Continuous in-line manufacturing of composite parts

Abstract

The present disclosure relates to continuous flow line manufacturing of composite parts. Systems and methods for forming a laminate are provided. The method includes indexing a layup mandrel to a laminating station at a first position, transporting the laminating station and the layup mandrel in a processing direction from the first position toward a second position, laying up, via a laminating machine, the laminate including a layer of fiber reinforced material onto the layup mandrel while the laminating machine and the layup mandrel are transported in the processing direction, removing the layup mandrel and the laminate at the second position, and returning the laminating machine to the first position to lay up another laminate on another mandrel.

Description

Technical Field

[0001] This disclosure relates to the field of manufacturing, and more specifically, to the manufacture of composite material parts. Background Technology

[0002] Multilayer laminates of constituent materials (e.g., carbon fiber reinforced polymer (CFRP)) can be formed into any of a variety of shapes to cure into composite parts. To facilitate the fabrication of composite parts, robots such as automated fiber placement (AFP) machines can be utilized. For example, a large (e.g., multi-ton) AFP machine can occupy a unit where it lays one or more layers of constituent material strands, which form a laminate that is then cured.

[0003] However, the manufacturing of composite parts remains time-consuming because individual operations such as laying, bonding, bagging and curing are performed in different units of the manufacturing environment, and technicians must physically transport the laminates on trolleys before proceeding to the next step of the manufacturing process in another unit.

[0004] Therefore, it is desirable to have methods and systems that take into account at least some of the problems discussed above, as well as other possible problems.

[0005] The abstract of EP 3653369 A1 describes "a manufacturing system comprising a plurality of laminating heads (300) and a head moving system defining a continuous annular laminating path (122), the head moving system being configured to move the laminating heads (300) serially along the laminating path (122). The manufacturing system also includes at least one laminating mandrel (146, 148, 150) disposed along a portion of the laminating path (122). Each laminating head (300) is configured to dispense layup material (316) onto at least one laminating mandrel (146, 148, 150) or onto layup material (316) previously applied to the laminating mandrel (146, 148, 150) while the laminating head (300) is moved by the head moving system through one or more turns of the laminating path (122) to lay up composite laminates (400, 402, 404)." Summary of the Invention

[0006] The embodiments described herein provide a laminating machine that actively lays the laminate while the mandrel for the laminate (and the laminating machine itself) is being transported. This provides the dual benefits of layup and transport within a single station and allows the laminate to be manufactured as part of a continuously moving assembly line process. This arrangement also breaks down the manufacturing work into smaller, multiple parts and allows for immediate detection and response to out-of-tolerance conditions encountered during layup.

[0007] One embodiment is a method for forming a laminate. The method includes: rotating a layup mandrel to a lamination station located at a first position; transporting the lamination station and the layup mandrel in a processing direction from the first position toward a second position; while transporting the lamination machine and the layup mandrel in the processing direction, laying the laminate having a layer of fiber-reinforced material onto the layup mandrel via the lamination machine; at the second position, removing the layup mandrel and the laminate; and returning the lamination station to the first position to lay another laminate on another mandrel.

[0008] Another embodiment is a non-transitory computer-readable medium implementing programming instructions that, when executed by a processor, operate to perform a method for forming a laminate. The method includes: rotating a layup mandrel to a lamination station located at a first position; transporting the lamination station and the layup mandrel in a processing direction from the first position toward a second position; while transporting the lamination machine and the layup mandrel in the processing direction, laying the laminate having a layer of fiber-reinforced material onto the layup mandrel via the lamination machine; at the second position, removing the layup mandrel and the laminate; and returning the lamination station to the first position to lay another laminate on another mandrel.

[0009] Another embodiment is a system for forming a laminate having multiple layers of fiber-reinforced material. The system includes a lamination station comprising a layup mandrel with a mandrel indexing element. The lamination system also includes a reciprocating motion member having a reciprocating motion member indexing element for engaging the mandrel indexing element of the layup mandrel. The lamination station further includes a lamination machine attached to the reciprocating motion member, and the lamination system further includes a drive system that transports the reciprocating motion member in a processing direction while the lamination machine lays the multiple layers of the laminate onto the layup mandrel.

[0010] Other exemplary embodiments (e.g., methods and computer-readable media related to the foregoing embodiments) may be described below. The features, functions, and advantages discussed may be implemented independently in various embodiments or may be combined in other embodiments, and further details of these aspects may be found with reference to the following description and drawings. Attached Figure Description

[0011] Now, some embodiments of the present disclosure will be described by way of example only with reference to the accompanying drawings. In all the drawings, the same reference numerals denote the same elements or elements of the same type.

[0012] Figure 1 This is a schematic diagram of a lamination system in an exemplary embodiment.

[0013] Figure 2 It is possible to be with Figure 1 The diagram shows a schematic block diagram of a lamination station used in conjunction with a lamination system.

[0014] Figure 3 It is possible to be with Figure 1 and Figure 2 The diagram shows a perspective view of the reciprocating motion components of the laminating machine and mandrel used together in the lamination station.

[0015] Figure 4 This is an exemplary implementation. Figure 3 A sectional side view of the reciprocating motion component.

[0016] Figure 5 The exemplary embodiments include Figure 3 A top view of the lamination station for reciprocating motion components.

[0017] Figure 6 This is a top view of multiple lamination stations that interact with each other in an exemplary embodiment.

[0018] Figure 7 This is an exemplary implementation. Figure 6 A top view of the mandrel transfer between lamination stations.

[0019] Figure 8 This is a top view of multiple lamination stations manufacturing laminates in two directions in an exemplary embodiment.

[0020] Figure 9 This demonstrates the operation. Figures 1 to 8 The flowchart shows the lamination system and lamination station method.

[0021] Figure 10 It is one of the usable ones Figures 1 to 8 Lamination station and / or Figure 9 The flowchart of the methods for aircraft manufacturing and maintenance.

[0022] Figure 11 It can be used Figures 1 to 8 Lamination station and / or Figure 9 and Figure 10 A block diagram of an aircraft manufactured using this method. Detailed Implementation

[0023] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. Therefore, it will be understood that those skilled in the art will be able to devise various arrangements that, while not expressly described or shown herein, implement the principles of this disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and are to be construed as not being limited to such specific examples and conditions. Consequently, this disclosure is not limited to the specific embodiments or examples described below, but is limited by the claims.

