Area lamination for composite parts in mobile production lines

Abstract

This invention relates to regional lamination of composite components for use in mobile production lines. A method for manufacturing composite components includes subdividing a laminate into multiple regions, laying tows of fiber reinforcement material for the laminate onto a laying mandrel via multiple laminations, such that each laminator applies the tows in a different region, and splicing the regions together during the laying of the tows to form the laminate.

Description

Technical Field

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

[0002] Large composite components, such as those spanning tens of feet, occupy a significant amount of space within the factory floor. Laminates for these components are laid on layup mandrels in stationary work cells, including automated fiber placement (AFP) machines for large end effectors of large robotic arms, which continue adding fiber reinforcement on a tow-tow basis. Individual AFP machines traverse the entire component individually according to an optimized layup pattern.

[0003] Patent document US 2010 / 193103 A1, according to its abstract, describes laying composite laminates by using multiple independently controlled strip application vehicles to apply different configurations of composite strips on different sections of the tool surface.

[0004] Patent document EP 3173218 A1 describes, according to its abstract: an apparatus for manufacturing fiber composite components, the apparatus comprising a forming tool and a plurality of mechanically independent deposition units, each of the deposition units being designed to deposit fiber material onto the forming tool, each deposition unit having a control device designed to control the respective deposition unit to automatically interact with at least one other deposition unit, thereby jointly depositing a predetermined fiber arrangement.

[0005] Patent document DE 102010015027 A1, according to its abstract, describes an apparatus having a tool for laying fiber mats and a closed guide rail system surrounding the tool. Two robots are movably guided by the guide rail system and include a laying head designed for laying the fiber mats. A rotating device moves the robots from one guide rail segment to another. A contact-type free contour detector is arranged for detecting the contour of the fiber mats and / or fiber composite molding blanks. The guide rail segments are arranged at an angle of less than 150 degrees.

[0006] Patent document EP 3406431 A1, according to its abstract, describes a system and method for laying laminates. Specifically, one method includes: laying a multilayer laminate of fiber-reinforced material onto a surface by feeding a strip of fiber-reinforced material to a strip cutter that cuts the strip into small pieces; picking up small pieces of fiber-reinforced material via a pick-and-place device at each of a plurality of laminating units in a direction of travel; and placing the small pieces of fiber-reinforced material via the pick-and-place device to form a laminate as the surface and laminating units change position relative to each other and the plurality of small pieces are laid simultaneously.

[0007] Therefore, existing technologies for manufacturing large composite components require a significant amount of time for the layup mandrel to be rotated and then the laminate to be laid. Thus, a method and apparatus that takes into account at least some of the aforementioned problems, as well as other potential issues, is desirable. Summary of the Invention

[0008] The embodiments described herein provide region-based lamination achieved via multiple laminating heads. By subdividing the laminate into multiple regions and assigning these regions to different laminating heads that operate sequentially, overall production speed is increased. Furthermore, because the laying mandrel travels in the processing direction during manufacturing (e.g., by periodically “pulsating” in the processing direction or by moving continuously in the processing direction), flow through the factory floor is enhanced. That is, the transport time of the composite component can be used to perform operations on the composite component, which improves efficiency.

[0009] One embodiment is a method for manufacturing a composite component. The method includes subdividing a laminate into multiple regions, laying bundles of fiber reinforcement material for the laminate onto a laying mandrel via multiple laminating heads, such that each laminating head applies the bundles in a different region, and splicing the regions together during the laying of the bundles to form the laminate.

[0010] Another embodiment is a non-transient computer-readable medium implementing programming instructions that, when executed by a processor, are operable to perform a method for manufacturing a composite part. The method includes subdividing a laminate into multiple regions, laying tows of fiber reinforcement material for the laminate onto a laying mandrel via multiple laminating heads, such that each laminating head applies the tows to a different region, and joining the regions together during the laying of the tows to form the laminate.

[0011] Another embodiment is an apparatus for manufacturing composite components. The apparatus includes a lamination station that allows lamination heads to follow the contour of a layup mandrel that moves in a processing direction during the manufacturing of the composite component. The lamination heads positioned at the lamination station are configured to lay fiber reinforcement onto the layup mandrel. The lamination heads are configured to operate sequentially to lay fiber reinforcement in different regions of the laminate at the layup mandrel and to join these regions together. In one embodiment, the lamination heads operate sequentially so that fiber reinforcement is laid simultaneously while joining the regions together.

[0012] Another embodiment is a system for manufacturing composite components. The system includes a track and a lamination station. The track follows the profile of a layup mandrel that moves in a processing direction during the manufacturing of the composite component. The lamination station includes a lamination head movably mounted to the track and configured to lay fiber reinforcement material onto the layup mandrel. The lamination heads are configured to operate sequentially to simultaneously lay fiber reinforcement material for the laminate in different areas at the layup mandrel while splicing areas together.

[0013] Other illustrative embodiments may be described below (e.g., methods and computer-readable media related to the foregoing embodiments). The features, functions, and advantages already discussed may be implemented independently in various embodiments or combined in other embodiments, further details of which can be seen in the following description and drawings. Attached Figure Description

[0014] Some embodiments of this disclosure will now 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.

[0015] Figure 1A This is an illustration of an aircraft that can be manufactured using composite components made according to the methods, systems, and devices described herein.

[0016] Figure 1B This is a block diagram of a manufacturing environment used in an illustrative embodiment for laying a laminate that will be hardened into a composite component.

[0017] Figure 2A This is a flowchart illustrating a method for laying laminates in an illustrative embodiment.

[0018] Figure 2B and Figure 2C A flowchart illustrating a method for selecting the splicing position at a laminate in an illustrative embodiment is described.

[0019] Figure 2D This is a flowchart illustrating a method for interlacing cuts of spliced ​​components in an illustrative embodiment.

[0020] Figure 2E This is an end view of the splice at the laminate in the illustrative embodiment.

[0021] Figure 2F An angled mating portion overlapping between regions is shown in the illustrative embodiment.

[0022] Figure 2G This is an end view of the splice at the laminate in the illustrative embodiment.

[0023] Figure 2H The illustration shows non-angled or straight mating portions between overlapping areas in the illustrative embodiment.

[0024] Figure 3A This is a perspective view of the manufacturing environment for laying the fuselage section in the illustrative embodiment.

[0025] Figure 3B In the illustrative implementation Figure 3A A side view of the manufacturing environment.

[0026] Figure 4A This is a top view of the laminated sheet of the fuselage section in the illustrative embodiment.

[0027] Figure 4B This is a top view of a sheet map of a laminate used for a wing panel in an illustrative embodiment.

[0028] Figures 5 to 6 This is a perspective view of a manufacturing environment used for laying wing skin in an illustrative embodiment.

[0029] Figure 7 This is a flowchart of an aircraft manufacturing and maintenance method in an illustrative implementation.

[0030] Figure 8 This is a block diagram of the aircraft in the illustrative embodiment. Detailed Implementation

[0031] The accompanying drawings and the following description provide specific illustrative embodiments of this disclosure. Therefore, it will be understood that those skilled in the art will be able to devise various arrangements that, while not expressly described or shown herein, implement the principles of this disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and are to be construed as not being limited to such specific examples and situations. Therefore, this disclosure is not limited to the specific embodiments or examples described below, but is defined by the claims and their equivalents.

[0032] Composite components, such as carbon fiber reinforced polymer (CFRP) components, are initially laid out in multiple layers, which together are referred to as preforms. Individual fibers within each layer of the preform are aligned parallel to each other, but different layers with different fiber orientations can be used to increase the strength of the resulting composite component along different dimensions. The preform includes a tackifying resin that cures to harden the preform into a composite component (e.g., for use in aircraft). Carbon fibers already impregnated with uncured thermosetting or thermoplastic resins are called “prepregs.” Other types of carbon fibers include “dry fibers,” which are not impregnated with thermosetting resins but may include tackifiers or adhesives. Dry fibers are infused with resin before curing. For thermosetting resins, curing is a unidirectional process called curing, while for thermoplastic resins, the resin reaches a tack form if it is reheated.

[0033] Now turn Figure 1A The illustration depicts an aircraft in which an illustrative embodiment can be implemented. Aircraft 10 is an example of an aircraft 10 formed by a semi-cylindrical section 24 of a fuselage 12.

[0034] In this illustrative example, aircraft 10 has wings 15 and 16 attached to fuselage 38. Aircraft 10 includes an engine 14 attached to wing 15 and an engine 16 attached to wing 16. Each wing 15, 16 has a wingtip 11 and a root 17. Each wing extends from a forward portion 19 to a rear portion 23.

[0035] The main body 38 has a tail section 18. Horizontal stabilizers 20, 21 and 22 are attached to the tail section 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 continuously connected to form the fuselage 12.

[0037] Both wings 15 and 16 are formed by wing panels 30, which include an upper wing panel 32 and a lower wing panel 34 connected together.

[0038] Figure 3AThis is a perspective view of a manufacturing environment 300 for laying the semi-cylindrical section preform 24-1. In this embodiment, the laying mandrel 110 includes a surface 112 that has been precisely formed to a desired profile 112-1. The laying mandrel 110 also includes a machining feature 114 that facilitates indexing into a manufacturing allowance 122 of the semi-cylindrical section preform 24-1. As the laying mandrel 110 travels in the processing direction 180, the laminate 120 is laid onto the surface 112. For example, the laying of the semi-cylindrical section preform 24-1 is performed by the lamination station 130 during micro-pulsations, pauses between pulsations, or during continuous movement of the laying mandrel 110. The laminate 120 includes a manufacturing allowance 122. The manufacturing allowance 122 may receive an indexing feature via machining after the laminate 120 has been hardened, or it may receive an indexing feature imposed into the manufacturing allowance 122 by the surface 112. Manufacturing allowance 122 includes Figure 1B The stripes shown and Figure 3B The door cutout range 375 and window cutout range 378 are shown.

[0039] The aforementioned semi-cylindrical preform 24-1 is executed via a laminating head 134 positioned along track 132. In one embodiment, the laminating head 134 begins placement of 124, 124-1 at a radial position and operates in a counter-clockwise direction 65 until it stops. In another embodiment, the laminating head 134 travels to perform layup in its corresponding area in the circumferential direction 66 as it performs a coordinated sweep in either a clockwise or counter-clockwise direction 64 (or both). In yet another embodiment, the laminating head 134 begins at a radial position and operates in a clockwise direction 64 until it stops at a distal end. The laminating head 134 can perform multiple strokes in this manner to apply multiple bundles 124, 124-1 in multiple fiber orientations. The laminating head 134 then pauses until the next micro-pulsation, pulsating, continuous movement of the structure, and operates in a clockwise direction 64 toward the starting point. The sweeping motion of the laminating head 134 in one direction and its return in the opposite direction is efficient, reducing movement to only that necessary for placing the filament bundles 124, 124-1. Individual laminating heads 134 can be removed and replaced, and then undergo maintenance while their replacement continues.

