Demolding of large composite parts for aircraft

Abstract

The present disclosure relates to de-molding of large composite parts for aircraft. Systems and methods for de-molding a composite part from a mandrel are provided. The method includes the steps of mechanically coupling a first arm of an extraction tool to a first arcuate portion of a composite part that has hardened onto a mandrel, mechanically coupling a second arm of the extraction tool to a second arcuate portion of the composite part, and decoupling the composite part from the mandrel by repeatedly performing the following operations until the composite part no longer contacts the mandrel: elastically straining the first arcuate portion of the composite part via the first arm; and elastically straining the second arcuate portion of the composite part via the second arm.

Description

Technical Field

[0001] This disclosure relates to the field of aircraft, and in particular to the manufacture of aircraft components. Background Technology

[0002] Large composite components, such as those spanning several meters (i.e., tens of feet), occupy a significant amount of space within the factory floor. The laminates of these components are laid on mandrels within fixed work cells. The mandrels are moved to another fixed work cell, and the laminates are hardened into composite components. The composite components are then removed from the mandrels and transported to the new fixed work cell for further processing.

[0003] Removing composite components from the mandrel can be particularly difficult because the composite components may have a shape that fills a groove on the surface of the mandrel.

[0004] The abstract of EP3 552 773 describes, “A stripping assembly for separating a workpiece from a manufacturing fixture has a horizontal beam assembly and a pair of vertical beam assemblies. The horizontal beam assembly includes a horizontal beam having a horizontal drive motor. Each vertical beam assembly includes a vertical beam operably engaged to the horizontal drive motor and has a workpiece attachment assembly operably engaged to the vertical drive motor. The workpiece attachment assembly has an attachment mechanism for attaching to a workpiece. The horizontal and vertical drive motors are operated such that the vertical beams are moved away from each other along the horizontal drive axis while each workpiece attachment assembly is moved along the vertical drive axis such that the attachment mechanism pulls a side portion of the workpiece away from the manufacturing fixture, while a central support of the horizontal beam keeps the crown of the workpiece in contact with the manufacturing fixture.”

[0005] The abstract of US2013 / 020030 describes “an apparatus for producing structural components from fiber composite materials, the components being three-dimensionally arched on a large surface, comprising a clamp having a convex mounting surface having a receiving channel for inserting the structural component, wherein the loaded clamp interacts with a lamination bonding device having a corresponding shape for forming the structural component under pressure, wherein the mounting surface comprises a plurality of individually resiliently deformable mounting housing components arranged adjacent to each other along at least one longitudinally extending pitch line and attached to a plurality of resiliently deformable support frame elements extending perpendicularly to the pitch line within the housing; and a plurality of actuators for deforming the mounting surface between an extended position (A) and at least one retracted position (B) to move the clamp from the bonding device relative to the receiving channel without undercut.”

[0006] The abstract of US2013 / 000815 describes “an apparatus and method for manufacturing a fiber-reinforced fuselage shell for an aircraft, the fuselage shell for reinforcement purposes comprising a plurality of spaced longitudinal beams, wherein the apparatus includes a base frame comprising a plurality of support walls of different lengths for forming a curved mounting surface for the fuselage shell to be manufactured, wherein a plurality of radially outwardly extending and longitudinally adjustable actuators are fixed to the mounting surface, and at the distal end of each actuator, in each case, are attached a mold channel for receiving the longitudinal beams, interconnected by means of a flexible intermediate element, and / or other mold channels for forming a closed mold surface for a vacuum seal.”

[0007] The abstract of US2004 / 050498 describes, “A molding fixture includes a grid pattern of support walls arranged on a support base and having upper free ends positioned along an imaginary curved surface, and modular cross-sectional profile members arranged on the walls to surround a vacuum chamber within the fixture. Grooves, channels, and air passages between adjacent profile members communicate into the vacuum chamber. The outer surface of the profile members matches the intended inner surface of a structural component manufactured using the fixture. During manufacturing, a thin film is applied to the outer surface to pre-establish a vacuum; the film is removed while the vacuum surface is being applied; a longitudinal beam member is placed in a groove; a fiber surface layer is laid; sealant is applied around the perimeter; the structural shell is evacuated to the surface layer; and then the pre-formed component is removed from the fixture and resin is injected, unless the surface layer has been pre-impregnated with and cured with resin.”

[0008] The abstract of US2008 / 196825 describes "a method and apparatus for manufacturing hollow components, such as specific parts of an aircraft fuselage (including skin and possible reinforcing elements), using composite materials. The method includes: inserting a multi-joint arm equipped with a fiber placement head into an elongated mold, the mold being opened via a longitudinal slit designed to receive the multi-joint arm; and applying fibers to the inner molding surface of the mold using a placement head to form the composite material skin by means of relative displacement of the placement head and translation of the support device of the multi-joint arm along the longitudinal slit using the multi-joint arm."

[0009] One solution is to utilize a mandrel composed of multiple separable parts, disassemble the mandrel, and then separate it into multiple parts to form a hardened composite component. However, separating the composite component from the mandrel during demolding remains a complex process. Specifically, it is difficult to remove the mandrel segments from the hardened composite component while keeping the strain of the composite component below the required level. Furthermore, segmented mandrels are costly to design due to their complexity. The seams between such mandrel components can also create undesirable ridges, bridges, or valleys in the hardened composite component, potentially requiring reprocessing after demolding. Another solution is to manufacture composite components with less complex geometries that are easily separable from the mandrel during hardening. However, in certain fields such as aerospace, reducing the complexity of curves in composite components is not feasible because a reduced-complexity composite component may not possess the required performance. These problems are amplified for large composite components.

[0010] Therefore, it is desirable to have methods and equipment that take into account at least some of the issues discussed above, as well as other possible problems. Summary of the Invention

[0011] The embodiments described herein provide systems and methods for dynamically demolding a composite component from a mandrel by repeatedly applying elastic strain to the various bow-shaped portions of the composite component. By applying elastic strain, the composite component bends without permanently changing its shape. By repeatedly applying strain to different portions of the composite component (e.g., to varying and increasing degrees), the composite component wobbles, twists, and / or bends from the mandrel without permanently bending or deforming.

[0012] One embodiment is a method for demolding a composite component from a mandrel. The method includes the steps of: mechanically attaching a first arm of an extraction tool to a first arcuate portion of the composite component that has been hardened to the mandrel; mechanically attaching a second arm of the extraction tool to a second arcuate portion of the composite component; and separating the composite component from the mandrel by repeatedly performing the following operations until the composite component no longer contacts the mandrel: elastically straining the first arcuate portion of the composite component via the first arm; and elastically straining the second arcuate portion of the composite component via the second arm.

[0013] Another embodiment is a non-transitory computer-readable medium containing program instructions that, when executed by a processor, are operable to perform a method for demolding a composite component from a mandrel. The method includes the steps of: mechanically engaging a first arm of an extraction tool to a first arcuate portion of the composite component that has been hardened to the mandrel; mechanically engaging a second arm of the extraction tool to a second arcuate portion of the composite component; and separating the composite component from the mandrel by repeatedly performing the following operations until the composite component no longer contacts the mandrel: elastically straining the first arcuate portion of the composite component via the first arm; and elastically straining the second arcuate portion of the composite component via the second arm.

[0014] Another embodiment is a system for demolding a composite component from a mandrel. The system includes a first arm comprising: a flexure member complementary to the contour of the composite component already hardened to the mandrel; and a clamping unit disposed along the flexure member and mechanically coupled to a first arcuate portion of the composite component. The system also includes a second arm comprising: a flexure member complementary to the contour of the composite component; and a clamping unit disposed along the flexure member and mechanically coupled to a second arcuate portion of the composite component. The system further includes a drive unit that selectively rotates the first and second arms such that elastic strain is repeatedly applied to the first and second arcuate portions.

[0015] Another embodiment is a method for demolding a composite component. The method includes the steps of: elastically straining a first arcuate portion of the composite component away from a mandrel; elastically straining a second arcuate portion of the composite component away from the mandrel; and repeatedly increasing the elastic strain applied to the first arcuate portion and the elastic strain applied to the second arcuate portion.

[0016] Another embodiment is a method for separating a composite component from a mandrel. The method includes the steps of: separating the composite component from the mandrel via an extraction tool that repeatedly and elastically deflects the arcuate portion of the composite component; transporting the composite component to a track via the extraction tool; and depositing the composite component onto the track.

[0017] Other exemplary embodiments (e.g., methods and computer-readable media related to the foregoing embodiments) may be described below. The features, functions, and advantages already discussed may be implemented independently in various embodiments or may be combined in other embodiments, further details of which can be seen in the following description and figures. Attached Figure Description

[0018] Now, some embodiments of this disclosure will be described by way of example only and with reference to the accompanying drawings. Throughout the drawings, the same reference numerals denote the same elements or elements of the same type.

[0019] Figure 1 This is a perspective view of the aircraft in an exemplary embodiment.

[0020] Figure 1A This is a block diagram of the demolding station for separating the composite component from the mandrel in an exemplary embodiment.

[0021] Figures 2A to 2C This is a flowchart illustrating a method for demolding a composite component from a mandrel in an exemplary embodiment.

[0022] Figures 3 to 7 An extraction tool is described in an exemplary embodiment, which repeatedly and elastically deflects the arcuate portion of the composite component.