[0024] Composite parts, such as CFRP parts, are initially laid out in multiple layers, which together are called a laminate or "preform." Individual fibers within each layer of a laminate are aligned parallel to each other, but different layers can exhibit different fiber orientations to increase the strength of the final composite part along different dimensions. Laminates may include a viscous resin that cures to harden the laminate into a composite part (e.g., for use in aircraft). Carbon fibers impregnated with uncured thermosetting or thermoplastic resins are called "prepregs." Other types of carbon fibers include "dry fibers," which are not impregnated with thermosetting resins but may include tackifiers or binders. Dry fibers can be injected with resin and then cured. For thermosetting resins, curing is a one-way process called curing, while for thermoplastic resins, if the resin is reheated, it can reach a viscous form.

[0025] Figure 1 This is a schematic diagram of a lamination system 50 used within a manufacturing production line 10. The lamination system 50 may be one of a series of systems comprising the manufacturing production line 10. For example, the manufacturing production line 10 may also include a fastener mounting system disposed after the lamination system 50. The lamination system 50, and more specifically, the lamination station 100, is used to form a laminate 140. The laminate 140 includes at least a first layer 141 and a second layer 142 of fiber-reinforced material 147.

[0026] The lamination system 50 has lamination stations 100 and laying mandrels 130. The lamination system 50 may include more than one lamination station 100, such that a first lamination station 100 and a second lamination station 100' are connected in series along the processing direction 190 of the manufacturing line 10. In such an embodiment, the lamination system 50 also includes a conveyor 60 movable between the lamination stations 100, 100' of the lamination system 50. (As relative to...) Figure 7 In more detail, the conveyor 60 is configured to remain stationary during the conveying of the laying mandrel 130.

[0027] Still refer to Figure 1The lamination system 50 also includes a drive system 150. The drive system 150 moves the lamination station 100 and / or the laying mandrel 130 to perform the methods described herein. More specifically, the drive system 150 moves the lamination station 100 along a processing direction 190 from a first position 102 toward or towards a second position 104. In the example described herein, the drive system 150 moves the reciprocating element 120 of the lamination station 100 from the first position 102 toward the second position 104. The lamination system 50 may also include a track system 160. When the lamination system 50 includes the track system 160, the drive system 150 moves the lamination station 100 and / or the laying mandrel 130 along the track system 160 at least from the first position 102 toward the second position 104. Additionally, the drive system 150 may include an energized / powered rail 162. The powered rail 162 may be integrated into a rail on the track system 160 or may be separate from the rail of the track system. When the power supply rail 162 is included in the lamination system 50, the drive system 150 causes the reciprocating motion component 120 to move along the power supply rail 162 to transport the lamination station 100.

[0028] Additionally, the lamination system 50 may include more than one layup mandrel 130, such as including layup mandrel 130 and new layup mandrels 130'. Layup mandrels 130, 130' may be used within the same lamination station 100, or may be used with corresponding lamination stations 100, 100'. Layup mandrel 130 includes a mandrel indexing element 132, as will be described in more detail below. When the lamination system 50 includes more than one layup mandrel 130, 130', each layup mandrel 130, 130' includes a mandrel indexing element 132.

[0029] Figure 2 This is a schematic block diagram of a lamination station 100 that can be used in the lamination system 50. The lamination station 100 includes any system, equipment, or component that operably lays the laminate 140 onto the lamination mandrel 130 while the mandrel 130 moves continuously in the processing direction 190. (As opposed to...) Figure 5 , Figure 6 and Figure 8 In more detail, the lamination station 100 can also move through the lamination system 50 in the opposite processing direction 192. (See reference...) Figure 2The lamination station 100 includes a reciprocating component 120 and a lamination machine 110. In this embodiment, the lamination station 100 is associated with a track system 160, and a drive system 150 transports the reciprocating component 120 along the track system 160. The drive system 150 may include a chain drive 152 coupled to the track system 160 or an engine 154 moving along the track system 160. In such an embodiment, power may be supplied to the reciprocating component 120 (e.g., a pressure plate, vacuum pressure plate, flat surface, etc.) (or the engine 154 driving the reciprocating component 120) via an energized or powered rail 162 of the track system 160. In another embodiment, the reciprocating component 120 is transported by an autonomous guided vehicle (AGV) or other automated equipment that acts as the drive system 150, without using the track system 160. The reciprocating component 120 includes a reciprocating component indexing element 122, such as a cup-cone indexing system.

[0030] The reciprocating motion element indexing element 122 allows the layup mandrel 130 to be removably placed at the reciprocating motion element 120, with a known offset from the laminating machine 110. The layup mandrel 130 includes a mandrel indexing element 132 complementary to the reciprocating motion element indexing element 122. The reciprocating motion element indexing element 122 is configured to engage (e.g., receive) the mandrel indexing element 132. Engagement of the reciprocating motion element indexing element 122 with the mandrel indexing element 132 aligns the layup mandrel 130 with the reciprocating motion element 120. For example, in such a case... Figure 4 In the embodiment shown, the reciprocating motion element 122 is a cup, and the mandrel element 132 is a cone with a shape complementary to that of the cup. This allows the laying mandrel 130 to be indexed to the reciprocating motion element 120 via complementary indexing elements located at the laying mandrel 130 and the reciprocating motion element 120.

[0031] A laminating machine 110 is disposed on / attached to a reciprocating motion member 120, which is driven in a processing direction 190. The laminating machine 110 lays a laminate 140 having layers 141, 142 of fiber-reinforced material 147, which comprises resin 148 reinforced with fibers 146. In one embodiment, each layer 141, 142 laid by the laminating machine 110 comprises a bundle of unidirectional fiber-reinforced polymer. The laminating machine 110 includes an end effector 115. The end effector 115 may be driven by a kinematic chain 114. In some embodiments, the kinematic chain 114 and the end effector 115 are robotic arms. The end effector 115 includes a head 116 capable of dispensing the fiber-reinforced material 147 stored in a spool 117 with a desired fiber orientation (e.g., zero degrees, +45 degrees, -45 degrees, and 90 degrees).

