Systems and methods for forming composite components

Abstract

Systems and methods for forming composite components. The systems and methods are configured to move different types of composite plies from different supply stations. Move the composite plies along a conveying member and then move them to a forming tool using a transfer station. One or more forming members form the composite plies on the forming tool.

Description

Technical Field

[0001] The present disclosure generally relates to the technical field of composite components, and more particularly, to a manufacturing system configured to move different types of composite plies to a forming tool to form a composite component. Background Art

[0002] The manufacture of composite components includes laying fiber-reinforced composite plies on a forming tool. Each individual composite ply has a fiber orientation angle in which the fibers are aligned within the ply. Different composite plies can be arranged in various orientations relative to other plies. When designing and manufacturing a composite component, the stacking sequence of the individual composite plies in the composite component is considered. Different types of composite plies have different design variables, such as but not limited to material and fiber orientation and ply width. The composite plies can be oriented and sequenced in an optimal arrangement to provide optimal structural performance. The number of composite plies and the type of material can be varied according to the intended use of the composite component. The stacked composite plies are then cured to form the composite component.

[0003] Multiple composite plies arranged in various orientations form a composite component that can provide structural performance superior to the individual material properties of each ply. This provides composite components for various applications, such as but not limited to various components on transportation vehicles such as airplanes, trucks, ships, and structural components for buildings. Using these components is effective due to their low weight, high strength-to-weight ratio, and design flexibility.

[0004] Current methods of laying the individual composite plies on the forming tool are performed manually or by machine. Manual laying is a time-consuming process that requires a large number of personnel to perform a large amount of manual labor to lay multiple composite plies. For large structures and high productivity, the amount of manual labor can be significant. Machines such as tape laying machines can reduce the amount of manual labor used to lay composite components. However, these machines are generally large and complex and can be prohibitively expensive. In addition, these machines may require a large amount of machine path programming, which can affect production costs and scheduling.

[0005] Current machines and manufacturing layouts result in inefficiencies in the manufacturing process. Machines are generally complex and, for safety reasons, limit the ability of personnel to approach the work (e.g., large mass, acceleration, and pinch points associated with the machine). Personnel are inefficient because they are outside the larger operating envelope of the machine, which is larger than the more restricted component envelope. Further, these machines result in poor work density and a small increase in value per unit area at the point of contact. To address these inefficiencies, current machines are designed with faster acceleration, deceleration, and speed. This increases the total cost and makes it more challenging to improve safety and work density. Summary of the Invention

[0006] On the one hand, a method for forming a composite member composed of a plurality of composite laminate layers is provided. The method includes: guiding a first composite laminate layer from a first supply station onto a conveying member, where the first composite laminate layer includes a first type; guiding a second composite laminate layer from one or more second supply stations onto the conveying member, the second supply stations being positioned along the conveying member away from the first supply station, where the second composite laminate layer from the second supply station includes a type different from the first type; orienting the first composite laminate layer and the second composite laminate layer on the conveying member; individually conveying each of the first composite laminate layer and the second composite laminate layer to a forming tool; and forming the first composite laminate layer and the second composite laminate layer on the forming tool.

[0007] On the other hand, orienting the first composite laminate layer and the second composite laminate layer includes: conveying the first composite laminate layer and the second composite laminate layer from the conveying member onto a support surface of a first support member, and individually orienting each of the first composite laminate layer and the second composite laminate layer at the support member relative to one or more reference planes.

[0008] On the other hand, the method further includes: cutting one or more of the first composite laminate layer and the second composite laminate layer at a first level, and then vertically conveying the first composite laminate layer and the second composite laminate layer to a second level before forming the composite laminate layer on the forming tool.

[0009] On the other hand, the method further includes: cutting the first composite laminate layer at the first supply station and cutting the second composite laminate layer at one or more second supply stations before guiding the respective first composite laminate layer and second composite laminate layer onto the conveying member.

[0010] On the other hand, the composite laminate layers introduced from the first supply station have various different widths.

[0011] On the other hand, the method further includes: moving the forming tool and positioning each of the first composite laminate layer and the second composite laminate layer at a predetermined position on the forming tool.

[0012] On the other hand, the method further includes: introducing a customized composite laminate layer between adjacent composite laminate layers of the first composite laminate layer and the second composite laminate layer, where the customized composite laminate layer is a type different from any of the first composite laminate layer and the second composite laminate layer.

[0013] On the other hand, the method further includes: individually orienting each of the first composite laminate layer and the second composite laminate layer on a carrier medium, and while the carrier medium supports the respective first composite laminate layer and second composite laminate layer, conveying each of the respective first composite laminate layer and second composite laminate layer to the forming tool.

[0014] On the one hand, a method for forming a composite member composed of multiple composite plies is provided, wherein the method includes: guiding the composite plies from multiple supply stations onto a conveying member in a single-line predetermined order, where each supply station supplies a different type of composite ply; moving each composite ply along the conveying member in a single-line predetermined order; orienting each composite ply individually with respect to one or more reference planes; when each composite ply reaches a predetermined position, transferring the composite ply to a forming tool positioned away from the conveying member; and forming the composite ply on the forming tool.

[0015] On the other hand, the method further includes: introducing a first composite ply as a first type into the composite plies from a first supply station among the supply stations, and introducing a second composite ply as a second type into the composite plies from a second supply station, where the second supply station is located downstream of the first supply station along the conveying member.

[0016] On the other hand, the method further includes: cutting each composite ply at the corresponding supply station before guiding the composite ply onto the conveying member, where the composite ply from the first supply station among the supply stations includes a leading edge aligned at a different angle from the composite ply from the second supply station among the supply stations.