[0023] Figure 8 This is an enlarged view of the vacuum connector of the arm of the extraction tool in an exemplary embodiment.

[0024] Figure 9 This is a perspective view of an inner mold line (IML) conveying device and an outer mold line (OML) conveying device for composite components in an exemplary embodiment.

[0025] Figures 10A to 10E The transport of composite components in an exemplary embodiment to a track via a conveying device is depicted.

[0026] Figure 11 This is a flowchart illustrating a method for transferring composite components to a transport conveying device in an exemplary embodiment.

[0027] Figure 12 This is another flowchart illustrating a method for transferring composite components to a transport conveying device in an exemplary embodiment.

[0028] Figure 13 This is another flowchart illustrating a method for demolding and transferring composite components in an exemplary embodiment.

[0029] Figure 14 This is a flowchart illustrating an exemplary method for aircraft production and maintenance.

[0030] Figure 15 This is a block diagram of an aircraft in an exemplary embodiment. Detailed Implementation

[0031] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. It will therefore be understood that those skilled in the art will be able to design various arrangements, although not explicitly described or shown herein, that embody 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 should be construed as not being limited to these specifically referenced examples and conditions. Therefore, this disclosure is not limited to the specific embodiments or examples described below, but is limited by the claims.

[0032] Composite components, such as carbon fiber reinforced polymer (CFRP) parts, are initially laid out in multiple layers, collectively referred to as preforms or laminates. Individual fibers within each layer of a preform are aligned parallel to each other, but different layers exhibit different fiber orientations to increase the strength of the resulting composite component along various dimensions. Preforms include a viscous resin that cures to harden the preform into a composite component (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” that are not impregnated with thermosetting resins but may contain tackifiers or binders. Dry fibers are injected with resin before curing. For thermosetting resins, curing is a one-way process called curing, while for thermoplastic resins, the resin reaches a viscous form if reheated.

[0033] Turn now Figure 1 The illustration depicts an example of an aircraft in which an illustrative embodiment can be implemented. Aircraft 10 is an example of an aircraft that can be formed from a pad. Aircraft 10 is an example of an aircraft 10 formed from a semi-cylindrical section 24 of a fuselage 12.

[0034] In this exemplary example, the aircraft 10 has wings 15 and 16 attached to the fuselage 38. The aircraft 10 includes an engine 14 attached to the wing 15 and an engine 16 attached to the wing 16.

[0035] The main body 28 has a tail 18. Horizontal stabilizers 20, 21 and 22 are attached to the tail 18 of the main body 38.

[0036] The fuselage 12 is made of semi-cylindrical sections 24, wherein the upper semi-cylindrical section 26 is joined to the lower semi-cylindrical section 28 to form complete cylindrical sections 29-1, 29-2, 29-3, 29-4, and 29-5. The complete cylindrical sections are connected in series to form the fuselage 12.

[0037] Wings 15 and 16 are formed by wingplates 30, which include an upper wingplate 32 and a lower wingplate 34 joined together. Section cutout 46 is a cut through wingplates 30 and 32 and corresponds to the uncured preforms 189 and 189-1. Figure 1 and Figure 1A The chord orientation of the 46th section cut is approximately perpendicular to the longitudinal beam 182.

[0038] Section cut 44 is a cut that passes through the composite component 55 and corresponds to the preformed semi-cylindrical section 24-1 before hardening. Figure 3 Section cutout 44 is oriented along the longitudinal direction 181 through profile 112-1 along the longitudinal beam.

[0039] Figure 1A This is a block diagram of a demolding station 100 for separating a composite component 120 (including fibers and cured resin 123) from a mandrel 110 in an exemplary embodiment. The mandrel 110 defines the outline of the composite component 120, which may be a semi-cylindrical section of an aircraft fuselage, aircraft wing, etc. The mandrel 110 includes a metal tool capable of withstanding heat and pressure applied during the curing of the composite component. The demolding station 100 includes any system, device, or component operable to demold the outlined composite component 120 (particularly the semi-cylindrical section 121) from the surface 112 of the mandrel 110.

[0040] Within the indexing feature addition and demolding station 100, the composite component 120 (particularly the semi-cylindrical section 121) is exemplified as having flash and / or trimmed to allow for a support edge 124 or a final trimmed edge 125. Trimming is performed before demolding and therefore while the composite component 120 is still on the mandrel 110. An indexing feature 122 is also installed in the indexing feature addition and demolding station 100 before demolding.

[0041] The mandrel 110 advances along the processing direction 199 during manufacturing. In this embodiment, the mandrel 110 advances along a track 140 (e.g., a series of discrete pillars or AGV mandrels 110 with rollers, guides, or a set of guides, etc.) for the indexing feature addition and demolding station 100, and can be fully pulsated 128 in and out of the station along the processing direction 199. The track 140 is used to transport the mandrel 110 in and out of the indexing feature addition and demolding station 100. The composite component 120 advances with full pulsation 128 out of the indexing feature addition and demolding station 100 and is placed on the track 144, and advances with micro-pulsation 115 through the work station 160 in the assembly line 102 where hardened assembly is performed. The micro-pulsation 115 is exemplified by the width of the work station 160, but the micro-pulsation 115 is contemplated as other multiples or fractions of the width of the work station 160. Then, mandrel 110 can return to the beginning of the cleaning and repair process to layup, while composite component 120 advances in the processing direction 199 through work station 160, where assembly work is performed on composite component 120. In embodiments where mandrel 110 advances with micro-pulses 115, work is performed on composite component 120 during pauses between micro-pulses 115, or during the pulsation itself, or during pauses between micro-pulses 115, or no work is performed during any micro-pulse 115 or during pauses between micro-pulses 115.

[0042] The extraction tool 130 aligns itself with the component indexing feature 122 in the mandrel 110 and / or the mandrel indexing feature 122-1 precisely placed in or on the composite component 120 or the mandrel 110. The component indexing feature 122 is also referred to as indexing feature 122 in different places in this application; both refer to similar parts of the aircraft. After alignment with the mandrel 110, the extraction tool 130 places the arm assembly 132 against the composite component 120, engaging the clamping unit 138. The vacuum connector 138-1 removably engages the arm assembly 132 to the composite component 120, and the end effector 138-2 physically clamps the indexing feature 122 at the composite component 120, etc. The lip 136 is placed against the support edge 124 of the composite component 120. Although in Figure 1A The image shows three arm groups 132, but it will be understood that, because Figure 1A This is a side view, so the other half of the arm assembly 132 is located on the other side of the extraction tool 130 (not shown). Furthermore, depending on the geometry of the composite component 120, the number of arm assemblies 132 on each side ranges from one or more as a design choice.

[0043] Although component shifting feature 122 is shown at the lower part of composite component 120, in other embodiments, component shifting feature 122 is provided in the final manufacturing allowance 127, 129 of composite component 120 that will be trimmed off, such as the edge above the support edge 124 of composite component 120, the manufacturing allowance 127 of window cutout, the manufacturing allowance of door cutout (not shown), or the manufacturing allowance of antenna cutout (not shown).

[0044] Once arm assembly 132 is engaged with composite component 120, the driver or drive unit 134 (e.g., motor, actuator, etc.) continues to rotate / lift arm assembly 132 upwards and away from spindle 110, while simultaneously engaging composite component 120 as part of the separation process. The rotation and / or lifting of the engaged arm assembly 132 resiliently deflects composite component 120 to break the resin from the composite component 120. Figure 4 The mandrel 110 and the longitudinal beam 332 are directed towards the groove 322 in the mandrel 110. Figure 3 The combination of these components creates elastic strain at the composite component 120. The separation / lifting process can be performed individually and repeatedly in a pulsating manner introduced into the composite component 120 by the arm assembly 132, depending on the processing direction 199 or its opposite direction. The separation / lifting process can be performed individually and repeatedly from the lip 136 to the actuable joint 137 by one or more arm assemblies 132 in a pulsating manner introduced into the composite component 120 by the arm assembly 132. The separation / lifting process can be performed individually and repeatedly on either side in a pulsating manner introduced into the composite component 120 by the arm assembly 132. The pulsating operation of the arm assembly 132 can be performed with increasing force or distance to slowly peel and break the resin adhesion of the composite component 120 from the mandrel 110. Furthermore, while one arm assembly 132 is applying force, other arm assemblies 132 can reduce or stop applying force, resulting in a fluctuating application of force to the composite component 120.

[0045] In one embodiment, the drive 134 includes one or more rotary actuators 135 that cause the actuated joint 137 to rotate about a shaft 341 coupled to the arm assembly 132. Figure 3Rotation. While rotary actuator 135 has been discussed and illustrated, linear application systems (not shown) are also envisioned as an alternative or complement to rotary actuator 135. This rotation causes arm assembly 132 to deflect angularly away from composite component 120. The amount of angular deflection of arm assembly 132 is dynamically measured via sensor 139. Because the amount of angular deflection of arm assembly 132 can be used to determine the strain at different locations within composite component 120 to be demolded. The strain at a specific location can be measured by various means, such as via adhesive strain gauges. Based on the measured deflection of composite component 120 relative to mandrel 110, the strain is attributed to the structure. In one embodiment, strain gauge adhesion occurs when component rotation feature 122 is mounted and / or radio frequency identification (RFID) tag is adhered to composite component 120, or when composite component 120 is trimmed or machined prior to demolding. In other embodiments, strain is determined based on test data from sensor measurements of deflection during demolding of the composite component 120, and this data is attributed to the composite component 120 during demolding and / or based on measured deflection of the composite component 120. Because strain is attributed to the composite component 120 based on measured deflection during demolding or strain measurements from the composite component 120, it can be used to control the actuator 134 managed by the controller 150 to dynamically adjust the amount of angular deflection applied in real time by the arm assembly 132. This process during demolding ensures that the desired strain level at the composite component 120 is not exceeded.