[0032] The laminating machine 110 also includes a controller 112 and a memory 113. The controller 112 operates the kinematic chain 114 to control the movement of the end effector 115 according to instructions in a numerically controlled (NC) program stored in the memory 113. After the fiber reinforcement material 147 from the spool 117 is depleted, the controller 112 operates the kinematic chain 114 and the end effector 115 to remove the head 116 and obtain a spare head 116' (spare part 119) and / or remove the spool 117 and replace it with a spare spool 117' loaded with fiber reinforcement material 147. The spare parts 119 (e.g., spare head 116', spare spool 117') may be stored on the reciprocating motion member 120, on the second reciprocating motion member 120', or at a known location along the track system 160. The controller 112 may be implemented as, for example, custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

[0033] In other embodiments, a power source 170 and / or a gas supply source 180 is provided on the reciprocating member 120 for supplying power to the laminating machine 110 and supplying pressurized gas thereto. In other embodiments, the reciprocating member 120 includes an interface (I / F) 124 connected to a power rail 162 of the drive system 150. The interface 124 is configured to draw power from the energized / powered rail 162 of the track system 160. That is, the interface 124 is connected to the power rail 162 (along which the drive system 150 transports the reciprocating member 120) to deliver power to components on the reciprocating member 120, such as to the laminating machine 110 on the reciprocating member 120.

[0034] During operation, the laying mandrel 130 is loaded onto the reciprocating component 120, and the reciprocating component 120 moves in the processing direction 190 as the laminating machine 110 lays the laminate 140 onto the laying mandrel 130. The laying mandrel 130 (and the laminate 140) then proceeds to the second lamination station 100' in the lamination system 50 or another system in the manufacturing line 10. Figure 1 (as shown in the image) to perform additional lamination (if necessary), thereby consolidation, bagging and curing, or other preparation in order to manufacture composite parts.

[0035] Figure 3This is a perspective view of the reciprocating member 120 carrying the laminating machine 110 and the laying mandrel 130 in an exemplary embodiment. In this embodiment, the laminating machine 110 moves along a path 318 attached to or defined in the body 320 of the reciprocating member 120. The path 318 allows the laminating machine 110 to move in a first direction 322, the same as the processing direction 190, or in a second direction 324, opposite to the processing direction 190. The laminating machine 110 can move along the path 318 in either the first direction 322 or the second direction 324, regardless of whether the reciprocating member 120 moves in either direction 190 or 192. Thus, the laminating machine 110 can move in the first direction 322 to lay a first layer 141 onto the laying mandrel 130, and move in the second direction 324 to lay a second layer 142 onto the first layer 141. The laminating machine 110 can move back and forth in path 318 to lay layers 141 and 142 of the laminate 140, while the reciprocating component 120 moves in processing direction 190, opposite processing direction 192, or remains stationary.

[0036] For example, during operation, the laminating machine 110 moves along path 318 at the reciprocating member 120, causing the end effector 115 of the laminating machine 110 (e.g., the head 116 of the end effector 115) to lay layers 141, 142 (such as belts) of fiber-reinforced material 147 along the length L of the laminating member 140. The body 320 of the reciprocating member 120 can be provided by a track system 160 ( Figure 1 and Figure 2 (As shown in the diagram) the carrier, driven by a towed platform along the track system 160, carried by an AGV, or otherwise transported between locations within the lamination station 100, the lamination system 50, and / or the manufacturing line 10. However, for simplicity, in Figure 3 Possible variations of the transport of the reciprocating motion component 120 are not illustrated. This transport process facilitates the handover of the laminate 140 between lamination stations 100, 100' that perform repetitive or different actions on the laminate 140.

[0037] Figure 4 This is an exemplary implementation. Figure 3 A cross-sectional view of the reciprocating motion component 120 in the middle. Figure 4 The reciprocating motion component 120 is illustrated, including components for use with a drive system 150 such as a chain drive. Figure 2 (as shown in the diagram) Engages a mechanical coupling 440 (e.g., a hook) so as to travel along the track system 160 ( Figure 1 and Figure 2 (As shown in the image) Transportation. Figure 4The example also illustrates a laying mandrel 130 including a cone 432 as a mandrel indexing element 132, and a reciprocating member 120 including a cup 422 as a reciprocating member indexing element 122. The cone 432 engages with the cup 422 (i.e., receives the cup 422) to facilitate indexing of the laying mandrel 130 onto the reciprocating member 120. When the laying mandrel 130 is positioned on the reciprocating member 120, the geometry of the reciprocating member indexing element 122 and the mandrel indexing element 132 automatically aligns the laying mandrel 130 with the reciprocating member 120 (provided that the tips of each cone 432 are placed anywhere within their corresponding cup 422). That is, the weight of the laying mandrel 130 pushes it into place such that when the laying mandrel 130 is released, the cone 432 is centered on the cup 422.

[0038] The above about Figure 3 and Figure 4 In the discussion of the design of the provided reciprocating motion component 120 and its constituent parts, Figure 5 and Figure 6 Further discussion in this paper focuses on arranging the track system 160 and reciprocating motion components 120 within the lamination station 100 in a manner that facilitates manufacturing processes.

[0039] Figure 5 The exemplary embodiments include Figure 3 A top view of the lamination station 100 of the reciprocating motion component 120. (See attached image.) Figure 5 As shown, the track system 160 may include a first track 510, a second track 530, and a third track 560. The track system 160 also includes a first switching track 520 and a second switching track 540 extending between at least two tracks 510 and 530 of the track system 160. Figure 5 In this process, the reciprocating element 120 traverses between the first track 510 and the second track 530 via switching tracks 520 and 540. The laminating machine 110 performs laying as the reciprocating element 120 advances along the first track 510. The laminating machine 110 can be refilled, restored, or otherwise replenished before advancing via the first switching track 520 and the second track 530 to accommodate another mandrel to be laid (e.g., Figure 1 The new laying mandrel 130' is shown in the diagram. After reaching the first switching track 520, the laminator 110 can be disconnected from the umbilical cable or other components that supply power and pressurized gas to the laminator 110. However, in other embodiments, the laminator 110 is powered by a self-contained power and pressure source (such as power source 170 and / or gas supply source 180) inside or on top of the reciprocating motion component 120.

