Forming tool and method for forming a bend into a composite reinforcement

Abstract

The invention provides a forming tool and method for forming a bend into a composite reinforcement. The composite reinforcement is positioned in a forming region formed by a base assembly and an upper assembly. A first gas flow is applied through material of the base assembly. A second gas flow is applied through material of the upper assembly. A plurality of supports of the upper assembly are moved relative to each other to change a bend of the forming region along a length of the forming region to form the bend into the composite reinforcement.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to shaped composite parts, and more particularly to forming a bend into a longitudinal composite structure. BACKGROUND

[0002] Composite stringers, also known as composite stiffeners, follow the bend of a composite skin. A composite stringer with a desired bend can be laid up. However, laying up a composite stringer with a bend can take an undesirable amount of time. In addition, laying up a composite stringer with a bend can take an undesirable amount of resources.

[0003] A bend can be placed into a composite stringer by bending and twisting an uncured stringer. In a traditional process, bending the stringer up and down causes compression build-up in the material. The compression build-up can cause excess material to collect. When the composite material is compressed, the likelihood of wrinkles forming increases due to the excess material collected.

[0004] In addition, traditional bending methods use a series of manual levers to perform successive adjustments. Using the traditional process and the series of manual levers does not provide consistent compliance and causes stress concentrations on the stringer. Some traditional methods do not effectively bend and twist around the longitudinal axis of the stringer, which is needed to match the composite skin.

[0005] Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the issues discussed above, as well as possibly other issues. SUMMARY

[0006] An embodiment of the present disclosure provides a shaping tool. The shaping tool includes a base assembly, an upper assembly, and an actuator. The base assembly is formed of a plurality of segments and material to distribute a first airflow to a shaping area formed by the base assembly and the upper assembly, the first airflow providing an air bearing or holding force. The upper assembly includes a plurality of cradles and material to distribute a second airflow to the shaping area in an opposite direction of the first airflow. The actuator is connected to the plurality of cradles and the plurality of segments, the actuator being configured to move each of the plurality of segments relative to one another to change a bend of the shaping area along a length of the shaping area.

[0007] Another embodiment of the present disclosure provides a method of forming a bend into a composite stiffener. The composite stiffener is positioned over a segment of a base assembly. A pair of cradles of an upper assembly is positioned over the composite stiffener to form a shaping area having a cross-section. The segment and the pair of cradles are moved within a manufacturing environment while maintaining the cross-section of the shaping area to form the bend into the composite stiffener.

[0008] Another embodiment of the present disclosure provides a method of forming a bend into a composite reinforcement. The composite reinforcement is positioned in a forming area formed by a base assembly and an upper assembly. A first air flow is applied through a material of the base assembly. A second air flow is applied through a material of the upper assembly. A plurality of cradles are moved relative to one another to change a bend of the forming area along a length of the forming area to form the bend into the composite reinforcement.

[0009] According to one aspect of the present disclosure, a forming tool comprises:

[0010] a base assembly formed from a plurality of segments and a material for distributing a first air flow to a forming area formed by the base assembly and an upper assembly, the first air flow providing an air bearing or holding force;

[0011] the upper assembly, the upper assembly comprising a plurality of cradles and a material for distributing a second air flow to the forming area in an opposite direction to the first air flow; and

[0012] an actuator connected to the plurality of cradles and the plurality of segments, the actuator configured to move each of the plurality of segments relative to one another to change a bend of the forming area along a length of the forming area.

[0013] Advantageously, the forming tool is a tool in which the plurality of cradles comprises pairs of cradles, each pair of cradles being individually movable relative to a longitudinal axis of the forming area.

[0014] Preferably, the forming tool is a tool in which the actuator comprises a plurality of actuators connected to the plurality of cradles such that the plurality of actuators move each pair of cradles of the plurality of cradles independently relative to the remaining cradles of the plurality of cradles.

[0015] Preferably, the forming tool is a tool in which the actuator is connected to the plurality of cradles and the plurality of segments such that the actuator changes the bend of the forming area while maintaining a cross-section of the forming area.

[0016] Preferably, the forming tool further comprises:

[0017] a controller configured to send commands to at least one of the actuators to change the bend of the forming area according to NC programming; a gas pressure source for controlling at least one of the first air flow or the second air flow; an actuation lock configured to selectively constrain the plurality of segments relative to a compliant connector or an actuation lock configured to selectively constrain the plurality of cradles relative to a compliant connector.

[0018] Preferably, the forming tool is a tool in which the material for distributing the second airflow is formed of a porous material to provide the second airflow to the forming area.

[0019] Preferably, the forming tool is a tool in which the material for distributing the second airflow includes at least one of perforations or channels to provide the second airflow to the forming area.

[0020] Preferably, the forming tool is a tool in which the material for distributing the first airflow is formed of a porous material to provide the first airflow to the forming area.

[0021] Preferably, the forming tool is a tool in which the material for distributing the first airflow of the base assembly includes at least one of perforations or channels to provide the first airflow to the forming area.

[0022] Preferably, the forming tool further includes a compliant connector extending through and connecting the plurality of segments and an actuation lock configured to selectively restrain the plurality of segments relative to the compliant connector.

[0023] Preferably, the forming tool further includes a compliant connector extending through and connecting the plurality of brackets and an actuation lock configured to selectively restrain the plurality of brackets relative to the compliant connector.

[0024] Preferably, the forming tool further includes a pneumatic source connected pneumatically to at least one of the plurality of segments or the material of the base assembly to provide the first airflow through the material and a pneumatic source connected pneumatically to at least one of the plurality of brackets or the material of the upper assembly to provide the second airflow through the material.

[0025] A composite stiffener for an aircraft is manufactured using a forming tool as described above.

[0026] According to one aspect of the disclosure, a method of forming a bend into a composite stiffener, the method comprising:

[0027] Positioning the composite stiffener over a segment of a base assembly;

[0028] Placing a pair of brackets of an upper assembly over the composite stiffener to form a forming area having a cross-section; and

[0029] moving the segments and the pair of brackets within a manufacturing environment while maintaining the cross section of the forming area to form the bend into the composite stiffener.

[0030] Advantageously, in the method, moving the segments and the pair of brackets is part of a synchronized movement of a plurality of brackets of the upper assembly and a plurality of segments of the base assembly to form the bend into the composite stiffener.

[0031] Preferably, the method further comprises sending a first airflow through the material of the base assembly in a first direction relative to the forming area, wherein the first direction is one of a positive airflow or a negative airflow, and sending a second airflow through the material of the upper assembly in a second direction relative to the forming area, wherein the second direction is opposite the first direction.

[0032] Preferably, the method further comprises sending a second airflow through the material of the upper assembly to the forming area, wherein sending the second airflow through the material of the upper assembly includes sending a negative airflow through the material associated with at least one bracket of a plurality of brackets of the upper assembly to the forming area and sending a positive airflow through the material associated with at least one bracket of the plurality of brackets to the forming area.

[0033] Preferably, the method further comprises sending a first airflow through the material of the base assembly to the forming area, wherein sending the first airflow through the material includes sending a negative airflow through a portion of the material associated with at least one segment of a plurality of segments of the base assembly to the forming area and sending a positive airflow through a portion of the material associated with at least one segment of the plurality of segments to the forming area.

[0034] A composite stiffener for an aircraft formed according to the method described above.

[0035] According to one aspect of the disclosure, a method of forming a bend into a composite stiffener, the method comprising:

[0036] positioning the composite stiffener in a forming area formed by a base assembly and an upper assembly;

[0037] applying a first airflow through the material of the base assembly;

[0038] applying a second airflow through the material of the upper assembly; and

[0039] moving a plurality of cradles of the upper assembly relative to one another to vary a bend of the forming area along a length of the forming area to form the bend into the composite stiffener.

[0040] Advantageously, in the method, the second airflow of the material through the upper assembly has an opposite direction to the first airflow of the material of the base assembly through the associated section of the base assembly.

[0041] Preferably, in the method, moving the plurality of cradles relative to one another includes moving the plurality of cradles vertically in pairs relative to a longitudinal axis of the composite stiffener.

[0042] Preferably, in the method, moving the plurality of cradles relative to one another includes rotating a pair of the plurality of cradles about the longitudinal axis of the composite stiffener to introduce roll into the composite stiffener.

[0043] Preferably, in the method, moving the plurality of cradles relative to one another includes moving a pair of the plurality of cradles in a first direction relative to the longitudinal axis of the composite stiffener to introduce pitch into the composite stiffener.

[0044] Preferably, in the method, moving the plurality of cradles relative to one another includes moving a pair of the plurality of cradles in a second direction relative to the longitudinal axis of the composite stiffener to introduce yaw into the composite stiffener.

[0045] Preferably, the method further includes moving a plurality of sections of the base assembly relative to one another to maintain a cross-section of the forming area as the plurality of cradles are moved relative to one another, wherein moving the plurality of sections relative to one another includes moving the plurality of sections vertically relative to a longitudinal axis of the forming area.

[0046] Preferably, the method further includes curing the composite stiffener after the bend is formed into the composite stiffener.

[0047] Preferably, the method further includes removing the plurality of cradles from the composite stiffener and lifting the composite stiffener with the bend from the base assembly, wherein the curing is performed after the composite stiffener is lifted.

[0048] Preferably, the method further includes removing the plurality of cradles from the composite stiffener and positioning a plurality of spacers on the composite stiffener.

[0049] A composite stiffener for an aircraft formed according to the method described above.

[0050] Features and functions can be implemented independently of one another or in combinations with one another in various embodiments of the present disclosure, where further details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF DRAWINGS

[0051] The novel features described herein are set forth with particularity in the claims that follow. These descriptive terms, however, are intended to be merely descriptive, and not limiting, as the illustrative embodiments and their preferred modes of use, further objects and features will become apparent to those skilled in the art upon reading the following detailed description of the illustrative embodiments taken in conjunction with the accompanying drawings:

[0052] Figure 1 is an illustration of a block diagram of a manufacturing environment in which the illustrative embodiments can be implemented;

[0053] Figure 2 is an illustration of an aircraft in accordance with an illustrative embodiment;

[0054] Figure 3 is an illustration of a composite stiffener having a bend in accordance with an illustrative embodiment;

[0055] Figure 4 is an illustration of a front view of a forming tool having indicated air flow in accordance with an illustrative embodiment;

[0056] Figure 5 is an illustration of a front view of a forming tool having indicated air flow in accordance with an illustrative embodiment;

[0057] Figure 6 is an illustration of an isometric view of a forming tool in accordance with an illustrative embodiment;

[0058] Figure 7 is an illustration of a simplified front view of a forming tool in accordance with an illustrative embodiment;

[0059] Figure 8 is an illustration of a simplified top perspective view of a forming tool in accordance with an illustrative embodiment;

[0060] Figure 9 is an illustration of a simplified side perspective view of a forming tool in accordance with an illustrative embodiment;

[0061] Figure 10 is an illustration of a simplified side view of material prior to forming a bend in accordance with an illustrative embodiment;

[0062] Figure 11 is an illustration of a simplified side view of material while a bend is being formed using a forming tool in accordance with an illustrative embodiment;

[0063] Figure 12 is an illustration of forces within a composite stiffener as a bend is formed in the composite stiffener by a forming tool according to an illustrative implementation;

[0064] Figure 13 is an illustration of forces within a composite stiffener having a bend formed by a forming tool according to an illustrative implementation;

[0065] Figure 14 is an illustration of a flowchart of a method of forming a bend into a composite stiffener according to an illustrative implementation;

[0066] Figure 15 is an illustration of a flowchart of a method of forming a bend into a composite stiffener according to an illustrative implementation;

[0067] Figure 16 is an illustration of a method of aircraft manufacture and service, in the form of a block diagram, according to an illustrative implementation; and

[0068] Figure 17 is an illustration of an aircraft in which an illustrative implementation can be implemented, in the form of a block diagram. DETAILED DESCRIPTION

[0069] Illustrative examples recognize and take into account that a composite material is a tough, lightweight material that is produced by combining two or more functional components. For example, a composite material can include reinforcing fibers that are incorporated in a polymeric resin matrix. The fibers can be unidirectional, or can take the form of a woven cloth or fabric. The fibers and resin are arranged and cured to form the composite material.