[0046] Controller 150 manages the operation of extraction tool 130. In this embodiment, controller 150 includes an interface for communicating with extraction tool 130 (e.g., Ethernet interface, Universal Serial Bus (USB) interface, wireless interface, etc.) and includes memory storing one or more numerical control (NC) programs for operating extraction tool 130. Controller 150 can further process feedback from extraction tool 130 and provide instructions based on such feedback. For example, controller 150 can individually adjust the amount of force applied to composite component 120 by each arm assembly 132 via drive 134. The release force applied by each arm assembly 132 achieves the desired strain within composite component 120. Controller 150 can determine the amount of strain based on measured deflection of each arm assembly 132. In this way, controller 150 ensures that the arm assemblies 132 operate consistently and produce uniform elastic strain across the entire side of composite component 120, or synchronously generate a wave effect. When the first arm assembly 132-1 imparts a first amount of elastic strain to the first portion 141-1 of the composite component 120, and then the elastic strain level imparted by the second arm assembly 132-2 in the second portion 141-2 of the composite component 120 increases to a second amount, a wave effect is generated in the composite component 120. When the elastic strain imparted to the second portion 141-2 increases to the second amount, the elastic strain imparted to the first portion 141-1 remains at the first amount or decreases. Then, the elastic strain level imparted by the third arm assembly 132-3 in the third portion 141-3 of the composite component 120 increases to a third amount, while the elastic strain in the first portion 141-1 or the second portion 141-2 remains at the first amount or the second amount, or decreases one or both. By repeatedly applying higher strain via any technique, the cured resin of composite component 120 separates from mandrel 110, and in particular from components of composite component 120 that are partially surrounded by mandrel 110 (such as longitudinal beams 332 in grooves 322 within mandrel 110).

[0047] The controller 150 can be implemented as, for example, a custom circuit, a hardware processor that executes programmed instructions, or some combination thereof.

[0048] Track 140 guides mandrel 110 in processing direction 199 and may include roller 312. Figure 3 The track 140 may include guide rails or other components that facilitate the movement of the mandrel 110. In one embodiment, the track 140 includes a drive 142 (e.g., a chain drive or other component) for moving the mandrel 110, while in other embodiments, an autonomous guided vehicle (AGV) is used to move the mandrel 110 on the track 140 or without a track. In one embodiment, the track 144 is also used to move the composite component 120 after it has been demolded and placed in place by the extraction tool 130.

[0049] After the composite component 120 has been demolded and moved along the processing direction 199, it can undergo operations such as frame installation, window opening, and fastening to other composite components at the downstream work station 160. The mandrel 110 can be returned to a cleaning station (not shown). For example, the mandrel 110 can be sent to the return line 103 and advanced in a pulsating or micro-pulsating manner for reprocessing to reuse through cleaning, and for surface finishing before receiving another laminate for curing into the composite component 120.

[0050] Regarding Figure 2A The following are illustrative details of the operation of the demolding station 100. It is assumed that, for this embodiment, the mandrel 110 has received the laminate, and heat and pressure have been applied to harden the laminate onto the mandrel 110 to form the composite component 120.

[0051] Figure 2A This is a flowchart illustrating a method 200 for demolding the composite component 120 from the mandrel 110 in an exemplary embodiment. (See also...) Figure 1A The demolding station 100 describes the steps of method 200, but those skilled in the art will understand that method 200 can be performed in other systems. The steps in the flowchart described herein are not all included and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0052] Step 202 includes mechanically attaching the first arm (350) of the extraction tool 130 to the first portion 141-1 of the composite component 120, which has been hardened on the mandrel 110. In one embodiment, the composite component 120 is a semi-cylindrical section 121 of the fuselage, which includes a skin 331 ( Figure 3 ) and longitudinal beam 332. For example, step 202 may include activating clamping unit 138 to secure arm assembly 132 to composite component 120. For example in Figure 3 These operations are described in the text. If the clamping unit 138 includes, for example, Figure 3 Vacuum devices such as the vacuum connector 343 shown include engaging the vacuum connector 343 to form a vacuum chamber 345 partially defined / formed by the composite component 120. The vacuum chamber 345 is then evacuated, and the clamping unit 342 is coupled to the skin 331 of the composite component 120. That is, the step of mechanically coupling the first arm 350 to the first portion 141-1 may include placing the vacuum connector 343 at a first arm assembly 132-1 including the first arm 350 and the second arm 360 to contact the first portion 141-1. If the clamping unit 138 includes another type of end effector (such as a pin, claw, or finger), this includes mechanically engaging the clamping unit 138 to the component indexing feature 122.

[0053] In one embodiment, before applying a vacuum to engage the vacuum connector 343 and the clamping unit 138 with the composite component 120, the lip 136 engages with the support edge 124 to align the clamping unit 138. In this way, the lip 136 provides overall alignment of the arm assembly 132 with the composite component 120 for clamping the unit 138 before engagement of the clamping unit 138.

[0054] Step 204 includes mechanically connecting a second arm assembly 132-2, which includes a first arm 350 and a second arm 360 of the extraction tool 130, to a second portion 141-2 of the composite component 120, and can be performed in a manner similar to step 202 described above.

[0055] In step 206, the actuator 134 initiates the separation of the composite component 120 from the mandrel 110 by performing the following operation until the composite component 120 separates from the mandrel 110. This operation includes repeatedly bending the arm assembly 132 to elastically strain the first portion 141-1 and the second portion 141-2 of the composite component 120 sequentially away from the mandrel 110, and adjusting and / or increasing the degree of elastic strain over a period of time as the arm assembly 132 is repeatedly manipulated to separate the composite component 120 from the mandrel 110. In this way, elastic strain is applied to the composite component 120 over a period of time via the vacuum connector 343 and the lip 136 of the extraction tool 130. Specifically, in step 208, the extraction tool 130 elastically strains the first portion 141-1 of the composite component 120 via the first arm assembly 132-1, and in step 210, elastically strains the second portion 141-2 of the composite component 120 via the second arm assembly 132-2. In one embodiment, the arms simultaneously elastically strain both the first portion 141-1 and the second portion 141-2, while in another embodiment, strain is applied to one or more first arms 350 on one side, followed by strain to one or more second arms 360 on the other side. In one embodiment, the amount of applied strain, deflection, and / or force is periodically increased and decreased by each arm in an out-of-phase cycle. Furthermore, even if the amounts of these strains, deflections, and / or forces continue to change periodically, their values ​​may increase slowly. Therefore, in one embodiment, the elastic strain is repeatedly increased by alternately increasing the strain applied to the first arcuate portion 334 and increasing the elastic strain applied to the second arcuate portion 336. The applied repeated strain separates the resin bond at the composite component 120 from the mandrel 110.

[0056] In one embodiment, the separation of the composite component 120 from the mandrel 110 is determined by a decrease in the translational resistance of the composite component 120. That is, once the composite component 120 translates into or out of the mandrel in response to an applied force... Figure 3On the page, the resin at composite part 120 is released / separated from mandrel 110, thus composite part 120 is demolded.

[0057] The movement of the arm assembly 132 causes the composite component 120 to begin separating to some extent from the mandrel 110, which allows for the separation of composite components 120 with complex shapes, such as longitudinal beams 332, inserts, and pads. For example, in embodiments where the mandrel 110 includes slots 322 for longitudinal beams below the semi-cylindrical section 121, the composite material can be successfully extracted from these slots without causing out-of-tolerance conditions requiring rework at the composite component 120.

[0058] From this perspective, the lifting device can lift the arm assembly 132 and the composite component 120 from the spindle 110, and / or can move the spindle 110 out from under the composite component 120 to the return line 103.

[0059] Method 200 offers technological advantages over existing technologies and systems because it enables the efficient and effective separation of large, complex composite components 120, particularly unique structures like the semi-cylindrical segment 121, from the mandrel 110 without resorting to mandrel tools that must be separated during demolding or otherwise disassembled to achieve separation from the composite component 120. This reduces the cost and complexity of the associated mandrel 110, while further reducing the labor associated with the disassembly and reassembly of such a mandrel. The time required to demold the composite component 120 from the mandrel 110 is less than the time required to demold by disassembling the mandrel 110.

