Composite assembly for unhardened fuselage components

Abstract

The present invention relates to composite assemblies for unhardened fuselage components. Systems and methods for manufacturing a preform for an aircraft fuselage section are provided. The method includes advancing a series of arc-shaped mandrel sections (112) in a process direction through an assembly line, laying stringer preforms onto the arc-shaped mandrel sections (112) via a stringer layup station, merging the series of arc-shaped mandrel sections (112) into a combined mandrel, and laying fiber reinforcement material onto the combined mandrel and the stringer preforms.

Description

Technical Field

[0001] This disclosure relates to the field of manufacturing, and more specifically, to the manufacturing of aircraft airframes. Background Technology

[0002] Large composite parts, such as those spanning several meters (i.e., tens of feet), occupy a significant amount of space within the factory floor. Prefabricated components for these parts are laid on a lay-up mandrel in a fixed work area. This work area includes an Automated Fiber Placement (AFP) machine, which comprises a large end effector with a large robotic arm. The end effector continues to traverse the work area, adding fiber reinforcement material bundle by bundle. Thus, a single AFP machine traverses the entire lay-up mandrel individually according to an optimized lay-up pattern.

[0003] WO2006 / 001860 discloses in its abstract a composite segment for an aircraft fuselage and methods and systems for manufacturing such segments. A composite segment configured according to one embodiment of this disclosure includes a skin and at least first and second stiffening ribs. The skin may include a plurality of unidirectional fibers forming a continuous surface extending 360 degrees around an axis. The first stiffening rib may include a first flange portion bonded to an inner surface of the skin and a first protrusion portion projecting inward and away from the inner surface of the skin. The second stiffening rib may include a second flange portion bonded to an inner surface of the skin and a second protrusion portion projecting inward and away from the inner surface of the skin. A method of manufacturing a fuselage segment according to one embodiment includes positioning a plurality of uncured stiffening ribs on a mandrel assembly. The method may also include applying a plurality of fiber bundles around the plurality of uncured stiffening ribs on the mandrel assembly.

[0004] EP2857186 discloses, in its abstract, a method for manufacturing a fiber composite component comprising a skin portion and a backing structure. Initially, a single-piece or multi-part foam component is prepared and positioned, including at least one recess opening toward a first side of the foam. Before, during, or after the positioning of the foam or its component, a rigidifying element for the backing structure, or a preform or first semi-finished product for forming the rigidifying element, is at least partially arranged in the recess. A skin portion or a second semi-finished product for forming the skin portion is provided and contacts the foam on its first side and the rigidifying element, preform, or first semi-finished product in a region such that the skin portion or second semi-finished product is at least partially laid against the foam and the rigidifying element, preform, or first semi-finished product is positioned relative to the skin portion or second semi-finished product. The skin portion or second semi-finished product and the rigidifying element, preform, or first semi-finished product in contact therewith are further processed to obtain a fiber composite component in which the skin portion and the rigidifying element are interconnected. This disclosure also relates to a fiber composite component and structural component for an aircraft or spacecraft.

[0005] WO2008 / 133748 describes a method for manufacturing a one-piece composite fuselage segment that minimizes out-of-plane fiber twist. This is achieved by manufacturing a mandrel with a coefficient of thermal expansion in the circumferential direction that is sufficiently greater than that of the laid composite ply assembly. Due to this difference in the coefficient of thermal expansion in the circumferential direction, the laid composite ply assembly is circumferentially stretched as the mandrel expands radially during curing, thereby eliminating or reducing out-of-plane fiber twist. Simultaneously, the mandrel and the part being manufactured should have substantially the same coefficient of thermal expansion in the longitudinal direction. As the perimeter of the outer surface of the mandrel increases, the circumferential reinforcing fibers of the inner ply are stretched, while the perimeter of the circumferential reinforcing fibers of the outer ply decreases, thus preventing the formation of waves or wrinkles.

[0006] Therefore, current technologies for manufacturing large composite parts require a significant amount of time for indexing the laying mandrel before laying the preform. Thus, a method and apparatus that addresses at least some of the issues discussed above, as well as other potential problems, is desirable. Summary of the Invention

[0007] The embodiments described herein provide assembly line systems and techniques for manufacturing preforms that will be hardened into fuselage sections of an aircraft body. These systems include stations arranged along the process direction of the laying mandrel. The laying mandrel continues along the process direction to receive additional fiber reinforcement components as it travels, until a finished preform for the fuselage section is manufactured at the laying mandrel location. By further separating the laying and compaction operations at the assembly line stations, the overall manufacturing speed is rapidly increased without the need for dedicated machinery. Furthermore, this arrangement ensures that the transport of the laminate includes the added-value time available for laying, compaction, and other operations.

[0008] One embodiment is a method for manufacturing a prefabricated component for an aircraft fuselage section. The method includes: advancing a series of bow-shaped mandrel segments in a process direction through an assembly line; laying stringer prefabricated components onto the bow-shaped mandrel segments via a stringer laying station; merging the series of bow-shaped mandrel segments into a composite mandrel; and laying fiber-reinforced material onto the composite mandrel and the stringer prefabricated components.

[0009] On the other hand, a system for manufacturing prefabricated components for aircraft fuselage sections is provided. The system includes: a series of bow-shaped mandrel segments advancing in a process direction through an assembly line; at least one stringer laying station operable to lay stringer prefabricated components onto the bow-shaped mandrel segments; at least one mandrel assembly station operable to combine the series of bow-shaped mandrel segments into a composite mandrel; and at least one laying station operable to lay fiber-reinforced material onto the composite mandrel and stringer prefabricated components.