[0070] Illustrative examples recognize and take into account that current composite stringers are manually twisted and bent to match the surface profile of a wing skin. However, illustrative examples recognize and take into account that current tools and methods struggle with consistency and accuracy.

[0071] There are traditional manually adjusted mechanically assisted end effectors. However, illustrative examples recognize and take into account that attempting to bend / twist a composite stringer in the air on a traditional end effector limits the ability to verify the stringer before it is transported to the composite skin. Illustrative examples recognize and take into account that traditional end effectors provide limited stringer inspection. Limited stringer inspection can result in an inability to detect out-of-tolerance inconsistencies in a formed stringer. A formed stringer with out-of-tolerance inconsistencies introduces out-of-tolerance inconsistencies to a composite panel having the stringer.

[0072] Illustrative examples recognize and take into account that building an end effector with all desired degrees of freedom sharply increases the weight of the end effector. Increasing the weight of the end effector increases the payload requirements of the equipment supporting the end effector. Increasing the payload requirements also increases the footprint requirements. For example, an end effector with all desired degrees of freedom can have hundreds of actuators, each with additional drive trains and mechanical supports; this increases the weight capacity. For example, for a 70 foot long spar, 6 actuators per foot would be 420 actuators, all with additional drive trains and mechanical supports; this increases the weight capacity. Having all of the actuation to form a three-dimensional bend into a composite spar built onto an airborne end effector can require a large gantry to move, and this can be undesirably heavy.

[0073] Illustrative examples also recognize and take into account that composite parts are traditionally handled using vacuum. Illustrative examples use a combination of outward airflow and vacuum to manipulate the composite stiffener.

[0074] The forming tool and method of illustrative examples separate the actuators that bend and twist the composite stiffener from the pick and place equipment. Separating the bend forming section from the pick and place equipment leaves most of the weight on the ground. In illustrative examples, the spar is only lifted after it has been bent / twisted. Thus, illustrative examples allow for inspection of the composite spar on the ground, and once verified, the composite spar is picked up and delivered to a desired location for installation.

[0075] The forming tool and method of illustrative examples provide the ability to handle the composite spar in full tension during bending. The design method of the forming tool and method of illustrative examples shifts the longitudinal axis such that the part is kept under tension by moving the longitudinal axis down to where the base assembly intersects the composite spar. In illustrative examples, the base assembly takes most of the compression while the composite spar part is kept under tension.

[0076] Turning now to the drawings, Figure 1 is an illustration of a block diagram of a manufacturing environment in which illustrative implementations can be implemented. The manufacturing environment 100 includes a forming tool 102 that is configured to form a bend 104 into a composite stiffener 106. The forming tool 102 is configured to form the bend 104 relative to a longitudinal axis 108 of the composite stiffener 106. In some illustrative examples, the longitudinal axis 108 is referred to as a centerline. The bend 104 is formed into the composite stiffener 106 along a length 110 of the composite stiffener 106.

[0077] The composite stiffener 106 has any desired thickness. The composite stiffener 106 is formed from a plurality of plies. In some illustrative examples, each ply has a thickness of less than 0.01 inches. In some illustrative examples, each ply has a thickness of approximately 0.0075 inches. In some illustrative examples, the composite stiffener 106 has between 8 and 80 plies. In some illustrative examples, the thickness of the composite stiffener 106 varies within the cross-section 118. In some illustrative examples, the flanges of the composite stiffener 106 have up to 40 plies. In some illustrative examples, the web of the composite stiffener 106 has up to 80 plies.

[0078] In some illustrative examples, the longitudinal axis 108 is a desired axis set by the base assembly 130. In these illustrative examples, the longitudinal axis 108 has a different location than the neutral axis 109 of the composite stiffener 106. In some illustrative examples, the longitudinal axis 108 is a desired axis positioned at the location of the base assembly 130 contacting the composite stiffener 106 of the forming tool 102.

[0079] The bend 104 includes at least one of a roll 112, a pitch 114, or a yaw 116. The roll 112 is a rotation or twist of the cross-section 118 about the longitudinal axis 108. The roll 112 is a movement of the cross-section 118 about the longitudinal axis 108 along the length 110 of the composite stiffener 106. A change in the roll 112 can be described as a twist.

[0080] The pitch 114 is a movement of the longitudinal axis 108 of the manufacturing environment 100 in the y-axis 120. The pitch 114 can be described as an upward or downward movement relative to the cross-section 118. A change in the pitch 114 can be described as a ramp or a dip.

[0081] The yaw 116 is a movement of the longitudinal axis 108 of the manufacturing environment 100 in the x-axis 122. The yaw 116 can be described as a left or right movement relative to the cross-section 118. A change in the yaw 116 can be described as a bend.

[0082] The composite stiffener 106 has any desired cross-section 118. In some illustrative examples, the composite stiffener 106 has a T-shaped 124 cross-section 118. In some illustrative examples, the longitudinal axis 108 is positioned within the base of the T-shaped 124 cross-section 118. When the cross-section 118 is T-shaped 124, the composite stiffener 106 can be referred to as a “blade spar.”

[0083] In some illustrative examples, the composite stiffener 106 can also be referred to as a longitudinal composite structure. The length 110 is substantially greater than the height or width of the cross-section 118. Prior to forming, the longitudinal axis 108 extends along the z-axis 126.

[0084] When the composite reinforcement 106 is uncured 128, the bend 104 is formed into the composite reinforcement 106. After the bend 104 is formed into the composite reinforcement 106, the composite reinforcement 106 is cured.

[0085] The forming tool 102 includes a base assembly 130, an upper assembly 129, and an actuator 176. The base assembly 130 is formed from a plurality of segments 132 and a material 146 for distributing a first airflow 134 to a forming area 136 formed by the base assembly 130 and the upper assembly 129, the first airflow 134 providing an air bearing or holding force. The base assembly 130 is configured to provide the first airflow 134 to the forming area 136 formed by the base assembly 130 and the upper assembly 129. The first airflow 134 provides the air bearing or holding force to the composite reinforcement 106 within the forming area 136. The base assembly 130 is formed from the plurality of segments 132 and the material 146 for distributing the first airflow 134.

[0086] The upper assembly 129 is configured to provide a second airflow 138 to the forming area 136 in a direction opposite the first airflow 134. The upper assembly 129 includes a plurality of supports 131 and a material 156 for distributing the second airflow 138 to the forming area 136 in a direction opposite the first airflow 134.

[0087] The actuator 176 is connected to the plurality of supports 131 and the plurality of segments 132. The actuator 176 is configured to move each of the plurality of segments 132 relative to one another to change a bend 178 of the forming area 136 along a length 180 of the forming area 136.

[0088] The material 146 is configured to provide the first airflow 134 to the forming area 136 formed by the base assembly 130 and the upper assembly 129. The material 156 is configured to provide the second airflow 138 to the forming area 136.

[0089] In some illustrative examples, the plurality of segments 132 are formed from the material 146. In some illustrative examples, the material 146 is a separate layer connected to each of the plurality of segments 132. In some of these illustrative examples, the material 146 is a plurality of sheets connecting the plurality of segments 132. In one illustrative example, a single sheet of material 146 connects each of the plurality of segments 132. In some illustrative examples, the material 146 includes more than one sheet, at least one sheet attached to more than one of the plurality of segments 132. In some illustrative examples, the material 146 includes a plurality of sheets, each sheet connected to a single one of the plurality of segments 132.

[0090] The first airflow 134 is movement of air through the material 146. In some illustrative examples, the first airflow 134 is in the same direction through all of the material 146 associated with the plurality of segments 132. In some illustrative examples, the first airflow 134 is a positive airflow 133. A positive airflow 133 through the material 146 applies positive pressure into the forming area 136. With a positive airflow 133, air flows through the material 146 and into the forming area 136. When present, a positive airflow 133 allows the composite reinforcement 106 to slide relative to the base assembly 130.

[0091] In some illustrative examples, the first airflow 134 is a negative airflow 135. A negative airflow 135 through the material 146 draws air from the forming area 136. With a negative airflow 135, air flows from the forming area 136 through the material 146. A negative airflow 135 can also be referred to as “pulling a vacuum” or pulling a partial vacuum.

[0092] In some illustrative examples, the first airflow 134 includes two different directions. In these illustrative examples, at least a portion of the material 146 has a positive airflow 133 into the forming area 136 and at least a portion of the material 146 has a negative airflow 135 drawing air from the forming area 136. In some illustrative examples, there is a positive airflow 133 through the material 146 at a first location along the length 180 of the forming area 136 and there is a negative airflow 135 through the material 146 at a second location along the length 180 of the forming area 136. In some illustrative examples, there is a positive airflow 133 through the material 146 associated with at least one of the plurality of segments 132 and there is a negative airflow 135 through the material 146 associated with another one of the plurality of segments 132.

[0093] In some illustrative examples, the positive airflow 133 and the negative airflow 135 are provided at the same location along the length 180 of the forming area 136. In some illustrative examples, there is a positive airflow 133 through a portion of the material 146 associated with one of the left or right braces and there is a negative airflow 135 through a portion of the material 146 associated with the other one of the left or right braces. In some illustrative examples, there is a positive airflow 133 through a portion of the material 146 associated with one of the left brace 170 or the right brace 172 and there is a negative airflow 135 through a portion of the material 146 associated with the other one of the left brace 170 or the right brace 172.

[0094] In some illustrative examples, the positive airflow 133 and the negative airflow 135 are disposed in one of the plurality of sections 132. In one illustrative example, the positive airflow 133 is disposed in a portion of the section 184 and the negative airflow 135 is disposed in a remaining portion of the section 184. In one illustrative example, the positive airflow 133 is disposed in the portion 141 of the section 184 associated with the left brace 170 and the negative airflow 135 is disposed in the portion 143 of the section 184 associated with the right brace 172. In one illustrative example, the negative airflow 135 is disposed in the portion 141 of the section 184 associated with the left brace 170 and the positive airflow 133 is disposed in the portion 143 of the section 184 associated with the right brace 172.

[0095] In some illustrative examples, the first airflow 134 includes more than one strength of airflow. In one illustrative example, the first airflow 134 includes more than one strength of positive airflow 133. In one illustrative example, the first airflow 134 includes more than one strength of negative airflow 135.

[0096] In some illustrative examples, the first airflow 134 through the section 184 includes more than one strength of airflow. In some illustrative examples, the first airflow 134 through the section 184 includes more than one strength of positive airflow 133. In some illustrative examples, the first airflow 134 through the section 184 includes more than one strength of negative airflow 135.

[0097] The second airflow 138 is movement of air through the material 156. In some illustrative examples, the second airflow 138 is in the same direction through all of the material 156. In some illustrative examples, the second airflow 138 is a positive airflow 137. A positive airflow 137 through the material 156 applies positive pressure into the forming area 136. In the case of a positive airflow 137, air flows through the plurality of braces 131 and into the forming area 136. When present, the positive airflow 137 allows the composite reinforcement 106 to slide relative to the upper assembly 129.

[0098] In some illustrative examples, the second airflow 138 is a negative airflow 139. A negative airflow 139 through the material 156 draws air from the forming area 136. In the case of a negative airflow 139, air flows from the forming area 136 through the material 156.

[0099] In some illustrative examples, the second airflow 138 includes two different directions. In these illustrative examples, at least a portion of the material 156 has a positive airflow 137 into the forming area 136, and at least a portion of the material 156 has a negative airflow 139 that draws air from the forming area 136. In some illustrative examples, there is a positive airflow 137 through the material 156 associated with one pair of the plurality of supports 131, and there is a negative airflow 139 through the material 156 associated with another pair of the plurality of supports 131.