[0060] Figure 2BThis is a flowchart illustrating another method 250 for demolding composite component 120 from mandrel 110 in an exemplary embodiment. Step 252 includes elastically straining a first portion 141-1 of composite component 120 away from mandrel 110. If a second arm assembly 132-2 is employed and performed simultaneously with or at a different time from step 252, step 254 includes elastically straining a second portion 141-2 of composite component 120 away from mandrel 110. If a third arm assembly 132-3 is employed and performed simultaneously with or at a different time from step 252, step 255 includes elastically straining a third portion 141-3 or additional portion of composite component 120 away from mandrel 110. Step 256 includes repeatedly increasing the elastic strain applied to the first portion 141-1 and the elastic strain applied to the second portion 141-2 and the third portion 141-3. In another embodiment, the composite component 120 is clamped to the skin 331 and lip 346 by clamping the clamping unit 342 to apply elastic strain to the support edge 124 of the first portion 141-1. In this way, if applicable, the first portion 141-1, the second portion 141-2, and the third portion 141-3 are first elastically strained into the support edge 124 via the lip 346, and then the clamping unit 342 is used to pass upward through the composite component 120 via the skin 331. If applicable, another version includes first elastically straining the first portion 141-1, the second portion 141-2, and the third portion 141-3 onto the skin 331 via the clamping unit 342, and then passing downward through the composite component 120 into the support edge 124 via the lip 346.

[0061] In another embodiment, the step of repeatedly increasing the elastic strain includes alternately increasing the elastic strain applied to the first bow-shaped portion and increasing the elastic strain applied to the second bow-shaped portion 336.

[0062] Figure 2CThis is a flowchart illustrating another method 270 for demolding the composite component from the mandrel 110 in an exemplary embodiment. Step 272 includes mechanically attaching the first arm assembly 132-1 of the extraction tool 130 to a first portion 141-1 of the composite component 120 that has been hardened to the mandrel 110. According to design specifications, this may include applying a vacuum connection to the composite component 120 via a vacuum connector 343 at the first arm assembly 132-1, or via component indexing features 122, 122-1. Step 274 includes mechanically attaching the second arm assembly 132-2 of the extraction tool 130 to a second portion 141-2 of the composite component 120, and may be performed in a manner similar to step 272 described above. Step 276 includes separating / releasing the hardened resin at the composite component 120 from the mandrel 110 by applying strain to the composite component 120 via the first arm assembly 132-1 and the second arm assembly 132-2. In one embodiment, the step of separating the hardened resin includes separating the hardened resin between the longitudinal beams 332 of the composite component 120 from the grooves 322 of the mandrel 110.

[0063] The controller 150 determines that the cured resin has separated from the mandrel based on the decrease in resistance to the translation of the composite component 120 from the mandrel 110. For example, when there is no longer any increased resistance to the movement of the composite component 120 due to the resin adhering to the mandrel 110, it can be concluded that the resin has separated from the mandrel 110.

[0064] Figures 3 to 7 An extraction tool 130 is depicted in an exemplary embodiment, which repeatedly and elastically deflects a composite component 120 including a semi-cylindrical section 121. These views correspond to... Figure 1A Arrow 3 in the view. Figure 3 In the cross-sectional view, the extraction tool 130 is placed on the composite component 120, which includes a skin 331 and a longitudinal beam 332. The actuator 134, rotary actuator 135, actuated joint 137, and sensor 139 are illustrated in block form. The actuator 134 includes one or more rotary actuators 135 that cause the actuated joint 137 about an axis 341 (…). Figure 3 The rotation actuates the joint 137 to engage the arm assembly 132. While the rotary actuator 135 has been discussed and illustrated, a linear application system (not shown) is also envisioned as an alternative or complement to the rotary actuator 135. This rotation causes the arm assembly 132 to deflect angularly away from the composite component 120. The amount of angular deflection of the arm assembly 132 is dynamically measured via sensor 139. The longitudinal beam 332 is currently held within a groove 322 (e.g., a recess) at the spindle 110. The spindle 110 moves along the roller 312 at the track 140 in the processing direction 199 into the page. Another embodiment uses an AGV (not shown) instead of roller 312.

[0065] In this embodiment, the extraction tool 130 includes a first arm assembly 132-1, a second arm assembly 132-2, and a third arm assembly 132-3, for respectively demolding the first portion 141-1, the second portion 141-2, and the third portion 141-3 of the composite component 120. Each arm assembly 132 includes a flexural member 344, a clamping unit 342, and a lip 346 connected to the flexural member 344 via a hinge 348. The contour 349 of the flexural member 344 is complementary to the contour 347 of the composite component 120. Therefore, in this embodiment, it forms an arc shape (e.g., Figures 3 to 7 (As shown). In another embodiment, the arc formed by the first arm group 132-1, the second arm group 132-2, and the third arm group 132-3 occupies different portions of the same circle 390. In another embodiment, multiple arms are provided at each portion of the circle 390. The lip 346 is kept in contact with the support edge 124 of the composite component 120 by applying bias or otherwise, and facilitates the application of a peeling force 351 from the extraction tool 130 via the hinge 348 through the lip 346.

[0066] One or more actuable joints 137 are disposed between the first arm 350 and the second arm 360, mechanically connecting / joining these components while allowing rotation 352 about axis 341. Clamping units 342 are distributed along the flexure member 344. When the extraction tool 130 is removably attached to the composite component 120, the clamping units 342 are clamped between the flexure member 344 and the profile 347. The clamping units 342 may include vacuum connectors 343, for example, vacuum attaching the clamping units 342 to the composite component 120 to form a vacuum chamber 345. Another embodiment has end effectors 138-2 arranged along the flexure member 344, which physically clamp component shifting features 122, 122-1 that have been incorporated into or integrated into the design of the composite component 120. Figures 3 to 7 These transposition features 122, 122-1, not shown in the diagram, may include holes, slits, notches, etc., and are not shown in the diagram. Figure 1A A specific example is shown below. The lift 370 is shown for raising the extraction tool 130 and the composite component 120 after extraction is complete.

[0067] exist Figure 4 In this configuration, the first arm 350 is driven outward and upward, away from the surface of the mandrel 110. This separates the arcuate portion 334 from the mandrel 110. In this way, the first arm 350 and the second arm 360 separate the hardened resin that binds the composite component 120 to the mandrel 110 by applying strain to the composite component 120 to deflect or peel it off from the mandrel 110. A gap 369 is illustrated between the composite component 120 and the mandrel 110 along the first arm 350.

[0068] exist Figure 5In the middle, the second arm 360 is driven outward and upward, which separates the bow-shaped portion 336 from the spindle 110. Although Figures 4 to 5 The operation is exemplified as a single movement, but in other embodiments, these operations are performed repeatedly and incrementally in a cyclical or pulsating manner, such that the first arm 350 and then the second arm 360 rotate 352 by a small angle, such as 5 degrees and / or a distance of 2.54 cm to 7.62 cm (one to three inches), and then the deflection is repeatedly increased to a larger angle, such as by a rocking motion increasing by 5 degrees or 2.54 cm to 7.62 cm (one to three inches), until demolding is complete. The same iterative process is possible when moving from the third arm group 132-3 to the second arm group 132-2 and possibly repeatedly entering the first arm group 132-1. That is, the operation is performed until the composite component 120 has separated from the mandrel 110 and the longitudinal beam 332 has separated from the groove 322. A gap 369 between the composite component 120 and the mandrel 110 along both the first arm 350 and the second arm 360 is illustrated. In another embodiment, when one of the first arm 350 or the second arm 360 applies a force to the composite component 120, the other of the first arm 350 or the second arm 360 reduces or removes the applied force to ensure that the strain applied to the first portion 141-1 and the third portion 141-3 remains elastic and does not cause permanent deformation of the composite component 120. In one embodiment, this includes releasing the elastic strain on the composite component, allowing the composite component to elastically return to the shape defined by the mandrel 110 at demolding.

[0069] exist Figure 6 In this process, the mandrel 110 is removed and sent to the return line 103. In one embodiment, this operation is performed by driving the mandrel 110 in and out of the page after a minimum clearance has been achieved (e.g., a clearance sufficient to allow the longitudinal beam 332 to pass through the slot 322 between the mandrel 110 and the composite component 120). In another embodiment, after demolding is complete, the extraction tool 130 is lifted from the mandrel 110 together with the composite component 120 via the operation of the lift 370.

[0070] Then move the extraction tool 130 to Figure 7The new position is shown and elastic strain is removed. The composite component 120 is balanced above the track including the support 700, which holds the composite component 120 in the groove 710 while allowing the composite component 120 to move along the roller 724 into the page in the processing direction 199. In one embodiment, the lip 346 is lowered via the hinge 348 to expose the edge 338, while the vacuum coupling 343 continues to apply suction and the composite component 120 is balanced above the support 700. Lowering the lip 346 further prevents the lip 346 from contacting the support 700 (and any rollers disposed at the support 700). The exposed edge 338 is then lowered into the groove 710, between the pinch rollers 722 and on the roller 724. In one embodiment, the weight of the composite component 120 is transferred through the support edge 124 and borne by the roller 724, while in another embodiment, the pinch roller 722 holds the support edge 124 in place. Even after the mandrel 110 has been removed, the groove 710 helps to conform the composite component 120 to the desired shape and profile 347. The lip 346 releases and disengages during this process, allowing the supporting edge 124 of the composite component 120 to be positioned appropriately within the groove 710. The extraction tool 130 then releases the clamping unit 342 and returns to retrieve another composite component 120 from the other mandrel 110. The composite component 120 advances along the processing direction 199 to a downstream workstation 160, which mounts frames, assembles composite components with other composite components, cuts windows and doors, and performs other tasks.

[0071] Although the extraction tool 130 is illustrated as separating the composite component 120 in the form of a semi-cylindrical section 121, repeated and cyclic techniques for elastically bending the composite component 120 from the mandrel 110 can be performed on the cross-sections of other composite components such as wings, cabins, etc.