[0040] The discussion presented herein is by no means limited to requiring all laminators to operate simultaneously in the same direction. The areas provided herein allow laminator 134 to simultaneously apply different layup orientations and / or patterns. This is particularly relevant because different areas will perform different layup requirements in the form of different skin thicknesses, different gaskets, including doublers and sacrificial layers. Therefore, the layup is not necessarily uniform from one end to the other or along the circumferential direction 66.

[0041] Figure 1B This is a block diagram of a manufacturing environment 100 for laying laminates that will harden into composite components 55, 55-1, in an illustrative embodiment. The manufacturing environment 100 includes any system, apparatus, or component operable to synchronously utilize a moving laminating head to lay laminate 120 onto a surface 112 of a laying mandrel 110 traveling in a processing direction 180 during manufacturing. The laying mandrel 110 already has a plurality of longitudinal beams (not shown) placed longitudinally 181 into the surface 112 and forming part of that surface. The longitudinal beams are positioned upstream 181-1 of laminating stations 130, 130-1. Laminating stations 130, 130-1 lay on the laying mandrel 110 and the longitudinal beams. When viewed from the end, surface 112 forms a semi-cylindrical section preform 129 (i.e., a semi-cylinder) and may define an inner mold line (IML) 121 for the semi-cylindrical section preform 129. Figure 1B The view shown only shows the proximal side of the laying mandrel 110 and laminate 120. Therefore, the entire area 117 is shown, only a portion of area 115 is shown, and the distal area 117-1 is not shown. (Refer to...) Figure 3A It shows regions 115, 117, and 117-1 depicted by line 319. In this embodiment, during manufacturing, the laying mandrel 110 travels along track 132, for example, the laying mandrel 110 is transported. The laying mandrel 110 can be incrementally pulsating, for example, micro-pulsations smaller than the length 181-7 of the laying mandrel 110 in the processing direction 180, or pulsations along its entire length 181-7. In such an embodiment, the work performed on the laying mandrel 110 can be performed during the pauses between pulsations. In another embodiment, the laying mandrel 110 travels continuously in the processing direction 180. The laying mandrel 110 defines the semi-cylindrical section 24 and the wing panel 30, respectively. Figure 1A The outlines 113 and 113-1 of the wing panel 30. In another embodiment, the mandrel 110 defines the outer mold line (OML) 521 of the wing panel 30. Figure 5 ).

[0042] Lamination stations 130, 130-1 lay tows 124 of fiber-reinforced material (e.g., carbon fiber reinforced polymer or carbon fiber reinforced plastic CFRP) onto a laying mandrel 110 via multiple lamination heads 134. In this embodiment, the multiple lamination heads 134 are arranged along a track 132 (e.g., sharing a track), but in another embodiment, the lamination heads 134 do not share a track 132, but rather each lamination head 134 independently utilizes a track 132 and thus lays the tow from an independent track. Furthermore, although only one lamination station 130 is shown in the longitudinal ranges 123, 123-1, multiple lamination stations 130, 130-1 or lamination heads 134 may be arranged longitudinally 181 to perform operations simultaneously or synchronously. Additionally, the lamination heads 134 may be arranged longitudinally 181 and / or circumferentially continuously and / or in parallel. Track 132 may be provided at an offset 135 from the laying mandrel 110 and may be arranged such that track 132 and laminator 134 can pass over another track 132 and another laminator 134 to improve versatility and avoid collisions, especially in splice areas 190, 123-5. The laminator 134 follows track 132 during laying and may include internal actuators or other components (not shown) to facilitate movement across track 132, which itself may be movable relative to the longitudinal direction 181 of the laying mandrel 110. In one embodiment, track 132 is complementary to the profiles 113, 113-1 of the laying mandrel 110. During the laying process, the laminating head 134 operates sequentially to apply the filament bundles 124 in parallel to lay them in regions 115, 117, and 117-1 and / or longitudinal ranges 123, 123-1 on the laying mandrel 110 to create a laminate 120 that will harden into a semi-cylindrical section preform 24 or a wing panel 30. In this embodiment, the visible layer of the laminate 120 includes filament bundles 124-1 at a 45-degree angle, but other layers may include filament bundles 124 arranged with a different fiber orientation than the filament bundles 124 shown at a zero-degree orientation.

[0043] The laminators 134 can operate in regions 191 and 123-2 that overlap with adjacent laminators 134. The splicing regions 190 and 123-5 at the overlapping regions 191 and 123-2 are executed in such a way that splicing regions 190 and 123-5 can be formed without the risk of collision between laminators 134. The laminators 134 operate collaboratively, laying not only regions 115 and 117 and the longitudinal ranges 123 and 123-1, but also splicing elements 392, 394, 395, 392-1, 394-1, and 395-1 in the splicing regions 190 and 123-5 to form a complete laminate 120. Furthermore, the laminators 134 can move in a specific orientation (e.g., 0°, + / -45°, 90°, etc.) or can be specifically used to lay filament bundles in only one orientation. In one embodiment, different lamination stations 130, 130-1 include different combinations of lamination heads 134. For example, upstream lamination station 130-1 181-1 may include five lamination heads 134, with one lamination head 134 for region 115, and two lamination heads 134 for each of region 117 and region 117-1. Downstream lamination station 130 181-2 may include three lamination heads 134, for example, one lamination head 134 for region 115, and one lamination head for each of region 117 and region 117-1. In another embodiment, the lamination head 134 serves as an end effector for a robotic arm (not shown) that sweeps across the laminate 120 without requiring a track 132. The lamination head 134 will be paired with the robotic arm in a one-to-one relationship.

[0044] In this embodiment, the laminate 120 includes a manufacturing allowance 122 that, during layup and processing, after hardening or forming into the laminate 120, can receive indexing features, such as holes, slots, or pins, by surface 112 to facilitate indexing of the composite components 55, 55-1 to a post-hardening assembly workstation after the composite components 55, 55-1 have been removed from the layup mandrel 110. Unlike existing systems that rely on a single integrated AFP machine, Figure 1B The manufacturing environment 100 described herein offers technical benefits by dividing the laying operation into several ranges across multiple laminators 134 and connecting these ranges together using splicers. Because it reduces the size of individual laying ranges to smaller areas for efficiency, multiple laminators can be operated immediately, and then the boundaries between ranges can be unified using interlocking or stepped overlap. Furthermore, the multi-layer laminator 134 system described herein facilitates the use of smaller, lighter, and dedicated laminators 134, which are simpler than conventional AFP heads, thus having a smaller volume for manipulation and lower complexity. This allows the laminator heads 134 to move faster and more precisely, and also increases reliability and ease of maintenance.

[0045] The laminator 134 can be designed to perform various movements relative to the lay mandrel 110. For example, the laminator 134 can move while the lay mandrel 110 remains stationary, the lay mandrel 110 can move relative to the fixed laminator 134, or a combination of the lay mandrel 110 and the laminator 134 moving relative to each other can be used to facilitate laying.

[0046] Track 132 has a profile complementary to that of the laying mandrel 110 and may include a rigid track set at an offset O known to the indexing unit 136. The indexing unit 136 mates with machining features 114 at the laying mandrel 110, such as slots, blind holes, bores, and pins, to precisely index the laying mandrel 110 to lamination stations 130, 130-1. Although in Figure 1B Only two lamination stations 130, 130-1 are shown in the diagram, but in another embodiment, more lamination stations 130, 130-1 are arranged in the processing direction 180 (i.e., longitudinal direction 181). Additionally, in one embodiment, the lamination stations 130, 130-1 to the pre-autoclave side are vacuum bag installation stations (not shown), followed by a partition installation station (not shown). Another embodiment has a partition that performs the dual function of partition and vacuum bag. In one embodiment, the lamination station 130 downstream of the current lamination station 130-1 includes a single lamination head 134 for performing any desired reprocessing or additional laying. If the upstream lamination head 134 181-1 lags behind, the single lamination head 134 can perform any missed additional laying. In another embodiment, each lamination station 130, 130-1 is movable back and forth in the processing direction 180 to facilitate the laying process. In another embodiment, fewer lamination heads 134 are provided in region 115 than in region 2 117 or region 3 117-1. Since region 115 typically has a less complex layout and / or fewer layers, fewer lamination heads 134 can be used for laying in region 115 compared to region 2 117 and region 3 117-1.

[0047] Figure 1BA lamination server 170 for controlling the operation of lamination stations 130, 130-1 is also shown. In this embodiment, the lamination server 170 includes an interface 172, optionally including a wired connection 171, such as an Ethernet interface, a Universal Serial Bus (USB) interface, or a wireless interface, for communicating with lamination stations 130, 130-1 and / or the rotary table unit 136. The lamination server 170 includes a memory 176 storing one or more numerical control (NC) programs for operating lamination stations 130, 130-1. In one embodiment, the NC program mitigates the risk of collision by ensuring that multiple lamination heads 134 do not operate close enough to each other to cause a collision. The operation of more than one lamination head 134 is coordinated to ensure that multiple lamination heads 134 do not collide during operation. Each laminator head 134 is paired with various offsets 135 on a track 132, reducing the complexity of guiding the laminator heads 134 through the overlapping regions 191, 123-2 by avoiding more than one laminator head 134 on each track 132 within the overlapping regions 191, 123-2. The various offsets 135 allow one track 132 to pass under another track 132. In another embodiment, the laminator head 134 includes sensors that detect proximity to other laminator heads 134, and the laminator heads 134 stop and / or move away when they approach each other closer than a threshold proximity. The controller 174 manages the operation of the laminator server 170 by processing feedback from lamination stations 130, 130-1 and / or the toggling unit 136 and providing instructions based on this feedback. The controller 174 can be implemented as, for example, a custom circuit system, a hardware processor executing programmed instructions, or some combination thereof.