[0010] Other exemplary embodiments (e.g., methods and computer-readable media related to the embodiments described above) may be described below. The features, functions, and advantages discussed may be implemented independently in various embodiments or in combination in other embodiments, further details of which can be seen from the following description and drawings. Attached Figure Description

[0011] Some embodiments of this disclosure will now be described by way of example only with reference to the accompanying drawings. The same reference numerals denote the same elements or elements of the same type throughout all the drawings.

[0012] Figure 1A An assembly line for manufacturing prefabricated components for the fuselage section is shown in an exemplary embodiment.

[0013] Figure 1B A conceptual assembly arrangement in an exemplary embodiment is depicted.

[0014] Figure 1C A conceptual assembly arrangement in an exemplary embodiment is depicted.

[0015] Figure 2 This illustrates an exemplary embodiment for operation. Figure 1A The flowchart shows the assembly line method.

[0016] Figure 3A This illustrates an exemplary embodiment for operation. Figure 1A A flowchart of another method for assembly lines.

[0017] Figure 3B This illustrates an exemplary embodiment for operation. Figure 1A A flowchart of another method for assembly lines.

[0018] Figure 4 The illustration shows a flat material laying station for the precast stringers in an exemplary embodiment.

[0019] Figures 5A to 5B The operation of the forming station for the precast stringer in the exemplary embodiment is shown.

[0020] Figures 6A to 6B The diagram illustrates the bow-shaped mandrel segment before and after the laying of the stringer prefabrication in an exemplary embodiment.

[0021] Figures 7A to 7B An exemplary embodiment is shown, comprising a combined mandrel assembled from multiple bow-shaped mandrel segments, which receives a stringer prefabricated component.

[0022] Figures 8A to 8B The laying of skin layers onto the composite mandrel in an exemplary embodiment is depicted.

[0023] Figures 9A to 9CThe illustration shows the laying of an interwoven silk fabric (IWWF) layer for a preform and the placement of a backing plate onto the preform in an exemplary embodiment.

[0024] Figures 10A to 10D The hardening of multiple combined mandrels in an autoclave is depicted in an exemplary embodiment.

[0025] Figures 10E to 10F The hardening of multiple combined mandrels in an autoclave is depicted in an exemplary embodiment.

[0026] Figure 11 This is a flowchart of an exemplary embodiment of an aircraft production and service method.

[0027] Figure 12 This is a block diagram of an aircraft in an exemplary embodiment. Detailed Implementation

[0028] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. It will therefore be understood that those skilled in the art will be able to conceive of various arrangements that, while not expressly described or shown herein, specifically 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 should not be construed as limiting oneself to the examples and conditions specifically described therein. Consequently, this disclosure is not limited to the specific embodiments or examples described below, but is limited by the claims and their equivalents.

[0029] The fuselage section described herein comprises one or more composite parts. Initially, composite parts, such as carbon fiber reinforced polymer (CFRP) parts, are laid in multiple layers, collectively referred to as a preform. Individual fibers within each layer of the preform are aligned parallel to each other, but different layers exhibit different fiber orientations to increase the strength of the resulting composite part along different dimensions. The preform includes a viscous resin, which solidifies to harden the preform into a composite part (e.g., for use in aircraft). Carbon fibers impregnated with uncured thermosetting or thermoplastic resins are referred to as “prepreg.” Other types of carbon fibers include “dry fibers” that are not impregnated with thermosetting resins but may include tackifiers or binders. Dry fibers are infused with resin before curing. For thermosetting resins, curing is a one-way process called hardening, while for thermoplastic resins, if reheated, the resin reaches a viscous form and can then be solidified into the desired shape. As used herein, the general term for the process of transforming a preform into its final hardened shape (i.e., transforming a preform into a composite part) is called “hardening,” which encompasses both the curing of thermosetting preforms and the molding / solidification of thermoplastic preforms into their final desired shape.

[0030] Figure 1AAn assembly line 100 is shown in an exemplary embodiment for manufacturing a preform 122 for a fuselage section. In this embodiment, the assembly line 100 performs various manufacturing processes together to produce the preform 122 for hardening into a composite part. Movement occurs along process directions 199-0 to 199-15 during these operations. The assembly line 100 includes a stringer manufacturing line 110 for creating stringer preforms 107. The stringer preforms 107 are laid onto bow-shaped mandrel sections 112, which are later assembled together to form a composite mandrel 118. In one embodiment, the laying of the stringer preforms 107 is performed during pauses between pulses of the bow-shaped mandrel sections 112. In another embodiment, the laying of the stringer preforms 107 is performed during continuous processing of the bow-shaped mandrel sections 112.

[0031] The bow-shaped mandrel section 112 is structurally combined into a combined mandrel 118. Although the combined mandrel 118 is shown as being used for a half-cylinder fuselage section in the illustrated embodiment, there are embodiments for a full-cylinder fuselage section as well as embodiments other than half-cylinder or full-cylinder fuselage sections.

[0032] One or more layers of fiber reinforcement material 121 are laid on the composite mandrel 118. These fiber reinforcement material layers 121 integrate the stringer preforms 107 at the composite mandrel 118 into a single unit, resulting in a preform 122 for the bow-shaped fuselage section. A pad 134 is sealed around the preform 122 to the composite mandrel 118, and the preform 122 is cured in an autoclave 136 (e.g., a straight-through autoclave) into a composite part 150 (e.g., during an autoclave curing cycle). Thus, in this embodiment, the pad 134 operates as both a vacuum bag and a pad. The composite part 150 is demolded, and the composite mandrel 118 is disassembled and cleaned to allow the bow-shaped mandrel section 112 to be reused on the assembly line 100. That is, after cleaning, the bow-shaped mandrel section 112 is returned to position A indicated on the left side of the page to receive another work iteration.