[0017] On the other hand, the method further includes: orienting each composite ply on the conveying member before transferring the composite ply to the forming tool.

[0018] On the other hand, the method further includes: moving each composite ply to a support member located downstream of the supply station along the conveying member, and orienting each composite ply individually on the support member before transferring the composite ply to the forming tool.

[0019] On the other hand, the method further includes: moving the support member to the forming tool while supporting the composite ply.

[0020] On the other hand, the method further includes: forming two or more composite plies into different widths at the corresponding supply station before guiding the composite ply onto the conveying member.

[0021] On the one hand, a system for forming a composite member from a plurality of composite laminate layers of different types is provided. The system includes: a conveying member; a forming tool spaced apart from the conveying member; a plurality of supply stations positioned along the conveying member, each supply station being configured to form a blank into one of the composite laminate layers and direct the composite laminate layer onto the conveying member, the one composite laminate layer having a predetermined type different from the composite laminate layers formed at the other supply stations; a transfer station positioned downstream of the plurality of supply stations along the conveying member, wherein the transfer station includes a support member having a support surface that supports and transfers the composite laminate layer from the conveying member to the forming tool; and one or more forming machines located at the forming tool to form the composite laminate layer on the forming tool.

[0022] On the other hand, the plurality of supply stations form blanks with various positive and negative rake angles.

[0023] On the other hand, the plurality of supply stations are positioned at a first level that is vertically higher than the one or more forming machines located at a second level.

[0024] On the other hand, the system includes: a carrier medium including a support surface for receiving one composite laminate layer, and wherein the carrier medium is movable along the conveying member before reaching the transfer station.

[0025] On the other hand, the transfer station includes a robotic device having a vacuum, wherein the robotic device grips each carrier medium and transfers the carrier medium to the forming tool.

[0026] The features, functions, and advantages discussed can be implemented independently in various aspects or can be combined in some other aspects, and further details thereof can be seen with reference to the following description and drawings. Description of the Drawings

[0027] Figure 1 is a schematic diagram of a system for manufacturing a composite member.

[0028] Figure 2 is a schematic diagram of one type of composite laminate layer.

[0029] Figure 3 is a schematic diagram of one type of composite laminate layer.

[0030] Figure 4 is a schematic diagram of one type of composite laminate layer.

[0031] Figure 5 is a schematic diagram of one type of composite laminate layer.

[0032] Figure 6 is a schematic diagram of a system for manufacturing a composite member.

[0033] Figure 7 Schematic diagram of a part of a transfer station.

[0034] Figure 8 Schematic diagram of a forming tool.

[0035] Figure 9 Schematic diagram of a composite laminate laid on a forming tool.

[0036] Figure 10 Schematic diagram of a forming machine

[0037] Figure 11 Schematic diagram of a system controller.

[0038] Figure 12 Flowchart of a method for manufacturing a composite component.

[0039] Figure 13 Schematic diagram of a system for manufacturing a composite component.

[0040] Figure 14 Schematic diagram of a system for manufacturing a composite component.

[0041] Figure 15 Schematic diagram of a system for manufacturing a composite component.

[0042] Figure 16 Schematic diagram of a system for manufacturing a composite component.

[0043] Figure 17 Schematic diagram of a system for manufacturing a composite component.

[0044] Figure 18 Schematic diagram of a system for manufacturing a composite component.

[0045] Figure 19 Schematic diagram of a system for manufacturing a composite component.

[0046] Figure 20 Schematic diagram of an aircraft including one or more composite components.

[0047] Figure 21 Perspective cross-sectional view of the interior of an aircraft wing. Detailed implementation

[0048] Figure 1System 50 for manufacturing composite member 1000 is shown. System 50 is configured to move different types of composite plies 75 from a plurality of different supply stations 200, 300. The composite plies 75 are moved along a conveying member 100 and then transferred to a forming tool 600 using a transfer station 500. One or more forming machines 700 form the composite plies 75 on the forming tool 600. Then, the composite member 1000 is removed from the forming tool 600 for additional processing as needed to complete the structure.

[0049] The composite plies 75 are laid on the forming tool 600 to form the composite member 1000. The total number, type, and orientation of the composite plies 75 forming the composite member 1000 can be varied. Figure 2 An embodiment of the composite ply 75 is shown. The composite ply 75 is a sheet member including one or more layers of fibers 76 pre-impregnated with one or more of a thermosetting and a thermoplastic matrix resin (e.g., prepreg). In one embodiment, most of the fibers 76 are oriented parallel to each other (e.g., parallel in the longitudinal direction). Other embodiments can include fibers 76 aligned in different orientations or randomly positioned (i.e., not aligned). The composite ply 75 can include one or more layers of fibers 76. In embodiments having multiple layers, the fibers 76 of different layers can be aligned in the same or different orientations. In another embodiment, the fibers 76 of one or more composite plies 75 are interwoven or braided and form a fabric.

[0050] The fibers 76 can be formed of various materials, including but not limited to aramid, polyolefin, metal, glass, carbon, boron, ceramic, mineral, and combinations. The fibers 76 are pre-impregnated with a thermosetting or thermoplastic matrix resin (e.g., prepreg). In another embodiment, the matrix resin includes a mixed system of thermosetting and thermoplastic. The matrix resin can be formed of various substances, including but not limited to acrylic, fluorocarbon, polyamide (PA), polyethylene (PE) such as polyethylene terephthalate (PET), polyester, polypropylene (PP), polycarbonate (PC), polyurethane (PU), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), and other material compositions.