[0040] During operation, as the laying mandrel 130 advances on top of the reciprocating member 120 in the processing direction 190, the second reciprocating member 550 transports across the third track 560 at the same rate as the reciprocating member 120 transports across the first track 510. The second laminating machine 570 at the second reciprocating member 550 performs the laying operation sequentially with the laminating machine 110. For example, both laminating machines 110 and 570 can operate according to the same NC program.

[0041] In short, such as Figure 5 As shown, the manufacturing process may include transporting an additional second laminating machine 570 from the first position 102 toward the second position 104 in the processing direction 190, and the laying of the laminate 140 may be performed via the coordinated operation of the laminating machine 110 and the additional second laminating machine 570. In this case, the manufacturing rate is increased by using two end effectors 115 (e.g., the heads 116 of the end effector 115) to work simultaneously to build the laminate 140. In this way, multiple laminating machines 110, 570 can operate simultaneously to lay layers 141, 142 (of fiber-reinforced material 147) Figure 1 and Figure 2 (As shown in the figure) are applied to the same laying mandrel 130. For example, laminating machine 110 lays a first layer 141 on laying mandrel 130, and second laminating machine 570 follows laminating machine 110 to lay a second layer 142 on the first layer 141 to form laminate 140.

[0042] Figure 5 The implementation also allows the lamination system 50 to simultaneously form at least two different portions 580, 582, 584, 586 of the laminate 140 using different lamination machines 110, 570 at the same lamination station 100. Alternatively, the different portions 580, 582, 584, 586 of the laminate 140 can be formed simultaneously by different lamination machines 110, 110' at different lamination stations 100, 100'. Figure 5 In the example shown, a first laminating machine 110 forms a first axial portion 582 / 586 of the laminate 140, and a second laminating machine 570 forms a second axial portion 580 / 584 of the laminate 140. Alternatively, the first laminating machine 110 forms a first longitudinal portion 584 / 586 of the laminate 140, and the second laminating machine 570 forms a second longitudinal portion 580 / 582 of the laminate 140. Portions 580, 582, 584 and / or 586 may also be individual layers or subsets of layers constituting the laminate 140.

[0043] Figure 6This is a top view of a lamination system 50 with multiple inter-interacting lamination stations 100, 100', 100" in an exemplary embodiment. When the layup mandrel 130 is transported in the processing direction 190 (e.g., along the track system 160), the lamination stations 100, 100', 100" can interact with each other to hand over laminated parts 140 (or hardened composite parts) to perform different tasks such as lamination, consolidation, bagging, and curing. Each lamination station 100, 100', 100" can be similarly configured (e.g., having the same components), as relative to... Figures 1 to 4 Described. However, in Figure 6 In this embodiment, each lamination station 100 is configured slightly differently. For example, as described above, the first lamination station 100 is a lamination station 610, the second lamination station 100' is a consolidation station 620, and the third lamination station 100" is a bagging station 630.

[0044] exist Figure 6 In this embodiment, a first lamination station 610 lays the laminate 140 onto a laying mandrel 130, and a second consolidation station 620 receives and consolidates the laminate 140 by picking up the laying mandrel 130 from the first lamination station 100. A third bagging station 630 receives the consolidated laminate 140 by picking up the laying mandrel 130 and applies a vacuum bag 640 to the top of the consolidated laminate 140. The laying mandrel 130 can then be moved to a heater (e.g., a pressurizer) for curing.

[0045] Figure 7 This is a top view showing the use of conveyor machine 60 to transport the laying mandrel 130 between lamination stations 100 and 100'. Figure 7 In an exemplary embodiment, the conveyor 60 conveys the laying mandrel 130 between the reciprocating member 120 of the first lamination station 100 and the second reciprocating member 120' of the second lamination station 100'. Figure 7 While the reciprocating components 120 and 120' move relative to the conveyor 60 to transfer the laying mandrel 130 between the reciprocating components 120 and 120', the conveyor 60 is stationary. The conveyor 60 has an arm 722 that can be inserted into the laying mandrel 130 and moves the arm 722 in a conveying direction 740. The conveying direction 740 may be the same as the processing direction 190; however, the conveying direction 740 may be opposite to the processing direction 190. This transfers the laying mandrel 130 from the reciprocating component 120 on the left side of the first lamination station 100 to the second reciprocating component 120' on the right side of the second lamination station 100' to continue laying the laminate 140.

[0046] Figure 8This is a top view of a lamination system 50 in an exemplary embodiment, having multiple lamination stations 100, 100', 100”, 100”' that manufacture laminates 140 in two directions 190 and 192. The implementation utilizing multiple lamination stations 100 operating in two directions 190, 192 provides technical benefits by increasing productivity and / or ensuring work is performed during all movement of the lamination stations 100. Additionally, each lamination station 100 can operate on the same track system 160, or at least one lamination station 100 can operate on a separate track system or AGV. Each of the first lamination station 100, the second lamination station 100', the third lamination station 100”', and the fourth lamination station 100”' includes at least some similar components to simultaneously perform similar lamination processes to form the corresponding laminate 140. Alternatively, lamination stations 100 on the same track (first track 510 or second track 530) of track system 160 work together to perform different parts of the composite manufacturing process to form laminates 140 or 140". Laminates 140 and 140" can be of the same type or different types of laminates. In such an embodiment, lamination station 100 may be similarly configured with end effector 115, which is capable of performing multiple different composite manufacturing processes and / or forming more than one type of laminate.

[0047] according to Figure 8 The reciprocating component 120 of the first lamination station 100 and the second reciprocating component 120' of the second lamination station 100' operate while moving to the right along the first track 510 to lay the first laminate 140. The third reciprocating component 120" of the third lamination station 100" and the fourth reciprocating component 120"' of the fourth lamination station 100"' operate while moving to the left along the second track 530 to lay the second laminate 140". The reciprocating components 120 and 120" move in a cyclical manner from the first track 510 to the first switching track 520, to the second track 530, to the second switching track 540 and back to the first track 510.