[0048] Figure 1B Also shown is a splicing region 190 between region 115 and region 217; similarly, a splicing region (not shown) exists between region 115 and region 317-1. Although splicing region 190 is shown as a circumferential splice arranged longitudinally 181, such as a circumferential splice... Figure 1BHowever, a splicing region 123-5, set along the length 181-7 of the laminate 120, can be used at the overlapping range 123-2 between the longitudinal ranges 123 and 123-1. In another embodiment, the splicing region 123-5 is omitted within region 115 of the laminate 120 because a single laminator head 134 with an appropriate offset 135 on the dedicated track 132 can apply all the filament bundles 124, 124-1 without splicing. Furthermore, although the laminate 120 is shown as having a short length 181-7 relative to its height 181-9, in one embodiment, the length 181-7 of the laminate 120 extends, for example, 7.62 m (twenty-five feet), and in another embodiment, the length 181-7 extends up to 12.2 m (forty feet) or longer. Thus, the first set of laminators 134 in the lamination station 130 can lay the sheets 126 along the length 181-7 of the laminate 120 at a first range R1. The first range R1 will coincide with the longitudinal range 123. Then, the laminate 120 is micro-pulsated in the processing direction 180 until the longitudinal range 123 coincides with the second range R2 and falls within the range of another set of laminators 134 in lamination station 130-1. Simultaneously, the longitudinal range 123-1 is micro-pulsated to coincide with the third range R3 (not shown) and enter the range of lamination station 130-N (not shown). Similarly, the mandrel advances in the processing direction 180 from lamination stations 130, 130-1 to lamination station 130-N until the laminate 120 is completed. The micro-pulsation is the advancement of the mandrel 110 and the laminate 120 in the processing direction 180 by less than a length 181-7. In the illustrated embodiment, the micro-pulsation is approximately half the length 181-7. Other embodiments with more closely spaced lamination stations 130, 130-1 have micro-pulsations of approximately one-third or less of the length 181-7. Full pulsation is the advancement of the lay-up mandrel 110 and the laminate 120 along its length 181-7 in the processing direction 180. After the micro-pulsation, the first range R1 becomes the second range R2, and the lamination station 130-1 is constructed on the filaments 124 placed in the first range R1 by the lamination station 130 by adding additional filament bundles 124, 124-1, while the lamination station 130 lays up sheets 128 for the next range R2 of the laminate 120. Furthermore, the lamination stations 130, 130-1 and / or the lamination head 134 can be positioned, and / or the pulsation of the laminate 120 can be coordinated to allow operation within the splicing areas 190, 123-2 as needed. Each splice may include a snap-fit ​​splice (not shown), an overlap splice 392-1, or a stepped overlap splice (not shown), and its thickness may vary compared to the unspliced ​​layers 396, 397, 398.

[0049] Unlike the laying of filament bundles 124, 124-1 for laminates distributed along length 181-7 and height 181-9 using a single AFP machine, each laminator head 134 is dedicated to a specific region 115, region 2 117, region 3 117-1, or longitudinal range 123 or 123-1, or combinations thereof. This reduces the likelihood of collisions while increasing laying efficiency. To accommodate this increased overall laying speed using multiple laminators 134, and to enable the manufacture of a single integral laminate 120, specific regions 115, region 2 117, region 3 117-1, or longitudinal range 123 or 123-1 are joined together.

[0050] In some implementations, such as Figures 2E to 2H As shown, splicing areas 190, 123-5 have interlaced splicing elements 392, 394, 395 that are laid out alternately through overlapping portions 399, 399-1 of the laminate 120, from adjacent sheets 396 to 398 to 397, etc. In this arrangement, the filament bundles 124, 124-1 of each sheet in splicing areas 190, 123-5, such as sheet segments 393, form angled butt joints 385, 386 at the splicing elements 392 (see...). Figure 2F ) and non-angled docking parts 387, 387-1 (see Figure 2HThe construction terminates at the layup splice 392-1, where it is not separated from the sheet segment 393-1 or has a small separation (e.g., a small portion of 2.54 cm (one inch)). The layup splice 392 has sheet segments 393 and 393-1, which are cut and placed into complementary angled butt joints 385, 386 and non-angled butt joints 387, 387-1 as part of the layup splice 392-1, wherein the overlaps 399, 399-1 are staggered relative to the layup splice 394. This type of overlap 399, 399-1, staggered with the subsequent layup splices 392, 394, 395, provides the layup splice 392-1, which facilitates load transfer through the splice areas 190, 123-5. Another embodiment features interlocking or stepped overlap panels (not shown). All panel types require trimming of sheet segments 393 and 393-1 to achieve complementary alignment. Sheet 396 has layup panels 392 that intersect with the layup panels 394 of sheet 398, and so on for each subsequent sheet of laminate 120. Furthermore, the interlocking regions 190, 123-5 are located in less complex or thinner portions of laminate 120, such as areas without window / door surrounds, gaskets, or other complex geometries. In this way, the panels are positioned between complex layup regions rather than within those regions. The panels may be thicker than the un-interlocked laminate 120, and therefore the panels may include staggered joints of one or more cut portions of sheets extending through the thickness of laminate 120. In another embodiment, within the splicing regions 190, 123-5, the cutting positions of the individual layers 396, 398, 397 within the splicing components 392, 394, 395 are staggered relative to the angled butt joints 385, 386 and non-angled butt joints 387, 387-1 of other layers. This causes the distances of the splicing components 392, 394, 395 across multiple overlaps 399, 399-1 to be staggered, which enhances the load-bearing characteristics of the overlapping splicing component 392-1. The staggered cutting positions of the layers within the splicing regions 190, 123-5 enhance their ability to withstand loads passing through them when hardened into composite components 55, 55-1. After receiving the layup, the laying mandrel 110 advances to the autoclave 193.

[0051] Will refer to Figure 2A Illustrative details of the operation of manufacturing environment 100 are discussed. For this embodiment, it is assumed that the laying mandrel 110 has been rotated but has not yet received any composite material, and has just begun to travel under track 132.

[0052] Figure 2AThis is a flowchart illustrating a method 200 for laying laminates in an illustrative embodiment. The steps of method 200 are referenced... Figure 1B The method 200 is described using the manufacturing environment 100 described herein, but those skilled in the art will understand that it 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.

[0053] In step 202, during the manufacture of composite components 55, 55-1, the laying mandrel 110 is moved continuously or intermittently to the lamination stations 130, 130-1 in the processing direction 180. Receiving the laying mandrel 110 may include the laying mandrel 110 traveling a first range R1 below the lamination station 130, or may include the laying mandrel 110 reaching a position where it can be indexed by the indexing unit 136.

[0054] In step 204, indexing unit 136 indexes layup mandrel 110 to a plurality of laminating heads 134. This is performed by placing complementary feature 136-1 at indexing unit 136 into one or more machining features 114 at layup mandrel 110 to precisely determine the position of layup mandrel 110 and surface 112 to laminating station 130. Because the overlap offset O 399 of indexing unit 136 is precisely known, the position of layup mandrel 110 relative to laminating stations 130, 130-1, and any laminating heads 134 can be programmatically determined based on the position of layup mandrel 110 relative to indexing unit 136. Based on this information, the NC program at controller 174 can be updated to account for any discrepancies between the layup mandrel 110 or surface 112 and the expected nominal orientation / position. Layup mandrel 110 can be repositioned relative to laminating station 130 and / or the NC program to eliminate such discrepancies.

[0055] In step 206, the layup is subdivided into zone 115, zone 217, zone 317-1, and longitudinal ranges 123, 123-1 by controller 174 and / or N / C program. Within each zone 115, zone 217, zone 317-1, and longitudinal range 123, 123-1, a single laminating head 134 is operated. By forming these zones 115, 117, 117-1, and longitudinal ranges 123, 123-1, and restricting the movement of the laminating head 134 within these zones or ranges, layup can be performed independently by the laminating head 134 at lamination stations 130, 130-1, and / or additional lamination stations 130-n, without the need for complex sensing and collision avoidance. That is, since the laminating heads 134 do not operate within each other's zones and ranges, and because the movements of the laminating heads 134 are coordinated relative to each other, there is no chance of collision when the laminating heads 134 are operating in parallel. Collision avoidance occurs even in environments including overlapping areas 191, 123-2 to form layup splices 392, 394, 395. For example, controller 174 can guide its laminators 134 to operate in parallel on the front portion 127-1 of areas 115, 117, 117-1, and longitudinal ranges 123, 123-1. The laminators 134 travel in parallel to the rear portion 127 of their respective areas or longitudinal ranges to ensure that the laminators 134 in longitudinal range 123 do not operate too close to the laminators 134 in longitudinal range 123-1 during layup.

[0056] In one embodiment, controller 174 places splice regions 190, 123-5 at the overlapping regions 191, 123-2 discussed above with respect to step 206. In another embodiment, controller 174 places splice regions 190, 123-5 at locations specified by the designer of composite components 55, 55-1 according to an NC program designed for a specific component. Splice regions 190, 123-5 allow structural strength to be carried from one region to an adjacent region in a manner similar to that of a portion without splice regions 190, 123-5. Splice regions 190, 123-5 facilitate the definition of regions 115, 117, 117-1, and longitudinal ranges 123, 123-1, rather than defining a large laminated region without splices. The number of laminated regions 115, 117, 117-1, and longitudinal ranges 123, 123-1 increases the material layup rate. Therefore, in one implementation, if each semi-cylindrical body is laminated in sections by three material laying areas, the material placement rate can be increased by up to six times compared to a complete cylindrical section using only one material placement device.

[0057] In step 208, filaments 124, 124-1 of the unidirectional fiber reinforcement material for the laminate 120 are simultaneously applied / laid onto the layup mandrel 110 via laminating heads 134, such that each laminating head 134 applies filaments 124, 124-1 in region one 115, region two 117, region three 117-1, and longitudinal ranges 123, 123-1. Therefore, the layup is performed either by directly applying the first layer 396 to the layup mandrel 110 or by applying it as a subsequent layer 398 on top of the first layer 396. That is, the controller 174 simultaneously and synchronously operates the laminating head 134 according to one or more stored NC programs to lay the filaments 124, 124-1 for the laminate 120. During these operations, the laminating head 134 precisely positions the filament bundles 124, 124-1 to ensure that the gaps 125 and overlaps 125-1 between the edges, as well as the start and end points, do not exceed the desired tolerances. Although the filament bundles 124 travel in the processing direction 180... Figure 1B As shown, however, the filament bundles 124 are positioned such that their fiber orientation (e.g., 0°, +45°, -45°, 90°) varies relative to the laminator 120, depending on the layer being laid. The laminator head 134 is also capable of lateral movement 134-1 relative to the track 132 for placement of 0° filament bundles, and / or bow-shaped movement 134-2 relative to the track 132 for placement of 45° filament bundles. This laying process can be completed at a single lamination station 130, or it can be performed in part by multiple lamination stations 130, 130-1, 130-N placed continuously relative to the processing direction 180. In many cases, multiple lamination stations 130, 130-1, 130-N are desirable because different parts of the fuselage 12 or wings 15, 16 of the aircraft may have very different thicknesses due to the spacers. For example, gaskets used for window or door surrounds, wing roots, or access doors, or for antennas, can be much thicker than other areas of the laminate 120.