[0100] In some illustrative examples, the positive airflow 137 and the negative airflow 139 are provided at the same location along the length 180 of the forming area 136. In some illustrative examples, there is a positive airflow 137 through a portion of the material 156 associated with one of the left or right supports, and there is a negative airflow 139 through a portion of the material 156 associated with the other of the left or right supports. In some illustrative examples, there is a positive airflow 137 through a portion of the material 156 associated with one of the left support 170 or the right support 172, and there is a negative airflow 139 through a portion of the material 156 associated with the other of the left support 170 or the right support 172.

[0101] In some illustrative examples, the positive airflow 137 and the negative airflow 139 are provided in the material 156 associated with a pair of the paired supports 166. In one illustrative example, the positive airflow 137 is provided in one of the pair of supports 168, and the negative airflow 139 is provided in the other of the pair of supports 168. In one illustrative example, the positive airflow 137 is provided in the material 156 associated with the left support 170, and the negative airflow 139 is provided in the material 156 associated with the right support 172. In one illustrative example, the negative airflow 139 is provided in the material 156 associated with the left support 170, and the positive airflow 137 is provided in the material 156 associated with the right support 172.

[0102] In some illustrative examples, the second airflow 138 includes more than one strength of airflow. In one illustrative example, the second airflow 138 includes more than one strength of positive airflow 137. In one illustrative example, the second airflow 138 includes more than one strength of negative airflow 139.

[0103] In some illustrative examples, the second airflow 138 through the pair of brackets 168 includes more than one strength of airflow. In some illustrative examples, the second airflow 138 through the pair of brackets 168 includes more than one strength of positive airflow 137. In one illustrative example, one of the left bracket 170 or the right bracket 172 has a greater strength of positive airflow 137 than the other of the left bracket 170 or the right bracket 172. In some illustrative examples, the second airflow 138 through the pair of brackets 168 includes more than one strength of negative airflow 139. In one illustrative example, one of the left bracket 170 or the right bracket 172 has a greater strength of negative airflow 139 than the other of the left bracket 170 or the right bracket 172.

[0104] The air pressure source 140 is pneumatically connected to the base assembly 130 to provide the first airflow 134 through the material 146. The air pressure source 140 is pneumatically connected to at least one of the material 146 or the plurality of segments 132 of the base assembly 130 to provide the first airflow 134 through the material 146. The air pressure source 140 is configured to apply the first airflow 134 through the material 146. In some illustrative examples, each of the air pressure sources 140 is individually controllable to control the air pressure to the portion of the material 146 associated with each of the plurality of segments 132. In some illustrative examples, each of the air pressure sources 140 is reversible to change between positive airflow 133 and negative airflow 135.

[0105] The air pressure source 142 is pneumatically connected to the upper assembly 129 to provide the second airflow 138 through the material 156. The air pressure source 142 is pneumatically connected to at least one of the material 156 or the plurality of brackets 131 of the upper assembly 129 to provide the second airflow 138 through the material 156. The air pressure source 142 is configured to apply the second airflow 138 through the material 156. In some illustrative examples, each of the air pressure sources 142 is individually controllable to control the air pressure to the portion of the material 156 associated with each of the plurality of brackets 131. In some illustrative examples, each of the air pressure sources 142 is reversible to change between positive airflow 137 and negative airflow 139.

[0106] The first airflow 134 is distributed across the surface 144 of the base assembly 130 by any desired method. In some illustrative examples, the material 146 of the base assembly 130 is a porous material 148. When the material 146 takes the form of a porous material 148, the pores in the porous material 148 distribute the first airflow 134 from the air pressure source 140 through the material 146. In other illustrative implementations, at least one of a channel 150 or a perforation 152 cut into the material 146 distributes the first airflow 134 from the air pressure source 140. In some of these illustrative examples, the material 146 functions as a manifold that distributes the first airflow 134. In some illustrative examples, the material 146 is flexible 154.

[0107] The material 146 is selected to be compatible with contact with the composite material. For example, the material 146 is selected to not react with the composite material, to not pull resin out of the composite material, and to not bond with the composite material. The material 146 is selected so that, when the base assembly 130 is used, the carbon fiber composite material does not create foreign object debris (FOD).

[0108] To form the bend 104, the plurality of segments 132 are moved to mimic the desired position for the composite reinforcement 106. For example, when the composite reinforcement 106 is configured to be connected to a wing panel, the plurality of segments 132 are moved to mimic the bend of the position of the wing panel to which the composite reinforcement 106 will be attached. The simultaneous movement of the plurality of supports 131 and the plurality of segments 132 is used to form the bend 104 into the composite reinforcement 106. The movement of the plurality of supports 131 and the plurality of segments 132 is a slow, incremental movement.

[0109] The plurality of segments 132 have any desired size. In some illustrative examples, each segment of the plurality of segments 132 has a length of 12 inches or less in the direction of the length 110 of the composite reinforcement 106, which is also referred to as the longitudinal direction. In some illustrative examples, each segment of the plurality of segments 132 has a length of between 2 and 3 inches in the direction of the length 110 of the composite reinforcement 106.

[0110] The base assembly 130 has a stiffness 155. The base assembly 130 of the forming tool 102 at the base of the composite reinforcement 106 is designed to have an equal or lower stiffness compared to the composite reinforcement 106. The base assembly 130 then remains curved and twisted around the longitudinal axis 167. The longitudinal axis 167 is positioned on the support surface 144 of the base assembly 130. The base assembly is the composite reinforcement 106 and twists the composite reinforcement 106 around the longitudinal axis 167 allows the composite reinforcement 106 to remain under full tension throughout the composite reinforcement 106 regardless of bending up or down. When the composite reinforcement 106 is under full tension at all times, each ply of the laminate is under tension during forming so that no ply is under compression. By always achieving full tension, wrinkles are reduced or eliminated.

[0111] The stiffness 155 of the base assembly 130 is controlled so that the neutral axis 109 is not the axis around which the composite reinforcement 106 is formed. By pulling the composite reinforcement 106 against the base assembly 130 and controlling the stiffness 155 of the base assembly 130 (but sliding along the compliant connector 188), the longitudinal axis 108 is shifted.

[0112] The second gas flow 138 is distributed across the plurality of supports 131 by any desired method. In some illustrative examples, the material 156 of the plurality of supports 131 is a porous material 158.

[0113] The porous material 158 includes a solid or foam matrix with pores that permeate through. The porous material 158 can be referred to as a porous medium. The porous material 158 is an open cell material. The pores permeate through the porous material 158 to all sides of the material 156.

[0114] The material 156 is formed from any desired type of porous material 158. In some illustrative examples, the material 156 is formed from a porous ceramic material, such as a sintered material. In some illustrative examples, the material 156 includes a porous polymeric material.

[0115] When the material 156 is formed from a porous material 158, the pores in the porous material 158 distribute the second gas flow 138 from the gas pressure source 142 through the material 156. In other illustrative examples, at least one of channels 160 or perforations 162 cut into the material 156 distribute the second gas flow 138 from the gas pressure source 142. In some of these illustrative examples, the material 156 functions as a manifold that distributes the second gas flow 138. In some illustrative examples, the material 156 is flexible 164.

[0116] Material 156 is selected to be permissive with the composite material. For example, material 156 is selected to not react with the composite material, to not pull resin out of the composite material, and to not bond with the composite material. Material 156 is selected such that the carbon fiber composite material does not generate foreign object debris (FOD) when using upper assembly 129.

[0117] As depicted, the plurality of brackets 131 includes pairs of brackets 166. Each pair of brackets is movable relative to a longitudinal axis 167 of the forming area 136. Each pair of brackets 166 is independently movable relative to the remaining pairs of brackets 166.

[0118] For example, a pair of brackets 168 includes a left bracket 170 and a right bracket 172. The pair of brackets 168 is independently movable relative to the remaining pairs of brackets 166.

[0119] The plurality of brackets 131 and the plurality of segments 132 form the forming area 136 having a cross-section 174. An actuator 176 is connected to the plurality of brackets 131 and the base assembly 130 and is configured to move the plurality of brackets 131 and the plurality of segments 132 of the base assembly 130 within the manufacturing environment 100 to change a curvature 178 of the forming area 136 along a length 180 of the forming area 136. The actuator 176 is configured to move each of the plurality of segments 132 independently of each other segment. The actuator 176 is configured to move each of the pairs of brackets 166 independently of each other pair of brackets.

[0120] By independently moving each of the plurality of segments 132, the curvature 178 is changed. By independently moving each of the pairs of brackets 166, the curvature 178 is changed.

[0121] The plurality of brackets 131 and the plurality of segments 132 are moved synchronously by the actuator 176 for changing the curvature 178 of the forming area 136. The plurality of brackets 131 and the plurality of segments 132 are moved by the actuator 176 is a slow, incremental movement.

[0122] The actuator 176 is configured to change the curvature 178 of the forming area 136 while maintaining the cross-section 174 of the forming area 136. The actuator 176 is configured to move each of the plurality of segments 132 and a corresponding pair of brackets 168 together to maintain the cross-section 174. The actuator 176 is configured to move each of the plurality of segments 132 and a corresponding pair of brackets 168 independently of the remaining ones of the plurality of segments 132 and the remaining pairs of brackets 166.

[0123] The change in the bend 178 of the forming area 136 forms the bend 104 into the composite stiffener 106 within the forming area 136. The bend 104 is formed into the composite stiffener 106 in any desired manner. In some illustrative examples, the bend 178 is changed by gradually moving successive segments of the plurality of segments 132. In some illustrative examples, the bend 178 is changed at a first end and gradually changes moving along the length 180 to an opposite end. In some illustrative examples, the bend 178 is changed from a middle of the length 180 and gradually moves outward.

[0124] In some illustrative examples, the synchronized movement of the actuators 176 includes simultaneous movement of a plurality of actuators. In some illustrative examples, at least two segments of the plurality of segments 132 are moved substantially simultaneously. In some illustrative examples, to gradually introduce a bend to achieve the bend 104, the actuators 176 are moved to increase the bend of the composite stiffener 106 being formed by successive iterations of increasing the bend.

[0125] Each of the plurality of brackets 131 has a respective plurality of actuators of the actuators 176 to move the respective bracket in at least 3 degrees of freedom (DOF). Each segment of the plurality of segments 132 has a respective plurality of actuators of the actuators 176 to move the respective segment in at least 3 degrees of freedom (DOF).

[0126] The actuators 176 include a plurality of actuators 181 and a plurality of actuators 182. The plurality of actuators 181 are configured to move a pair of brackets 168. The plurality of actuators 182 are configured to move a segment 184 of the plurality of segments 132. By having a respective plurality of actuators, the plurality of actuators 181, a pair of brackets 168 of the pairs of brackets 166 move independently of the other pairs of brackets. By having a respective plurality of actuators, the plurality of actuators 182, a segment 184 of the plurality of segments 132 moves independently of the other segments.

[0127] The actuators 176 take any desired form. In some illustrative examples, the actuators 176 are selected from pneumatic actuators, electric actuators, hydraulic actuators, or any other desired type of actuator.

[0128] In some illustrative examples, the cross-section 174 of the forming area 136 is T-shaped 186. In some illustrative examples, the plurality of brackets 131 each have an L-shaped cross-section 187. Each of the plurality of brackets 131 having an L-shaped cross-section 187 provides the T-shaped 186 cross-section 174 of the forming area 136.

[0129] Material 156 has any desired features to provide second airflow 138 to forming area 136. In some illustrative examples, material 156 is formed of a porous material 158 to provide second airflow 138 to forming area 136. In some illustrative examples, material 156 includes at least one of perforations 162 or channels 160 to provide second airflow 138 to forming area 136.