[0048] The first lamination station 100 operates the lamination machine 110 to place the first laminate 140 onto the laying mandrel 130, and the third lamination station 100" operates the lamination machine 110" to place the second laminate 140" onto the mandrel 130". The first laminate 140 is conveyed from the reciprocating member 120 to the second reciprocating member 120' (e.g., using the conveyor 60) and moves to the right (e.g., in the processing direction 190), while the second laminate 140" is conveyed from the third reciprocating member 120" to the fourth reciprocating member 120"' (e.g., using the second conveyor 60') and moves to the left (e.g., in the object processing direction 192). In this way, by iterative operation, the lamination stations 100, 100', 100"', 100"' can manufacture two separate types of laminates 140, 140' along the processing direction 190 and the opposite processing direction 192.

[0049] Will target Figure 9 The following are illustrative details of the operation of the lamination system 50 and the lamination station 100. For this embodiment, it is assumed that the laying mandrel 130 is positioned close to the reciprocating member 120, within the reach of the end effector 115, such as within the reach of the actuating arm of the end effector 115.

[0050] Figure 9 This demonstrates the operation. Figures 1 to 8 The flowchart shown herein illustrates a method 900 for forming a laminate 140 using a lamination system 50 and a lamination station 100. The steps in method 900 are described with reference to lamination station 100, but those skilled in the art will understand that method 900 can be performed in other systems. Not all steps in the flowcharts described herein are included, and other steps not shown may be included. The steps described herein may also be performed in an alternative order.

[0051] Reference Figure 1 , Figure 2 and Figure 9 Method 900 includes: indexing 902 onto laying mandrel 130; transporting 904 laminating station 100 and laying mandrel 130; and laying 906 a laminate 140 onto laying mandrel 130 via laminating machine 110. Method 900 further includes: removing 908 laying mandrel 130 and laminate 140; and returning laminating station 100 910 to first position 102.

[0052] When the lamination system 50 Figure 5In the intermediate configuration, method 900 may begin by subdividing the laminate 140 912 into portions 580, 582, 584, and / or 586. At each of the plurality of laminating machines 110, 570 arranged along the processing direction 190, the steps of positioning 902, transporting 904, laying 906, removing 908, and returning 910 are performed independently. Each of the plurality of laminating machines 110, 570 forms one of portions 580, 582, 584, and / or 586 of the laminate 140. In one embodiment, the laminate 140 is subdivided 912 into portions 580, 582, 584, and / or 586 (e.g., longitudinal portions, specific subsets of layers, etc.), and the steps of transposition 902, transport 904, lay-up 906, removal 908, and return 910 are independently performed at each of a plurality of laminating machines 110, 110' and / or a plurality of laminating stations 100, 100' arranged along the processing direction 190. Each of the plurality of laminating machines 110, 110' lays one of the subdivided portions 912 580, 582, 584, and / or 586 of the laminate 140, and the laminate 140 in process is transferred between the laminating machines 110, 110'.

[0053] During indexing 902, the laying mandrel 130 is indexed to the laminating station 100. More specifically, when the laminating station 100 is in the first position 102 (e.g., to the left of the track system 160), the laying mandrel 130 is indexed 902 to the reciprocating element 120 of the laminating station 100. Indexing the laying mandrel 130 to the laminating station 100 also indexes the laying mandrel 130 to the laminating machine 110. When the laying mandrel 130 is indexed to the reciprocating element 120 (on which the laminating machine 110 is mounted), the indexing 902 of the laying mandrel 130 to the laminating machine 110 occurs. Inverting the laying mandrel 130 to the laminating machine 110 includes inverting the laying mandrel 130 to the reciprocating motion member 120 via a mandrel indexing element 132 and a reciprocating motion member indexing element 122 disposed at the laying mandrel 130 and the reciprocating motion member 120.

[0054] The indexing 902 of the laying mandrel 130 may include raising or sliding the laying mandrel 130 to a position in which the mandrel indexing element 132 is aligned and / or engaged with the reciprocating motion indexing element 122. The indexing 902 may be performed by an actuating arm (e.g., the kinematic chain 114 and end effector 115 of the laminating machine 110 or another robotic arm outside the laying station 100) to pick up the laying mandrel 130 and place it in place on the reciprocating motion element 120 based on instructions in the NC program. In other embodiments, picking is not necessary by a robot, as engagement via the indexing 902 can occur where the platform track and mandrel track intersect and the reciprocating motion indexing element 122 and the mandrel indexing element 132 are aligned and / or engaged.

[0055] During transport 904, the laminating machine 110 and the laying mandrel 130 are transported in the processing direction 190 from a first position 102 toward a second position 104 (e.g., the final position to the right of the track system 160 when viewing the accompanying drawings). For example, the reciprocating motion component 120 is driven in the processing direction 190 to transport the laminating machine 110 and the laying mandrel 130. To perform the transport 904 operation, the controller 112 may guide the drive system 150 to move the reciprocating motion component 120 along the track system 160 at a desired rate. In embodiments where the drive system 150 includes an AGV, the drive system 150 may be operated independently by another controller. In embodiments where the drive system 150 includes a chain drive, the mechanical coupling 440 at the reciprocating motion component 120 ( Figure 4 (As shown in the diagram) It can be engaged with a chain drive to transport the reciprocating component 120 904 at a desired rate. In such a case... Figures 6 to 8 In the example of the lamination system 50 shown, the reciprocating motion element 120 at each of the plurality of lamination stations 100 can be transported via the drive system 150 to ensure that the lamination stations 100 operate at a uniform rate.

[0056] During layup 906, layup station 110 lays the laminate 140, consisting of layers 141, 142 having fiber reinforcement material 147, onto layup mandrel 130. In an exemplary embodiment, layup 906 occurs during lamination station 100 and layup mandrel 130 transported 904 in processing direction 190. When the lamination system 50 as... Figure 8 During the intermediate configuration, while the lamination station 100 and the laying mandrel 130 are moving in opposite processing directions 192, transport 904 and laying 906 are also performed. Laying 906 includes laying the first layer 141 onto the laying mandrel 130, laying the second layer 142 onto the first layer 141, and so on, until multiple layers of the laminate 140 are laid 906 onto the laying mandrel 130.