[0072] Figure 8 This is an enlarged view of the vacuum connector 343 of the arm of the extraction tool in the exemplary embodiment, and corresponds to... Figure 7 Area 8. In Figure 8 In this configuration, vacuum connector 343 forms a vacuum chamber 345, which is defined by a flexible element 820 (e.g., a rubberized component conforming to the surface geometry of composite component 120). Suction force travels via tube 810 to pump 830, which evacuates the vacuum chamber 345 in each of the one or more vacuum connectors 343 and is controllably operated by controller 840 to consistently apply the desired amount of vacuum. The evacuated vacuum chamber removably connects the vacuum connector 343 and extraction tool 130 to composite component 120.

[0073] Figure 9This is a perspective view of a machining system 800 in an exemplary embodiment, which includes an IML conveying device 850 and an outer mold line (OML) conveying device 860 for a composite part 1000. The composite part 1000 is produced by longitudinally cutting a hardened, complete cylindrical section in half before or after demolding to form an upper and / or lower cylindrical section. The composite part 1000 is formed on a complete cylindrical section OML mandrel tool or a complete cylindrical section IML mandrel tool. For reference, mandrel 110 is a half-cylinder section IML tool. The machining system 800 operates as a switching device to facilitate the transfer of the composite part 1000 from an IML or OML complete cylindrical section mandrel.

[0074] The IML conveying device 850 is mounted in the recess 1002 defined by the composite component 1000. Figures 10A to 10E The composite component 1000 is located within the IML conveyor and has a semi-circular cross-section. The IML conveyor 850 includes a frame 852, rollers 854, and a fixing element 856 that contacts the composite component. The fixing element 856 allows the composite component 1000 to be fixed to the IML conveyor 850, for example, by physical fitting and / or bolting. The rollers 854 are fixed to the IML conveyor 850 and facilitate the transport of the IML conveyor 850 while the composite component is fixed to it.

[0075] OML conveyor 860 surrounds the outer surface 1004 defined by composite component 1000 and presents a complementary semi-circular cross-section surrounding IML conveyor 850. OML conveyor 860 includes a frame 862 and a fixing element 866. The fixing element 866 secures the composite component to OML conveyor 860, for example, via physical mating to composite component 1000 and / or bolting to composite component 1000. A coupling 868 joins IML conveyor 850 to OML conveyor 860 to clamp composite component 1000 therebetween. In one embodiment, the fixing element 856 at IML conveyor 850 is coupled to a different feature at composite component than the fixing element 866 at OML conveyor 860.

[0076] Figures 10A to 10E The composite component in the exemplary embodiment is described via Figure 9 The conveyor device moves towards track 144 ( Figure 10D (transportation). Figure 10A In this process, the demolded composite component 1000 is fixed to the IML conveyor 850 via a fixing element 856 connected to the complementary indexing feature 1006 of the composite component 1000, the mass and quantity of which are similar to the component indexing feature 122 of the composite component 120. Figure 10BIn this assembly, OML conveyor 860 and connector 868 are installed to combine OML conveyor 860 and IML conveyor 850. The combined components are then transported under a crane 1050 or other tool for picking up composite components 1000, OML conveyor 860, and IML conveyor 850, or on rollers 854 or similar devices. Figure 10C In the process, the IML conveyor 850 is removed, and the crane 1050 picks up the OML conveyor 860 holding the composite component 1000. Figure 10D In the process, crane 1050 sets the OML conveyor 860 and composite component 1000 onto track 144, which includes supports 1062 with rollers 1064, and then... Figure 10E In the middle, the OML conveyor 860 is removed. The composite component 1000 then moves in and out of the page along track 144 in the processing direction 199.

[0077] Figure 11 This is a flowchart illustrating a method 1100 for transferring composite component 1000 to a conveying device in an illustrative embodiment, and can be accessed via... Figure 9 , Figures 10A to 10E The machining system 800 is operated. Step 1102 includes operation via an external mold line (OML) mandrel tool 130 (such as... Figure 1A Extraction tool 130), for example via Figures 2A to 2C Any method used in the process of demolding the composite component 1000 from the mandrel 110. In one embodiment, the composite component 1000 is produced by cutting a hardened, complete cylindrical section in half before or after demolding to form an upper or lower cylindrical section. A processing system 800 is then introduced to transfer the demolded composite component 1000 to assembly line 102 and track 144. The composite component 1000 is then placed on track 144 and advances through assembly line 102 in a manner similar to that of composite component 120.

[0078] Step 1104 includes transferring the composite component 1000 from the OML mandrel tool to the IML conveyor 850. In one embodiment, the step of transferring the composite component 1000 from the OML mandrel tool to the IML conveyor 850 includes: mating a shifting feature 1006 into a manufacturing allowance of the composite component 1000, which will be removed from the composite component 1000 before assembly is complete; and shifting the shifting feature 1006 of the composite component 1000 to the IML conveyor 850 before demolding from the OML mandrel tool.

[0079] In one embodiment, this includes attaching the composite component 1000 to the IML conveyor 850 and then engaging the retaining element 856 with the complementary indexing feature 1006 at the composite component 1000. In another embodiment, the composite component 1000 is attached to the IML conveyor 850 by vacuum coupling or via fasteners.

[0080] Step 1106 includes transferring the composite component 1000 from the IML conveyor 850 to the OML conveyor 860 before or after rolling the composite component 1000 to the desired track 144 placement position at the assembly line 102 via the IML conveyor 850. In one embodiment, the step of transferring the composite component 1000 from the IML conveyor 850 to the OML conveyor 860 includes engaging a shift feature 1006 in the manufacturing allowance of the composite component 1000 with a complementary shift feature at the OML conveyor 860 and releasing the IML conveyor 850. The composite component 1000 will include a manufacturing allowance, for example in Figure 1A Manufacturing allowances 127 and 129 are shown on the composite component 120. These manufacturing allowances in the composite component 1000 will subsequently be removed from the composite component 1000. In another embodiment, this includes releasing the IML conveyor 850 from the composite component 1000 and securing the OML conveyor 860 to the composite component 1000.

[0081] Step 1108 includes transporting the composite component via the OML conveyor 860. In one embodiment, this includes operating a crane 1050 to lift the OML conveyor 860 onto the track 144, and then lowering the OML conveyor 860 to position the composite component 1000 in contact with the track 144. The OML conveyor 860 is then removed, and the composite component 1000 advances along the track 144.

[0082] Figure 12This is a flowchart illustrating a method 1200 for transporting composite component 1000 to transport track 144 in an exemplary embodiment. Step 1202 includes securing a tool, such as extraction tool 130, to composite components 120, 1000 disposed on an IML mandrel. Step 1204 includes demolding composite components 120, 1000 from the mandrel while securing extraction tool 130. Step 1206 includes lowering composite components 120, 1000 onto an inner mold line (IML) conveyor 850 complementary to the IML of composite components 120, 1000. Step 1208 includes securing the IML conveyor 850 to composite components 120, 1000. Step 1210 includes removing extraction tool 130. Step 1212 includes aligning OML conveyor 860 with the outer mold line (OML) of composite components 120, 1000. Step 1214 includes securing the OML conveyor 860 to the composite components 120 and 1000. Step 1216 includes removing the IML conveyor 850. Step 1218 includes transporting the composite components 120 and 1000 while keeping them secured to the OML conveyor 860.

[0083] Figure 13 This is another flowchart illustrating a method 1300 for demolding and transferring composite component 120 in an exemplary embodiment. According to method 1300, step 1302 includes separating composite component 120 from mandrel 110 via extraction tool 130, which repeatedly and elastically deflects a first portion 141-1, a second portion 141-2, and a third portion 141-3 of composite component 120. Step 1302 can be performed in any suitable manner, and in one embodiment via… Figures 2A to 2C Methods 200, 250, and / or 270 are performed. Step 1304 includes transporting the composite component 120 to the track 144 via the extraction tool 130. This step can be performed as described regarding... Figures 3 to 6 As shown and described. Step 1306 includes depositing the composite component 120 onto the orbital 144. This step can be performed as described regarding... Figure 7 The process is performed as shown and described. In one embodiment, the step of depositing the composite component 120 onto the track 144 includes lowering the support edge 124 of the composite component 120 onto the track 144. In another embodiment, method 1300 further includes holding the composite component 120 in a recess at the track 144 and advancing the composite component 120 along the track 144 to a work station 160 where work is performed on the composite component 120.

[0084] Example

[0085] For more specific details, please refer to the accompanying drawings, as shown in... Figure 14 The aircraft manufacturing and maintenance methods shown in 1400 and Figure 15 Embodiments of this disclosure are described within the context of the illustrated aircraft 1402. During pre-production, method 1400 may include the specification and design 1404 of aircraft 1402 and material procurement 1406. During production, the manufacturing of components and sub-assemblies of aircraft 1402 and system integration 1410 occur. Thereafter, aircraft 1402 can be certified and delivered 1412 for entry into service 1414. When serviced by a customer, aircraft 1402 is scheduled for routine maintenance and repair work 1416 (this may also include modifications, reconfigurations, refurbishments, etc.). The equipment and methods embodied herein may be used during any one or more suitable phases of production and maintenance described in method 1400 (e.g., specification and design 1404, material procurement 1406, component and sub-assembly manufacturing 1408, system integration 1410, certification and delivery 1412, service 1414, maintenance and repair 1416), and / or any suitable component of aircraft 1402 (e.g., fuselage 1418, system 1420, interior 1422, propulsion system 1424, electrical system 1426, hydraulic system 1428, environmental system 1430).