[0130] Material 146 has any desired features to provide first airflow 134 to forming area 136. In some illustrative examples, material 146 of base assembly 130 is formed of a porous material 148 to provide first airflow 134 to forming area 136. In some illustrative examples, material 146 of base assembly 130 includes at least one of perforations 152 or channels 150 to provide first airflow 134 to forming area 136.

[0131] In some illustrative examples, the distance between the plurality of segments 132 during formation of composite reinforcement 106 is controlled by a compliant connector 188. Compliant connector 188 extends through and connects the plurality of segments 132. In these illustrative examples, an actuation lock 189 is present and is configured to selectively restrain the plurality of segments 132 relative to compliant connector 188. Actuation lock 189 takes any desired form. In some illustrative examples, actuation lock 189 is a gas lock.

[0132] In some illustrative examples, the distance between the plurality of brackets 131 during formation of composite reinforcement 106 is controlled by a compliant connector 190. Compliant connector 190 extends through and connects the plurality of brackets 131. In these illustrative examples, an actuation lock 191 is configured to selectively restrain the plurality of brackets 131 relative to compliant connector 190.

[0133] In some illustrative implementations, a smooth continuous (or discontinuous) open-cell foam is used to form the base assembly 130 such that the base assembly 130 maintains a vacuum at the base of the composite stiffener 106 while a plurality of brackets 131 having an L-shaped cross-section 187 apply a clamping force and outward air pressure to the composite stiffener 106. The combination of the vacuum maintained at the bottom of the composite stiffener 106 and the outward second air flow 138 at the top of the composite stiffener 106 creates an air bearing surface that is used to bend and twist the composite stiffener 106 about a desired axis (i.e., the longitudinal axis 167) that is centered at the base of the cross-section 118 of the composite stiffener 106. Depending on whether the bend and twist of a given section is up or down, the flow of the vacuum and air can be reversed such that the first air flow 134 and the second air flow 138 are still opposite pressures. In some illustrative examples, the plurality of brackets 131 remain locked in place once the bend 104 in the composite stiffener 106 is achieved. In some illustrative examples, the plurality of brackets 131 are then coupled to a pick and place system to be transported to a desired location, such as a wing panel. In some other illustrative examples, the plurality of brackets 131 can be removed from the forming tool 102, exposing the composite stiffener 106 for a pick and place system to lift the composite stiffener 106 without the plurality of brackets 131.

[0134] The outward second air flow 138 and the compression of the plurality of brackets 131 having an L-shaped cross-section 187 creates an air bearing surface to eliminate shear friction on the composite stiffener 106 that can cause delamination and wrinkling. The outward second air flow 138 and the compression of the plurality of brackets 131 having an L-shaped cross-section 187 allows the composite stiffener 106 to slide relative to the plurality of brackets 131.

[0135] Likewise, the base assembly 130 that supports the composite stiffener 106 has a stiffness 155 that is designed to have an equal or lower stiffness compared to the composite stiffener 106. The base assembly 130 having an equal or lower stiffness compared to the composite stiffener 106 allows the composite stiffener 106 to remain in full tension at all times regardless of the bend up or down. When the composite stiffener 106 is in full tension, each ply of the laminate is under tension during forming such that no plies are under compression. By maintaining full tension at all times, wrinkling is reduced or eliminated.

[0136] The bend 104 of the composite stiffener 106 is selected based on a desired location of the composite stiffener 106. In some illustrative examples, the bend 104 is unique to the desired location of the composite skin. The bend 104 is formed based on at least one of a scan of the composite skin, a model of the composite stiffener 106, or a model of the composite skin.

[0137] The controller 192 is configured to send commands to the forming tool 102 to form the bend 104 into the composite stiffener 106. In some illustrative examples, the controller 192 sends commands to form the bend 104 based on at least one of a scan of the composite skin, a model of the composite stiffener 106, or a model of the composite skin. The forming tool 102 further includes the controller 192 configured to send commands to at least one of the actuators 176 to change the bend 178 of the forming area 136 according to the NC programming, a gas pressure source 140, 142 to control at least one of the first gas flow 134 or the second gas flow, an actuation lock 189 configured to selectively restrain the plurality of segments 132 relative to the compliant connector 188, or an actuation lock 191 configured to selectively restrain the plurality of brackets 131 relative to the compliant connector 190.

[0138] Figure 1 The illustration of the manufacturing environment 100 in FIG. 1 is not meant to imply physical or architectural limitations to the manner in which illustrative

[0139] In one illustrative example, the base assembly 130 does not have the perforations 152 or the channels 150. In some illustrative examples, the composite stiffener 106 has a cross section 118 that is different than the T-shape 124. The composite stiffener 106 has a cross section 118 of any desired shape. In one illustrative example, the cross section 118 is hat-shaped.

[0140] In another illustrative example, a sensor is associated with a component of the upper assembly 129 or a component of the base assembly 130. When present, the sensor provides position data for a component of the forming tool 102 to the controller 192.

[0141] Turning now to Figure 2 FIG. 2 depicts an illustration of an aircraft, in accordance with an illustrative embodiment. The aircraft 200 is an example of an aircraft having a composite stiffener 106 with a bend 104. Figure 1 FIG. 2 depicts an illustration of an aircraft, in accordance with an illustrative embodiment. The aircraft 200 is an example of an aircraft having a composite stiffener 106 with a bend 104.

[0142] In this illustrative example, the aircraft 200 has a wing 202 and a wing 204 attached to a body 206. The aircraft 200 includes an engine 208 attached to the wing 202 and an engine 210 attached to the wing 204.

[0143] The body 206 has a tail portion 212. A horizontal stabilizer 214, a horizontal stabilizer 216, and a vertical stabilizer 218 are attached to the tail portion 212 of the body 206.

[0144] The aircraft 200 is an example of an aircraft in which composite stiffeners formed using the forming tool 102 can be implemented in accordance with illustrative implementations. Figure 1 The forming tool 102 of FIG. 1 can be used to form a bend into a composite stiffener for any desired portion of the aircraft 200. In some illustrative examples, the composite stiffener formed by the forming tool 102 is present in at least one of the wing 202, the wing 204, or the body 206.

[0145] Turning now to Figure 3 , a depiction of a composite stiffener having a bend is depicted in accordance with illustrative implementations. The composite stiffener 300 is a physical implementation of the composite stiffener 106 having the bend 104 formed by the forming tool 102. The composite stiffener 300 has a cross-section 302. As depicted, the cross-section 302 is a T-shape 304. The composite stiffener 300 has a longitudinal axis 306 and a length 308. In some illustrative examples, the longitudinal axis 306 is referred to as a centerline.

[0146] The composite stiffener 300 has a bend 310 that varies along the length 308. The bend 310 includes a roll 312, a pitch 314, and a yaw 316. The roll 312 causes the cross-section 302 to rotate about the longitudinal axis 306. The pitch 314 causes the longitudinal axis 306 to move perpendicular to a base 318 of the composite stiffener 300. The yaw 316 causes the longitudinal axis 306 to move parallel to the base 318 of the composite stiffener 300.

[0147] Turning now to Figure 4 , a depiction of a front view of a forming tool having indicated airflow is depicted in accordance with illustrative implementations. The view 400 is Figure 1 of the forming tool 102 of FIG. 1. The forming tool 402 is Figure 1 a physical implementation of the forming tool 102 of FIG. 1.

[0148] The forming tool 402 can be used to form a composite stiffener for the wing 202, the wing 204, the body 206, or other components of the aircraft 200 of FIG. 2. The forming tool 402 having the segment 406 and the pair of brackets 404 can be used to form the bend 310 into the composite stiffener 300. The segment 406 is one of a plurality of segments of a base assembly 407. The pair of brackets 404 is one of a plurality of brackets of an upper assembly 409. Figure 2

[0149] ​The pair of brackets 404 includes a left bracket 408 and a right bracket 410. The pair of brackets 404 provides the second airflow 412 to the forming area 414. The forming area 414 is formed by the pair of brackets 404 and the section 406. As shown, the forming area 414 has a T-shape 416 cross-section 418. The forming area 414 has a cross-section 418 that has substantially the same shape as the composite reinforcement to be formed. In this illustrative example, the cross-section 418 is a T-shape 416 to support Figure 3 the T-shape 304 of the cross-section 302 of the composite reinforcement 300.

[0150] In this illustrative example, the second airflow 412 is a positive airflow. The second airflow 412 as a positive airflow allows one face of the material in the forming area 414 to slide relative to the left bracket 408 and the right bracket 410 to avoid wrinkling. The positive airflow will move through the component and into the forming area 414. In this illustrative example, the second airflow 412 through the left bracket 408 and the right bracket 410 is a positive airflow. In some illustrative examples, the second airflow 412 is referred to as an outward air pressure flow. The second airflow 412 through the left bracket 408 and the right bracket 410 is disposed through at least one of a porous material, a perforation, or a channel.

[0151] In some illustrative examples, the second airflow 412 has different strengths in the left bracket 408 and the right bracket 410. In some illustrative examples, the strength of the second airflow 412 through the left bracket 408 is greater than the strength of the second airflow through the right bracket 410. In some illustrative examples, the strength of the second airflow 412 through the left bracket 408 is less than the strength of the second airflow through the right bracket 410.

[0152] Although the second airflow 412 is depicted as a positive airflow through both the left bracket 408 and the right bracket 410, in other illustrative examples, the second airflow 412 is both a negative airflow and a positive airflow. In some un-depicted examples, the second airflow 412 through one of the left bracket 408 and the right bracket 410 is a positive airflow, while the second airflow 412 through the other of the left bracket 408 and the right bracket 410 is a negative airflow.

[0153] Although the second airflow 412 is depicted as moving through each of the left bracket 408 and the right bracket 410, in some illustrative examples, a separate contact surface is present on the left bracket 408 and the right bracket 410 to distribute the second airflow 412. In these illustrative examples, the separate material includes at least one of a porous material, a perforation, or a channel to distribute the second airflow 412.

[0154] The material 419 of the base assembly 407 provides a first airflow 420 to the forming area 414. The first airflow 420 is opposite in direction to the second airflow 412. The first airflow 420 is a negative airflow. A negative airflow will move from the forming area 414 through a component, such as a material on or forming a stent or a material on or forming a segment. In this illustrative example, the first airflow 420 through the material 419 is a negative airflow. In some illustrative examples, providing the first airflow 420 is referred to as "pulling a vacuum" or "pulling a partial vacuum." In some illustrative examples, the composite material to be formed can be referred to as forming a vacuum chamber with the base assembly 407.

[0155] In some illustrative examples, the first airflow 420 has more than one intensity in the material 419. In some illustrative examples, the intensity of the first airflow 420 through a portion of the material 419 associated with the left stent 408 is greater than the intensity of the first airflow through a portion of the material 419 associated with the right stent 410. In some illustrative examples, the intensity of the first airflow 420 through a portion of the material 419 associated with the left stent 408 is less than the intensity of the first airflow through a portion of the material 419 associated with the right stent 410.

[0156] Although the first airflow 420 is depicted as a negative airflow through the material 419, in other illustrative examples, the first airflow 420 is both a negative airflow and a positive airflow. In some un-depicted examples, the first airflow 420 through a portion of the material 419 is a negative airflow, while the first airflow 420 through a remaining portion of the material 419 is a positive airflow.

[0157] In some un-depicted examples, the first airflow 420 through a portion of the material 419 associated with the left stent 408 is a positive airflow, while the first airflow 420 through a portion of the material 419 associated with the right stent 410 is a negative airflow. In some un-depicted examples, the first airflow 420 through a portion of the material 419 associated with the left stent 408 is a negative airflow, while the first airflow 420 through a portion of the material 419 associated with the right stent 410 is a positive airflow.

[0158] In this illustrative example, the material 419 is connected to the segment 406. In other illustrative examples, the segment 406 is formed from the material 419. In this illustrative example, the material 419 is one of a porous material or a perforated material. In other un-depicted examples, the material 419 has channels to distribute the first airflow 420.