[0058] In step 210, controller 174 operates laminating head 134 to join the regions together while applying filament bundle 124. That is, concurrently with step 208, during the laying of the regions, laminating head 134 joins the regions together. This is done to form a single, monolithic laminate. Any suitable join or joint can be prepared, such as interlocking joints (not shown), overlapping joins 392-1, stepped overlaps (not shown), etc., and overlaps 399-1 sufficient to ensure high bonding strength can also be selected, for example, an overlap 399-1 slope ratio of 30:1 or higher to the sheet thickness. Furthermore, the "joint" may include angled butt joints 385, 386 or non-angled butt joints 387, 387-1 constructions, overlaps 399, 399-1, or otherwise stacking the layers of region 115, region 2 117, and region 3 117-1, as well as longitudinal ranges 123, 123-1, against each other. This can be performed as a separate process or integrated into step 208, such that the filament bundles 124, 124-1 from each of region 115, region 217 and region 317-1 and longitudinal ranges 123, 123-1 extend into the splicing regions 190, 123-5 with a desired overlap of 399, 399-1 or a uniform slope, so as to form a splice between region 115, region 217 and region 317-1 and longitudinal ranges 123, 123-1.

[0059] In one embodiment, fiber-reinforced material bundles 124, 124-1 are applied to a laying mandrel 110 simultaneously at lamination stations 130, 130-1 via lamination heads 134. Each of the lamination heads 134 applies the bundles 124, 124-1 in a distribution area at the laying mandrel 110, and the lamination heads 134 at different lamination stations 130, 130-1, 130-n apply the bundles 124, 124-1 in different distribution areas and / or ranges. The steps of moving the laying mandrel 110, rotating the laying mandrel 110, and applying the bundles 124, 124-1 are then repeated. In this implementation, each laminator 134 is assigned to region 115, region 117 and region 117-1 and longitudinal ranges 123, 123-1, while a filament bundle 124 is applied, and the region assigned to each laminator 134 varies as the laying mandrel 110 moves in the processing direction 180.

[0060] The process can also be continued by further moving the layup mandrel 110 in the processing direction 180 and simultaneously applying additional bundles 124, 124-1 of fiber reinforcement material to the layup mandrel 110 via laminating heads 134, such that each laminating head 134 applies bundles in a different region. In another embodiment, this may include further moving the layup mandrel 110 in the processing direction 180, rotating the layup mandrel 110 to the laminating head 134, and simultaneously applying additional bundles 124, 124-1 of fiber reinforcement material to the layup mandrel 110 via the laminating head 134, wherein each of the laminating heads 134 applies bundles in a different region. Figure 3A A filament bundle is applied to one of the new regions Z1 to Z3. Then, adjacent regions 115, 117 and 117-1, as well as longitudinal ranges 123 and 123-1, are structurally joined by using splicing regions 190 and 123-5.

[0061] The completed laminate 120 is compacted and fed into an autoclave 193. At the autoclave 193, the laminate 120, which was hardened in step 212, is applied to a laying mandrel 110 to form composite components 55, 55-1. The composite components 55, 55-1 are then demolded, machined, and assembled with other components to form the aircraft 10.

[0062] Method 200 offers technological benefits superior to existing technologies and systems because it enables a doubling of lamination production. This is because, for composite components 55, 55-1, more laminating heads 134 operate on the laminate 120 at once, considering the 7.6 to 12.2 meter (twenty-five to forty-foot) long semi-cylindrical prefabricated section 24-1 of the laminate 120, or... Figure 5 The laminate 509 of the wing panel 510 reduces the layup time of these components. The wing panel 510 corresponds to the wing panel 30 after hardening and post-hardening assembly. Furthermore, because the components travel along the manufacturing environment 100, the increase in transport time to non-value-added time is minimal.

[0063] Figure 2B This is a flowchart illustrating a method 250 for selecting the splice position at a laminate in an illustrative embodiment. Step 252 includes subdividing the laminate design into areas for the laminator 134 (e.g., ...). Figure 3B Regions Z2A, Z2B, Z2C, Z3A, Z3B, Z3C) are selected such that different regions receive layups from different laminators 134. Step 254 includes identifying continuous ranges within the laminate (e.g., Figure 3B The continuous range 377 has a fewer layer count than the average layer count within the laminate. In step 256, the controller places splicing regions 190, 123-5 into regions within the continuous range (e.g., Figure 3B In the design between regions Z2A, Z2B, Z2C, Z3A, Z3B, and Z3C, in step 258, the laminate 120 is laid according to the design. Method 250 provides technical benefits by reducing the complexity of the laying process. That is, adding splicing regions 190 and 123-5 does not substantially increase the complexity of the existing laying process, nor does it increase the complexity of already highly complex areas (e.g., areas near windows, doors, etc.).

[0064] Figure 2C The illustration depicts another method 260 for selecting the splice positions at the laminate in an illustrative embodiment. Step 262 includes cutting the applied filament bundles 124, 124-1 into lengths to facilitate the allocation of splice areas 190, 123-5 between regions 115, 117, and 117-1 and longitudinal ranges 123, 123-1 to different laminator heads 134 in the design for the laminates 120, 509. In one embodiment, the layup splice 392 is formed by a combination of angled butt joints 385, 386 staggered at the overlaps 399, 399-1 across layers 396, 398, 397 (e.g., ...). Figure 2E , Figure 2F , Figure 2G , Figure 2H (As shown). Step 264 includes identifying adjacent layers 398. Adjacent layers 398 include adjacent layers in laminates 120, 509. Step 266 includes overlapping the trimmed positions of adjacent layers 398 with the previous layer 396 length layup splice 392 by 399, 399-1. In one embodiment, overlapping the filament bundles 124, 124-1 by 399 may include changing the trimmed angle of the filament bundles 124, 124-1, or offsetting the layup splice 392 of layer 396 from the layup splice 394 of adjacent layer 398.

[0065] Figure 2D This is a flowchart illustrating a method 270 for interleaving laying splices 392, 394, and 395 in an illustrative embodiment, and referenced to... Figure 2E Provide a description. Figure 2E , Figure 2G Corresponding to Figure 1BObserve arrows 2E and 2G. Step 272 includes inserting layup splices 392 into sheets 396 at splice regions 190 between regions 115, 117, and 117-1 assigned to different laminators 134 in the design of laminate 120, and step 274 includes identifying adjacent sheets 398 adjacent to sheets 396 of laminate 120. Step 276 includes offsetting the cut position of the layup splices 394 of adjacent sheets 398 from the trimmed length of sheets 396. This can be done by overlapping the layup splices 394 by a predetermined amount 399. Layup splices 392 within splice regions 190 refer to layup splices 392 within sheets 396 in the longitudinal ranges 123, 123-1 and regions 115 and 117 laid with different laminators 134. The layup splice 394 of layer 398 is staggered relative to the subsequent layup splice 395 in layer 397 and the previous layup splice 392 in splicing area 190 of layer 396. Figure 2G In this context, the overlapping splice 392-1 within the splicing region 123-5 refers to the splice 392-1 within the layers 396-1 laid in the longitudinal ranges 123, 123-1 and regions 115 and 117, respectively, using different laminating heads 134. The laying splice 394-1 of layer 398-1 is staggered relative to the subsequent laying splice 395-1 and the previous overlapping splice 392-1 of layer 396-1 in the splicing region 123-5. Steps 272 to 276 can be repeated for the layers until the laying splices 392, 394, and 395 travel through the entire laminate 120 at the overlap 399. In one embodiment, the splicing region 123-5 is formed by a combination of laying splices 392, 394, and 395, and staggers across layers 396, 398, and 397. Method 270 provides technical benefits by distributing layers 396, 398, and 397 across the splicing region 123-5 at the overlap 399.

[0066] In another embodiment, the method includes operating a plurality of laminating heads 134 to place material on regions 117 and 117-1 of the laminate 120, while simultaneously operating a single laminating head 134 to place material on region 115 of the laminate 120. In yet another embodiment, the method includes selecting the amount of overlap 399, 399-1 between the different layers 396, 398, 397 of the layup pieces 392, 394, 395.

[0067] In another embodiment, the method further includes selecting the amount of stagger between cuts in different layers of the splice. In some embodiments, splicing regions 190, 123-5 have lay-up splices 392, 394, 395 that are staggered by adjacent sheets from sheet 396 to sheet 398 to sheet 397 through the laminate 120 with overlaps 399, 399-1. In this arrangement, the filament bundles 124, 124-1 (such as sheet segments 393) of the individual sheets within splicing regions 190, 123-5 terminate at the lay-up splice 392 with angled butt joints 385, 386 and non-angled butt joints 387, 387-1, as part of the overlapping splice 392-1, and are not separated from the sheet segments 393-1 at the lay-up splice 392 or have a small separation (e.g., a small portion of 2.54 cm (one inch)). Laying splice 392 has sheet segments 393 and 393-1, which are cut and placed into complementary angled butt joints 385, 386 and non-angled butt joints 387, 387-1 as part of overlapping splice 392-1, wherein overlapping portions 399, 399-1 are staggered relative to splice 394. This type of overlapping portion 399, 399-1 allows subsequent laying splices 392, 394, 395 to stagger, providing overlapping splice 392-1, which facilitates load transfer through splice areas 190, 123-5. Another embodiment has splices (not shown) with interlocking or stepped overlapping structures. All splice types require trimming of sheet segments 393 and 393-1 to achieve complementary alignment. Layer 396 has layup joints 392 that intersect with layup joints 394 of layer 398, and so on for each subsequent layer of laminate 120. Furthermore, the joint areas 190, 123-5 are located in less complex or thinner portions of laminate 120, such as areas without window / door surrounds, gaskets, or other complex geometries. In this way, the joints are positioned between complex layup areas rather than within those areas. The joints may be thicker than the unjoined laminate 120, and therefore the joints may include staggered joints of one or more cut portions of layers extending through the thickness of laminate 120. In another embodiment, in joint areas 190, 123-5, the cut positions of the individual layers 396, 398, 397 within joints 392, 394, 395 are staggered with angled butt joints 385, 386 and non-angled butt joints 387, 387-1 relative to other layers. This results in the staggered distances of splice pieces 392, 394, and 395 across multiple overlapping portions 399 and 399-1, which enhances the load-bearing characteristics of the overlapping splice piece 392-1.The staggered cutting positions of the sheets within the splicing areas 190 and 123-5 enhance their ability to withstand loads passing through them when hardened into composite components 55 and 55-1. After receiving the layup, the laying mandrel 110 advances to the autoclave 193.