[0033] Figure 1AEach of the various workstations shown is designed to perform its work within a specific time period. For example, the workload assigned to a workstation may be tailored so that each workstation can perform its work during a unified pause between the pulses of the stringer preform 107, the arc mandrel segment 112, and / or the combined mandrel 118 (e.g., a pause shared / synchronized among multiple workstations at assembly line 100). In one embodiment, an integer number of pauses (equal and synchronized among the stringer preform 107, the arc mandrel segment 112, and / or the combined mandrel 118) equals the hardening time of the stringer preform 107. In another embodiment, pauses are synchronized for workstations working on the same component but not shared between different types of components. For example, a workstation performing stringer manufacturing is synchronized to a pause, a workstation performing laying on the arc mandrel segment 112 is synchronized to a different pause, and a workstation performing work on the combined mandrel 118 is synchronized to other pauses. In some embodiments, a larger pause is an integer multiple of a smaller pause. In another embodiment, some portions of the assembly line 100 operate continuously, while others are pulsating.

[0034] All operations discussed above are performed for prefabricated component 122 in accordance with the desired takt time. Enforcing uniform working times across multiple workstations allows for coordinated and synchronized operations between workstations based on a shared schedule.

[0035] In one implementation, the advancement includes mandating uniform working hours across multiple workstations performing laying, merging, and splicing, thereby allowing for coordinated and synchronized operations across workstations based on a common schedule.

[0036] In one implementation, the workload at each station is based on the time span of the heating cycle of the autoclave 136. Therefore, in one implementation, the amount of time spent at each station during pauses on the stringer preform 107, the bow mandrel segment 112, or the combined mandrel 118 is equal to the expected hardening time of the preform 122 at the autoclave 136 (or equal to a period of time divisible by the hardening time). This allows various components to proceed synchronously across multiple stations (whether continuously or intermittently) in sync with the hardening process performed at the autoclave 136. Further dividing the manufacturing of larger structures into smaller structures for processing and assembly allows for parallel processing and assembly of smaller structures, thereby increasing the overall throughput and manufacturing speed of the larger structures.

[0037] In another embodiment, components used as inputs to the workstations of assembly line 100 are manufactured in a just-in-time (JIT) manner via a feed line (described further below) that supplies components directly to the workstations. JIT supply of components to the workstations reduces the amount of space required in the factory warehouse and the amount of space required to transport materials from the warehouse to the workstations. In some embodiments, components supplied by a single line (e.g., stringer prefabrication 107) are slightly different from each other, and a specific type of component required at a given point in time is supplied in a JIT manner.

[0038] With this broad understanding of assembly line 100, further details of the various components of assembly line 100 are provided below. In this embodiment, each stringer manufacturing line 110 includes a lamination station 102, which lays and trims flatbeds 104 of fiber-reinforced material (e.g., uncured CFRP). These flatbeds 104 may additionally receive layers of fluorinated ethylene propylene (e.g., FEP), insulating layers (e.g., glass fiber layups electrically insulating carbon fibers from aluminum components), etc. The flatbeds 104 are advanced toward forming station 106 in the process direction 199-0.

[0039] The flat material 104 is formed into stringer preforms 107 on a mandrel 105 via forming station 106. After forming, the stringer preforms 107 move in the process direction 199-1 and are laid onto a tray 108, which advances along a track 109 (e.g., a power conveyor belt or other component). The track 109 may be linear or arranged in a raceway (e.g., loop) layout, wherein one or more stringer preforms 107 enter the track 109 and leave when laying and forming are complete (e.g., after the stringer preforms 107 continue laying during one or more crossings of the loop). In one embodiment, multiple lamination stations 102 are followed by multiple forming stations 106, which are arranged along the track 109. Within the track 109, the mandrel 105 cycles through the same lamination stations 102 and then the same forming stations 106 multiple times before leaving the track 109. Further details of this arrangement are provided below. Figure 1C To depict. According to the design, tray 108 stores one or more stringer prefabricated components 107.

[0040] A stringer placement station 113, such as pick-and-place (PNP) station 114, places stringer preforms 107 from pallet 108 onto arched mandrel sections 112 in process direction 199-2. In one embodiment, PNP station 114 (including PNP machine 115) picks up and places a single stringer preform 107 at a time, while in other embodiments, PNP station 114 picks up and places a batch of stringer preforms 107 onto the arched mandrel sections 112 advancing in process direction 199-3. Additional stringer preforms 107 are stored in warehouse 125 for later use by PNP station 114 or other stations. In another embodiment, PNP station 114 applies frame filler (e.g., pads for adapting to frames) simultaneously with the application of stringer preforms 107, and the frame filler mates with the stringer preforms 107 onto pallet 108 at the desired location. In another embodiment, the stringer prefabricated members 107 and the frame filler are picked up in groups, and these groups are applied to the bow mandrel section 112 at a time.

[0041] Bow-shaped mandrel section 112 in Figure 1A The arrow indicates the process direction (P) in which the mandrel segment 112 is advanced. In one embodiment, the mandrel segment 112 moves continuously in the process direction, while in another embodiment, the mandrel segment 112 pulsates in the process direction, depending on the direction of the next station. A movement of the mandrel segment 112 less than its length is referred to as "micro-pulsation," while a movement of the mandrel segment 112 equal to or greater than its length is referred to as "full pulsation." In the pulsating embodiment, the station can perform work on the mandrel segment 112 during the pause between pulsations, and multiple stations perform work on the same mandrel segment 112 during the same pause between pulsations. In the continuous motion embodiment, the station can perform operations during the movement of the mandrel segment 112. In another embodiment, two separate versions can be implemented. The first version is a "passing-through" version, in which the station tool is fixed and performs work on the mandrel segment 112 as it advances through or passes the station. The second version is a "piggyback" version, in which the station tool is physically connected to the bow-shaped mandrel segment 112 and performs work on the bow-shaped mandrel segment 112 while both are advancing, until the connection is broken, and the station tool returns to the beginning of the station. Depending on the type of manufacturing process and the work being performed, both versions can be implemented to perform work simultaneously on the same bow-shaped mandrel segment 112. This discussion relating to the bow-shaped mandrel segment 112 also applies to manufacturing processes relating to the stringer preform 107, the combined mandrel 118, and other components moving at assembly line 100.