[0159] In view 400, the composite reinforcement (not shown) within the forming area 414 pushes against the material 419 on the segment 406 with the second airflow 412 as a positive airflow. In view 400, the composite reinforcement (not shown) within the forming tool 402 pulls against the material 419 on the segment 406 with the first airflow 420 as a negative airflow. In some illustrative implementations, as shown in view 400, the composite reinforcement (not shown) within the forming area is formed downward 422 with the second airflow 412 and the first airflow 420. To form the composite reinforcement downward 422, each of the pair of supports 404 and the segment 406 are moved downward 422.

[0160] The outward second airflow 412 and the compression of the L-shaped plurality of supports 404 create an air bearing surface to eliminate shear friction on the composite reinforcement (not shown) that can cause out-of-tolerance inconsistencies. Also, the base assembly 407 is designed to have equal or lower stiffness than the composite reinforcement (not shown) that then remains curved and twisted around the longitudinal axis. The outward second airflow 412 and the compression of the L-shaped plurality of supports 404 allow the composite reinforcement (not shown) to be kept under full tension throughout the forming, regardless of bending upward or downward.

[0161] Turning now to Figure 5 , a depiction of an elevational view of a forming tool with the indicated airflows is depicted according to illustrative implementations. View 500 is a view of the forming tool 402 with the second airflow 412 and the first airflow 420 reversed.

[0162] In this illustrative example, the second airflow 502 is a negative airflow. In this illustrative example, the second airflow 502 through the left support 408 and the right support 410 is a negative airflow. In some illustrative examples, the second airflow 502 is referred to as "pulling a vacuum" or "pulling a partial vacuum."

[0163] The material 419 provides a first airflow 504 to the forming area 414. The first airflow 504 is opposite in direction to the second airflow 502. The first airflow 504 is a positive airflow. In this illustrative example, the first airflow 504 through the material 419 is a positive airflow. In some illustrative examples, providing the first airflow 504 is referred to as "outward air pressure."

[0164] In view 500, with negative second airflow 502, a composite stiffener (not shown) within the forming area 414 is pulled against the pair of brackets 404. In view 500, with positive first airflow 504, the composite stiffener (not shown) within the forming tool 402 is pushed against the pair of brackets 404. In some illustrative examples, as shown in view 500, the composite stiffener (not shown) within the forming area 414 is formed upward 506 with the second airflow 502 and the first airflow 504. To form the composite stiffener upward 506, each of the pair of brackets 404 and the section 406 move upward 506. The first airflow 504, which is a positive airflow, allows one face of the material 419 in the forming area 414 to slide relative to the material 419 to avoid wrinkling.

[0165] Figure 4 and Figure 5 The illustration of the forming tool 402 in

[0166] In some illustrative examples, the material 419 is not a separate layer on the section 406. In some illustrative examples, the section 406 is formed of a porous material, such as the material 419. In some illustrative examples, the section 406 has at least one of perforations or channels for distributing the first airflow 420 or the first airflow 504.

[0167] In some illustrative examples, the material 419 is not a separate layer on the section 406. In some illustrative examples, the pair of brackets 404 has a separate layer of porous material for distributing the second airflow 412 or the second airflow 502. In some illustrative examples, the pair of brackets 404 has at least one of perforations or channels for distributing the second airflow 412 or the second airflow 502. In some illustrative examples, the pair of brackets 404 has a separate layer with at least one of perforations or channels for distributing the second airflow 412 or the second airflow 502.

[0168] Turning now to Figure 6 , an illustration of an isometric view of a forming tool is depicted in accordance with an illustrative implementation. The forming tool 600 is a physical implementation of the forming tool 102 of Figure 1 . The forming tool 600 can be used to form a composite stiffener of the wing 202, the wing 204, the body 206, or other components of the aircraft 200 of Figure 2 . The forming tool 600, with the plurality of brackets 602 and the base assembly 604, can be used to form the bend 310 into the composite stiffener 300. In some illustrative examples, the view 610 of the forming tool 600 is Figure 4an isometric view of a forming tool 402. In some illustrative examples, a pair of cradles 404 and a segment 406 are components of the forming tool 600.

[0169] The base assembly 604 is formed from a plurality of segments 606 and is configured to provide a first airflow to a forming area 608 formed by the base assembly 604 and the plurality of cradles 602. The plurality of cradles 602 is configured to provide an airflow to the forming area 608.

[0170] In view 610, the plurality of cradles 602 includes pairs of cradles 612, each pair of cradles is movable relative to a longitudinal axis 614 of the forming area 608. Each pair of cradles is movable relative to the longitudinal axis 614, i.e., rotated at least one revolution about the longitudinal axis 614.

[0171] Each pair of cradles is independently movable relative to every other pair of cradles in the plurality of cradles 602. Actuators (not all shown) are connected to the plurality of cradles 612 and the base assembly 604 and are configured to move the plurality of cradles 602 and the plurality of segments 606 of the base assembly 604 within a manufacturing environment 616 to change the curvature 618 of the forming area 608 along a length 619 of the forming area 608. Not all of the actuators are shown in view 610. In view 610, an actuator 621 is shown. The actuator 621 is connected to some of the plurality of cradles 612 and is provided merely as an illustrative example. As depicted, the actuator 621 is pneumatic, but the actuators take any desired form.

[0172] The actuators are configured to change the curvature 618 of the forming area 608 while maintaining a cross-section 620 of the forming area 608. To maintain the cross-section 620 of the forming area 608, a pair of cradles in the plurality of cradles 612 and a corresponding segment in the plurality of segments 606 maintain their orientation relative to one another. For example, to maintain the T-shaped 624 cross-section 620, a pair of cradles 623 and a segment 625 maintain their orientation relative to one another as the pair of cradles 623 and the segment 625 move relative to the rest of the plurality of cradles 612 and the plurality of segments 606. By maintaining the pair of cradles 623 and the segment 625 relative to one another, the T-shaped 624 cross-section 620 is maintained between the pair of cradles 623 and the segment 625.

[0173] As shown, the plurality of cradles 612 each have an L-shaped cross-section 622. The plurality of cradles 612 each having an L-shaped cross-section 622 form the T-shaped 624 cross-section 620 of the forming area 608.

[0174] The plurality of supports 612 have any desired features to provide airflow to the forming area 608. In some illustrative examples, the plurality of supports 612 are formed of a porous material to provide airflow to the forming area 608. In some illustrative examples, the plurality of supports 612 include at least one of perforations or channels to provide airflow to the forming area 608.

[0175] The plurality of segments 606 have any desired features to provide airflow to the forming area 608. In some illustrative examples, the plurality of segments 606 of the base assembly 604 are formed of a porous material to provide airflow to the forming area 608. In some illustrative examples, the plurality of segments 606 of the base assembly 604 include at least one of perforations or channels to provide airflow to the forming area 608.

[0176] The compliant connectors 626 extend through and connect the plurality of segments 606. The compliant connectors 626 extend through holes in the plurality of segments 606. The compliant connectors 626 take any desired form. As depicted, the compliant connectors 626 are flexible polymer tubes. In some illustrative examples, the compliant connectors 626 are rubber cords. An actuation lock (not shown) is configured to selectively restrain the plurality of segments 606 relative to the compliant connectors 626.

[0177] The plurality of segments 606 move along the compliant connectors 626 unless the actuation lock is engaged. When the actuation lock is engaged, the plurality of segments 606 are restrained relative to the compliant connectors 626. By selectively restraining the plurality of segments 606 relative to the compliant connectors 626, the spacing between the plurality of segments 606 is controlled. Controlling the spacing between the plurality of segments 606 controls the stiffness of the base assembly 604. Controlling the spacing between the plurality of segments 606 maintains tension within the composite reinforcement in the forming area 608.

[0178] The compliant connectors 628 extend through and connect the plurality of supports 612. The compliant connectors 628 extend through holes in the plurality of supports 612. The compliant connectors 628 take any desired form. As depicted, the compliant connectors 628 are flexible polymer tubes. An actuation lock (not shown) is configured to selectively restrain the plurality of supports 612 relative to the compliant connectors 628. The actuation lock can be referred to as a brake.

[0179] The plurality of supports 612 move along the compliant connectors 628 unless the actuation lock is engaged. When the actuation lock is engaged, the plurality of supports 612 are restrained relative to the compliant connectors 628. By selectively restraining the plurality of supports 612 relative to the compliant connectors 628, the spacing between the plurality of supports 612 is controlled. Controlling the spacing between the plurality of supports 612 prevents or reduces inconsistencies in the composite reinforcement in the forming area 608.

[0180] The plurality of brackets 612 that are L-shaped are held in place by a compliant connector 628 (rod) that passes through all of the brackets. When there is airflow through the plurality of brackets 612, the plurality of brackets 612 move to place the bend in the composite reinforcement. When there is airflow through the plurality of brackets 612, the actuation lock is released so the plurality of brackets 612 can slide along the compliant connector 628. When the airflow is terminated, the actuation lock engages the plurality of brackets 612 and holds them in the current orientation. The bend has then been formed in the composite reinforcement and is ready for transport by a pick and place machine.

[0181] The synchronized movement of the plurality of brackets 602 and the plurality of segments 606 is used to form the bend into the composite reinforcement. The movement of the plurality of brackets 602 and the plurality of segments 606 is a slow, incremental movement. By incrementally moving the plurality of segments 606, the curve approximates a series of straight line segments.

[0182] Figure 6 The illustration of the forming tool 600 in FIG. 6 is not meant to imply physical or architectural limitations to the manner in which illustrative

[0183] In some illustrative examples, a porous material is present as a separate layer on at least one of the plurality of brackets 602 or the plurality of segments 606. In some illustrative examples, a separate layer having at least one of a channel or a perforation is present on at least one of the plurality of brackets 602 or the plurality of segments 606 to distribute airflow.

[0184] Turning now to Figure 7 FIG. 7, a simplified elevation view of a forming tool is depicted in accordance with an illustrative implementation. The view 700 is of the forming tool 600 during movement of the plurality of brackets 602 and the base assembly 604 to form a bend into a composite reinforcement (not shown). In the view 700, some of the plurality of brackets 602 and some of the plurality of segments 606 of the base assembly 604 have been rotated about the longitudinal axis 614 of the forming area 608. In the view 700, the plurality of brackets 602 and the plurality of segments 606 are in a position 702 to place a roll into the composite reinforcement (not shown). As each pair of brackets and corresponding segment is rotated about the longitudinal axis 614, the legs of each pair of brackets maintain parallelism with the corresponding segment during the forming process.

[0185] Turning now to Figure 8depicts a simplified top perspective view of the forming tool, according to illustrative implementations. View 800 is a top perspective view of forming tool 600 during movement of multiple cradles 602 and base assembly 604 to form a bend into a composite stiffener (not shown). In view 800, some of multiple cradles 602 and some of multiple segments 606 of base assembly 604 have rotated about longitudinal axis 614 of forming area 608. Each pair of cradles rotates while maintaining the parallel relationship of the legs of the pair of cradles to the respective segment. Multiple cradles 602 and multiple segments 606 are in a position 802 to place a roll into the composite stiffener (not shown). Additionally, in view 800, longitudinal axis 614 of forming area 608 has been curved on X-axis 804. Multiple cradles 602 and multiple segments 606 have moved upward and / or downward to introduce yaw into the composite stiffener.

[0186] Turning now to Figure 9 depicts a simplified side perspective view of the forming tool, according to illustrative implementations. View 900 is a top perspective view of forming tool 600 during movement of multiple cradles 602 and base assembly 604 to form a bend into a composite stiffener (not shown). In view 900, some of multiple cradles 602 and some of multiple segments 606 of base assembly 604 have rotated about longitudinal axis 614 of forming area 608. Multiple cradles 602 and multiple segments 606 are in a position 902 to place a roll into the composite stiffener (not shown). Additionally, in view 900, longitudinal axis 614 of forming area 608 has been curved on Y-axis 904. Multiple cradles 602 and multiple segments 606 have moved to introduce pitch into the composite stiffener. During movement of multiple cradles 602 and multiple segments 606, each pair of cradles maintains parallel to the respective segment of multiple segments 606.