[0051] Figures 2 to 5 An embodiment of different types of composite plies 75 is shown. As Figure 2 shown, each composite ply 75 includes opposite ends 77, 78 and opposite sides 79. In one embodiment, these ends 77, 78 are referred to relative to their movement along the conveying member 100, where end 77 is the front end, end 78 is the trailing end, and side 79 is the lateral side. The composite ply 75 includes a length L measured between the ends 77, 78 and a width W measured between the sides 79. Different types of composite plies 75 can include various different shapes and sizes.

[0052] The fibers 76 can be aligned in different orientations within the composite ply 75. In Figure 2 , Figure 3 and Figure 4 embodiments, most of the fibers 76 are oriented parallel to the longitudinal direction measured between the ends 77, 78 (referred to as the 0° composite ply 75). Figure 5 Another embodiment shown in includes a 90° composite ply 75 in which the fibers 76 are substantially perpendicular to the longitudinal direction. Other embodiments include the fibers 76 aligned at various angular positions between these types. In a composite ply 75 having multiple layers of fibers 76, the fibers 76 of each layer can be aligned in the same or different orientations. Different types of composite plies 75 can include various thicknesses. Embodiments of the thickness of each composite ply 75 include, but are not limited to, between about 0.0025 - 0.0175 feet.

[0053] The respective composite plies 75 are supplied from respective supply stations 200, 300. In one embodiment, each different supply station 200, 300 supplies a different type of composite ply 75. Different types can include, but are not limited to, different outer shapes (e.g., rectangular, parallelogram), different widths, different fiber orientations (e.g., 0°, 90°), different thicknesses, and different constructions (e.g., different fibers and / or resins). Supplying different types of composite plies 75 from different supply stations 200, 300 increases efficiency. This prevents the supply stations 200, 300 from changing different composite plies 75, which slows down the supply process.

[0054] Figure 6 A manufacturing system 50 for producing a composite member 1000 is shown. The system 50 includes four supply stations 200, 300a, 300b, 300c that supply composite plies 75 to a conveying member 100. One supply station 200 is aligned at the end of the conveying member 100. In one embodiment, this main supply station 200 supplies the most frequently used type of composite ply 75. For example, the main supply station 200 supplies 0° rectangular composite plies 75 of one or more widths (e.g., 60-foot composite ply 75, 30-foot composite ply 75, 75-foot composite ply 75). In a specific embodiment, the main supply station 200 supplies 0° rectangular composite plies 75 of three different widths.

[0055] Additional supply stations 300a, 300b, 300c are located downstream of the main supply station 200 along the conveying member 100. These additional supply stations 300a, 300b, 300c supply composite laminate layers 75 of a different type than the main supply station 200. In one embodiment, each of the supply stations 300a, 300b, 300c supplies a different type of composite laminate layer 75. One or more of the additional supply stations 300a, 300b, 300c can supply composite laminate layers 75 of different widths.

[0056] In one embodiment, one or more of the supply stations 200, 300 include a cutting machine 101 to cut the composite laminate layer 75 into a desired shape and size. The cutting machine 101 includes one or more blades for cutting the composite laminate layer 75. In a specific embodiment, the cutting machine 101 is a guillotine cutter. The supply stations 200, 300 can further include a workbench 103 having a support surface for positioning the composite laminate layer 75 to be cut. In one embodiment, a roll of composite material is positioned at the supply stations 200, 300. The roll is unrolled on the workbench 103 and then cut by the cutting machine 101 to form the composite laminate layer 75. Once cut, the composite laminate layer 75 is fed onto the conveying member 100. The supply stations 200, 300 can further include a smaller conveying member 102 for moving the cut composite laminate layer 75 to the conveying member 100. In another embodiment, the composite laminate layer 75 has been cut and stored at the supply stations 200, 300. Then, the cut composite laminate layer 75 is moved by the supply stations 200, 300 to the conveying member 100.

[0057] The composite laminate layer 75 can be cut into a desired shape and / or size at the supply stations 200, 300. This prevents and / or reduces the amount of composite material that would otherwise be wasted if the composite laminate layer 75 were not customized before reaching the forming tool 600.

[0058] In one embodiment, the composite material includes a backing paper for controlling the dispensing length. The workbench 103, the conveying member 102, or other structures are configured to remove the backing paper before the composite laminate layer 75 reaches the conveying member 100.

[0059] As Figure 6 shown, each of the supply stations 200, 300 can be aligned with the conveying member 100 in various orientations. Figure 6 Shown are the supply station 200 aligned with the conveying member 100 (i.e., at a 0° angle), the supply station 300a at a 90° angle, the supply station 300b at a 45° angle, and the supply station 300c at a -45° angle.

[0060] The conveying member 100 is used to move the composite panel layer 75 from the corresponding supply stations 200, 300 to the transfer station 500. The conveying member 100 can include a support surface on which the composite panel layer 75 is positioned, such as a conveyor. In another embodiment, the composite panel layer 75 is initially conveyed to a carrier medium, such as a pallet or sheet moved by the conveying member 100. In one embodiment, the composite panel layer 75 is oriented and placed on the conveying member 100 after leaving the supply stations 200, 300. In another embodiment, only the composite panel layer 75 is moved by the conveying member 100 and oriented at a downstream location.

[0061] In Figure 6 In one embodiment shown, the conveying member 100 includes a belt 105. The belt 105 directly supports the composite panel layer 75 or indirectly supports the composite panel layer 75 through a support member as the composite panel layer moves along its length. The belt 105 can be solid to fully support the composite panel layer 75. In one embodiment, the belt 105 includes openings, and a vacuum source 106 applies a vacuum to maintain the composite panel layer 75 in contact with the belt 105. The conveying member 100 can include various lengths and shapes. In a specific embodiment, the conveying member 100 is a flatbed conveyor.