[0042] The arc-shaped mandrel segment 112 is advanced in process direction 199-4 and assembled together at mandrel assembly station 116 to form a composite mandrel 118. Depending on the design, the engagement location of the arc-shaped mandrel segment 112 may include the circumferential position of the stringers. In embodiments where the engagement location is the circumferential position of the stringers, after assembly / engagement is complete, additional stringer prefabricated pieces 107 are laid at the intersections between the arc-shaped mandrel segments 112 forming the composite mandrel 118. The composite mandrel 118 is advanced in process directions 199-5 and 199-6 to one or more laying stations 120, where a series of end effectors 123 lay fiber reinforcement material 121 for one or more skin layups to create prefabricated pieces 122 for fuselage sections (e.g., 7.62-meter (25-foot) or 12.2-meter (40-foot) fuselage sections). Fiber reinforcement 121 is laid on the mandrel 118 and over the stringer preforms 107 placed within the mandrel 118. Skin layups integrate the fiber reinforcement from the stringer preforms 107, resulting in the individual stringer preforms 107 being integrated together by skin layups to form a preform 122. Different combinations of layups and fiber orientations are used in each of the end effectors 123 and / or layup stations 120 to complete the preform 122. Each layup station 120 is operable to lay the fiber reinforcement 121 according to multiple different orientations. Alternatively, the multiple layup stations 120 are implemented such that each layup is in a specific orientation. In one embodiment, the mandrel 118 is advanced continuously according to a cycle time, and the laying of fiber reinforcement 121 onto the mandrel 118 and the laying of fiber reinforcement for the stringer preforms 107 are performed during the advancement of the mandrel 118. In such an implementation, multiple laying stations 120 can perform work on the combined mandrel 118 during continuous advance.

[0043] Preform 122 is advanced in process direction 199-7 to interwoven silk fabric (IWWF) and surface material station 124, which lowers IWWF 126-1 and surface material 126-2 (also collectively referred to as "IWWF and surface material 126"). These components can be laid simultaneously or separately, or even laid in combination as part of a lay-up / compact step or together with pad 134 and / or vacuum bag. In this embodiment, IWWF 126-1 and surface material 126-2 are laid onto preform 122 for the fuselage section via opening 128. In the illustrated embodiment, opening 128 is located in interlayer 127, and by lowering from the height of interlayer 127, pad 134 / vacuum bag and IWWF 126-1 and surface material 126-2 move to the appropriate position on preform 122 from the feed line. In this embodiment, instead of a feed line providing the feed product at ground level, the feed line can provide the material of IWWF 126-1 and surface material 126-2 at the height of interlayer 127. Thus, input and output are received from the feeder to the elevated station. IWWF 126-1 and surface material 126-2 are applied to the preform 122 (e.g., integrally therewith) such that, after hardening, IWWF 126-1 and surface material 126-2 are integral components of the resulting composite part 150.

[0044] After the preform 122 is further advanced in the process direction 199-8, the pad loading station 130 lowers the pad 134 onto the preform 122 using the opening 132 in the interlayer 127. This allows the pad 134 to enter from the "third side" 135 (i.e., neither from the left nor the right side of the preform 122). The pad 134 is sealed to the composite mandrel 118 on which the preform 122 has been laid, and pressure is applied to the pad 134 during hardening, which reinforces and ensures conformity to the desired outer mold line (OML) of the composite part 150.

[0045] After the pad 134 is laid, the preform 122 is advanced in the process direction 199-9 through the inlet 138 of the autoclave 136 and sealed into the autoclave 136. In one embodiment, when moved into place, the assembly mandrel 118 itself forms the boundary of the autoclave 136, resulting in a "properly sized" autoclave. The autoclave 136 is operated under heat (e.g., a desired curing temperature, such as above 90°C (i.e., several hundred degrees Fahrenheit)) and pressure (e.g., a desired compaction pressure, such as 620 kPa (i.e., 90 psi)) to harden the preform 122 into the composite part 150. The composite part 150 is removed from the autoclave 136 through boundary 140 in the process direction 199-10 from the cleanroom environment 191 and into the main plant workshop 193. In one embodiment, boundary 140 is located at the autoclave outlet, so the autoclave 136 serves as a doorway for exiting the cleanroom environment 191. In some embodiments, an indexing feature 152, such as a hole, is added to the manufacturing excess 151 of the composite part 150 at the demolding station 142.