[0187] Figures 4 to 9 The illustrations of the forming tool, forming tool 402, and forming tool 600 in the various figures are not meant to imply physical or architectural limitations to the manner in which illustrative implementations can be implemented. Other components can be used in addition to or instead of the components depicted. Some components can be unnecessary.

[0188] For example, in Figures 4 to 9 described or not described in the description of the actuator controlling movement and rotation of both multiple cradles 602 and base assembly 604 is not limiting. For example, an actuator is not shown to move multiple segments 606 of base assembly 604. The actuator moving multiple segments 606 of base assembly 604 takes any desired form. The actuator moving multiple cradles 602 also takes any desired form. The described cylinder rods are not limited to the manner in which the actuator for multiple cradles 602 can be implemented.

[0189] Turning now to Figure 10 depicts an illustration of a simplified side view of a material prior to forming a bend, according to an illustrative implementation. In view 1000, a plurality of points 1002 of a first side 1004 of a material 1006 are uniformly spaced apart. In view 1000, a plurality of points 1008 of a second side 1010 of the material 1006 are uniformly spaced apart. A longitudinal axis 1012 is positioned between the first side 1004 and the second side 1010.

[0190] If the material 1006 is to be formed into a curve by hand, a distance between at least one of the plurality of points 1002 or the plurality of points 1008 will decrease. If the material 1006 is to be formed into a curve by hand, compression will be introduced into at least one of the first side 1004 or the second side 1010. In one illustrative example, if the material 1006 is to be formed into a curve by hand, a distance between the plurality of points 1008 will decrease and compression will be introduced into the second side 1010.

[0191] Turning now to Figure 11 depicts an illustration of a simplified side view of a material while forming a bend using a forming tool, according to an illustrative implementation. In view 1100, a curve placed in the material 1006 is exaggerated for illustrative purposes.

[0192] View 1100 is Figure 10 a view of the material 1006 having a bend 1101 formed using a forming tool 1102. The forming tool 1102 includes a plurality of struts (not shown) and a base assembly 1104. The base assembly 1104 includes a plurality of segments 1106. The plurality of segments 1106 are connected by compliant connectors including compliant connectors 1108.

[0193] To reduce compression forces in the material 1006 during formation of the bend 1101, a distance between the plurality of segments 1106 is controlled by locking and unlocking the plurality of segments 1106 relative to the compliant connectors 1108.

[0194] Although a length between the plurality of points 1002 of the first side 1004 of the material 1006 is increased due to the bend 1101, a length between the plurality of points 1008 is maintained. Although a length between the plurality of points 1002 of the first side 1004 of the material 1006 is increased due to the bend 1101, the material 1006 is maintained under tension. Maintaining a length between the plurality of points 1008 of the second side 1010 reduces or eliminates compression in the material 1006 and maintains the material 1006 under tension. Forming the bend 1101 using the forming tool 1102 provides tension to a greater amount of the material 1006 compared to forming the bend 1101 using a conventional process or a conventional tool.

[0195] In some illustrative examples, forming the bend 1101 is controlled by a controller, such as Figure 1 controller 192. The controller is configured to send commands to the forming tool 1102 to form the bend 1101 into the material 1006. In some illustrative examples, the controller sends the commands to form the bend 1101 based on at least one of a scan of a desired location, a model of a final bend of the material, or a model of a desired location of the material.

[0196] Turning now to Figure 12 , a depiction of forces within a composite reinforcement is depicted in accordance with an illustrative implementation. Figure 12 the depiction of forces in FIG. 1 1 10 is depicted as a bend being formed by a forming tool in a composite reinforcement. The composite reinforcement 1200 is a physical implementation of the composite reinforcement 106 of Figure 1 . The composite reinforcement 1200 is positioned on a plurality of segments 1202 of a base assembly 1204. The base assembly 1204 is part of a forming tool that has a plurality of supports (not depicted). The plurality of supports are not depicted for purposes of illustration.

[0197] The plurality of segments 1202 can be a physical implementation of the plurality of segments 132 of the forming tool 102 of Figure 1 , the segment 406 of Figures 4 to 5 may be one of the plurality of segments 1202 of Figure 12 In some illustrative examples, the plurality of segments 606 of Figures 6 to 9 are the same as the plurality of segments 1202 of Figure 12 In some illustrative examples, the plurality of segments 1106 of Figure 11 are the same as the plurality of segments 1202 of Figure 12 .

[0198] The composite reinforcement 1200 has a neutral axis 1206. The neutral axis 1206 is a longitudinal axis 1207 of the composite reinforcement 1200. If the composite reinforcement 1200 is twisted or bent about the neutral axis 1206, then tension will exist on one side of the neutral axis 1206 and compression will exist on the opposite side of the neutral axis 1206. Introducing an undesirable amount of compression to the composite reinforcement 1200 can introduce out-of-tolerance inconsistencies (e.g., wrinkles) into the composite reinforcement 1200.

[0199] The plurality of segments 1202 have an equal or low stiffness compared to the composite stiffener 1200. The plurality of segments 1202 hold the composite stiffener 1200 during bending and twisting of the composite stiffener 1200. By having the plurality of segments 1202 with the same stiffness as the composite stiffener 1200, the longitudinal axis about which the composite stiffener 1200 bends and twists is reduced. By having the plurality of segments 1202 with the same stiffness as the composite stiffener 1200, the longitudinal axis about which the composite stiffener 1200 bends and twists is shifted from the neutral axis 1206 to the desired axis 1208. This design method shifts the longitudinal axis by moving the longitudinal axis down to where the base assembly 1204 intersects the composite stiffener 1200 such that the composite stiffener 1200 remains under tension. The longitudinal axis is shifted from the neutral axis 1206 to the desired axis 1208 by forcing the composite stiffener 1200 down 1210 by means of a vacuum drawn through the plurality of segments 1202.

[0200] Bending and twisting the composite stiffener 1200 about the desired axis 1208 can keep the composite stiffener 1200 under tension throughout the composite stiffener 1200 regardless of the upward or downward bending of the composite stiffener 1200. Bending and twisting the composite stiffener 1200 about the desired axis 1208 places the base assembly 1204 in compression. For example, when the composite stiffener 1200 is bent down 1210, tension 1212 is maintained within the composite stiffener 1200 while compression 1214 exists in the base assembly 1204. In some illustrative examples, by the base assembly 1204 taking the majority of the compression while the composite stiffener 1200 remains under tension, wrinkle formation is reduced or prevented. In some illustrative examples, if small wrinkles exist in the composite stiffener 1200, these small wrinkles are pulled out / straightened by maintaining tension in the composite stiffener 1200.

[0201] This forming tool design is used for soft manipulation of parts that are desired to have tight control over bending and twisting about a dimensionally defined longitudinal axis. The forming tool provides at least one of consistent part formation and out-of-tolerance inconsistency prevention.

[0202] Turning now to Figure 13 a depiction of forces within a composite stiffener having a bend formed by a forming tool is depicted in accordance with illustrative implementations. The view 1300 is of a composite stiffener 1200 having a bend 1302 formed by a forming tool that includes a plurality of segments 1202. The composite stiffener 1200 is kept under tension 1304 throughout all of the composite stiffener 1200. In the view 1300, the vanes and flanges of the composite stiffener 1200 are under tension 1304.

[0203] Turning now to Figure 14FIG. 14 depicts an illustration of a flowchart of a method of forming a bend into a composite stiffener, in accordance with illustrative embodiments. In some illustrative examples, the method 1400 is implemented in the manufacturing environment 100 using the forming tool 102. In some illustrative examples, the method 1400 is implemented to form a composite stiffener of the aircraft 200. In some illustrative examples, the method 1400 is implemented to form the bend 310 into the composite stiffener 300. In some illustrative examples, the method 1400 is implemented using the forming tool 402. In some illustrative examples, the method 1400 is implemented using the forming tool 600. In some illustrative examples, the method 1400 is implemented to form a bend into the material 1006. Figure 2 Figure 3 Figures 4 to 5 Figures 6 to 9 Figures 10 to 11

[0204] The method 1400 positions a composite stiffener over a segment of a base assembly (operation 1402). In some illustrative examples, the segment is one of a plurality of segments of the base assembly. The method 1400 places a pair of supports of a plurality of supports over the composite stiffener to form a forming area having a cross-section (operation 1404). The method 1400 moves the segment and the pair of supports in the manufacturing environment while maintaining the cross-section of the forming area to form a bend into the composite stiffener (operation 1406). The method 1400 then terminates.

[0205] In some illustrative examples, moving the segment and the pair of supports is part of a synchronized movement of a plurality of supports of an upper assembly and a plurality of segments of the base assembly to form a bend into the composite stiffener (operation 1408). In some illustrative examples, the synchronized movement is controlled by a controller, such as the controller 192 of the forming tool 102, the controller being configured to send commands to the forming tool to form a bend into the composite stiffener. In some illustrative examples, the controller sends the commands to form the bend based on at least one of a scan of the composite skin, a model of the composite stiffener, or a model of the composite skin. Figure 1

[0206] In some illustrative examples, the method 1400 sends a first air flow through a material of the base assembly in a first direction relative to the forming area, where the first direction is one of a positive air flow or a negative air flow (operation 1410). In some illustrative examples, the method sends a second air flow through a material of the upper assembly in a second direction relative to the forming area, where the second direction is opposite the first direction (operation 1412).

[0207] ​​​​​​In some illustrative examples, the method 1400 sends the second airflow through the material of the upper assembly to the forming area, where sending the second airflow through the material of the upper assembly includes sending a negative airflow through the material associated with at least one of the plurality of stents of the upper assembly to the forming area, and sending a positive airflow through the material associated with at least one of the plurality of stents to the forming area (operation 1414).

[0208] In some illustrative examples, the method 1400 sends the first airflow through the material of the base assembly to the forming area, where sending the first airflow through the material includes sending a negative airflow through a portion of the material associated with at least one of the plurality of segments of the base assembly to the forming area, and sending a positive airflow through a portion of the material associated with at least one of the plurality of segments to the forming area (operation 1416).

[0209] Turning now to Figure 15 , a depiction of a flowchart of a method of forming a bend into a composite stiffener is depicted in accordance with an illustrative implementation. In some illustrative examples, the method 1500 is implemented in the manufacturing environment 100 using the forming tool 102. In some illustrative examples, the method 1500 is implemented to form a composite stiffener of the aircraft 200. In some illustrative examples, the method 1500 is implemented to form the bend 310 into the composite stiffener 300. In some illustrative examples, the method 1500 is implemented using the forming tool 402. In some illustrative examples, the method 1500 is implemented using the forming tool 600. In some illustrative examples, the method 1500 is implemented to form the bend into the material 1006. Figure 2 Figure 3 Figures 4 to 5 Figures 6 to 9 Figures 10 to 11

[0210] The method 1500 positions a composite stiffener in a forming area formed by a base assembly and an upper assembly (operation 1502). The method 1500 applies a first airflow through material of the base assembly (operation 1504). The method 1500 applies a second airflow through material of the upper assembly (operation 1506). The method 1500 moves a plurality of stents of the upper assembly relative to one another to change a bend of the forming area along a length of the forming area to form the bend into the composite stiffener (operation 1508). The method 1500 then terminates.

[0211] In some illustrative examples, the movement of the plurality of stents is controlled by a controller, such as the controller 106. Figure 1 ​​​​​controller 192. The controller is configured to send commands to the forming tool to form a bend into the composite stiffener. In some illustrative examples, the controller sends the commands to form the bend based on at least one of a scan of the composite skin, a model of the composite stiffener, or a model of the composite skin. In some illustrative examples, the controller monitors a state of the forming tool through sensors attached to the tool. In some illustrative examples, the sensors are associated with components of the upper assembly 129, such as Figure 1 Figure 1 components of the base assembly 130. When present, the sensors provide position data for the components of the forming tool to the controller.