[0086] Each process of Method 1400 may be performed or conducted by a systems integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a systems integrator may include, but is not limited to, any number of aircraft manufacturers and major systems 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 provider, etc.

[0087] like Figure 15 As shown, an aircraft 1402 produced by method 1400 may include a fuselage 1418 having multiple systems 1420 and an interior 1422. Examples of systems 1420 include one or more of a propulsion system 1424, an electrical system 1426, a hydraulic system 1428, and an environmental system 1430. Any number of other systems may be included. Although an aerospace example is shown, the principles of this disclosure can be applied to other industries, such as the automotive industry.

[0088] As mentioned above, the equipment and methods embodied herein may be employed during any one or more phases of production and maintenance described in method 1400. For example, a component or sub-assembly corresponding to component and sub-assembly manufacturing 1408 may be manufactured or assembled in a manner similar to that of a component or sub-assembly produced during the service of aircraft 1402. Furthermore, one or more equipment implementations, method implementations, or combinations thereof may be utilized during sub-assembly manufacturing 1408 and system integration 1410, for example, to significantly accelerate the assembly of aircraft 1402 or reduce its cost. Similarly, during the service of aircraft 1402, such as, but not limited to, maintenance and repair 1416, one or more equipment implementations, method implementations, or combinations thereof may be used. Therefore, this disclosure can be used at any stage or any combination thereof discussed herein, such as specifications and design 1404, material procurement 1406, component and sub-component manufacturing 1408, system integration 1410, certification and delivery 1412, service 1414, maintenance and repair 1416) and / or any suitable component of the aircraft 1402 (e.g., fuselage 1418, systems 1420, interior 1422, propulsion system 1424, electrical system 1426, hydraulic system 1428 and / or environmental system 1430).

[0089] In one embodiment, the component comprises a portion of the fuselage 1418 and is manufactured during component and subassembly manufacturing 1408. The component can then be assembled into the aircraft in systems integration 1410 and used in service 1414 until wear renders it unusable. Then, in repair and maintenance 1416, the component can be discarded and replaced with a newly manufactured component. The components and methods of the present invention can be utilized throughout component and subassembly manufacturing 1408 to manufacture new components.

[0090] 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 can be referred to as a “processor,” a “controller,” or some similar term. When provided by a processor, functionality can be provided by a single dedicated processor, a single shared processor, or multiple separate processors, some of which may share the functionality. Furthermore, the explicit use of the terms “processor” or “controller” should not be construed as referring specifically 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 circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic, or certain other physical hardware components or modules.

[0091] Furthermore, control elements can be implemented as instructions executable by a processor or computer to perform the functions of the 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 memory, magnetic storage media such as disks and tapes, hard disk drives, or optically readable digital data storage media.

[0092] This article also provides the following examples, which involve:

[0093] Example 1: A method 250 for demolding a composite part 120, the method 250 comprising the following steps:

[0094] The first arcuate portion 334 of the composite component 120 is elastically strained away from the spindle 110 (252);

[0095] The second arcuate portion 336 of the composite component 120 is elastically strained away from the mandrel 110 (254); and

[0096] The elastic strain applied to the first bow-shaped portion 334 and the elastic strain applied to the second bow-shaped portion 336 are repeatedly increased (256).

[0097] Example 2: According to the method 250 of Example 1, the method 250 further includes: determining that the resin at the composite component 120 has been released from the mandrel 110 based on the reduction of the translational resistance of the composite component 120.

[0098] Example 3: The method 250 according to Example 1 or 2, wherein: elastic strain of the first bow-shaped portion 334 is performed by clamping the support edge 124 of the first bow-shaped portion 334.

[0099] Example 4: The method 250 according to Example 1 or 2, wherein: elastic strain is performed on the first bow portion 334 from the support edge 124 of the first bow portion 334.

[0100] Example 5: The method 250 according to any one of Examples 1 to 4, wherein the step of repeatedly increasing the elastic strain includes: alternately increasing the elastic strain applied to the first bow-shaped portion 334 and increasing the elastic strain applied to the second bow-shaped portion 336.

[0101] Example 6: The method 250 according to any one of Examples 1 to 5, the method 250 further includes: elastically straining the third portion 141-3 of the composite component 120 away from the mandrel 110.

[0102] Example 7: A method 270 for demolding a composite part 120, the method 250 comprising the following steps:

[0103] The first arm assembly 132-1 of the extraction tool 130 is mechanically connected (272) to the first arcuate portion 141-1 of the composite component 120, which has been hardened to the mandrel 110;

[0104] The second arm 360 of the extraction tool 130 is mechanically connected (274) to the first arcuate portion 141-1 of the composite component 120, which has been hardened to the mandrel 110; and

[0105] The hardened resin 276 at the composite component 120 is separated from the mandrel 110 by applying strain to the composite component 120 via the first arm 350 and the second arm 360.

[0106] Example 8: A method 1100 for demolding a composite part 1000, the method 1100 comprising the following steps:

[0107] The composite part 120 is demolded away from the mandrel 110 via the outer mold line (OML) mandrel tool 130;

[0108] The composite component 1000 is transferred away from the OML mandrel tool 130 to the inner mold line (IML) conveyor 850;

[0109] Transferring the composite component 1000 away from the IML conveyor 850 to the OML conveyor 860; and

[0110] The composite component 1000 is transported via the OML conveyor 860.

[0111] Example 9: A method 1200 for demolding composite parts 120, 1000, the method 1200 comprising the following steps:

[0112] Fix tool 130 (1202) to the outer mold line (OML) of the composite component 120, 1000, which is located at the mandrel 110;

[0113] While the tool 130 is fixed, the composite components 120, 1000 are demolded (1204) from the mandrel 110;

[0114] The composite components 120, 1000 are lowered (1206) onto an IML conveying device 850 that is complementary to the IML of the composite components 120, 1000.

[0115] Fix the IML conveying device (1208) to the composite components 120, 1000;

[0116] Remove tool 130 (1210);

[0117] Align the OML delivery device 860 with the OML of the composite components 120, 1000 (1212);

[0118] Secure the OML conveying device 860 (1214) to the composite components 120, 1000;

[0119] Receiver (1216) the IML conveying device 850; and

[0120] The composite components 120 and 1000 are transported (1218) while being held and fixed to the IML conveying device 850.

[0121] Example 10: A method 1300 for separating a composite component 120 from a mandrel 110, the method 1300 comprising the following steps:

[0122] The composite component 120 is separated from the mandrel 110 by the extraction tool 130 which repeatedly and elastically deflects a portion of the composite component 120;

[0123] The composite component 120 is transported to the track 144 via the extraction tool 130; and

[0124] The composite component 120 is deposited onto the track 144.

[0125] Example 11: A portion of an aircraft assembled according to the method described in any of Examples 1 to 10.

[0126] Example 12: A part of an aircraft assembled according to a method defined by instructions stored on a computer-readable medium according to this disclosure.

[0127] This article also provides the following examples, which involve:

[0128] Example 1A: A method 200 for demolding a composite component 120 from a mandrel 110, the method 200 comprising the following steps:

[0129] The first arm 350 of the extraction tool 130 is mechanically connected (202) to the first arcuate portion 334 of the composite component 120, which has been hardened to the mandrel 110;

[0130] The second arm 360 of the extraction tool 130 is mechanically connected (204) to the second arcuate portion 336 of the composite component 120; and

[0131] The composite component 120 is separated from the mandrel 110 by repeatedly performing the following operations until the composite component 120 no longer contacts the mandrel 110 (206):

[0132] The first arcuate portion 334 of the composite component 120 is elastically strained (208) via the first arm 350; and

[0133] The second bow-shaped portion 336 of the composite component 120 is elastically strained (210) via the second arm 360.

[0134] Example 2A: According to the method of Example 1A, the method further includes: determining that the composite component 120 is no longer in contact with the mandrel 110 based on the reduction of the translational resistance of the composite component 120.

[0135] Example 3A: According to the method described in Example 1A, the method further includes:

[0136] Positioning the lip 136 of the first arm 350 to contact the end of the first arched portion 334; and

[0137] Position the lip 136 of the second arm 360 to contact the end of the second bow-shaped portion 336.

[0138] Example 4A: The method 200 according to any one of Examples 1A to 3A, wherein the step of mechanically coupling the first arm 350 to the first arcuate portion 334 includes: positioning the vacuum connector 343 at the first arm 350 in contact with the first arcuate portion 334; and

[0139] The step of mechanically connecting the second arm 360 to the second bow portion 336 includes: positioning the vacuum connector 343 at the second arm 360 in contact with the second bow portion 336.

[0140] Example 5A: The method 200 according to any one of Examples 1A to 4A, wherein the step of mechanically connecting the first arm 350 to the first bow-shaped portion 334 includes: clamping the rotation feature 122 in the first bow-shaped portion 334 via the first arm 350; and

[0141] The step of mechanically connecting the second arm 360 to the second bow-shaped portion 336 includes: clamping the rotation feature 122 in the second bow-shaped portion 336 via the second arm 360.