[0046] Then, the composite mandrel 118 moves to the demolding station 142 in the hardened assembly environment (e.g., a non-cleanroom environment), where the composite part 150 is removed and sent to another assembly line to receive the installation of frames, window frames, and other features. The pad 134 is cleaned and returned to the cleanroom environment via process directions 199-15. This can be achieved via a pulsating, micro-pulsating, or continuous line for cleaning and preparation, so as to reintroduce it into the cleanroom environment 191 at the mezzanine 127. In a similar manner, the composite mandrel 118 is advanced in process directions 199-11 to the disassembly station 160, where it is separated into individual arcuate mandrel segments 112 that move in process directions 199-12. The arcuate mandrel segment 112 moves (e.g., pulsatingly) along a return line 180 in process directions 199-13, returning it from the factory floor 193 to the beginning of assembly line 100 in cleanroom environment 191, as indicated by process directions 199-14. The return line 180 can be a pulsating, micro-pulsating, or continuous line for cleaning and preparation before reintroduction into the cleanroom. At the return line 180, the arcuate mandrel segment 112 undergoes surface repair and cleaning at one or more cleaning stations 170 (which may include disassembly stations, cleaning stations, and surface repair stations) before returning to cleanroom environment 191 for reuse in assembly line 100 (as indicated by node "A"). In another embodiment, the mandrel 105 for the stringer preform 107 also moves pulsatingly, micro-pulsatingly, or continuously along a line for cleaning and preparation of the mandrel 105 before reintroduction into cleanroom environment 191. This line can be located entirely or partially outside the cleanroom environment 191.

[0047] Controller 190 manages the operations of the stations at assembly line 100 and coordinates actions along assembly line 100 to ensure that the stations perform actions synchronously as needed. In some exemplary examples, controller 190 is capable of operating to enforce uniform working hours across at least one laying station 120 and at least one mandrel assembly station 116, and to coordinate and synchronize laying and merging according to a common schedule. However, one or more controllers may be implemented to coordinate actions, and controller 190 need not be a centralized device. In some embodiments, controller 190 maintains and supplies numerical control (NC) programs to the stations and tracks the timing of operations defined in these NC programs to ensure a desired level of synchronization during operation. In one embodiment, controller 190 is implemented as custom circuitry, a hardware processor that executes programmed instructions stored in memory, or some combination thereof.

[0048] Figure 1B A conceptual assembly arrangement 195 in an exemplary embodiment is depicted. Figure 1B In this embodiment, feed lines 196-1 to 196-13 and 196-15 feed materials to various other assembly lines according to cycle time (e.g., the expected production time of products such as aircraft or wings), and synchronously supply components to other assembly lines in just-right time to facilitate manufacturing. Specifically, feed lines 196-1, 196-2, and 196-3 supply laying materials such as CFRP tow or broad goods to feed line 196-6 for manufacturing half-tube or full-tube sections, feed line 196-5 for laying frames, and feed line 196-4 for laying perimeters, respectively. In this embodiment, feed line 196-6 also feeds stringer prefabricated parts via feed line 196-7, and feed line 196-7 itself also feeds laying materials via feed line 196-8.

[0049] Feed line 196-5 feeds the frame (e.g., after hardening) to feed line 196-9 for the frame section, and feed line 196-4 feeds the perimeter to feed line 196-10 for the perimeter (e.g., door and window frames). The various components discussed above are fed to feed line 196-11, which performs sequential assembly using inputs from feed lines 196-6, 196-9, and 196-10. Feed line 196-11 also receives fasteners from feed line 196-12, sealant from feed line 196-13, and miscellaneous materials from feed line 196-15. Outflow 196-14 removes trimming or machining debris, waste, etc., from feed line 196-11. The feed lines 196-1 to 196-15 and / or any of the outflows discussed in this article can be operated in a micro-pulsating, continuous, or full-pulsating manner according to the same or different cycle times.

[0050] Figure 1CA conceptual assembly arrangement in an exemplary embodiment is depicted. This arrangement is described... Figure 1A An alternative implementation of the stringer laying method depicted in the text. According to... Figure 1C The mandrel 198-2 enters the track 198-5 (e.g., an elliptical track, a rectangular track with square ends, etc.) along direction 198-6 and receives fiber reinforcement material 198-1 from the lamination station 198-3. The fiber reinforcement material 198-1 is formed at the molding station 198-4 downstream of the lamination station 198-3 and molding station 198-4, and advances in directions 198-7, 198-8, 198-9, and 198-10. The mandrel 198-2 advances multiple turns of each track 198-5 until a finished stringer preform with the same configuration as the stringer preform 107 is produced, at which point the mandrel 198-2 leaves the track via direction 198-11 for further processing. Figure 1C In the embodiments depicted, laying the fiber reinforcement material includes circulating the mandrel 198-2 multiple times through a lamination station 198-3 and then a forming station 198-4 to form a preform for the stringers. In some exemplary examples, the lamination station 198-3 may be referred to as the laying station.

[0051] Regarding Figure 2 The following are illustrative details of the operation of assembly line 100. For this embodiment, it is assumed that stringer preforms 107 have been manufactured by stringer manufacturing line 110 and are awaiting placement on the bow-shaped mandrel section 112.

[0052] Figure 2 This illustrates the operation in an exemplary embodiment. Figure 1A The flowchart of method 200 for the assembly line is shown. The steps of method 200 are as follows: Figures 1A to 1C The method is described using assembly line 100, but those skilled in the art will understand that method 200 can be performed in other systems. The steps in the flowchart described herein are not exhaustive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0053] Method 200 includes dispensing 202 of fiber reinforcement material for a preform (e.g., for preform 122) onto a first arcuate mandrel segment 112. In this embodiment, dispensing 202 of the fiber reinforcement material includes picking up the stringer preform 107 and laying it onto the arcuate mandrel segment 112. However, in other embodiments, this also includes applying ply packages, frame fillers (“postage stamps”), barrier plies, etc., or directly laying one or more material plies onto the arcuate mandrel segment 112. Thus, the dispensing 202 step includes laying any material to be laid onto the arcuate mandrel segment 112 prior to laying the skin for the fuselage. The arcuate mandrel segment 112 can then be further advanced along the assembly line 100.