[0062] Sensors 405 are positioned along the supply stations 200, 300 and the conveying member 100. The sensors 405 are for the system controller 400 (see Figure 11 ) to monitor and control the movement of the composite panel layer 75. In one embodiment, the sensors 405 include one or more cameras or other recording devices that detect the leading end 77 and / or the trailing end 78 of the composite panel layer 75. In another embodiment, the sensors 405 include a servo motor controller attached to the motor that drives the conveying member 100. The system controller 400 can maintain the forward registration of the composite panel layer 75 as it moves through the system 50. For each composite panel layer 75, the registration can include, but is not limited to, orientation, type, initial position, current position, and travel path. In one embodiment in which the composite panel layer 75 is transported on a carrier medium, the medium has a forward registration position, which enables the medium to be conveyed quickly and rapidly between stations and ultimately conveyed onto the forming tool 600.

[0063] The transfer station 500 is located downstream of the conveying member 100 and receives the composite panel layer 75 from the conveying member 100. As Figure 6As shown, transfer station 500 includes a first datum plane 503 positioned near conveying member 100 and a second datum plane 513 positioned near forming tool 600. Datum planes 503, 513 provide reference points for the alignment of support member 501 that supports composite panel layer 75. In one embodiment, first datum plane 503 and second datum plane 513 include one or more pins that extend upwardly and are positioned to receive in corresponding openings 507 in support member 501. In another embodiment, datum planes 503, 513 include one or more edges that contact support member 501 and position support member 501. In one embodiment, datum planes 503, 513 are the same (e.g., each includes a pair of pins). In another embodiment, datum planes 503, 513 are different.

[0064] Transfer station 500 further includes support member 501 and a movable support surface 502. In one embodiment, support member 501 is positioned immediately downstream of conveying member 100 such that composite panel layer 75 moves directly from conveying member 100 onto support surface 502. In Figure 6 Another embodiment shown, movable support member 504 extends between conveying member 100 and support surface 502 to transfer composite member 75 to support surface 502. Movable support member 504 can include a conveyor belt or rollers, or can include a surface along which composite panel layer 75 slides to reach support surface 502.

[0065] As Figure 6 and Figure 7 shown, support member 501 extends around support surface 502. In one embodiment, support member 501 extends around the entire support surface 502. Other embodiments include support member 501 that extends around a portion of support surface 502 or is positioned below support surface 502. One or more openings 507 extend through support member 501 and are for engaging with datum planes 503, 513.

[0066] Support surface 502 is sized to receive and support one composite panel layer 75. In one embodiment, support surface 502 is relatively flat to contact and support composite panel layer 75. One or more openings can extend through support surface 502 and are connected to a vacuum source 505 to apply a vacuum to maintain the position of composite panel layer 75. Support surface 502 is also configured to be adjustable relative to support member 501. Motor 506 is provided for adjusting support surface 502. The adjustability is used to align composite panel layer 75 at a predetermined position. Scanner 508 including one or more cameras scans composite panel layer 75 while positioned on support surface 502. One or more additional sensors 405 can be positioned at transfer station 500 to detect the position of support surface 502 and / or composite panel layer 75.

[0067] The transfer station 500 is further configured to transfer the support member 501 and the support surface 502 supporting the composite panel layer 75 from the conveying member 100 to the forming tool 600. In Figure 6 and Figure 7 In one illustrated embodiment, a track 515 extends between the conveying member 100 and the forming tool 600. The support member 501 includes a receiver 516 that engages the track 515 and is configured to move the support member 501 from the conveying member 100 to the forming tool 600. In another embodiment, a robotic arm engages the support member 501 and moves the support member 501.

[0068] During use, a single composite panel layer 75 is moved from the conveying member 100 to the support surface 502. The composite panel layer 75 can be transferred directly to the support surface 502, or it can remain on the carrier medium when it is transferred on the carrier medium. The composite panel layer 75 is aligned relative to a reference plane 503. Once aligned, the composite panel layer 75 is transferred to the forming tool 600.

[0069] The forming tool 600 is shaped and sized to represent the machining surface of the desired composite member 1000, e.g., an aircraft wing spar or other primary or secondary structure, i.e., a Z-beam, an I-beam, a hat stiffener, a C-channel, a J-stiffener, a blade stiffener, a floor beam, a rib, a frame, or a spar. Although the forming tool 600 can include various shapes and sizes, however, the present disclosure is particularly applicable to a forming tool 600 having an elongated shape. For example, in an aircraft wing, the forming tool 600 for a spar can have a length of up to 130 feet or more.

[0070] As Figure 8 schematically shown in, the forming tool 600 is mounted on a tool table 602 configured to move along a forming lane 601. The tool table 602 is adapted to move along a pair of tracks 603 to facilitate moving the forming tool 600 and sequentially applying a series of composite panel layers 75 at different spanwise positions along the forming tool 600. The tracks 603 can be mounted in a workshop or on another surface. In one embodiment, rollers 604 extend outwardly from the bottom and / or sides of the tool table 602 and contact the tracks 603 and travel along the tracks 603.

[0071] In one embodiment, the track 603 has a discrete length. The tool table 602 moves back and forth along the track 603. In another embodiment, the track 603 forms a continuous loop. The tool table 602 repeatedly moves around the loop in a single direction.

