shape:


*Due to bending along the rotational axis the cargo roller does not react the container loads directly when a rigid container is assumed.


Page 02 of 3

In our calculations an open body design and a closed surface design has been considered.

Open Body design

This design leads to the highest weight savings due to optimum material distribution. Furthermore, due to the AM appropriate design (overhangs α < 40°) preven...