[0054] Method 200 includes distributing 204 of fiber reinforcement material 121 for preform 122 onto a second arcuate mandrel segment 112. Distributing step 204 can be performed in a manner similar to distributing step 202 described above. However, depending on whether the second arcuate mandrel segment 112 receives a layup for the crown or sides of the fuselage, the arrangement and type of stringer preforms 107 laid on the second arcuate mandrel segment 112 may differ from those laid on the first arcuate mandrel segment 112. In one embodiment, distributing step 204 includes picking up a stringer preform 107 and laying it onto the next arcuate mandrel segment 112 immediately following the first arcuate mandrel segment 112 along the assembly line 100. However, in another embodiment, this further includes applying a ply package, frame filler (“pad”), barrier ply, etc., or directly laying one or more material plies onto the arcuate mandrel segment 112. Therefore, the allocation 204 includes laying any material that needs to be laid on the bow-shaped mandrel section 112 before laying the skin for the fuselage.

[0055] Continuing, the first and second arcuate mandrel segments 112 are structurally merged 206 to form a combined mandrel 118. The merging step 206 is performed after the first and second arcuate mandrel segments 112 have received the fiber-reinforced material 121 as discussed in previous paragraphs. In one embodiment, the structural merging 206 of the arcuate mandrel segments 112 is performed by laying the arcuate mandrel segments 112 on a frame such that the arcuate mandrel segments 112 are adjacent to each other. In another embodiment, the structural merging 206 of the arcuate mandrel segments 112 includes bolting or fastening the arcuate mandrel segments 112 together while they are chordally adjacent. In one embodiment, each arcuate mandrel segment 112 includes approximately a 60-degree portion of the entire cylinder, and three arcuate mandrel segments 112 are assembled together to form the combined mandrel 118. Any suitable number of arc-shaped mandrel segments 112 (each comprising any suitable arc segment) can be assembled together in this step to form a combined mandrel 118. Therefore, although... Figures 1A to 1CEach assembled mandrel 118 shows only three arcuate mandrel segments 112, but in other embodiments, a different number of segments are used. The assembled mandrel 118 then receives additional stringer preforms 107 (e.g., at the intersections between the arcuate mandrel segments) and moves to the laying station 120. In another embodiment, only the underlay material is applied during dispensing 202, 204, but in another embodiment, the underlay material is applied, and then the skin is applied before the arcuate mandrel segments 112 are joined together. The skin is then stitched together when the arcuate mandrel segments 112 are assembled. Thus, the merging step 206 may include stitching the fiber reinforcement material 121 for the preform 122 dispensed on the first arcuate mandrel segment 112 with the fiber reinforcement material 121 on the second arcuate mandrel segment 112.

[0056] Finally, by integrating the fiber reinforcement 121 distributed 202 onto the first arcuate mandrel segment 112 with the fiber reinforcement 121 distributed onto the second arcuate mandrel segment 112, the distribution 208 completes the fiber reinforcement 121 of the preform 122. In one embodiment, this includes a layup station 12, which lays one or more skin layups on the surface of the composite mandrel 118 defining the inner mold line (IML) of the preform 122. The skin layups form an arc covering the stringer preform 107, so that after curing, the skin layups and the stringer preform 107 form part of the same composite part 150 for the fuselage segment. In another embodiment, the distribution 208 includes picking up additional preforms, layup packages, or other components and laying them onto the composite mandrel 118.

[0057] Method 200 offers significant advantages over existing technologies because it allows the larger composite part 150 to be laid in segments at various smaller mandrels (e.g., bow-shaped mandrel segment 112, mandrel 105) via a standardized process. The smaller mandrels are then integrated with additional layups to form the finished preform 122. This simplifies the layup process by increasing speed while reducing layup difficulty. It also facilitates parallel processing, increasing manufacturing rates.

[0058] Figure 3A This illustrates the operation in an exemplary embodiment. Figure 1A A flowchart of another method 300 for the assembly line. Method 300 is used in conjunction with... Figure 2 There are 200 similar but different ways to describe manufacturing processes.

[0059] Initially, a series of bow-shaped mandrel segments 112 are assembled in the process direction via assembly line 100 (i.e., the same assembly line, Figure 1BThe feed lines 196-6, etc., are advanced 302 (e.g., pulsating). As described above, depending on the design considerations, the arcuate mandrel segment 112 may be pulsated or fully pulsated along the assembly line 100 as needed. In one embodiment, the arcuate mandrel segment 112 is advanced 302 along a powered track (e.g., a conveyor belt or a series of supports, each topped with a powered roller), while in another embodiment, the arcuate mandrel segment 112 is carried by an automated guided vehicle (AGV) or other transport vehicle. The arcuate mandrel segment 112 (or its longitudinal portion) is rotated to a station on the assembly line 100 during pauses between pulsations.

[0060] In one embodiment, the arc-shaped mandrel segment 112 pulsates along the assembly line 100 in the process direction less than the length of the arc-shaped mandrel segment 112. In another embodiment, the arc-shaped mandrel segment 112 pulsates along the assembly line 100 in the process direction at least the length of the arc-shaped mandrel segment 112. In yet another embodiment, the arc-shaped mandrel segment 112 advances continuously along the assembly line 100 in the process direction.

[0061] Via stringer manufacturing line 110 (e.g., Figure 1B Feed lines 196-7 supply stringer prefabricated parts 107 to assembly line 100 (e.g., ...). Figure 1B The stringer preform 107 is supplied by JIT 304 to the PNP station 114 at the feed line 196-6. In one embodiment, the stringer preform 107 is supplied by JIT 304 to the PNP station 114, and the end of the stringer manufacturing line 110 is connected to the input of the PNP station 114. Since the size and shape of the individual stringer preforms 107 can vary depending on the fuselage section being manufactured, it is highly beneficial for JIT to supply stringer preforms 107 with shapes and sizes that match the requirements of the PNP station 114, as those requirements change over time. Therefore, coordination between the stringer manufacturing process and the PNP process is useful to ensure that the correct stringer preforms 107 are manufactured and supplied by JIT 304 to the PNP station 114 at the correct time. In another embodiment, the stringer preforms 107 from the stringer manufacturing line 110 are stored in a warehouse 125 and then retrieved by JIT for use at the PNP station 114.