[0068] Figure 2F The illustrative embodiment describes angled mating portions 385, 385-1, and 386 that overlap 399-1 between regions. For example... Figure 2F As shown, the first region 381 and the second region 382 include upper layers 383, 383-1 and lower layers 384, 384-1. An angled mating portion 385 at the upper layers 383, 383-1 is disposed at an overlap portion 399-1 with an angled mating portion 386 at the lower layers 384, 384-1. The angled mating portions 385, 385-1, 386 are at an angle 386-2 of 45 degrees, as shown. In other embodiments, the angle 386-2 of the angled mating portions 385, 385-1, 386 is set at any angle between approximately 20 and 90 degrees, as long as the angled mating portions 385, 385-1, 386 are configured to maintain a minimum overlap portion 399-1. Figure 2G In the illustrative embodiment, 385, 385-1 show non-angularly overlapping mating portions 387, 387-1, 387-2 between regions. For example... Figure 2H As shown, the first region 381 and the second region 382 include upper layers 383 and 383-1 and lower layers 384 and 384-1. The non-angled mating portion 387 at the upper layers 383 and 383-1 is disposed at the overlapping portion 399 of the angled mating portion 387-1 with the lower layers 384 and 384-1.

[0069] Figure 3B Is Figure 3A From above and Figure 1B A side view of the semi-cylindrical section 24-2 viewed from the same perspective, but after separation from the laying mandrel 110. Semi-cylindrical section 24 corresponds to semi-cylindrical section 24-2, except that the post-hardening assembly has been completed.

[0070] exist Figure 3BIn the design, the regions are divided radially and longitudinally, resulting in regions Z2A, Z2B, and Z2C positioned above regions Z3A, Z3B, and Z3C. A continuous range 377 has a layer count lower than the average layer count across the laminate. Regions Z3A, Z3B, and Z3C include a gasket 372 for a window strip, where a window cutout range 378 is provided. However, the gasket 372 is interrupted by the window cutout range 378, in which material is cut from the laminate 320, corresponding to laminate 120, to allow for window installation. Region Z3C includes a gasket 374 for a door and a door cutout range 375 for mounting the door therein. Meanwhile, region Z2A includes a gasket 376 for a crown module. During design, additional and more complex layer arrangements can be implemented in each region as needed. The longitudinal splicing members 379 corresponding to the splicing area 190 are placed between areas in a continuous range 377 and travel in the longitudinal direction L. The longitudinal splicing members 379 have a predetermined width, although in Figure 3B They are shown as lines. In addition, circumferential splicing pieces 373 corresponding to splicing areas 123-5 are placed between these areas and travel around the laminate 320 in the circumferential direction C.

[0071] In other words, after each micropulse or pulsation, the laminating head 134 switches its operating direction from counterclockwise to clockwise, and vice versa. Therefore, all laminating heads 134 operate counterclockwise, then wait for a micropulse or pulsation, then clockwise, then wait for a micropulse or pulsation, and so on. This can be performed without any type of "carriage return" or during a single micropulse and pause sequence, returning from a counterclockwise stroke to a clockwise return stroke after placing the filament bundles 124, 124-1. To place filament bundles 124, 124-1 with different fiber orientations, combinations of movement of the track 132, the laying mandrel 110, and / or the laminating head 134 can be performed.

[0072] In another embodiment, the laminator 134 performs layup in a clockwise direction 64 until it reaches the end of its radial regions (e.g., Z1, Z2, Z3), and then returns to the beginning of its radial regions (e.g., Z1, Z2, Z3) counterclockwise 65 in a manner similar to the carriage return of a typewriter. Thus, after a micro-pulse or pulsation, the laminator 134 operates clockwise 64, then returns to its starting position, and operates clockwise (CW) again after the next pulsation. Of course, a similar operation can be performed for counterclockwise 65 operation instead of clockwise 64. In another embodiment, the sheets are laid longitudinally (along dimension L) by the movement of the track 132, the laminator 134, or the pulsating movement (P) of the layup mandrel 110 below. Figure 1B Layers 126 and 128).

[0073] In another embodiment, after the structure (i.e., the layup mandrel 110) has been pulsated (P), the laminating head 134 moves incrementally in one direction (e.g., clockwise 64, counterclockwise 65) and performs layups during these movements as they all travel across their respective regions (Z1, Z2, Z3). The laminating head 134 then moves back to the starting point 338 in the opposite direction during a micro-pulsation or pulsation / pause cycle to prepare for additional layups. The layup mandrel 110 can then be pulsated to the next lamination station 130, and the laminating head continues to place laminating material in the counterclockwise direction 65.

[0074] In another embodiment in which the laying mandrel 110 moves continuously in the processing direction 180 (e.g., at a rate of 2.54 cm (one inch) per minute), a combination of movement of the track 132, the laying mandrel 110 and / or the laminating head 134 may be performed to perform laying on the moving mandrel.

[0075] Although Figure 3AThe diagram shows regions 115, 117, and 117-1, all approximately 60 degrees apart, and also shows splices 190 and 123-5 that structurally combine regions 115, 117, and 117-1. Any suitable number of regions 115, 117, and 117-1 can be selected, and the number and size of regions 115, 117, and 117-1 can vary along the length 181-7 of the laying mandrel 110 or relative to each other in the same longitudinal portion 318 of the laying mandrel 110. Furthermore, in some embodiments, certain lamination stations 130 may skip certain regions 115, 117, and 117-1. For example, a lamination station 130 may be laid in zones 2 117 and 3 117-1, but not in zone 1 115, while downstream lamination station 130 181-2 may be laid in zones 1 115, 2 117, and 3 117-1. This accommodates environments where zones 2 117 and 3 117-1 have more layers in the laminate than Z2. In another embodiment, the laying mandrel 110 may be designed for the position cylindrical sections 29-1, 29-2, 29-3, 29-4, 29-5, quarter-cylinder sections, or any suitable curved portion of the fuselage. In another embodiment, the zone size 317 is selected such that each zone takes a similar (or the same) amount of time to lay at each lamination station 130. This facilitates a common cycle time for each lamination station 130 and allows for a more even distribution of work among the lamination stations 130. In such an implementation, areas with more layers or requiring more complex patterns are made smaller than thinner or less complex areas.

[0076] In one embodiment, during downtime of lamination station 130 or lamination head 134, lamination head 134 is suitable for maintenance, such as by reloading lamination head 134 with new filament, replacing or cleaning the cutter at lamination head 134, or replacing the entire lamination head. Maintenance can be a factor in dividing workloads and generating a common cycle time for the production line, where planned downtime for lamination station 130 or lamination head 134 constitutes part of the process for producing laminate 120 or laminate 509. In such an embodiment, the amount of material laid in each area is selected to be less than the maximum rate of the lamination head 134 serving that area, with the remaining downtime reserved for maintenance. In this way, lamination head 134 can be maintained during any relevant downtime when no laying occurs.

[0077] Figure 4A This is a top view of the sheet map 400 for the laminate 120 after all the filament bundles 124, 124-1 have been placed in the illustrated embodiment. Figure 4A and Figure 3A The observation arrow 4 corresponds to this. According to... Figure 4A The sheet map 400 includes region A used by the first lamination station 130 and region B used by the second lamination station 130-1. The splice 410 between regions 115, 117, and 117-1 varies along the length 181-7 of the sheet map 400, forming an interlaced pattern 430 and preventing the formation of a single seam along the length 181-7 of the sheet map 400. Overlapping regions 191 appear between regions 115 and 117, and between regions 115 and 117-1. When a splice can be formed between regions A and B at either the first lamination station 130 or the second lamination station 130-1, the sheet map 400 has sheet segments 393 placed by the lamination station 130 and sheet segments 393-1 placed by the lamination station 130-1 for laying the splice 392. That is, zonal lamination is performed such that the boundaries 412 between zonal regions are staggered across the layers to avoid layup splices 392 in laminate 120 or laminate 509. In another embodiment, zonal regions A and B overlap in an angled shape according to the fiber orientation of the laid material and the local construction of the laid structure.

[0078] Each splice 410 can be operated by multiple laminators 134 dedicated to specific regions 115, 117, and 117-1. For example, the portion of splice 410 located between two regions 431-1 can receive layup from two laminators 134 at different times (one laminator for each region 115 and region 117, or one laminator for each region 115 and region 117-1). The portion of splice 410 at the corner 431 between the four regions 431-2 can receive layup from four laminators 134 at different times (one laminator for each region 115, region 117, and region 117-1). Although splices 410 are shown as lines, each splice 410 occupies splicing areas 190, 123-5 between adjacent regions where sheets from these regions are spliced ​​together or otherwise physically integrated with each other. In other words, the position of the splice 410 changes incrementally between layers, thereby forming an interlacing pattern 430 (e.g., a stepped pattern, an interlaced shape, etc.) across the laminate 120. The interlacing pattern 430 of the splice 410 prevents overlapping splices 392-2 from being directly stacked on top of previous overlapping splices 392-1 or subsequent overlapping splices 392-3, and also helps to prevent undesirable thickening of the laminate 120 within the splicing area 190. Therefore, in one embodiment, the position of the layup splices 392, 394, 395 for the splice 410 varies between the layers. The splice 410 extends across the thickness of the laminate 120. The splices 410 are selected / placed such that they do not intersect with the spacer 420 to prevent a significant increase in thickness or complexity near the spacer 420. Therefore, the boundary 412 is staggered from layer 396 to layer 398 to form an staggered pattern 430 for each layer 396, 398, 397.

[0079] Figure 4B Regions A and B of the sheet map 450 for the wing panels and a similar arrangement of the splice 410 are shown. A shim 420 is also included in the sheet map 450 and can be used to provide reinforcement for access panels, rib ridges, spar ridges, etc. Figures 4A to 4B This demonstrates that the regional lamination technique discussed in this article can be used in a variety of lamination designs. Figure 4B This is a top view of the laminate 509 after all the filament bundles 124, 124-1 have been placed, in the embodiment corresponding to the wing panel 30 before hardening. According to... Figure 4BThe sheet map 450 includes region A used by the first lamination station 130 and region B used by the second lamination station 130-1. The splice 410-1 between regions 115-1, 117-2, and 117-3 varies along the length 181-8 of the sheet map 450, forming an interlaced pattern 430-1 and preventing single seams from forming along the length 181-8 of the sheet map 450. Overlapping regions 191 appear between region 115-1 and region 117-2, and between region 115-1 and region 117-3. When a splice can be formed between region A and region B at either the first lamination station 130 or the second lamination station 130-1, the sheet map 450 has sheet segments 393 placed at lamination station 130 and sheet segments 393-1 placed at lamination station 130-1 for laying splice 392. That is, performing zone lamination causes the boundary 412-1 between regions to cross-layer stagger to avoid laying splice 392 in the laminate 509. In another embodiment, regions A and B overlap in an angled shape according to the fiber orientation of the laid material and the local construction of the laid structure.