[0072] The forming tool 600 moves along the forming path 601 to receive the composite laminate 75 from the transfer station 500. In one embodiment, the forming tool 600 is initially positioned such that its first end is at the transfer station 500 to receive the composite laminate 75. The forming tool 600 then continues to move through the transfer station 500 to receive additional composite laminates 75 in an end-to-end configuration. Since the forming tool 600 moves along the forming path 601 in an end-to-end manner relative to the first layer of material, this process can continue to place multiple composite laminates 75 in the machine direction position. Additional composite laminates 75 can be applied on top of previously laid layers in this manner until the desired laminate stack sequence is achieved.

[0073] Figure 9 An embodiment of the forming tool 600 shaped to correspond to the desired composite part is schematically shown. The forming tool 600 includes a top 605 and sides 606. In one embodiment, the forming tool 600 is configured to translate back and forth, as shown by arrow X. In another embodiment, the forming tool 600 moves around a loop. In various embodiments, a first composite laminate 75a is positioned at the end of the forming tool 600. The first composite laminate 75a is on a portion of the top 605 and extends along the sides 606 (including the end side and the opposite transverse side). For additional composite laminates 75b - 75e placed sequentially along the forming tool 600 in an end-to-end configuration, the forming tool 600 continues to move. In one embodiment, adjacent composite laminates 75 overlap by a limited amount. In another embodiment, adjacent composite laminates 75 abut together without overlapping. Figure 9 The composite laminate 75 partially laid thereon along the forming tool 600 is shown. The process continues to position additional composite laminates 75 along the remaining length of the forming tool 600. Once complete, one or more additional composite laminates 75 can be laid along all or one or more portions. The sensor 405 can be positioned to detect the number of composite laminates 75 and the positioning of the composite laminates 75 on the forming tool 600.

[0074] One or more formers 700 form the composite laminate 75 on the forming tool 600. The former 700 includes one or more arms having a contact surface that contacts the composite laminate 75 and applies a mechanical force to the composite laminate 75. Figure 10 An embodiment of the former 700 is shown. The former 700 spans the forming path 601 along which the forming tool 600 travels. In one embodiment, one or more formers 700 are fixed in place while the forming tool 600 travels along the forming path 601 relative to the former 700.

[0075] The former 700 may include one or more supports 701, which include legs 702 and one or more cross braces 703. The legs 702 are spaced apart to be positioned on opposite sides of the former path 601. A shroud 704 extends below the support 701 and includes an internal space 705 for receiving the former tool 600. The shroud 704 is configured to surround the former tool 600 and / or extend at least partially around the former tool 600. In Figure 10 In one illustrated embodiment, the shroud 704 includes a generally U-shaped cross-sectional shape. The shroud 704 may be formed of any suitable material to be rigid or at least substantially rigid. A joining member 708 can maintain and position the shroud 704. The joining member 708 can include one or more of a screw jack, a linear actuator, a motor, an electric motor, and a pneumatic motor.

[0076] A force applying device 706 is positioned within the shroud 704 and is configured to apply a force to conform the composite laminate 75 to the tool table 602. In one embodiment, the force applying device 706 is an inflatable airbag. In another embodiment, the force applying device 706 includes a robotic arm having a contact member that contacts the composite laminate 75 at a distal end and applies a force to the composite laminate 75. A sensor 405 is positioned to detect and adjust the amount of force applied by the force applying device 706.

[0077] In one embodiment, the force applying device 706 directly contacts the topmost composite laminate 75. In another embodiment, an intermediate film is placed on the uppermost composite laminate 75. Under these conditions, the force applying device 706 directly contacts the intermediate film and may indirectly contact the composite laminate 75. Examples of the intermediate film include, but are not limited to, a contact film, a release film, and a fluoropolymer film.

[0078] In one embodiment, the former 700 forms a single-layer composite laminate 75 on the former tool 600. In another embodiment, multiple composite laminates 75 are laid on the former tool 600 to form multiple layers. The former 700 is configured to apply pressure to conform each composite laminate 75 in the multiple layers to the former tool 600. This may include simultaneously pressing at least two or even multiple stacked composite laminates 75 against the former tool 600.

[0079] The former 700 may maintain a pressure against the composite laminate 75. Examples of the threshold pressure difference include a threshold pressure difference less than 5 kilopascals (kPa), less than 10 kPa, less than 15 kPa, less than 20 kPa, less than 25 kPa, less than 30 kPa, less than 50 kPa, or less than 75 kPa.

[0080] The former machine 700 may further include one or more heaters 709 that heat the composite laminate 75 while applying pressure. Heating of the composite laminate 75 can be performed before the composite laminate 75 is formed on the forming tool 600. Heating the composite laminate 75, as opposed to the composite laminate 75 being at ambient temperature or room temperature, allows it to conform more easily to the forming tool 600. Heating can be achieved using infrared lamps, conventional light bulbs, or any other known heating technique. Depending on the composition of the composite laminate 75, the temperature can be raised to about less than or equal to 200°F. The temperature of the composite laminate 75 can be measured in any conventional manner, such as using an attached thermocouple.

[0081] Some or all of the functions of the system 50 can be controlled by the system controller 400. The system controller 400 communicates with each component and controls and supervises the operation of the composite member 1000. The system controller 400 can be housed at a distance from the components in a cabinet or the like. In another embodiment, the system controller 400 is housed within one of the components.

[0082] As Figure 11 shown, the system controller 400 includes a processing circuit 401 control circuit having one or more microprocessors, microcontrollers, and ASICs with appropriate software and / or firmware. The memory circuit 402 stores data and computer-readable program code that configures the control circuit to implement the above techniques. The memory circuit 402 is a non-transitory computer-readable medium and can include various memory devices such as random access memory, read-only memory, and flash memory.