[0142] Example 6A: The method 200 according to any one of Examples 1A to 5A, wherein the step of mechanically connecting the first arm 350 to the first arcuate portion 334 includes: positioning the first arm 350 in contact with the side of the semi-cylindrical section 121 of the fuselage; and

[0143] The step of mechanically connecting the second arm 360 to the second bow-shaped portion 336 includes: positioning the first arm 350 in contact with the side of the semi-cylindrical section 121 of the fuselage.

[0144] Example 7A: The method 200 according to any one of Examples 1A to 6A, the method 200 further includes: releasing the elastic strain on the composite component 120 such that the composite component 120 elastically returns to the shape defined by the mandrel 110.

[0145] Example 8A: The method 200 according to any one of Examples 1A to 7A, the method 200 further includes: lifting the composite component 120 away from the mandrel 110 and placing the composite component 120 onto a track 144 for an assembly line.

[0146] Example 9A: The method 200, 250 according to any one of Examples 1A to 8A, wherein the step of separating the composite component 120 from the mandrel 110 (206) further includes: repeatedly increasing (256) the elastic strain applied to the first arcuate portion 334 and the elastic strain applied to the second arcuate portion 336.

[0147] Example 10A: According to the method 250 of Example 9A, the method 250 further includes: determining that the resin at the composite component 120 has been released from the mandrel 110 based on the reduction of the translational resistance of the composite component 120.

[0148] Example 11A: The method 250 according to Example 9A or 10A, wherein elastic strain of the first bow-shaped portion 334 is performed by clamping the support edge 124 of the first bow-shaped portion 334.

[0149] Example 12A: The method 250 according to Example 9A or 10A, wherein elastic strain is caused to the first bow portion 334 from the support edge 124 of the first bow portion 334.

[0150] Example 13A: The method 250 according to any one of Examples 9A to 12A, wherein the step of repeatedly increasing the elastic strain includes: alternately increasing the elastic strain applied to the first bow-shaped portion 334 and increasing the elastic strain applied to the second bow-shaped portion 336.

[0151] Example 14A: The method 250 according to any one of Examples 9A to 13A, the method 250 further includes: elastically straining the third portion 141-3 of the composite component 120 away from the mandrel 110.

[0152] Example 15A: Method 270 according to any one of Examples 1A, 4A, and 5A, wherein method 250 includes: mechanically engaging (272) the first arm assembly 132-1 of the extraction tool 130 to the first arcuate portion 141-1 of the composite component 120,

[0153] The first arm group 132-1 includes the first arm 350 and the second arm 360.

[0154] Example 16A: According to the method 270 of Example 15A, the step of mechanically connecting the second arm assembly 132-2 of the extraction tool 130 to the second arcuate portion 141-2 of the composite component 120 includes: applying a vacuum connection to the composite component 120 via a vacuum connector 343 at the second arm assembly 132-2.

[0155] Example 17A: The method 270 according to any one of Examples 15A and 16A, wherein the step of separating the hardened resin 276 at the composite component 120 from the mandrel 110 by applying strain to the composite component 120 via the first arm 350 and the second arm 360 includes: separating the hardened resin 276 between the longitudinal beams 332 of the composite component 120 from the grooves 322 of the mandrel 110.

[0156] Example 18A: The method 1100 according to any of the foregoing examples, wherein the extraction tool 130 includes an outer mold line (OML mandrel tool 130), and the method 1100 further includes the following steps:

[0157] The composite component 1000 is transferred away from the OML mandrel tool 130 to the inner mold line (IML) conveyor 850;

[0158] Transferring the composite component 1000 away from the IML conveyor 850 to the OML conveyor 860; and

[0159] The composite component 1000 is transported via the OML conveyor 860.

[0160] Example 19A: According to the method 1100 of Example 18A, the step of transferring the composite component 1000 away from the OML mandrel tool 130 to the IML transport device 850 includes: engaging the indexing feature 1006 of the composite component 120 in the manufacturing allowances 127, 129 of the composite component 1000 with the IML transport device 850.

[0161] Example 20A: The method 1100 according to Example 19A, wherein the indexing feature 1006 of the composite component 1000 is indexed to the IML conveyor 850 before demolding from the OML mandrel tool 130.

[0162] Example 21A: The method 1100 according to any one of Examples 18A to 20A, wherein the step of transferring the composite component 1000 away from the OML mandrel tool 130 to the IML transport device 850 includes: attaching the composite component 1000 to the IML transport device 850; and engaging the fixing element 856 to the indexing feature 1006 at the composite component 1000.

[0163] Example 22A: The method 1100 according to any one of Examples 18A to 21A, wherein the composite component 1000 is attached to the IML conveying device 850 by vacuum coupling or via fasteners.

[0164] Example 23A: The method 1100 according to any one of Examples 18A to 22A, wherein the step of transferring the composite component 1000 away from the IML conveyor 850 to the OML conveyor 860 includes: engaging the indexing feature 1006 of the composite component 120 in the manufacturing allowances 127, 129 of the composite component 1000 with the indexing feature 1006 at the OML conveyor 860; and releasing the IML conveyor 850.

[0165] Example 24A: The method 1100 according to any one of Examples 18A to 23A, wherein the step of transporting the composite component 1000 via the OML conveyor 860 includes: operating a crane 1050 to lift the OML conveyor 860 above the track 144; and lowering the OML conveyor 860 to place the composite component 1000 in contact with the track 144.

[0166] Example 25A: The method 1100 according to Example 24A, wherein the OML conveying device 860 is removed and the composite component 1000 is advanced along the track 144.

[0167] Example 26A: The method 1200 according to any one of Examples 18A to 25A, wherein the steps of transferring the composite component 1000 away from the OML mandrel tool 130 to the inner mold line (IML) conveyor 850 and transferring the composite component 1000 away from the IML conveyor 850 to the OML conveyor 860 include:

[0168] The composite components 120, 1000 are lowered (1206) onto an IML conveying device 850 that is complementary to the IML of the composite components 120, 1000.

[0169] Fix the IML conveying device (1208) to the composite components 120, 1000;

[0170] Remove (1210) the OML mandrel tool 130;

[0171] Align the OML delivery device 860 with the OML of the composite components 120, 1000 (1212);

[0172] Secure the OML conveying device 860 (1214) to the composite components 120, 1000;

[0173] Receiver (1216) the IML conveying device 850; and

[0174] The composite components 120 and 1000 are transported (1218) while being held and fixed to the IML conveying device 850.

[0175] Example 27A: The method 1300 according to any of the foregoing examples includes the following steps:

[0176] The composite component 120 is separated from the mandrel 110 by repeatedly and elastically deflecting a portion of the composite component 120;

[0177] The composite component 120 is transported to the track 144 via the extraction tool 130; and

[0178] The composite component 120 is deposited onto the track 144.

[0179] Example 28A: According to the method 1300 of Example 27A, the step of depositing the composite component 120 onto the track 144 includes: lowering the support edge 124 of the composite component 120 onto the track 144.

[0180] Example 29A: The method 1300 according to Example 27A, wherein the track includes a support 700 for holding the composite component 120 in a groove 710, and the method 1300 further includes the steps of: holding the composite component 120 in the groove 710; and advancing the composite component 120 along the track 144 to a work station 160 for performing operations on the composite component 120.

[0181] Example 30A: A system for demolding a composite part 120 from a mandrel 110, the system comprising:

[0182] First arm 350, the first arm 350 includes:

[0183] A flexural member 344, the contour of which is complementary to that of the composite component 120, which has been hardened onto the mandrel 110; and

[0184] Clamping units 138, 342 are arranged along the flexural member 344 and mechanically connected to the first arcuate portion 334 of the composite component 120.

[0185] The second arm 360 includes:

[0186] A flexural member 344, the contour of which is complementary to that of the composite component 120; and

[0187] Clamping units 138, 342, which are disposed along the flexural member 344 and mechanically connected to the second arcuate portion 336 of the composite component 120; and

[0188] A control actuator 134 selectively rotates the first arm 350 and the second arm 360 such that elastic strain is repeatedly applied to the first bow-shaped portion 334 and the second bow-shaped portion 336.

[0189] Example 31A: The system according to Example 30A, wherein the first arm 350 further includes a lip 136 engaging with the end of the first arcuate portion 334; and the second arm 360 further includes a lip 136 engaging with the end of the second arcuate portion 336.

[0190] Example 32A: The system according to Example 30A or 31A, wherein the clamping units 138, 342 include a vacuum connector 343 that contacts the composite component 120 and applies suction to the composite component 120.

[0191] Example 33A: The system according to Example 30A or 31A, wherein the clamping unit 138, 342 includes an end effector 138-2 that physically clamps the indexing feature 122 at the composite component 120.

[0192] Example 34A: The system according to any one of Examples 30A to 33A further includes an actuable joint 137 connecting the first arm 350 and the second arm 360.

[0193] Example 35A: The system according to any one of Examples 30A to 34A further includes a crane 1050.

[0194] Example 36A: A portion of an aircraft assembled according to the method described in any of Examples 1A through 29A.

[0195] Example 37A: A non-transitory computer-readable medium containing program instructions that, when executed by a processor, are operable to perform the method described according to any one of Examples 1A to 29A.

[0196] Example 38A: A part of an aircraft assembled according to instructions defined on a computer-readable medium stored in Example 37A.