[0080] Each splice 410-1 can be operated at different times by multiple laminators 134 dedicated to specific zones 115-1, 117-2, and 117-3. For example, the portion of splice 410-1 located between two zones 431-7 can receive layup from two laminators 134 (one laminator for each zone 115-1 and zone 217-2, or one laminator for each zone 115-1 and zone 317-3) at different times. The portion of splice 410-1 at the corner 431-9 between the four zones 431-8 can receive layup from four laminators 134 (one laminator for each zone 115-1, zone 217-2, and zone 317-3) at different times. Although the splice pieces 410-1 are shown as lines, each splice piece 410-1 occupies splicing areas 190, 123-5 between adjacent areas where sheets from these areas are spliced ​​together or otherwise physically integrated with each other. That is, the position of the splice pieces 410-1 changes incrementally between layers, thereby forming an interlacing pattern 430-1 (e.g., a stepped pattern, an interlaced shape, etc.) through the laminate 509. The interlacing pattern 430-1 of the splice pieces 410-1 prevents overlapping splice pieces 392-2 from being directly stacked on top of previous overlapping splice pieces 392-1 or subsequent overlapping splice pieces 392-3, and also helps prevent undesirable thickening of the laminate 509 within the splicing area 190. Therefore, in one embodiment, the position of the layup splice pieces 392, 394, 395 of the splice pieces 410-1 varies between the layers. The splice 410-1 extends across the thickness of the laminate 509. The splices 410-1 are selected / placed such that they do not intersect with the gasket 420 to prevent a significant increase in thickness or complexity near the gasket 420. Thus, the boundary 412 staggers from layer 396 to layer 398 to form an staggered pattern 430-1 for each layer 396, 398, 397.

[0081] Figures 5 to 6 This is a perspective view of a manufacturing environment for laying wing skin (e.g., wing panels 510 and 610) in an illustrative embodiment. Wing panels 510 and 610 correspond to the hardened and post-hardened assembled wing panel 30. According to... Figure 5The wing panel 510 is subdivided into regions 117-3, 115-1, and 117-2 from front to back in the manufacturing environment 500. Laminators 522 at lamination stations 520 travel along tracks 524 to lay the wing panel 510 in these regions 117-3, 115-1, and 117-2. Assembly pieces 540 are placed between regions 117-3, 115-1, and 117-2. In another embodiment, laminators 522 at different lamination stations 520 operate simultaneously at different portions of the wing panel 510. For example, laminators 134 at different stations may lay the wing panel in different regions such as regions 117-1, 115-1, and 117-2. In this embodiment, the laminating heads 522 are staggered between different laminating stations 520, such that the laminating heads 522 at each laminating station 520 do not perform operations on adjacent areas 117-3, 115-1, 117-2, but instead perform operations on every other area 117-3, 115-1, 117-2.

[0082] according to Figure 6 In manufacturing environment 600, wing panel 610 is subdivided into regions Z1, Z2, and Z3 from the outside to the inside. A laminator head 622 at lamination station 620 travels along track 624 to perform lamination in these regions. Regions Z1, Z2, and Z3 are physically formed together via splices 640. Within each splice 640, sheets from different regions overlap in an alternating manner. In another embodiment, more than three regions are implemented for each wing. Furthermore, regions Z1, Z2, and Z3 can be arranged in a checkerboard pattern at the front / back (e.g.,...). Figure 5 (as shown) and inner / outer side (as shown) Figure 6 The wing panels 510 and 610 are separated within the combined outline shown, and as they travel in processing directions 180-1 and 180-2, multiple laminating heads 522 and 622, arranged across multiple laminating stations 520 and 620, can operate on the wing panels 510 and 610 to increase manufacturing speed. For example, Figures 5 to 6 Each lamination station 520, 620 shown may include lamination heads 522, 622, and the tracks 524, 624 for the lamination heads 522, 622 may be substantially flat, or otherwise sized to accommodate the passage of wing panels 510, 610. In another embodiment, the lamination heads 522, 622 at different lamination stations 520, 620 operate simultaneously at different portions of the wing panels 510, 610. For example, the lamination heads 622 at different lamination stations 620 perform laying at different regions Z1, Z2, Z3. In this embodiment, the lamination heads 622 are staggered between different lamination stations 620, such that the lamination head 622 at each lamination station 620 does not perform work on adjacent regions Z1, Z2, Z3, but rather performs work on every other region Z1, Z2, Z3.

[0083] Example

[0084] Referring more specifically to the accompanying drawings, embodiments of this disclosure can be implemented as follows: Figure 7 The aircraft manufacturing and maintenance in method 700 shown and such Figure 8 The description is based on the background of the aircraft 702 shown. During pre-production, method 700 may include the specification and design 704 of the aircraft 702 and material procurement 706. During production, the manufacturing of components and sub-assemblies of the aircraft 702 and system integration 710 occur. Subsequently, the aircraft 702 may undergo certification and delivery 712 for entry into service 714. When used by the customer, the aircraft 702 is scheduled for routine work in maintenance and repair 716 (which may also include modification, remodeling, refurbishment, etc.). The devices and methods implemented herein may be employed during any one or more suitable phases of production and maintenance described in method 700 (e.g., specifications and design 704, material procurement 706, component and sub-assembly manufacturing 708, system integration 710, certification and delivery 712, commissioning 714, maintenance and repair 716) and / or during any suitable component of aircraft 702 (e.g., fuselage 718, system 720, interior 722, propulsion system 724, electrical system 726, hydraulic system 728, environmental system 730).

[0085] Each step in Method 700 can be performed or implemented by a systems integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a systems integrator can include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party can include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator can be an airline, leasing company, military entity, maintenance organization, etc.

[0086] like Figure 8 As shown, an aircraft 702 produced by method 700 may include a fuselage 718 and an interior 722 having multiple systems 720. Examples of systems 720 include one or more of a propulsion system 724, an electrical system 726, a hydraulic system 728, and an environmental system 730. 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.

[0087] As described above, the equipment and methods implemented herein may be employed during any one or more phases of production and maintenance as described in method 700. For example, a component or sub-component corresponding to component and sub-component manufacturing 708 may be manufactured or produced in a manner similar to that of a component or sub-component produced when the aircraft 702 is in service. Moreover, during sub-component manufacturing 708 and system integration 710, one or more equipment implementations, method implementations, or combinations thereof may be utilized, for example, by sufficiently accelerating the assembly of the aircraft 702 or reducing its cost. Similarly, for example, and not limited to, during maintenance and repair 716, one or more of the equipment implementations, method implementations, or combinations thereof may be utilized when the aircraft 702 is in service. Therefore, this disclosure can be used for any stage or any combination thereof discussed herein, such as specifications and design 704, material procurement 706, component and sub-component manufacturing 708, system integration 710, certification and delivery 712, entry into service 714, maintenance and repair 716 and / or any suitable component of aircraft 702 (e.g., fuselage 718, system 720, interior 722, propulsion system 724, electrical system 726, hydraulic system 728 and / or environmental system 730).

[0088] In one embodiment, the component comprises a portion of fuselage 718 and is manufactured during component and subassembly manufacturing 708. The component can then be assembled into the aircraft in system integration 710 and used in service 714 until wear renders it unusable. Then, in maintenance and repair 716, the component can be discarded and replaced with a newly manufactured component. The components and methods of the present invention can be used throughout component and subassembly manufacturing 708 to manufacture new components.

[0089] Any of the various control elements (e.g., electrical or electronic components) shown in the accompanying drawings or described herein may be implemented as hardware, a processor implementing software, a processor implementing firmware, or some combination thereof. For example, an element may be implemented as dedicated hardware. A dedicated hardware element may be referred to as a “processor,” a “controller,” or some similar term. When provided by a processor, functionality may be provided by a single dedicated processor, a single shared processor, or multiple separate processors, some of which may be shared. Furthermore, the explicit use of the terms “processor” or “controller” should not be construed as exclusively referring to hardware capable of executing software, and may implicitly include, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuit systems, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile storage devices, logic, or some other physical hardware components or modules.

[0090] 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. When executed by a processor, the instructions operate 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.

[0091] Although specific embodiments have been described herein, the scope of this disclosure is not limited to those specific embodiments. The scope of this disclosure is defined by the appended claims and any equivalents thereof.

[0092] This disclosure also includes the following examples, which should not be confused with the appended claims that define the scope of protection:

[0093] 1. A method 200 for manufacturing composite parts 55, 55-1, the method 200 comprising:

[0094] The layup of the laminate 120 is subdivided (206) into multiple regions 115, 117, 117-1;

[0095] A bundle 124 of fiber reinforcement material for the laminate 120 is applied (208) over a layup mandrel 110 via multiple laminating heads 134, such that each laminating head 134 applies the bundle 124 in different regions 115, 117, 117-1; and

[0096] During the laying of the filament bundle 124, the regions 115, 117, 117-1 are spliced ​​(210) together to form the laminate 120.

[0097] 2. The method 200 according to Example 1, wherein the laying mandrel 110 includes a mandrel for the semi-cylindrical section; and subdividing the laying (208) of the laminate 120 into regions includes assigning the laminating head 134 to regions 115, 117, 117-1.

[0098] 3. The method 200 according to Example 1, wherein the layup mandrel 110 includes a wing panel layup mandrel; and subdividing the layup of the laminate 120 into a plurality of regions 115, 117, 117-1 includes distributing the laminator head 134 to regions 115, 117, 117-1 that travel from the wingtip 11 of the wing panel to the root 17 of the wing panel.

[0099] 4. The method 200 according to Example 1, wherein the laying mandrel 110 includes a laying mandrel for the wing panel; and the laying subdivision (206) of the laminate into a plurality of regions 115, 117, 117-1 includes distributing the laminating head 134 to the regions 115, 117, 117-1 that travel from the front portion 19 of the wing panel to the rear portion 23 of the wing panel.

[0100] 5. The method 200 according to any one of Examples 1 to 4, further comprising:

[0101] The laying mandrel 110 is moved (202) in the processing direction; and

[0102] Additional filament bundles 124 of fiber-reinforced material are simultaneously applied (208) via the laminating head 134, such that each laminating head 134 applies filament bundles 124 in different regions 115, 117, 117-1.

[0103] 6. The method 200 according to any one of Examples 1 to 4, further comprising:

[0104] The laying mandrel 110 is moved (202) in the processing direction;

[0105] Rotate the laying mandrel 110 (204) to the laminating head 134; and

[0106] Additional filament bundles 124 of fiber reinforcement material are simultaneously applied (208) via the laminating head 134, wherein each of the laminating heads 134 applies filament bundles 124 in a new region.

[0107] 7. Method 200 according to any one of Examples 1 to 6, wherein applying (208) the filament bundle 124 includes operating the laminating head 134 along a shared track to lay the filament bundle 124.

[0108] 8. Method 200 according to any one of Examples 1 to 7, wherein applying (208) the filament bundle 124 comprises operating the laminating head 134 along a separate track to lay the filament bundle 124.

[0109] 9. Method 200 according to any one of Examples 1 to 8, wherein applying (208) the filament bundle 124 includes applying the filament bundle 124 through a first lamination station 130 and applying the filament bundle 124 through a second lamination station 130-1.