[0062] The stringer prefabricated parts 107 are laid 306 onto the arched mandrel section 112 via stringer laying station 113 (e.g., PNP station 114). In an embodiment where the arched mandrel section 112 is pulsating, the stringer prefabricated parts 107 are laid 306 during pauses between pulsations of the arched mandrel section 112. In one embodiment, the PNP station 114 lays an entire batch of stringer prefabricated parts 107 306 onto the arched mandrel section 112 at a time. Thus, the stringer prefabricated parts 107 are laid in batches, with each batch comprising multiple stringer prefabricated parts 107. In another embodiment, the PNP station 114 lays the stringer prefabricated parts 107 306 onto the arched mandrel section 112 individually. Thus, the desired materials and components (e.g., stringer prefabricated parts, etc.) are laid 306 onto the arched mandrel section 112 prior to skin laying.

[0063] The arc-shaped mandrel segments 112 are combined 308 into a composite mandrel 118. In one embodiment, structurally combining 308 of the arc-shaped mandrel segments 112 is performed by laying the arc-shaped mandrel segments 112 on a frame such that the arc-shaped mandrel segments 112 are chordally adjacent to each other (i.e., joined along adjacent longitudinal edges). In another embodiment, structurally combining 308 of the arc-shaped mandrel segments includes bolting or fastening the arc-shaped mandrel segments 112 to each other.

[0064] Fiber-reinforced material 121 is laid 310 onto the composite mandrel 118 and stringer preform 107 via layup station 120, thereby obtaining a fuselage section preform 122 including the stringer preform 107. The fiber-reinforced material 121 is laid 310 onto the composite mandrel 118 and stringer preform 107 to form a skin layup. This step forms the fuselage skin of this section (e.g., composite part 150). This step is performed via one or more layup stations 120. In one embodiment, different combinations of layup 310 layers and fiber orientations are applied at each layup station 120. In one embodiment where the composite mandrel 118 is pulsated, the operation is performed during pauses between pulsations of the composite mandrel 118. The operation of the layup station 120 yields a fuselage section preform (i.e., preform 122) including the stringer preform 107. In one embodiment, this includes operating an end effector 123 to dispense fiber reinforcement material 121 filaments or to lay fiber reinforcement fabric sheets onto the composite mandrel 118. In some exemplary examples, at least one laying station 120 includes at least one end effector 123 operable to dispense fiber reinforcement material 121 filaments onto the arched mandrel segment 112. In some exemplary examples, at least one laying station 120 includes at least one end effector 123 operable to lay fiber reinforcement fabric sheets onto the arched mandrel segment 112. In some exemplary examples, laying fiber reinforcement material 121 310 onto the arched mandrel segment 112 includes at least one of the following: operating at least one end effector 123 to dispense fiber reinforcement material 121 filaments onto the arched mandrel segment 112; and laying fiber reinforcement fabric sheets onto the arched mandrel segment 112.

[0065] A pad 134 is applied 312 to the fuselage section preform 122. This involves lowering the pad 134 above the mandrel 118 and sealing the pad 134 (also operating as a vacuum bag) to the mandrel 118 just beyond the periphery of the preform 122. When a vacuum is applied to the space between the pad 134 and the mandrel 118, the pad 134 is pulled tightly against the preform 122, which forces the desired OML shape on the preform 122 during curing.

[0066] The fuselage section prefabricated part 122 is hardened 314 into a composite part 150. This is performed by inserting the combined mandrel 118 into the autoclave 136 (e.g., an autoclave of suitable size partially defined by the combined mandrel 118) and operating the autoclave 136 at the hardening temperature (e.g., the curing temperature of a thermosetting resin or the melting temperature of a thermoplastic) and pressure while evacuating between the pad 134 and the combined mandrel 118 for the desired time period (e.g., four hours, eight hours, etc.).

[0067] The composite mandrel 118 exits the autoclave 136, and the resulting composite part undergoes additional operations, such as adding indexing features to the manufacturing excess 151 of the composite part 150 and trimming the edges of the composite part 150 to form support edges. Therefore, the composite part 150 is demolded 316 from the composite mandrel 118 at the demolding station 142. In one embodiment, demolding 316 includes iteratively and variably flexing the composite part 150 by increasing the amount to remove the composite part 150 from the composite mandrel 118. The composite part 150 then proceeds to the post-hardening assembly line for further processing and integration into the machine body.

[0068] The composite mandrel 118 is separated 318 into bow-shaped mandrel segments 112 (e.g., by removing bolts or loosening the bow-shaped mandrel segments 112 relative to each other or the underlying frame). The bow-shaped mandrel segments 112 are then cleaned / reworked and returned to the assembly line 100.

[0069] Method 300 offers significant advantages over the prior art because, in a manner similar to Method 200, it allows larger composite parts to be received and laid in segments at various smaller mandrels, which are then merged and laid together to form the finished preform 122. This simplifies the laying process by increasing speed while also reducing laying difficulty.