[0083] The system controller 400 may also include a communication interface 403 that sends data to and receives data from the components. The communication interface can communicate through a wiring system having various cables extending between the components. The cables are configured to carry various data signals. In one design, the system communicates via a LAN, and another design feature is communication via a communication bus. The communication interface 403 can also be used for wireless communication, such as via a Bluetooth interface or a wireless local area network (WLAN) interface. Some embodiments feature a combination of wired and wireless communication.

[0084] The user interface 404 includes one or more user input devices such as a keyboard, touchpad, function keys, scroll wheel, or other types of computer input devices. The user interface 404 can include a display screen, such as a conventional liquid crystal display (LCD) or a touchscreen display that also serves as a user input device. The user interface 404 enables a worker to control the functions of the various components that communicate with the system controller 400.

[0085] One or more sensors 405 can detect the position of the composite ply 75 as the composite ply moves through the system 50. The sensors 405 can also detect the operating conditions of one or more components. A variety of sensor types can be used, including cameras, thermal sensors, and motion sensors. A scanner 508 can be located at the transfer station 500 to obtain the orientation of the composite ply 75. Figure 11 Schematically shows the sensors 405 and the scanner 508 included in the system controller 400. One or more of the sensors 405 and / or the scanner 508 can be part of an associated component and communicate with the system controller 400 via a communication interface 403.

[0086] Figure 12 Shows a method of forming a composite member 1000 from a composite ply 75. The method includes: guiding a first type of composite ply 75 from a supply station 200 onto a conveying member 100 (block 150). Introducing a different second type of second composite ply 75 from one or more other supply stations 300 (block 152). Orienting the first and second composite plies 75 on the conveying member 100 (block 154). The orientation can be performed when the composite ply 75 is placed on the conveying member 100 at the supply stations 200, 300, or when it is placed on a support surface 502 at the transfer station 500. In one embodiment, the composite ply 75 is placed and oriented on a carrier medium while the remaining composite plies are on the carrier medium and moved through the system 50. In another embodiment, the composite ply 75 is directly positioned on the conveying member 100. Individually conveying the composite ply 75 to a forming tool 600 (block 156). Then forming the composite ply 75 on the forming tool 600 (block 158).

[0087] A more detailed method can be used in conjunction with Figure 6 the system 50 shown and controlled by the system controller 400. The system controller 400 is used to supply composite plies 75 in a predetermined order from supply stations 200, 300a, 300b, 300c to the conveying member 100. For example, a first type of composite ply 75 is supplied from supply station 200, and then, a second type of composite ply 75 is supplied from supply station 300a, and then, a third type of composite ply 75 is supplied from supply station 300c.

[0088] In one embodiment, the composite ply 75 is placed and oriented on a carrier medium. The composite ply 75 remains oriented on the carrier medium while moving through the system 50 and is conveyed to a downstream point.

[0089] Starting from supply stations 200, 300a, 300b, 300c, a conveying member moves the composite laminate 75 away from the supply stations 200, 300a, 300b, 300c to a transfer station 500. The system controller 400 can monitor the orientation and positioning of the composite laminate 75 through sensors 405 positioned along the supply stations 200, 300a, 300b, 300c and the conveying member 100.

[0090] At the transfer station 500, each composite laminate 75 is individually moved onto a support surface 502. The composite laminate 75 is scanned by a scanner 508 and the support surface 502. When needed, the composite laminate 75 is reoriented so that the composite laminate 75 is aligned relative to one or more reference planes 503. Once aligned, the transfer station 500 moves the composite laminate 75 to a forming tool 600. The support surface 502 is aligned with one or more reference planes 513 to maintain the desired orientation of the composite laminate 75. Then the composite laminate 75 is placed on the forming tool 600. Before placement, the forming tool 600 is positioned along a forming path 601 to receive the composite laminate 75.

[0091] Multiple composite laminates 75 are oriented, transferred, and placed on the forming tool. Once a predetermined number of composite laminates 75 are positioned on the forming tool 600, the forming tool 600 is moved along the forming path 601, and the composite laminates 75 are positioned at a forming machine 700. The forming machine 700 forms the composite laminates 75 on the forming tool to conform to the desired shape.

[0092] System 50 can further include a Figure 6 custom supply station 800 as shown, for custom types of composite laminates 75 not supplied from one of the other supply stations 200, 300. For example, the custom composite laminate 75 can include different shapes, sizes, or configurations. The custom supply station 800 can include one or more of a cutting machine 801, a conveying member 802, and a workbench 803. In one embodiment, the composite laminate 75 is manually transferred from the custom supply station 800 to the transfer station 500 or directly onto the forming tool 600. In another embodiment, the custom supply station 800 includes a placement mechanism 804, such as a conveyor or a gripper (e.g., a vacuum-assisted mechanical finger gripper), for moving the composite laminate 75 to the transfer station 500 or directly to the forming tool 600.

[0093] System 50 can also be configured to include additional components and / or different configurations. Figure 13 Including system 50, which has a custom supply station 800 positioned to transfer the composite laminate 75 to the transfer station 500. The custom supply station 800 includes a support table 803 that translates or rotates to orient the composite laminate 75 before being transferred to the transfer station 500.