[0212] In some illustrative examples, the second airflow through the material of the upper assembly has an opposite direction from the first airflow through the material of the base assembly of the relevant segment (operation 1510). With the airflow through the pair of brackets having opposite directions of the relevant segment, an air bearing surface is created that prevents friction with the composite stiffener. With the airflow through the pair of brackets having opposite directions of the relevant segment, the composite stiffener is held against one of the pair of brackets or the relevant segment during formation of the composite stiffener.

[0213] In some illustrative examples, moving the plurality of brackets relative to one another includes moving the plurality of brackets vertically in pairs relative to a longitudinal axis of the composite stiffener (operation 1512). In some illustrative implementations, moving the plurality of brackets relative to one another includes rotating a pair of the plurality of brackets about a longitudinal axis of the composite stiffener to introduce roll into the composite stiffener (operation 1514). In some illustrative examples, moving the plurality of brackets relative to one another includes moving a pair of the plurality of brackets in a first direction relative to a longitudinal axis of the composite stiffener to introduce pitch into the composite stiffener (operation 1516). In some illustrative examples, moving the plurality of brackets relative to one another includes moving a pair of the plurality of brackets in a second direction relative to a longitudinal axis of the composite stiffener to introduce yaw into the composite stiffener (operation 1518). In some illustrative examples, when the plurality of brackets are moved relative to one another to maintain a cross-section of the forming area, the method 1500 moves a plurality of segments of the base assembly relative to one another, where moving the plurality of segments relative to one another includes moving the plurality of segments vertically relative to a longitudinal axis of the forming area (operation 1520).

[0214] ​In some illustrative examples, the method 1500 cures the composite stiffener after forming the bend into the composite stiffener (operation 1528). In some illustrative examples, the composite stiffener is cured before the composite stiffener is lifted from the forming tool. In other illustrative examples, the composite stiffener is cured as it is brought into contact with a desired location, such as a wing panel.

[0215] In some illustrative examples, the method 1500 removes the plurality of supports from the composite stiffener (operation 1522); and the method 1500 lifts the composite stiffener with the bend from the base assembly, wherein curing is performed after the composite stiffener is lifted (operation 1526). In some illustrative examples, the composite stiffener is lifted by a pick and place system having a set head.

[0216] In some illustrative examples, the method 1500 removes the plurality of supports from the composite stiffener (operation 1522). In some illustrative examples, the method 1500 positions a plurality of spacers on the composite stiffener (operation 1524). In some illustrative examples, the plurality of spacers protect the bend of the composite stiffener. In some illustrative examples, the plurality of spacers are equipment used to cure the composite stiffener.

[0217] As used herein, the phrase "at least one of" when used with a list of items indicates that one or more of the listed items can be used and that only one item from the list can be needed. For example, "at least one of item A, item B, or item C" can include, but is not limited to, only item A, only item A and item B, or only item B. The example can also include only item A, only item B, and only item C, or only item B and item C. Of course, any combination of these items can be included. In other examples, "at least one of" can be, for example, but not limited to, two of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations. The item can be a specific object, thing, or category. In other words, at least one of means that any combination of the items in the list and the number of items can be used, but not all items in the list are required.

[0218] As used herein, "a number of" when used with reference to an item means one or more items.

[0219] The flow and block diagrams in the various described embodiments illustrate the architecture, functionality, and operations of possible implementations of apparatuses and methods in illustrative embodiments. In this regard, each block in the flow and block diagrams can represent at least one of a module, segment, function, or portion of an operation or step.

[0220] In some alternative implementations of the illustrative embodiments, one or more functions marked in the boxes may occur in a different order than those shown in the figures. For example, in some cases, depending on the functions involved, two consecutively shown boxes may be executed substantially simultaneously, or these boxes may sometimes be executed in reverse order. Furthermore, in addition to the boxes shown in the flowchart or block diagram, other boxes may be added. Some boxes may be optional. For example, operations 1408 to 1416 may be optional. As another example, operations 1510 to 1528 may be optional.

[0221] The illustrative embodiments of this disclosure can be implemented as follows: Figure 16 The aircraft manufacturing and maintenance methods shown in 1600 and such Figure 17 The background description of the aircraft 1700 is shown. First, turn to... Figure 16 The illustration depicts a method for manufacturing and repairing an aircraft according to an illustrative embodiment. During pre-production, the aircraft manufacturing and repair method 1600 may include... Figure 17 Specifications and design of the aircraft 1700 1602 and material procurement 1604.

[0222] During production, the manufacturing of components and sub-assemblies of aircraft 1700 (1606) and system integration (1608) occur. Afterward, aircraft 1700 may undergo certification and delivery (1610) for entry into service (1612). While in service by the customer (1612), aircraft 1700 is scheduled for routine maintenance and repairs (1614), which may include modifications, remodeling, refurbishment, or other maintenance and repairs.

[0223] Each process of the Aircraft Manufacturing and Maintenance Method 1600 can be performed or implemented by a systems integrator, a third party, and / or an operator. In these examples, the operator can be the customer. For the purposes of this specification, the systems integrator can be, but is not limited to, any number of aircraft manufacturers and main system subcontractors; the third party can be, but is not limited to, any number of suppliers, subcontractors, and suppliers; and the operator can be an airline, leasing company, military entity, maintenance organization, etc.

[0224] Now for reference Figure 17 The illustration depicts an aircraft in which an illustrative implementation can be achieved. In this example, aircraft 1700... Figure 16 The aircraft manufacturing and maintenance method 1600 produces an aircraft and may include a fuselage 1702 having multiple systems 1704 and an interior 1706. Examples of systems 1704 include one or more of a propulsion system 1708, an electrical system 1710, a hydraulic system 1712, and an environmental system 1714. Any number of other systems may be included.

[0225] The apparatus and methods implemented herein can be employed during at least one stage of the aircraft manufacturing and service method 1600. In Figure 16 One or more illustrative embodiments can be manufactured or used during at least one of the following: component and subassembly manufacturing 1606, system integration 1608, and final assembly 1610 into a vehicle 1700. The vehicle 1700 can include composite stiffeners 106 formed using the forming tool 102. Figure 1 The composite stiffeners 106 can be formed during the component and subassembly manufacturing 1606. As an example, the method 1400 can be used to form a bend in a composite stiffener of the aircraft 1700 during the component and subassembly manufacturing 1606. As another example, the method 1500 can be used to form a bend in a composite stiffener of the aircraft 1700 during the component and subassembly manufacturing 1606.

[0226] The proposed forming tool design is configured for soft manipulation of parts that are desired to have tight control of bending, lofting, and twisting around a dimensionally set / defined longitudinal axis. The forming tool provides at least one of consistent part formation or prevention of out-of-tolerance inconsistencies.

[0227] The illustrative examples provide a solution to the problem of forming a bend into a composite stiffener without introducing out-of-tolerance inconsistencies (e.g., wrinkles). The illustrative examples loft and twist a full-tension composite stiffener (stringer) to match a contoured shape of a panel (e.g., a wing skin panel) while mitigating wrinkle propagation.

[0228] The illustrative examples actively control 3-DOF (degrees of freedom) at specified intervals across the span of the pre-cured stringer, while the other 3-DOF are passively supported. The specified intervals have any desired value. In some illustrative examples, the specified intervals are every 2”, every 3”, every 6”, every 12”, every 18”, or any other desired interval.

[0229] In some illustrative examples, the base assembly is formed from a smooth continuous (or discontinuous) open-cell foam. The smooth continuous (or discontinuous) open-cell foam is used to maintain a vacuum at the base of the stringer. The L-shaped brackets apply a clamping force and an outward air pressure to the composite stiffener. The combination of the vacuum maintained at the base and the outward air flow at the top of the composite stiffener creates an air bearing surface for the stringer to bend and twist around a desired axis at the centered base of the stringer. The outward air flow and compression of the L-shaped brackets creates the air bearing surface to eliminate shear friction on the stringer that can cause delamination and wrinkles.

[0230] The flow of vacuum and air can be reversed depending on whether the bend and twist of a given section is upward or downward. Once the spar position is reached, the cradles can also remain locked in place. In some illustrative examples, the cradles are then coupled to a pick and place system to be delivered to the wing panel.

[0231] The base assembly is designed to have equal or lower stiffness than the spars, which then remain bent and twisted around the longitudinal axis. Controlling the stiffness of the base assembly allows the spars to remain under full tension throughout shaping, regardless of the upward or downward bend.

[0232] Illustrative examples shift the longitudinal axis by moving the longitudinal axis down to a position where the base assembly intersects the composite stiffeners, such that the composite stiffeners remain under tension. The base assembly takes most of the compression, while the composite stiffeners remain under tension. Keeping the composite stiffeners under tension reduces or prevents wrinkle formation. In some illustrative examples, keeping the composite stiffeners under tension pulls out / straightens small wrinkles that exist in the composite stiffeners.

[0233] Also provided herein are the following clauses, which relate to:

[0234] 1. A forming tool 102, comprising:

[0235] a base assembly 130 formed from a plurality of sections 132 and material 146 for distributing a first airflow 134 to a forming area 136 formed by the base assembly 130 and an upper assembly 129, the first airflow 134 providing an air bearing or holding force;

[0236] the upper assembly 129, the upper assembly 129 including a plurality of cradles 131 and material 156 for distributing a second airflow 138 to the forming area 136 in an opposite direction from the first airflow 134; and

[0237] an actuator 176 connected to the plurality of cradles 131 and the plurality of sections 132, the actuator 176 configured to move each of the plurality of sections 132 relative to one another to change a bend 178 of the forming area 136 along a length 180 of the forming area 136.

[0238] 2. The forming tool 102 of clause 1, wherein the plurality of cradles 131 includes pairs of cradles 166, each pair of cradles being individually movable relative to a longitudinal axis 108 of the forming area 136.

[0239] 3. The forming tool 102 of clause 2, wherein the actuator 176 comprises a plurality of actuators 181 connected to the plurality of supports 131 such that the plurality of actuators 181 independently move each pair of supports 131 relative to the remaining supports 131 of the plurality of supports 131.

[0240] 4. The forming tool 102 of clause 3, wherein the actuator 176 is connected to the plurality of supports 131 and the plurality of segments 132 such that the actuator 176 changes the curvature 178 of the forming area 136 while maintaining the cross-section 174 of the forming area 136.

[0241] 5. The forming tool 102 of clause 4, further comprising:

[0242] a controller 192 configured to send commands to at least one of the actuators 176 to change the curvature 178 of the forming area 136 according to NC programming; a gas pressure source for controlling at least one of the first gas flow 134 or the second gas flow 138; an actuation lock 189 configured to selectively restrain the plurality of segments 132 relative to a compliant connector or an actuation lock 191 configured to selectively restrain the plurality of supports 131 relative to a compliant connector.

[0243] 6. The forming tool 102 of any one of clauses 1-5, wherein the material for distributing the second gas flow 138 is formed of a porous material to provide the second gas flow 138 to the forming area 136.

[0244] 7. The forming tool 102 of any one of clauses 1-6, wherein the material for distributing the second gas flow 138 comprises at least one of perforations or channels to provide the second gas flow 138 to the forming area 136.

[0245] 8. The forming tool 102 of any one of clauses 1-7, wherein the material for distributing the first gas flow 134 is formed of a porous material to provide the first gas flow 134 to the forming area 136.

[0246] 9. The forming tool 102 of any one of clauses 1-5, wherein the material for distributing the first gas flow 134 of the base assembly 130 comprises at least one of perforations or channels to provide the first gas flow 134 to the forming area 136.

[0247] 10. The forming tool 102 of any one of clauses 1-9, further comprising:

[0248] a compliant connector 188 extending through and connecting the plurality of segments 132; and

[0249] an actuation lock 189 configured to selectively constrain the plurality of segments 132 relative to the compliant connector 188.

