Sikorsky Aircraft Corporation

Bell Helicopter Textron Inc.

Eric Charles Boyle

Sven Roy Lofstrom

David W Littlejohn

Timothy James Conti

Frank M Caputo

Ryan Lehto

Robert D Higbie

Ajay Sehgal

Scott Oren Smith

Joseph Pantalone, Iii

Keith M Schenone

Alicia Fernandez

Jose De Anda

Cecil E Covington

Robert Shawn Thompson

David Allen Haynie

Joseph J Zierer

Glen A Shimek

Christopher Finch

Christopher O Finch

A method of mounting a replacement tip section to an exposed end of a rotor blade includes removing an existing tip section from the rotor blade to create the exposed end of the rotor blade, installing the rotor blade having the exposed end onto a holding fixture, assembling the replacement tip section about the exposed end of the rotor blade, positioning a bonding fixture about the replacement tip section, and curing the replacement tip section to the exposed end of the rotor blade.

Method of removal and replacement of a tip section of a rotor blade

A system for regenerating fastener holes in a replacement tip section of a rotor blade includes a first fixture, a second fixture, and a third fixture positionable adjacent a tip section of the rotor blade. The first fixture is used to verify a position of an opening formed in the spar. The second fixture includes a removable bushing having a drillable opening. The drillable opening is aligned with the at least one opening formed in the spar and defines at least one hole to be formed in the replacement tip section. The third fixture includes a countersink opening. The countersink opening is aligned with the at least one hole to be formed in the replacement tip section and the at least one opening formed in the spar to define a countersink feature to be formed in the at least one hole.

Method and apparatus for locating and forming fastener holes in a replacement tip section of a rotor blade

A bond fixture for bonding a component includes a frame defining a chamber for receiving the component. A first pad and a second pad are mounted to the frame. At least one of the first pad and the second pad is movable relative to the frame to adjust a pressure applied to the component. A caul assembly is adapted to be disposed in thermal communication with the component. The caul assembly heats a localized portion of the component.

Bond fixture for composite splice cap assembly

A bond fixture includes a first fixture having a heater and a plurality of clamps. Each of the plurality of clamps includes a first member and a second member rotatable between a first position and a second position. A second fixture includes a root end lift translatable vertically between a retracted position and an extended position and a root end clamp translatable along a horizontal axis. The root end clamp is configured to cooperate with the root end.

Bond fixture for sheath assembly of rotor blade

A rotor blade disassembly method includes applying spanwise support to a rotor blade body and heating a bond disposed on an end of the rotor blade body. The method also includes removing the spanwise support from the rotor blade body and exerting shear stress on the bond using weight of the rotor blade body. A blade disassembly system is also described.

Methods for separating rotor blade cuffs from rotor blade bodies

A method of making a rotor blade assembly includes receiving a sheath assembly and a blade body at a blade assembly tool. The sheath assembly is spread by applying force to an interior surface of the sheath assembly. The blade body is inserted within the interior of the sheath assembly, registered with the sheath assembly, and the force removed from the interior surface of the sheath assembly such that the sheath assembly collapses on the blade body.

Apparatus and methods for making rotorcraft rotor blades

A system for transferring a hole pattern from a first component to a second component configured to couple to the first component is provided including a contour plate having a drill plate with a hole pattern substantially identical to the hole pattern of the first component. The position of the drill plate is adjustable to match the hole pattern of the drill plate with the hole pattern of the first component. A slidable fixture configured to support the second component is movable to align the second component with the drill plate such that the hole pattern of the drill plate in relation to the second component matches the hole pattern of the drill plate in relation to the hole pattern of the first component. The hole pattern of the drill plate is used to create a hole pattern in the second component matching the hole pattern of the first component.

Composition hole pattern transfer tooling

A multi-bladed tail rotor assembly is disclosed that provides higher aerodynamic performance, damage tolerant design with 10,000-hour life expectancy, and which requires low maintenance through the use of composites and elastomerics. The tail rotor hub assembly includes two stacked yoke assemblies having multi-bladed teetering rotors, each mounted on a single drive mast. Each yoke assembly includes a yoke hub having a transverse bore therethrough, a bearing assembly disposed within the bore, and retention means for aligning and securing the bearing assembly within the bore. Each bearing assembly includes a trunnion portion having trunnion arms that extend outwardly from a trunnion body portion, and an elastomeric bearing disposed about each trunnion arm. The tail rotor assembly utilizes a composite twist strap flexure to accommodate collective pitch control integral with each rotor blade.

Multi-bladed tail rotor hub design for coriolis relief

The present invention comprises a rotor blade and method of manufacture thereof. The rotor blade of the present invention incorporates a number of novel features in order to increase its reliability and strength while reducing its weight. In certain embodiments, the rotor blade of the present invention incorporates a flexural strap in place of traditional pitch bearings. In certain embodiments, the rotor blade of the present invention is manufactured using a unique fiber placement layup technique to reduce failure modes and maximize the fatigue strength of the part.

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Haslet, TX, United States of America

Eric Charles Boyle