[0197] Example 39A: Use the system described in any one of Examples 30A to 35A to manufacture a part of an aircraft.

[0198] Although specific embodiments have been described herein, the scope of this disclosure is not limited to these specific embodiments. The scope of this disclosure is defined by the appended claims.

Claims

1. A method (200) for demolding a composite component (120) from a mandrel (110), the method (200) comprising the steps of: The first arm (350) of the extraction tool (130) is mechanically connected to the first arcuate portion (334) of the composite component (120) that has been hardened to the mandrel (110). The second arm (360) of the extraction tool (130) is mechanically connected to the second arcuate portion (336) of the composite component (120); and The composite component (120) is separated from the mandrel (110) (206) by repeatedly performing the following operations until the composite component (120) no longer contacts the mandrel (110): - The first arcuate portion (334) of the composite component (120) is elastically strained (208) via the first arm (350); and - The second bow-shaped portion (336) of the composite component (120) is elastically strained (210) via the second arm (360).

2. The method (200) according to claim 1, wherein the method (200) further comprises one or more of the following steps: - Based on the reduction in translational resistance of the composite component (120), it is determined that the composite component (120) is no longer in contact with the mandrel (110); and / or - Positioning the lip (136) of the first arm (350) to contact the end of the first arched portion (334), and positioning the lip (136) of the second arm (360) to contact the end of the second arched portion (336); and / or - Release the elastic strain on the composite component (120) so that the composite component (120) elastically returns to the shape defined by the mandrel (110); and / or - Lift the composite component (120) away from the mandrel (110) and place the composite component (120) onto the track (144) for the assembly line; and / or in, The steps of mechanically connecting the first arm (350) to the first bow-shaped portion (334) include: positioning the first arm (350) in contact with the side of the semi-cylindrical section (121) of the fuselage; and the steps of mechanically connecting the second arm (360) to the second bow-shaped portion (336) include: positioning the first arm (350) in contact with the side of the semi-cylindrical section (121) of the fuselage.

3. The method (200) according to claim 1 or 2, wherein: The steps of mechanically connecting the first arm (350) to the first bow-shaped portion (334) include: placing a vacuum connector (343) at the first arm (350) in contact with the first bow-shaped portion (334); and the steps of mechanically connecting the second arm (360) to the second bow-shaped portion (336) include: placing a vacuum connector (343) at the second arm (360) in contact with the second bow-shaped portion (336).

4. The method according to claim 1 or 2, wherein, The step of separating the composite component (120) from the mandrel (110) (206) further includes: repeatedly increasing (256) the elastic strain applied to the first bow-shaped portion (334) and the elastic strain applied to the second bow-shaped portion (336).

5. The method according to claim 1, wherein the method comprises: The first arm assembly (132-1) of the extraction tool (130) is mechanically connected to the first arcuate portion of the composite component (120), wherein the first arm assembly (132-1) includes the first arm (350) and the second arm (360).

6. The method according to claim 1, wherein, The extraction tool (130) includes an external mold line OML mandrel tool, and the method further includes the following steps: - Transfer the composite component away from the OML mandrel tool to the inner mold line IML conveyor (850). - Transfer the composite component away from the IML conveyor (850) to the OML conveyor (860); and - The composite component is transported via the OML conveyor (860).

7. The method according to claim 6, wherein: The step of transferring the composite component away from the OML mandrel tool to the IML transport device (850) includes: engaging the indexing feature of the composite component (120) located in the manufacturing allowance (127, 129) of the composite component with the IML transport device (850).

8. The method according to claim 6 or 7, wherein, The steps of transporting the composite component via the OML conveyor (860) include: Operate the crane (1050) to lift the OML conveyor (860) above the track (144); and Lower the OML conveyor (860) to place the composite component into contact with the track (144).

9. The method according to claim 1 or 2, wherein: The step of separating the composite component (120) from the mandrel (110) via the extraction tool (130) involves repeatedly and elastically deflecting portions of the composite component (120); The composite component (120) is transported to the track (144) via the extraction tool (130); and The composite component (120) is deposited onto the orbital (144).

10. The method (200) according to claim 1 or 2, wherein: The steps of mechanically connecting the first arm (350) to the first bow-shaped portion (334) include: clamping the rotation feature (122) in the first bow-shaped portion (334) via the first arm (350); and the steps of mechanically connecting the second arm (360) to the second bow-shaped portion (336) include: clamping the rotation feature (122) in the second bow-shaped portion (336) via the second arm (360).

11. The method according to claim 1 or 2, further comprising: The decrease in translational resistance of the composite component (120) indicates that the resin at the composite component (120) has been released from the mandrel (110).

12. The method according to claim 1 or 2, wherein, Elastic strain of the first bow-shaped portion (334) is performed by clamping the support edge (124) of the first bow-shaped portion (334), or by performing elastic strain of the first bow-shaped portion (334) from the support edge (124) of the first bow-shaped portion (334).

13. The method according to claim 4, wherein, The step of repeatedly increasing the elastic strain includes: alternately increasing the elastic strain applied to the first bow-shaped portion (334) and increasing the elastic strain applied to the second bow-shaped portion (336).

14. The method according to claim 1 or 2, further comprising: The third portion (141-3) of the composite component (120) is elastically strained away from the mandrel (110).

15. The method according to claim 1, wherein, The step of mechanically connecting the second arm assembly (132-2) of the extraction tool (130) to the second bow-shaped portion of the composite component (120) includes applying a vacuum connection to the composite component (120) via a vacuum connector (343) at the second arm assembly (132-2).

16. The method according to claim 1, wherein, The step of separating the hardened resin (276) at the composite component (120) from the mandrel (110) by applying strain to the composite component (120) via the first arm (350) and the second arm (360) includes: separating the hardened resin (276) between the longitudinal beams (332) of the composite component (120) from the groove (322) of the mandrel (110).

17. The method according to claim 7, wherein, The step of transferring the composite component away from the OML mandrel tool to the IML transport device (850) includes: attaching the composite component to the IML transport device (850); and engaging the fixing element (856) with the indexing feature at the composite component.

18. The method according to claim 6, wherein, The composite component is attached to the IML conveyor (850) by vacuum connection or via fasteners.

19. The method according to claim 6, wherein, The step of transferring the composite component away from the IML conveyor (850) to the OML conveyor (860) includes: engaging a rotation feature of the composite component (120) in the manufacturing allowance (127, 129) of the composite component with the rotation feature at the OML conveyor (860); and releasing the IML conveyor (850).

20. The method according to claim 6, wherein, The steps of transferring the composite component away from the OML mandrel tool to the inner mold line IML conveyor (850) and transferring the composite component away from the IML conveyor (850) to the OML conveyor (860) include: The composite component is lowered (1206) onto an IML conveying device (850) that is complementary to the IML of the composite component; Fix the IML conveying device (1208) to the composite component; Remove (1210) the OML mandrel tool; Align the OML delivery device (860) with the OML of the composite component (1212). Secure the OML delivery device (860) (1214) to the composite component (120, 1000). Receive (1216) the IML conveying device (850); and The composite component is transported (1218) while it remains fixed to the IML conveying device (850).

21. The method according to claim 7, wherein: The indexing feature of the composite component is indexed to the IML conveyor (850) before being demolded from the OML mandrel tool.

22. The method according to claim 8, wherein, Remove the OML conveyor (860) and advance the composite component along the track (144).

23. The method according to claim 9, wherein: The step of depositing the composite component (120) onto the track (144) includes lowering the support edge (124) of the composite component (120) onto the track (144).

24. The method according to claim 9, wherein: The track includes a support (700) for holding the composite component (120) in a groove (710), and the method further includes the following steps: - Holding the composite component (120) in the groove (710); and - Advance the composite component (120) along the track (144) to the work station (160) where the composite component (120) is to perform the operation.

25. A system for demolding a composite component (120) from a mandrel (110), the system comprising: - A first arm (350) comprising: a flexure member (344) having a profile complementary to that of a composite component (120) hardened to a mandrel (110); and clamping units (138, 342) disposed along the flexure member (344) and mechanically coupled to a first arcuate portion (334) of the composite component (120); - A second arm (360), comprising: a flexural member (344) of the second arm having a contour complementary to that of the composite component (120); and clamping units (138, 342) of the second arm disposed along the flexural member (344) of the second arm and mechanically coupled to a second arcuate portion (336) of the composite component (120); and - Control driver (134) selectively rotates the first arm (350) and the second arm (360) such that elastic strain is repeatedly applied to the first bow portion (334) and the second bow portion (336).

26. The system according to claim 25, wherein: The first arm (350) further includes a lip (136) that engages with the end of the first arched portion (334); and the second arm (360) further includes a lip (136) that engages with the end of the second arched portion (336); and / or The clamping unit (138, 342) includes: - A vacuum connector (343) that contacts the composite component (120) and applies suction to the composite component (120); or - An end effector (138-2) that physically clamps the indexing feature (122) at the composite component (120).

27. The system according to claim 25 or 26, the system further comprising an actuable joint (137) connecting the first arm (350) and the second arm (360).

28. The system according to claim 25 or 26, the system further comprising a crane (1050).

29. A non-transitory computer-readable medium comprising program instructions that, when executed by a processor, are operable for performing the method according to any one of claims 1 to 24.

30. Manufacturing a part of an aircraft using the system of any one of claims 25 to 27.

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