[0057] In one embodiment, laying the laminate 140 906 includes operating the laminator 110 914 in a first direction 322 along the processing direction to lay a first layer 141 of 906, and operating the laminator 110 916 in a second direction 324 opposite to the processing direction 190 to lay a second layer 142 of 906. Operation steps 914 and 916 are repeated to add more layers to build the laminate 140. That is, during laying 906, the laminator 110 moves 918 independently of the processing direction 190 and can move in any suitable direction to perform laying 906.

[0058] Laminating 906 laminate 140 includes moving the laminating machine 110 independently of the processing direction 190 by 918. More specifically, the laminating machine 110 moves independently of the direction of movement of the reciprocating motion component 120 of the laminating station 100 by 918, because the laminating machine 110 moves 918 relative to the reciprocating motion component 120 along path 318, such as relative to... Figure 3 More detailed description.

[0059] When Figure 5 When the lamination system 50 shown includes multiple lamination machines 110, 570, the layup 906 laminate 140 includes simultaneously operating multiple lamination machines 110, 570 to apply layers 141, 142 of fiber-reinforced material 147 onto the layup mandrel 130.

[0060] Because the laying mandrel 130 is indexed 902 to the reciprocating motion member 120, and because the laminating machine 110 is attached to the reciprocating motion member 120, any offset between the laminating machine 110 and the laying mandrel 130 is known. This means that regardless of the position of the reciprocating motion member 120 along the track system 160, the laminating machine 110 continues to operate uninterruptedly according to the NC program.

[0061] Referring again to transport 904, in other embodiments, at the lamination station 100 and the laying mandrel 130 in the processing direction 190 (and / or when the lamination system 50 is as follows) Figure 8 When transporting 904 in the opposite processing direction 192 (as in the central configuration), the end effector 115 secures the laminate 140 to 922. This is achieved by using the lamination station 100 and the laying mandrel 130 in the processing direction 190 (and / or when the lamination system 50 is as follows). Figure 8 When transported in the opposite direction of processing (192) during the central configuration, pressure is applied to the laminate 140 to perform consolidation 922. The transport speed of the reciprocating motion member 120 904 can be any desired speed such as one-tenth of a mile per hour (0.05 meters per second) or other speeds.

[0062] During layup 906, the spool 117 at head 116 may run out of fiber reinforcement material 147, or the laminating machine 110 may be programmed to perform subsequent processing using a different head. In this case, method 900 includes replacing head 116 and / or spool 117 during transport 904. For example, when laminating station 100 transports 904 in processing direction 190 or the opposite processing direction 192, head 116 is replaced 924 by spare head 116' and / or spool 117 is replaced 924 by spare spool 117'. In a particular example, controller 112 may operate kinematic chain 114 and end effector 115 to replace head 116 (or spool 117) of laminating machine 110 during transport 904. Replacement 924 may include obtaining a spare part 119 from reciprocating component 120 or from a second reciprocating component 120' that is traveling at the same speed in the same direction and / or at a known offset position relative to reciprocating component 120 and / or track system 160.

[0063] During removal 908, at the second position 104, the layup mandrel 130 and the laminate 140 are removed. More specifically, at the second position 104, the layup mandrel 130 with the laminate 140 thereon is removed 908 from the lamination station 100. In one embodiment, removal 908 includes operating a robotic arm (e.g., at the lamination machine 110) and / or a conveyor 60 to move the layup mandrel 130 (and thus the laminate 140) from the lamination station 100 to another station in the lamination system 50 or manufacturing line 10. At the other station, another portion of the laminate 140 may be laid 906, the laminate 140 may be bonded 922 by applying pressure, a vacuum bag 640 may be applied to the laminate 140, or the laminate 140 may be cured even by applying heat.

[0064] Upon return to position 910, lamination station 100 returns to first position 102 to form additional laminates 140' on a new laying mandrel 130'. For example, lamination machine 110 is carried on a reciprocating member 120, which is transported 928 along a track system 160 (e.g., along parallel tracks 510, 530, 560) to return to first position 102. In one embodiment, track system 160 forms a loop or includes switching tracks 520, 540 for transporting reciprocating member 120 to a return track (e.g., a second track 530). In this way, multiple reciprocating members 120, 120' can travel back and forth between first position 102 and second position 104 concurrently without interfering with each other.

[0065] In one implementation, before or simultaneously with the return on loop 910, a new laying mandrel 130' is indexed 926 to lamination station 100. The indexing 926 of the new laying mandrel 130' is similar to the indexing 902 of the first laying mandrel 130. For example, the mandrel indexing element 132 of the new laying mandrel 130' is aligned and / or engaged with the reciprocating motion indexing element 122 to index the new laying mandrel 130' 926 to the reciprocating motion element 120. In a particular example, when lamination station 100 is in the second position 104, the new laying mandrel 130' is indexed 926 to lamination machine 110.

[0066] When a new layup mandrel 130' is provided to lamination station 100, lamination machine 110 can continue to perform layup 906 to form an additional laminate 140' on the new layup mandrel 130'. In such an embodiment, after removal 908 of the first layup mandrel 130, lamination station 100 and the new layup mandrel 130' are transported 928 from second position 104 toward first position 102 in the opposite processing direction 192 to the processing direction 190. Lamination machine 110 lays 906 of the additional laminate 140' having layers 141, 142 of fiber reinforcement material 147 onto the new layup mandrel 130' while lamination station 100 and the new layup mandrel 130' are transported 928 opposite to the processing direction 190. The transport 928 in the opposite processing direction 192 can be substantially similar to the transport 904 described above. For example, laying 906, consolidation 922 and / or replacement 924 can occur during transport 928 in the opposite processing direction 192.

[0067] To enable the laminating machine 110 to perform the steps of method 900, power 930 is supplied to the laminating machine 110. More specifically, the laminating machine 110 is powered 930 by a power source 170 located at the reciprocating motion member 120. Alternatively or additionally, the laminating machine 110 is powered 930 via a power supply rail 162 (along which the laminating station 100 travels during transport 904). The supply of power 930 occurs at least during laying 906, and may also occur during transport 904 (e.g., to perform consolidation 922 and / or replacement 924) or during any other step of method 900 (when the laminating machine 110 is performing an action or is in an inactive but ready state).