[0094] Figure 14 Including system 50, wherein supply stations 200, 300a, 300b, 300c supply a pair of forming tools 600a, 600b. Supply stations 200, 300a, 300b, 300c move composite laminate 75 to conveying member 100. The first transfer station 500a receives the composite laminate 75 and transfers it to the first forming tool 600a. A portion of the composite laminate 75 remains on the conveying member 100 and travels through the first transfer station 500a to the second transfer station 500b. These composite laminates 75 are moved to the second transfer station 500b to the second forming tool 600b. The advantage of this system 50 is that a worker or a group of workers can be positioned at supply stations 200, 300a, 300b, 300c and supply the composite laminate 75 to two different forming tools 600a, 600b.

[0095] Figure 15 Including system 50, which has a plurality of supply stations 200, 300 for supplying different types of composite laminates 75 to the conveying member 100. In one embodiment, supply station 200 provides composite laminates 75 of different widths of a first configuration. Supply station 300 provides different types of composite laminates 75. In one embodiment, different supply stations 300 provide different sizes and shapes of 30-foot and 60-foot wide products. Figure 15 The system 50 in provides a single workstation for the user to reload different types of composite materials to supply stations 200, 300. As Figure 16 shown in Figure 15 the system 50 in can be replicated such that a single workstation is used to supply two separate conveying members 100.

[0096] Figure 17 Including system 50, which has a custom supply station 800 for providing a custom type of composite laminate 75 to the conveying member 100.

[0097] In Figure 6 one embodiment shown, the composite laminate 75 is placed directly on the conveying member 100 and moved from supply stations 200, 300 to the transfer station 500. In Figure 18 another embodiment shown, the composite laminate 75 is placed and moved onto a carrier medium 900. The composite laminate 75 is moved from supply station 200 and aligned on the carrier medium 900. Figure 18It includes a single supply station 200. Other embodiments can include multiple different supply stations 200, 300 for supplying different types of composite laminate layers 75. The carrier medium 900 and the composite laminate layer 75 are moved along the conveying member 100 to the transfer station 500. The transfer station 500 includes a robotic device 520 having a movable arm 521 and a gripper 522 located at the distal end. The gripper 522 can include one or more vacuum openings. The robotic device 520 can move from a first position where the gripper 522 is attached to the surface of the carrier medium 900 to a second position at the forming tool 600. At the second position, the robotic device 520 aligns the carrier medium 900 with the forming tool 600. Then the composite laminate layer 75 is released from the carrier medium 900 onto the forming tool 600. In one embodiment, the vacuum from the robotic device 520 is used to hold the composite laminate layer 75 positioned on the carrier medium 900. Once the carrier medium 900 is positioned on the forming tool 600 at a slightly compacted level, the vacuum is released and the composite laminate layer 75 is placed on the forming tool 600.

[0098] In Figure 18 In one embodiment shown, after the composite laminate layer 75 is transferred, the carrier medium 900 is attached to the processing system 950. The processing system 950 moves the carrier medium 900 and then transfers it back to the start of the conveying member 100 to repeat the process.

[0099] In one embodiment, the system 50 includes various components (e.g., the conveying member 100, the supply stations 200, 300, the forming tool 600) positioned at the same level. In this system, the composite laminate layer 75 moves along this level during the manufacturing process. In another embodiment, one or more components are positioned at different levels. This can reduce the size of the working area and also reduce the travel of the composite laminate layer 75 when moving between the respective components.

[0100] Figure 19 System 50 is schematically shown with components located at multiple different levels 349, 350. In this embodiment, the supply stations 200, 300 each including one or more cutting machines 101 are positioned at a second level 350 which is higher than the first level 349 due to the support 351. The composite laminate layer 75 having the desired shape and size is cut and moved to the transfer station 500. In one embodiment, each composite laminate layer 75 is cut while at the first level 349. In another embodiment, one or more composite laminate layers 75 are already in the desired shape and / or size and are not cut at the first level 349. The transfer station 500 vertically moves the composite laminate layer 75 from the second level 350 to the first level 349. The composite laminate layer 75 is positioned on the forming tool 600 and then formed by the forming machine 700.

[0101] In another embodiment, the supply stations 200, 300 include a cutting machine 101 for cutting the composite panel layer 75 into desired shapes and sizes. The composite panel layer 75 is then transferred from the supply stations 200, 300 to the transfer station 500.

[0102] Each system 50 overcomes the problems of prior art designs. In the area where it performs work and only in a limited area of the entire system 50, the system 50 provides a workstation for the user. The workstation is remote from other equipment that is part of the system 50 and allows the worker to work closely to the equipment that is part of the process that they need to operate. For example, while located remote from the transfer station 500, the forming tool 600, and the forming machine 700, the user can be positioned at one or more of the supply stations 200, 300 to cut the composite panel layer 75 and / or position the composite panel layer 75 on the conveying member 100.

[0103] The system 50 includes components that are relatively smaller than more complex machines. The components of the system 50 have a smaller mass, more limited functionality, and a smaller machine envelope. This enables a safer and greater process packaging density with multiple workers and machines included within a given area. This also allows an increase in the number of parallel operations that can be performed at any given time, thereby increasing the process packaging density (process equipment or personnel per square foot of area) and the production work density (the number of times value-added operations are performed on the product at any given time). The combination of smaller workstations, simpler and smaller equipment and processes, and the number of parallel processing operations coupled with greater process packaging density and production work density results in a step function change in productivity.

[0104] In one embodiment, most operations are automated, thereby reducing the number of workers required to operate the system 50. In a specific embodiment, the worker operates one or more of the supply stations 200, 300 to supply the composite panel layer 75. The remaining operations are automated and run without involving in-house workers.

[0105] The system 50 and method can be used to manufacture a variety of different composite components 1000. One embodiment is various parts of a vehicle such as an aircraft 250, as Figure 20 shown. Embodiments include, but are not limited to, one or more parts of the fuselage 251 and the wings 252.