[0110] 10. The method 200 according to any one of Examples 1 to 9, further comprising:

[0111] Identify the area at the laminate 120 where the receiving pad will be received, wherein:

[0112] Subdividing the layup of the laminate 120 into regions 115, 117, 117-1 includes distributing laminators 134 to perform layup in each region 115, 117, 117-1, and placing splices between regions 115, 117, 117-1 at locations that do not intersect with the gaskets at the laminate 120.

[0113] 11. The method 200 according to any one of Examples 1 to 10, wherein subdividing the layup of the laminate 120 into regions 115, 117, 117-1 includes distributing laminating heads 134 to perform layup in each region and placing splices in an alternating pattern between the regions 115, 117, 117-1.

[0114] 12. The method 200 according to any one of Examples 1 to 11, the method further comprising moving (202) the laying mandrel 110 in the processing direction during the manufacture of the composite components 55, 55-1.

[0115] 13. The method 200 according to any one of Examples 1 to 12, the method further comprising hardening (212) the laminate 120 onto the laying mandrel 110.

[0116] 14. A portion of an aircraft assembled according to method 200 of any one of Examples 1 to 13.

[0117] 15. An apparatus 100 for manufacturing composite components 55, 55-1, said apparatus comprising:

[0118] Lamination stations 130 and 130-1, wherein the lamination head 134 can follow the contour of the layup mandrel 110, which moves in the processing direction during the manufacture of composite components 55 and 55-1; and

[0119] A laminating head 134 is disposed at the laminating stations 130 and 130-1. The laminating head is configured to lay fiber reinforcement material bundles 124 onto the laying mandrel 110. The laminating head 134 is configured to operate in a front-to-back manner to lay fiber reinforcement material for the laminate 120 in different regions 115, 117, and 117-1 at the laying mandrel 110, while splicing the regions 115, 117, and 117-1 together.

[0120] 16. The device 100 according to Example 15, wherein the laying mandrel 110 defines the outline of a section of the body; and the device further includes a controller that, based on instructions in a numerical control (NC) program, subdivides the laminate 120 into a plurality of regions 115, 117, 117-1 by assigning the laminating head 134 to regions 115, 117, 117-1 including the arcuate portion of the section of the body.

[0121] 17. The device 100 according to Example 15, wherein the laying mandrel 110 defines the outline of the wing panel; and the device further includes a controller 174 that, based on instructions in a numerical control (NC) program, subdivides the laminate 120 into a plurality of regions 115, 117, 117-1 by assigning the laminating head 134 to regions 115, 117, 117-1 traveling from the wingtip 11 of the wing panel to the root 17 of the wing panel.

[0122] 18. The device 100 according to Example 15, wherein the laying mandrel 110 defines the outer mold line (OML) of the wing.

[0123] 19. The device 100 according to Example 15, wherein the laying mandrel 110 defines the inner mold line (IML) of a section of the body.

[0124] 20. The device 100 according to Example 15, wherein the laying mandrel 110 defines the outline of the wing panel; and the device further includes a controller 174 that, based on instructions in a numerical control (NC) program, subdivides the laminate 120 into regions 115, 117, 117-1 by assigning the laminating head 134 to regions 115, 117, 117-1 traveling from the front portion 19 of the wing panel to the rear portion 23 of the wing panel.

[0125] 21. The device 100 according to any one of Examples 15 to 20, the device further comprising a controller that identifies the area at the laminate 120 to receive a gasket and subdivides the laminate 120 into a plurality of regions 115, 117, 117-1, wherein the controller sets boundaries between the regions 115, 117, 117-1 at locations that do not intersect with the gasket at the laminate 120.

[0126] 22. The device 100 according to any one of Examples 15 to 21, the device further comprising a controller that subdivides the laminate 120 into a plurality of regions 115, 117, 117-1 and sets boundaries between the regions 115, 117, 117-1 in an alternating pattern.

[0127] 23. The device 100 according to any one of Examples 15 to 22, the device further comprising a laminating head 134 disposed downstream of the laminating head 134 and performing reprocessing on the laminate 120.

[0128] 24. The device 100 according to Example 15, wherein the laminating head 134 simultaneously lays the fiber-reinforced material and splices the regions 115, 117, 117-1 together.

[0129] 25. Use the device 100 of any one of Examples 15 to 24 to manufacture a part of an aircraft.

[0130] 26. A system for manufacturing composite components 55, 55-1, the apparatus comprising:

[0131] Track 132, which follows the profile of the laying mandrel 110 that moves in the processing direction during the manufacture of composite components 55, 55-1; and

[0132] Lamination station, the lamination station including:

[0133] A laminating head 134 is movably mounted to the track 132 and configured to lay fiber reinforcement material onto the laying mandrel 110. The laminating head 134 is configured to operate in a front-to-back manner to simultaneously lay fiber reinforcement material for the laminate 120 in different regions 115, 117, 117-1 at the laying mandrel 110, while splicing the regions 115, 117, 117-1 together.

[0134] 27. The system according to Example 26, wherein the laying mandrel 110 defines the outer mold line (OML) of the wing.

[0135] 28. The system according to Example 26, wherein the laying mandrel 110 defines the inner mold line (IML) of a section of the fuselage.

[0136] 29. Use the system of any one of Examples 26 to 28 to manufacture a part of an aircraft.

[0137] 30. A method 250 for designing a laminate 120, the method 250 comprising:

[0138] The design for the laminate 120 is subdivided (252) into multiple regions 115, 117, 117-1 for the laminator 134, such that different regions 115, 117, 117-1 receive layup from different laminators 134; and

[0139] The splice is placed (256) into the design between the regions 115, 117, 117-1 in a continuous range.

[0140] 31. The method 250 according to Example 30, wherein the splice is formed by staggered cuts.

[0141] 32. The method 250 according to Example 30 or 31, the method further comprising operating a plurality of heads 134 to place material on the side of the laminate 120, while operating a single head 134 to place material on the crown module of the laminate 120.

[0142] 33. The method 250 according to any one of Examples 30 to 32, the method further comprising selecting the amount of overlap between the sheets in different layers of the splice.

[0143] 34. The method 250 according to any one of Examples 30 to 33, the method further comprising selecting the amount of stagger between cuts in different layers of the splice.

[0144] 35. The method 250 according to any one of Examples 30 to 34, the method further comprising:

[0145] Lay the laminate 120 according to the design (258); and

[0146] Within the laminate, identify a continuous range of laminate counts that are less than the average laminate count.

[0147] 36. A portion of an aircraft assembled according to the method of any one of Examples 30 to 35.

[0148] 37. A method 260 for inserting a splice into a laminate 120, the method 260 comprising:

[0149] Cut through the applied filament bundle (262) to form splices between regions 115, 117, 117-1 that are assigned to different laminators 134 in the design for laminate 120;

[0150] Identify (264) adjacent layers; and

[0151] The cutting position of the adjacent lamellae is offset from the cut (266).

[0152] 38. The method 260 according to Example 37, wherein the splice is formed by a combination of interlocking mating portions across layers.

[0153] 39. A part of an aircraft assembled according to the method 260 in Example 37 or 38.

[0154] 40. A method 200 for manufacturing composite parts 55, 55-1 from a laminate 120, the method 200 comprising:

[0155] During the manufacture of composite components 55, 55-1, the mandrel 110 is moved (202) in the processing direction to expose the lamination areas 115, 117, 117-1 to the lamination head 134.

[0156] The layup of the laminate 120 is subdivided (206) into multiple regions 115, 117, 117-1;

[0157] A bundle 124 of fiber-reinforced material is applied (208) to a layup mandrel 110 via multiple laminators 134, such that each laminator 134 applies the bundle 124 in a different region; and

[0158] While applying the filament bundle 124, the regions 115, 117, 117-1 are spliced ​​(210) together to form a single laminate 120.

[0159] 41. The method 200 according to Example 40, wherein the laying mandrel 110 is a laying mandrel 110 for a section of the fuselage; and the layup of the laminate 120 is subdivided (206) into a plurality of regions 115, 117, 117-1 including the distribution of the laminating head 134 to the regions 115, 117, 117-1 including the arcuate portion of the section of the fuselage.

[0160] 42. The method 200 according to Example 40 or 41, wherein moving (202) the layup mandrel 110 includes receiving the layup mandrel 110 for the wing panel; and subdividing (206) the layup of the composite material into a plurality of regions 115, 117, 117-1 includes distributing the laminator 134 to the regions 115, 117, 117-1 that travel from the wingtip 11 of the wing panel to the root 17 of the wing panel.

[0161] 43. The method 200 according to any one of Examples 40 to 42, wherein the layup mandrel 110 includes a layup mandrel for the wing panel; and the layup of the composite material is subdivided (206) into a plurality of regions 115, 117, 117-1 including distributing the laminator 134 to the regions 115, 117, 117-1 that travel from the front portion 19 of the wing panel to the rear portion 23 of the wing panel.

[0162] 44. The method 200 according to any one of Examples 40 to 43, the method further comprising:

[0163] The laying mandrel 110 is further moved in the processing direction (202); and

[0164] Additional bundles 124 of fiber-reinforced material are simultaneously applied (208) to the laying mandrel 110 via the laminating head 134, such that each laminating head 134 applies bundles 124 in different regions.

[0165] 45. The method 200 according to any one of Examples 40 to 44, the method further comprising:

[0166] The laying mandrel 110 is further moved in the processing direction (202);

[0167] Rotate the laying mandrel 110 (204) to the laminating head 134; and

[0168] Additional bundles 124 of fiber-reinforced material are simultaneously applied (208) to the laying mandrel 110 via the laminating head 134, wherein each of the laminating heads 134 applies bundles 124 in a new region.

[0169] 46. ​​Method 200 according to any one of Examples 40 to 45, wherein applying 208 the filament bundle 124 includes operating the laminating head 134 along a shared track 132 to lay the filament bundle 124; and moving (202) the laying mandrel 110 in the processing direction.

[0170] 47. The method 200 according to any one of Examples 40 to 46, the method further comprising:

[0171] The area at the laminate 120 that will receive the gasket is identified, wherein:

[0172] Subdividing the layup of the laminate 120 into multiple regions 115, 117, 117-1 includes setting boundaries between regions 115, 117, 117-1 at locations that do not intersect with the gaskets at the laminate 120.

[0173] 48. The method 200 according to any one of Examples 40 to 47, wherein subdividing the layup of the laminate 120 into a plurality of regions 115, 117, 117-1 includes setting boundaries between the regions 115, 117, 117-1 in an interlaced pattern.

[0174] 49. The method 200 according to any one of Examples 40 to 48, the method further comprising hardening (214) the laminate onto the layup mandrel 110.

[0175] 50. A portion of an aircraft assembled according to any one of Examples 40 to 49.