[0068] Method 900 offers advantages over existing systems and technologies because it enables continuous production line manufacturing techniques to be applied to applications such as aircraft (e.g., Figure 11 Composite material parts such as stringers or frames of aircraft 1002 shown in the figure, while laminates for these parts are manufactured via production line 10. Figure 1(as shown in the diagram) movement. Furthermore, method 900 does not require specialized heavy machinery such as an AFP machine. Therefore, if a laminating machine 110 requires maintenance during the execution of method 900, the laminating machine 110, end effector 115, head 116, or spool 117 can be quickly replaced by a technician (or another AFP machine) without interrupting the manufacturing process.

[0069] Example

[0070] In the following examples, additional processes, systems, and methods are described in the context of continuous production line manufacturing processes for composite material parts.

[0071] For more details, please refer to the accompanying drawings, as shown in... Figure 10 The aircraft manufacturing and maintenance method 1000 shown and as Figure 11 Embodiments of this disclosure are described within the context of the aircraft 1002 shown. In the early stages of production, method 1000 may include the specification and design 1004 of the aircraft 1002 and material procurement 1006. During production, the manufacturing of components and sub-assemblies of the aircraft 1002 is performed 1008, along with system integration 1010. Method 900 ( Figure 9 (As shown in the diagram) This process can be performed during component and sub-assembly manufacturing 1008 to produce a portion of aircraft 1002. Thereafter, aircraft 1002 can undergo inspection and delivery 1012 for entry into service 1014. During its service with the customer, aircraft 1002 is scheduled for routine maintenance and overhaul work 1016 (which may also include modifications, refits, refurbishments, etc.).

[0072] The systems and methods implemented herein may be employed during any one or more suitable phases of production and maintenance described in method 1000 (e.g., specification and design 1004, material procurement 1006, component and sub-assembly manufacturing 1008, system integration 1010, certification and delivery 1012, service entry 1014, maintenance and overhaul 1016) and / or in the production of any suitable component of aircraft 1002 (e.g., airframe 1018, system 1020, interior 1022, propulsion system 1024, electrical system 1026, hydraulic system 1028, environmental system 1030).

[0073] Each of the processes in method 1000 may be performed or executed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0074] like Figure 11As shown, an aircraft 1002 produced using method 1000 may include an airframe 1018 and an interior 1022 having multiple advanced systems 1020. Examples of systems 1020 include one or more of a propulsion system 1024, an electrical system 1026, a hydraulic system 1028, and an environmental system 1030. Any number of other systems may be included. Although examples from aerospace are shown, the principles of this disclosure can be applied to other industries such as the automotive industry.

[0075] As mentioned above, the lamination system 50 and method 900 implemented herein can be used during any one or more phases of production and maintenance as described in method 1000. Figure 10 (As shown in the diagram). For example, components or sub-assemblies corresponding to component and sub-assembly manufacturing 1008 can be made or manufactured in a manner similar to that used to produce components or sub-assemblies when aircraft 1002 is in service. Additionally, one or more system implementations, method implementations, or combinations thereof can be utilized during sub-assembly manufacturing 1008 and system integration 1010, for example, by significantly accelerating the assembly of aircraft 1002 or reducing the cost of aircraft 1302.

[0076] Similarly, one or more of the system implementations, method implementations, or combinations thereof can be utilized during the service of aircraft 1002 (e.g., but not limited to maintenance and overhaul 1016). For example, the method 900 and lamination system 50 described herein can be used for material procurement 1006, component and sub-assembly manufacturing 1008, system integration 1010, service 1014 and / or maintenance and overhaul 1016, and / or can be used for airframe 1018 and / or interior 1022. These methods 900 and lamination system 50 can even be used to form any suitable parts for system 1020, including, for example, propulsion system 1024, electrical system 1026, hydraulic system 1028, and / or environmental system 1030.

[0077] In one embodiment, the part comprises a portion of the fuselage 1018 and is manufactured during component and subassembly manufacturing 50 using method 900 and lamination system 50. The part can then be assembled into the aircraft 1002 in system integration 1010 and utilized in service 1014 until it is to be replaced. Then, during maintenance and overhaul 1016, the part can be discarded and replaced with a newly manufactured part made using any suitable method such as method 900. To manufacture new parts, the systems and methods of the present invention can be utilized throughout component and subassembly manufacturing 1008.

[0078] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein can be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination thereof. For example, an element can be implemented as dedicated hardware. A dedicated hardware element may be referred to as a “processor,” a “controller,” or some similar term. When provided by a processor, these functions may be provided by a single dedicated processor, a single shared processor, or multiple separate processors, some of which may be shared. Furthermore, the explicit use of the terms “processor” or “controller” should not be construed as exclusively referring to hardware capable of executing software, and may implicitly include, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuits, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic devices, or some other physical hardware component or module.

[0079] Additionally, control elements can be implemented as instructions executable by a processor or computer to perform the functions of that element. Some examples of instructions are software, program code, and firmware. Instructions are operable when executed by a processor to instruct the processor to perform the functions of the element. Instructions can be stored on a processor-readable storage device. Some examples of storage devices are digital or solid-state memories, magnetic storage media such as disks and magnetic tapes, hard drives, or optically readable digital data storage media.

[0080] Although specific embodiments have been described herein, the scope of this disclosure is not limited to those specific embodiments. The scope of this disclosure is defined by the following claims.

Claims

1. A method (900) for forming a laminate (140), the method (900) comprising the following steps: The laying mandrel (130) is rotated (902) to the lamination station (100) located in the first position (102). The lamination station (100) and the laying mandrel (130) are transported (904) from the first position (102) toward the second position (104) in the processing direction (190). While transporting the laminating machine (110) and the laying mandrel (130) in the processing direction (190), the laminate (140) having layers (141, 142) of fiber-reinforced material (147) is laid (906) onto the laying mandrel (130) via the laminating machine (110); At the second position (104), the laying mandrel (130) and the laminate (140) are removed (908); and Return the lamination station (100) (910) to the first position (102) to lay another laminate (140') on the new laying mandrel (130').