[0250] 11. The forming tool 102 of any of clauses 1-10, further comprising:

[0251] a compliant connector 190 extending through and connecting the plurality of brackets 131; and

[0252] an actuation lock 191 configured to selectively constrain the plurality of brackets 131 relative to the compliant connector 190.

[0253] 12. The forming tool 102 of any of clauses 1-11, further comprising:

[0254] a gas pressure source 140 pneumatically connected to at least one of the plurality of segments 132 or the material 146 of the base assembly 130 to provide the first gas flow 134 through the material 146; and

[0255] a gas pressure source 142 pneumatically connected to at least one of the plurality of brackets 131 or the material 156 of the upper assembly 129 to provide the second gas flow 138 through the material 156.

[0256] 13. Manufacturing a composite stiffener 106 for an aircraft using the forming tool 102 of any of clauses 1-12.

[0257] 14. A method 1400 of forming a bend 104 into a composite stiffener 106, the method comprising:

[0258] positioning 1402 the composite stiffener 106 over a segment 184 of a base assembly 130;

[0259] placing 1404 a pair of brackets 166 of an upper assembly 129 over the composite stiffener 106 to form a forming area 136 having a cross-section 174; and

[0260] moving 1406 the segment 184 and the pair of brackets 166 within a manufacturing environment 100 while maintaining the cross-section 174 of the forming area 136 to form the bend 104 into the composite stiffener 106.

[0261] 15. The method 1400 of clause 14, wherein the 1408 moving the segments 184 and the pair of brackets 168 is part of a synchronized movement of a plurality of brackets 131 of the upper assembly 129 and a plurality of segments 132 of the base assembly 130 to form the bend 104 into the composite stiffener 106.

[0262] 16. The method 1400 of clause 14 or 15, further comprising:

[0263] sending 1410 a first gas flow 134 through material of the base assembly 130 in a first direction relative to the forming area 136, wherein the first direction is one of a positive gas flow or a negative gas flow; and

[0264] sending 1412 a second gas flow 138 through material of the upper assembly 129 in a second direction relative to the forming area 136, wherein the second direction is opposite the first direction.

[0265] 17. The method 1400 of any of clauses 14-16, further comprising:

[0266] sending 1414 a second gas flow 138 through material of the upper assembly 129 to the forming area 136, wherein sending the second gas flow 138 through the material of the upper assembly 129 includes sending a negative gas flow through the material associated with at least one bracket of a plurality of brackets 131 of the upper assembly 129 to the forming area 136 and sending a positive gas flow through the material associated with at least one bracket of the plurality of brackets 131 to the forming area 136.

[0267] 18. The method 1400 of any of clauses 14-17, further comprising:

[0268] sending 1416 a first gas flow 134 through material of the base assembly 130 to the forming area 136, wherein sending the first gas flow 134 through the material includes sending a negative gas flow through a portion of the material associated with at least one segment of a plurality of segments 132 of the base assembly 130 to the forming area 136 and sending a positive gas flow through a portion of the material associated with at least one segment of the plurality of segments 132 to the forming area 136.

[0269] 19. A composite stiffener 106 for an aircraft formed according to the method of any of clauses 14-18.

[0270] 20. A method 1500 of forming a bend 104 into a composite reinforcement 106, the method comprising:

[0271] positioning 1502 the composite reinforcement 106 in a forming area 136 formed by a base assembly 130 and an upper assembly 129;

[0272] applying 1504 a first gas flow 134 through a material 146 of the base assembly 130;

[0273] applying 1506 a second gas flow 138 through a material 156 of the upper assembly 129; and

[0274] moving 1508 a plurality of cradles 131 of the upper assembly 129 relative to one another to change a bend 178 of the forming area 136 along a length 180 of the forming area 136 to form the bend 104 into the composite reinforcement 106.

[0275] 21. The method 1500 of clause 20, wherein 1510 the second gas flow 138 through the material 156 of the upper assembly 129 has an opposite direction than the first gas flow 134 through the material 146 of the base assembly 130 associated with a section of the base assembly 130.

[0276] 22. The method 1500 of clause 20 or 21, wherein 1512 moving the plurality of cradles 131 relative to one another comprises moving the plurality of cradles 131 vertically in pairs relative to a longitudinal axis 108 of the composite reinforcement 106.

[0277] 23. The method 1500 of clause 22, wherein 1514 moving the plurality of cradles 131 relative to one another comprises rotating a pair of cradles 168 of the plurality of cradles 131 about the longitudinal axis 108 of the composite reinforcement 106 to introduce a roll 112 into the composite reinforcement 106.

[0278] 24. The method 1500 of clause 22 or 23, wherein 1516 moving the plurality of cradles 131 relative to one another comprises moving a pair of cradles 168 of the plurality of cradles 131 in a first direction relative to the longitudinal axis 108 of the composite reinforcement 106 to introduce a pitch 114 into the composite reinforcement 106.

[0279] 25. The method 1500 of any of clauses 22-24, wherein 1518 moving the plurality of cradles 131 relative to one another includes moving a pair of cradles 168 of the plurality of cradles 131 in a second direction relative to the longitudinal axis 108 of the composite stiffener 106 to induce a yaw 116 into the composite stiffener 106.

[0280] 26. The method 1500 of any of clauses 20-25, further comprising:

[0281] while moving the plurality of cradles 131 relative to one another, moving 1520 a plurality of segments 132 of the base assembly 130 relative to one another to maintain a cross-section 174 of the forming area 136, wherein moving the plurality of segments 132 relative to one another includes moving the plurality of segments 132 perpendicularly relative to a longitudinal axis 108 of the forming area 136.

[0282] 27. The method 1500 of any of clauses 20-25, further comprising:

[0283] after forming the bend 104 into the composite stiffener 106, curing 1528 the composite stiffener 106.

[0284] 28. The method 1500 of clause 27, further comprising:

[0285] removing 1522 the plurality of cradles 131 from the composite stiffener 106; and

[0286] lifting 1526 the composite stiffener 106 having the bend 104 from the base assembly 130, wherein the curing is performed after lifting the composite stiffener 106.

[0287] 29. The method 1500 of clause 27 or 28, further comprising:

[0288] removing 1522 the plurality of cradles 131 from the composite stiffener 106; and

[0289] positioning 1524 a plurality of bulkheads on the composite stiffener 106.

[0290] 30. A composite stiffener 106 for an aircraft formed according to the method of any of clauses 20-29.

[0291] The description of the different illustrative embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Moreover, different illustrative embodiments can provide different features. The embodiment was chosen and described in order to best explain the principles of the embodiment, the practical application, and to enable others skilled in the art to understand the disclosure with various modifications as are suited to the particular use contemplated.

Claims

1. A forming tool (102), the forming tool (102) comprising: A base assembly (130) is formed of multiple segments (132) and a material (146) for distributing a first airflow (134) to a shaped region (136) formed by the base assembly (130) and the upper assembly (129), the first airflow (134) providing an air bearing or holding force; The upper assembly (129) includes a plurality of supports (131) and a material (156) for distributing a second airflow (138) to the forming region (136) in a direction opposite to the first airflow (134). as well as An actuator (176) is connected to the plurality of supports (131) and the plurality of segments (132), the actuator (176) being configured to move each of the plurality of segments (132) relative to each other to change the curvature (178) of the forming region (136) along the length (180) of the forming region (136).

2. The forming tool (102) according to claim 1, wherein, The plurality of supports (131) include pairs of supports (166), each pair of supports being movable individually relative to the longitudinal axis (108) of the forming region (136).

3. The forming tool (102) according to claim 2, wherein, The actuator (176) includes a plurality of actuators (181) connected to the plurality of supports (131) such that the plurality of actuators (181) cause each pair of supports (131) to move independently relative to the remaining supports (131), wherein the actuator (176) is connected to the plurality of supports (131) and the plurality of segments (132) such that the actuator (176) alters the bend (178) of the forming region (136) while maintaining the cross-section (174) of the forming region (136), and the forming tool further includes: A controller (192) configured to send a command to at least one of the actuators (176) to change the bend (178) of the forming region (136) according to NC programming; a pressure source for controlling at least one of the first airflow (134) or the second airflow (138); an actuation lock (189) configured to selectively constrain the plurality of segments (132) relative to the compliant connector or an actuation lock (191) configured to selectively constrain the plurality of supports (131) relative to the compliant connector.

4. The forming tool (102) according to claim 1, wherein, The material used to distribute the second airflow (138) is formed of a porous material to provide the second airflow (138) to the shaped region (136).

5. The forming tool (102) according to claim 1, wherein, The material used for distributing the second airflow (138) includes at least one of perforations or channels to provide the second airflow (138) to the forming region (136).

6. The forming tool (102) according to claim 1, wherein, The material used to distribute the first airflow (134) is formed of a porous material to provide the first airflow (134) to the shaped region (136).

7. The forming tool (102) according to claim 1, wherein, The material for distributing the first airflow (134) to the base assembly (130) includes at least one of perforations or channels to provide the first airflow (134) to the forming region (136).

8. The forming tool (102) according to claim 1, wherein the forming tool (102) further comprises: A compliant connector (188) extends through the plurality of segments (132) and connects the plurality of segments (132); as well as An actuation lock (189) is configured to selectively constrain the plurality of segments (132) relative to the compliant connector (188).

9. The forming tool (102) according to claim 1, wherein the forming tool (102) further comprises: A compliant connector (190) extends through the plurality of brackets (131) and connects the plurality of brackets (131); as well as An actuation lock (191) is configured to selectively constrain the plurality of supports (131) relative to the compliant connector (190).

10. The forming tool (102) according to claim 1, wherein the forming tool (102) further comprises: A pneumatically connected source (140) to at least one of the plurality of sections (132) of the base assembly (130) or the material (146) to provide a pressure source (140) for the first airflow (134) through the material (146); and At least one of the plurality of supports (131) or the material (156) pneumatically connected to the upper assembly (129) to provide a pressure source (142) for the second airflow (138) through the material (156).

11. A method (1400) for forming a bent portion (104) into a composite reinforcement (106), the method comprising: Position the composite reinforcement (106) (1402) above a section (184) of the base assembly (130); A pair of supports (166) of the upper component (129) are placed (1404) above the composite reinforcement (106) to form a shaped region (136) having a cross-section (174); and While maintaining the cross section (174) of the forming region (136), the segment (184) and the pair of supports (166) are moved (1406) within the manufacturing environment (100) to form the bend (104) into the composite reinforcement (106); The method further includes: A first airflow (134) is delivered (1410) in a first direction relative to the forming region (136) through the material of the base assembly (130), wherein the first direction is one of a positive airflow or a negative airflow; and A second airflow (138) is delivered (1412) in a second direction relative to the forming region (136) so that it passes through the material of the upper component (129), wherein the second direction is opposite to the first direction; or, The method further includes: Sending (1414) a second airflow (138) through the material of the upper component (129) to the forming region (136), wherein sending the second airflow (138) through the material of the upper component (129) includes sending a negative airflow through the material associated with at least one of the plurality of supports (131) of the upper component (129) to the forming region (136), and sending a positive airflow through the material associated with at least one of the plurality of supports (131) to the forming region (136). or The method further includes: Sending (1416) a first airflow (134) through the material of the base assembly (130) to the forming region (136), wherein sending the first airflow (134) through the material includes sending a negative airflow through a portion of the material associated with at least one of the plurality of segments (132) of the base assembly (130) to the forming region (136), and sending a positive airflow through a portion of the material associated with at least one of the plurality of segments (132) to the forming region (136).

12. The method (1400) according to claim 11, wherein, (1408) Moving the segment (184) and the pair of supports (168) is part of the synchronous movement of the plurality of supports (131) of the upper assembly (129) and the plurality of segments (132) of the base assembly (130) to form the bend (104) into the composite reinforcement (106).

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