[0106] In as Figure 21In one specific aspect shown, the wing 252 includes a plurality of wing spars 742 that can extend along the length of the wing. The wing 252 can also include ribs, which may also be referred to as stringers 254 herein. Together, the spars 742 and the stringers 254 can form and / or define at least a part of the internal support structure of the wing 252, which can support the inner surface of the skin segment 255. The composite member 1000 formed by the methods and systems disclosed herein can be used to fabricate one or more of the skin segment 255, the spar 253, and the stringer 254.

[0107] Various other types of vehicles that can include the composite member 1000 include, but are not limited to, unmanned aerial vehicles, manned spacecraft, unmanned marine vehicles, manned rotorcraft, unmanned rotorcraft, satellites, rockets, missiles, manned ground aircraft, unmanned ground aircraft, manned seaplanes, unmanned seaplanes, manned submersible aircraft, unmanned submersible aircraft, and combinations thereof.

[0108] For the term "substantially" with respect to a quantity or measured value, it means that the stated feature, parameter, or value need not be precisely achieved. Instead, deviations or variations can occur within the amount that does not preclude the effect the feature is intended to provide, including, for example, tolerances, measurement errors, limits of measurement accuracy, and other factors known to those skilled in the art.

[0109] Without departing from the essential characteristics of the invention, the invention can be accomplished in other ways than those specifically set forth herein. This embodiment is to be considered in all respects as illustrative and not restrictive, and all changes falling within the meaning and scope of the appended claims are intended to be embraced herein.

Claims

1. A method for forming a composite member composed of a plurality of composite plate layers, wherein, The method includes: feeding a first composite panel layer from a first supply station onto a conveying member, wherein the first supply station is located at a first longitudinal end of the conveying member, and a second longitudinal end of the conveying member is located at a transfer station; feeding a second composite panel layer from one or more second supply stations onto the conveying member, the one or more second supply stations being positioned between the first longitudinal end and the second longitudinal end along a lateral side of the conveying member away from the first supply station; orienting the first composite panel layer and the second composite panel layer on the conveying member; transferring the first composite panel layer and the second composite panel layer from the conveying member to a transfer station located at the second longitudinal end of the conveying member; individually transferring each of the first composite panel layer and the second composite panel layer to a forming tool; and forming the first composite panel layer and the second composite panel layer on the forming tool; the first composite panel layer has design variables different from those of the second composite panel layer, wherein the design variables include one or more of material, fiber orientation, and layer width.

2. The method according to claim 1, wherein Orienting the first composite panel layer and the second composite panel layer includes: transferring the first composite panel layer and the second composite panel layer from the conveying member to a support surface of a first support member, and individually orienting each of the first composite panel layer and the second composite panel layer relative to one or more reference planes at the support member.

3. The method according to claim 1, further comprising: Before feeding the respective first composite panel layer and second composite panel layer onto the conveying member, cutting the first composite panel layer at the first supply station and cutting the second composite panel layer at the one or more second supply stations.

4. The method according to claim 1, wherein, The first composite panel layer introduced from the first supply station has various different widths.

5. The method according to claim 1, further comprising: Moving the forming tool and positioning each of the first composite panel layer and the second composite panel layer at a predetermined position on the forming tool.

6. The method according to claim 1, further comprising: Introducing a customized composite panel layer between adjacent composite panel layers of the first composite panel layer and the second composite panel layer, wherein the customized composite panel layer is a different type from any of the first composite panel layer and the second composite panel layer.

7. A method for forming a composite member composed of a plurality of composite laminate layers, wherein, The method includes: feeding composite panel layers from a plurality of supply stations onto a conveying member in a single-line predetermined order, wherein the supply stations each supply different types of composite panel layers, wherein a first supply station is provided at a first longitudinal end of the conveying member, and a plurality of second supply stations are provided along one or more lateral sides of the conveying member; moving each of the composite panel layers along the conveying member in the single-line predetermined order; individually orienting the composite panel layers relative to one or more reference planes; when each of the composite panel layers reaches a predetermined position beyond the second longitudinal end of the conveying member, transferring the composite panel layer to a forming tool positioned away from the conveying member; and forming the composite panel layer on the forming tool; Among them, the different types of the composite laminate include one or more of different materials, different fiber orientations, and different layer widths.

8. The method according to claim 7, further comprising: A first composite laminate, which is a first type of composite laminate, is introduced into the composite laminate from a first supply station among the supply stations, and a second composite laminate, which is a second type of composite laminate, is introduced into the composite laminate from a second supply station among the supply stations. The second supply station is located downstream of the first supply station along the conveying member.

9. The method according to claim 8, further comprising: Before introducing the composite laminate onto the conveying member, each composite laminate in the composite laminate is cut at a corresponding supply station, wherein the composite laminate from the first supply station among the supply stations includes a leading edge aligned at an angle different from that of the composite laminate from the second supply station among the supply stations.

10. The method according to claim 8, further comprising: Each composite laminate in the composite laminate is moved to a support member located downstream of the supply station along the conveying member, and each composite laminate in the composite laminate is individually oriented on the support member before the composite laminate is conveyed to the forming tool.

11. The method according to claim 10, further comprising: While supporting the composite laminate, the support member is moved to the forming tool.

12. The method according to claim 7, further comprising: Before the composite laminate is conveyed to the forming tool, each composite laminate in the composite laminate is oriented on the conveying member.

13. The method according to claim 7, further comprising: Before introducing the composite laminate onto the conveying member, two or more composite laminates in the composite laminate are formed into different widths at a corresponding supply station.

Images