[0176] 51. A method 200 for manufacturing composite parts 55, 55-1 from a laminate 120, the method 200 comprising:

[0177] The layup of the laminate 120 is subdivided (206) into multiple regions 115, 117, 117-1;

[0178] A bundle 124 of fiber-reinforced material is simultaneously applied (208) to a layup mandrel 110 via multiple laminating heads 134, such that each laminating head 134 applies the bundle 124 in a different region; and

[0179] While applying the filament bundle 124, the regions 115, 117, and 117-1 are spliced ​​together to form a single laminate 120.

[0180] 52. The method 200 according to Example 51, wherein the layup mandrel 110 includes layup mandrels for sections of the fuselage; and subdividing the layup of the laminate 120 into a plurality of regions 115, 117, 117-1 includes arcuate portions of the layup mandrels subdividing the sections of the fuselage.

[0181] 53. The method 200 according to Example 51, wherein the layup mandrel 110 includes a layup mandrel for a wing; and subdividing the layup of the laminate 120 into a plurality of regions 115, 117, 117-1 includes subdividing the layup mandrel 110 into portions extending from the wingtip 11 of the wing to the root 17 of the wing.

[0182] 54. The method 200 according to Example 51, wherein the layup mandrel 110 includes a layup mandrel for a wing; and subdividing the layup of the laminate 120 into a plurality of regions 115, 117, 117-1 includes subdividing the layup mandrel 110 into portions extending from the front portion 19 of the wing to the rear portion 23 of the wing.

[0183] 55. The method 200 according to any one of Examples 51 to 54, the method further comprising:

[0184] Move the laying mandrel 110 in the processing direction; and

[0185] Additional filament bundles 124 of fiber reinforcement material are simultaneously applied to the layup mandrel 110 via the laminating head 134, such that each laminating head 134 applies filament bundles 124 in different regions.

[0186] 56. The method 200 according to any one of Examples 51 to 55, the method further comprising:

[0187] Move the laying mandrel 110 in the processing direction;

[0188] Rotate the laying mandrel 110 to the laminating head 134; and

[0189] Additional bundles 124 of fiber-reinforced material are simultaneously applied to the laying mandrel 110 via the laminating head 134, wherein each of the laminating heads 134 applies bundles 124 in a new region.

[0190] 57. The method 200 according to any one of Examples 51 to 56, wherein applying the filament bundle 124 includes operating the laminating head 134 along a shared track 132 to lay the filament bundle 124; and moving the laying mandrel 110 in the processing direction.

[0191] 58. The method 200 according to any one of Examples 51 to 57, the method further comprising:

[0192] The area at the laminate 120 that will receive the gasket is identified, wherein:

[0193] Subdividing the layup of the laminate 120 into multiple regions 115, 117, 117-1 includes setting boundaries between regions 115, 117, 117-1 at locations that do not intersect with the gaskets at the laminate 120.

[0194] 59. The method 200 according to any one of Examples 51 to 58, wherein subdividing the layup of the laminate 120 into a plurality of regions 115, 117, 117-1 includes setting boundaries between the regions 115, 117, 117-1 in an interlaced pattern.

[0195] 60. The method 200 according to any one of Examples 51 to 59, the method further comprising hardening the laminate 120 onto the layup mandrel 110.

[0196] 61. The method 200 according to any one of Examples 51 to 60, wherein the laminating head 134 simultaneously applies the fiber bundle 124 in parallel.

[0197] 62. The method 200 according to any one of Examples 51 to 61, the method further comprising the laminating head 134 simultaneously and continuously applying the fiber bundle 124.

[0198] 63. The method 200 according to any one of Examples 51 to 62, the method further comprising the laminating head 134 simultaneously and continuously applying the fiber bundle 124 in parallel.

[0199] 64. A portion of an aircraft assembled according to any one of Examples 51 to 63.

[0200] 65. A method 200 for manufacturing composite parts 55, 55-1 from a laminate 120, the method comprising:

[0201] Lay the mandrel 110 by moving (202) in the processing direction;

[0202] At lamination stations 130 and 130-1, the laying mandrel 110 is rotated (204) to the lamination head 134; and

[0203] At the lamination stations 130 and 130-1, fiber-reinforced material bundles 124 are simultaneously applied (208) to the laying mandrel 110 via lamination heads 134, wherein each of the lamination heads 134 applies the bundles 124 to a distribution area at the laying mandrel 110, and the lamination heads 134 at different lamination stations 130 and 130-1 apply the bundles 124 to different distribution areas 115, 117, and 117-1; and

[0204] Repeat the movement (202), transposition (204), and application (208).

[0205] 66. The method 200 according to Example 65, wherein applying (208) the filament bundle 124 includes operating the laminating head 134 along the shared track 132 to lay the filament bundle 124.

[0206] 67. The method 200 according to Example 65 or 66, wherein applying (208) the filament bundle 124 includes independently operating the laminating head 134 to lay the filament bundle 124.

[0207] 68. The method 200 according to any one of Examples 65 to 67, wherein, while applying the filament bundle 124, each laminating head 134 is assigned to a different region; and the region assigned to each laminating head varies as the laying mandrel 110 travels in the processing direction.

[0208] 69. A portion of an aircraft assembled according to the method of any one of Examples 65 to 68.

[0209] 70. A method 270 for inserting a splice into a laminate 120, the method comprising:

[0210] In the design for the laminate 120, cuts are inserted into the (272) sheets at the splices between the regions 115, 117, 117-1 that are assigned to different laminators 134;

[0211] Identify (274) adjacent layers; and

[0212] The cutting position used for adjacent layers is offset from the cut (276).

[0213] 71. The method according to Example 70, wherein the cutting position offset (276) used for the adjacent layers is performed by offsetting the splice by a predetermined amount.

[0214] 72. A portion of an aircraft assembled according to the method described in Example 70 or 71.

Claims

1. A method (200) for manufacturing a composite component (55, 55-1), the method (200) comprising: During the manufacture of the composite components (55, 55-1), the mandrel (110) is laid in the processing direction by moving (202); The layup of the laminate (120) is subdivided (206) into multiple regions (115, 117, 117-1); A bundle (124) of fiber-reinforced material for the laminate (120) is applied (208) onto the laying mandrel (110) via a plurality of laminating heads (134), such that each laminating head (134) applies the bundle (124) in a different region (115, 117, 117-1); and During the laying of the filament bundle (124), the plurality of regions (115, 117, 117-1) are spliced ​​(210) together to form the laminate (120).

2. The method (200) according to claim 1, further comprising: Additional filaments (124) of fiber-reinforced material are simultaneously applied (208) via the laminating head (134), such that each laminating head (134) applies filaments (124) in different regions (115, 117, 117-1); or The laying mandrel (110) is rotated (204) onto the laminating head (134), and Additional bundles (124) of fiber-reinforced material are simultaneously applied (208) via the laminating head (134), wherein each of the laminating heads (134) applies bundles (124) in a new region.

3. The method (200) according to any one of claims 1 to 2, wherein: Applying (208) the filament bundle (124) includes: The laminating head (134) is operated along the shared track (132) to lay the filament bundle (124); and the laying mandrel (110) is moved (202) in the processing direction.

4. The method (200) according to any one of claims 1 to 3, further comprising: Identify the area at the laminate (120) where the gasket will be received, wherein: Subdividing the layup of the laminate (120) into multiple regions (115, 117, 117-1) includes setting boundaries between the multiple regions (115, 117, 117-1) at locations that do not intersect with the gaskets at the laminate (120).

5. The method (200) according to any one of claims 1 to 4, wherein: Subdividing the layup of the laminate (120) into multiple regions (115, 117, 117-1) includes setting boundaries between the multiple regions (115, 117, 117-1) in an interlaced pattern.

6. An apparatus (100) for manufacturing composite components (55, 55-1), said apparatus comprising: The lamination station (130, 130-1) enables the lamination head (134) to follow the contour of the laying mandrel (110) that moves in the processing direction during the manufacture of the composite component (55, 55-1); as well as A laminating head (134) is disposed at the laminating station (130, 130-1) and is configured to lay fiber reinforcement material bundles (124) onto the laying mandrel (110). The laminating head (134) is configured to operate in a forward and backward manner to lay fiber reinforcement material for the laminate (120) in different regions (115, 117, 117-1) at the laying mandrel (110) while splicing the different regions (115, 117, 117-1) together.

7. The device (100) according to claim 6, further comprising: The laminating head (134) is located downstream of the laminating head (134) and performs reprocessing on the laminate (120).

8. The device (100) according to claim 6, wherein: The laminating head (134) simultaneously lays the fiber-reinforced material and splices the different regions (115, 117, 117-1) together.

9. To manufacture a part of an aircraft using the equipment (100) according to any one of claims 6 to 8.

10. A system for manufacturing composite components (55, 55-1), the system comprising: Track (132) follows the profile of a laying mandrel (110) that moves in the processing direction during the manufacture of the composite component (55, 55-1); as well as Lamination station, the lamination station including: A laminating head (134) is movably mounted to the track (132) and configured to lay fiber reinforcement material onto the laying mandrel (110). The laminating head (134) is configured to operate in a forward-backward manner to simultaneously lay fiber reinforcement material for the laminate (120) in different regions (115, 117, 117-1) at the laying mandrel (110) and splice the different regions (115, 117, 117-1) together.

11. The system according to claim 10, wherein: The laying mandrel (110) defines the outer mold line (OML) of the wing, or The laying mandrel (110) defines the inner mold line (IML) of the section of the fuselage.

12. To manufacture a part of an aircraft using the system according to any one of claims 10 to 11.

13. A method (200) for manufacturing a composite component (55, 55-1) from a laminate (120), the method comprising: Lay the mandrel (110) by moving (202) in the processing direction; The laying mandrel (110) is rotated (204) to the laminating head (134) at the laminating station (130, 130-1); and The fiber-reinforced material bundles (124) are simultaneously applied (208) to the laying mandrel (110) via the laminating heads (134) at the laminating stations (130, 130-1), wherein each of the laminating heads (134) applies the bundles (124) to a distribution area at the laying mandrel (110), and the laminating heads (134) at different laminating stations (130, 130-1) apply the bundles (124) to different distribution areas (115, 117, 117-1); and Repeat the movement (202), transposition (204), and application (208).

14. The method (200) according to claim 13, wherein: Applying (208) the filament bundle (124) includes operating the laminating head (134) along the shared track (132) to lay the filament bundle (124), or Applying (208) the filament bundle (124) includes independently operating the laminating head (134) to lay the filament bundle (124).

15. The method (200) according to any one of claims 13 to 14, wherein: While the filament bundle (124) is being applied, each laminating head (134) is assigned to a different region; as well as The area assigned to each laminator varies as the laying mandrel (110) advances in the processing direction.

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