2. The method (900) for forming a laminate (140) according to claim 1, wherein: The laminating machine (110) is mounted on a reciprocating motion component (120), which is driven in the processing direction (190), and The step of indexing (902) the laying mandrel (130) to the lamination station (100) includes indexing the laying mandrel (130) to the reciprocating motion member (120) via complementary indexing elements (132, 122) disposed at the laying mandrel (130) and the reciprocating motion member (120).

3. The method (900) for forming a laminate (140) according to claim 1 or 2, wherein: The step of laying (906) the laminate (140) includes moving (918) the laminating machine (110) independently of the processing direction (190).

4. The method (900) for forming a laminate (140) according to claim 1 or 2, the method (900) further comprising the following steps: Power (930) is supplied to the laminating machine (110) via a power supply rail (162), and the laminating station (100) travels along the power supply rail (162) during the transport (904) step.

5. The method (900) for forming a laminate (140) according to claim 1 or 2, said method (900) further comprising the step of: During the transport (904) step, replace (924) the head (116) of the laminating machine (110), and / or During the transport (904) step, replace the spool (117) of the laminating machine (110) described in (924), and / or While transporting (904) the lamination station (100) and the laying mandrel (130) in the processing direction (190), the laminate (140) is fixed (922), and / or wherein: The step of laying (906) the laminate (140) includes: operating (914) the laminating machine (110) in the processing direction (190) to lay (906) the first layer (141); and operating (916) the laminating machine (110) in a second direction (324) opposite to the processing direction (190) to lay (906) the second layer (142), and / or The new laying mandrel (130') is rotated (926) to the lamination station (100). The lamination station (100) and the new laying mandrel (130') are transported (928) from the second position (104) toward the first position (102) in a opposite processing direction (192) to the processing direction (190); and While transporting (928) the lamination station (100) and the new laying mandrel (130') in the opposite processing direction (192), another laminate (140') comprising layers (141, 142) of fiber-reinforced material (147) is laid (906) onto the new laying mandrel (130') via the lamination machine (110).

6. The method (900) for forming a laminate (140) according to claim 1 or 2, wherein, The lamination station (100) includes multiple lamination machines (110, 570), and the method (900) further includes the following steps: The laminate (140) is subdivided (912) into multiple parts (580, 582, 584, 586); and The steps of transposition (902), transport (904), lay-up (906), removal (908) and return (910) are performed independently at each of the plurality of laminating machines (110, 570) arranged along the processing direction (190), wherein each of the plurality of laminating machines (110, 570) forms one of the plurality of portions (580, 582, 584, 586) of the laminate (140).

7. The method (900) for forming a laminate (140) according to claim 6, wherein, The lamination station (100) includes multiple lamination machines (110, 570) and: The step of laying (906) the laminate (140) includes simultaneously operating (920) the plurality of laminating machines (110, 570) to apply layers (141, 142) of fiber-reinforced material (147) onto the laying mandrel (130).

8. The method (900) for forming a laminate (140) according to claim 2, the method further comprising providing power (930) to the laminating machine (110) via a power source (170) disposed at the reciprocating member (120).

9. Manufacturing a portion of an aircraft (1002) using the method (900) for forming a laminate (140) according to any one of claims 1 to 8.

10. A lamination system (50) for forming a laminate (140) having a plurality of layers (141, 142) of fiber-reinforced material (147), the lamination system (50) comprising: Laying mandrel (130), which has mandrel indexing element (132); Lamination station (100), which includes: A reciprocating motion element (120) includes a reciprocating motion element indexing element (122) for engaging the laying mandrel (130) with the mandrel indexing element (132); and Laminating machine (110), which is attached to the reciprocating motion member (120); and A drive system (150) transports the reciprocating member (120) in the processing direction (190) while the laminator (110) lays the plurality of layers (141, 142) of the laminate (140) onto the laying mandrel (130).

11. The lamination system (50) for forming a laminate (140) according to claim 10, wherein the lamination system (50) further comprises: A conveyor (60) transports the laying mandrel (130) from the lamination station (100) to another lamination station (100') after the laminate (140) has been laid.

12. The lamination system (50) for forming a laminate (140) according to claim 10 or 11, wherein: The reciprocating motion component (120) includes a power source (170) and a gas supply source (180), which enable the laminating machine (110) to operate while the drive system (150) is transporting the reciprocating motion component (120).

13. The lamination system (50) for forming a laminate (140) according to claim 10 or 11, wherein: The drive system (150) includes a power rail (162) along which the drive system (150) transports the reciprocating component (120); and The reciprocating motion component (120) includes an interface (124) that is connected to the power supply rail (162).

14. The lamination system (50) for forming a laminate (140) according to claim 10 or 11, wherein: The drive system (150) includes an autonomous guided vehicle, and / or The drive system (150) includes a chain drive (152) connected to the reciprocating motion component (120), and / or The reciprocating component (120) includes at least one of a spare head (116') and a spare spool (117') for the laminating machine (110), and / or The lamination station (100) lays a portion (580, 582, 584, 586) of the laminate (140), and The lamination system (50) further includes an additional lamination station (100') for laying additional portions (580, 582, 584, 586) of the laminate (140), and the lamination system (50) is configured to transfer the laying mandrel (130) from the lamination station (100) to the additional lamination station (100'), and / or The laminating machine (110) is configured to lay multiple layers (141, 142) of the laminate (140) while being transported in the processing direction (190), and / or The reciprocating motion component indexing element (122) includes a cup (422), and the spindle indexing element (132) includes a cone (432).

15. The lamination system (50) for forming a laminate (140) according to claim 10 or 11, further comprising: The second reciprocating motion component (550) includes a second laminating machine (570), wherein the laminating machine (110) and the second laminating machine (570) are configured to lay the laminate (140) via coordinated action.

16. The lamination system (50) for forming a laminate (140) according to claim 11, wherein, The conveying machine (60) includes an arm (722) inserted into the laying mandrel (130).

17. Manufacturing a part of an aircraft (1002) using the lamination system (50) for forming a laminate (140) as claimed in any one of claims 10 to 16.

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