[0070] Figure 3B This illustrates the operation in an exemplary embodiment. Figure 1A A flowchart of another method 350 for the assembly line. Method 350 includes passing a series of bow-shaped mandrel segments 112 through the assembly line (e.g., ...) in the process direction. Figure 1B The feed line 196-6) is advanced 352. The method includes via stringer manufacturing line 110 (e.g., Figure 1B The feed line 196-7 supplies the stringer prefabricated component 107 to the stringer laying station 113 at the assembly line 100 via the feed line 196-7. Figure 1B At the stringer laying station 113 at feed line 196-6, stringer preforms 107 are laid 356 onto the arched mandrel section 112. Fiber-reinforced material 121 is laid 358 onto the arched mandrel section 112 and stringer preforms 107 via a laying station 120 located before the mandrel assembly station 116. In some exemplary examples, laying fiber-reinforced material 121 310 onto the arched mandrel section 112 includes simultaneously laying fiber-reinforced material 121 310 onto the arched mandrel section 112 via multiple laying stations 120. In some exemplary examples, laying fiber-reinforced material 121 310 onto the arched mandrel section 112 includes advancing the arched mandrel section 112 via multiple laying stations 120 via one or both continuous or intermittent advancement.

[0071] In one embodiment, this includes operating a laying station 120 located along assembly line 100. The arc-shaped mandrel segments 112 are combined 360 into a composite mandrel 118. Fiber-reinforced material 121 is spliced ​​362, i.e., laid onto the arc-shaped mandrel segments 112, and this can be performed via the aforementioned laying station 120 or at an additional laying station 120 where the material can be received from feed line 196-1. This yields the fuselage section preform 122.

[0072] The manufacturing process of prefabricated component 122 for the fuselage section was discussed above. The following... Figures 4 to 10F The specific components and systems used to perform one or more steps of these processes are shown. Specifically, Figure 4 Further details of the laying of the flat material 104 are depicted. Figures 5A to 5B The operation of a forming machine that shapes the flat material 104 into stringer preforms 107 is depicted. Figures 6A to 6B The image depicts the laying of the precast stringer 107 onto the arched mandrel section 112. Figures 7A to 7B A fully formed composite mandrel 118 with a half-cylinder configuration is depicted. Figures 8A to 8B The process of laying the composite mandrel 118 to manufacture the preform 122 is described. Figures 9A to 9C The image depicts the application of IWWF 126-1, surface material 126-2, and backing plate 134 onto preform 122. Figures 10A to 10F The hardening process at point 136 of the autoclave is described.

[0073] Figure 4 The illustration shows a lamination station 102 for the stringer prefabrication 107 in an exemplary embodiment, and corresponds to... Figure 1A Observe arrow 4. In this embodiment, the lamination station 102 includes a plurality of heads 420, each head 420 distributing material bundles to form a flatbed 104. The heads 420 are mounted to a frame 410 and moved along the frame 410 (in one embodiment, a gantry) to a desired location for material layup. The frame 410 provides structural strength to the lamination station 102 while also allowing the heads 420 to move. A conveyor belt 440 moves the flatbed 104 into and / or out of the pages via a belt 430. By iteratively moving the flatbed 104 into and out of the pages, the conveyor belt 440 enables the respective heads 420 to lay up multiple layers of fiber-reinforced material 121 in any desired combination of fiber orientations (e.g., + / -45°, 0°, 90°).

[0074] Figures 5A to 5B The operation of the forming station 106 for the stringer prefabricated component 107 in the exemplary embodiment is shown, and corresponds to Figures 1A to 1CObserve arrow 5. In this embodiment, forming station 106 drives forming head 500 onto flat material 104 resting on forming mandrel 105. This shapes a portion of flat material 104 into the desired shape of stringer preform 107. Although four layups are shown, this can be achieved by laying and forming two or more layups, then iteratively laying and forming additional layups until a complete layup is formed. Another portion of flat material 104 is then advanced into the page and formed, and the process continues iteratively (e.g., back and forth on a track) until the entire flat material 104 is formed into stringer preform 107. In another embodiment, stringer preform 107 may also include additional layers, forming elements, and / or flat material 104 laid after leaving forming station 106 (e.g., to form cap stringers, Z stringers, C stringers, etc.).

[0075] Figures 6A to 6B The illustration shows the bow-shaped mandrel segment 112 before and after the laying of the stringer prefabricated member 107 in an exemplary embodiment. Specifically, Figure 6A Corresponding to Figures 1A to 1C Observe arrow 6A, Figure 6B Corresponding to Figure 1A Observe arrow 6B. In Figure 6A In this embodiment, the arc-shaped mandrel segment 112 includes a body 602 defining an IML surface 630 for the fuselage section preform 122, and also includes a groove 610 for receiving the stringer preform 107. In another embodiment, additional receiving portions in the arc-shaped mandrel segment 112 are provided for frame filler (“shims”) or similar structures to be laid before skinning. The arc-shaped mandrel segment 112 also includes partial grooves 620. These partial grooves 620 become complete grooves after engaging with other partial grooves 620 in other arc-shaped mandrel segments 112. Figure 7A The resulting finished groove 622 will receive the stringer prefabricated component 107 after the bow-shaped mandrel section is assembled into the combined mandrel 118. Figure 6B In this process, the stringer prefabricated component 107 is laid in the groove 610. After the stringer prefabricated component 107 is laid and compacted at the arched mandrel section 112, the outer edge of the stringer prefabricated component 107 aligns with the IML surface 630. As the stringer is compacted into the arched mandrel section 112, the OML side of the stringer prefabricated component 107 provides a portion of the laying surface for the skin.

[0076] Figures 7A to 7BA combined mandrel 118 assembled from the arcuate mandrel segments 112 is shown. Although the arcuate mandrel segments 112-1 to 112-3 have the same design in this embodiment, in other embodiments, the arcuate mandrel segments on the left (arcuate mandrel segment 112-1), right (arcuate mandrel segment 112-3), and crown (arcuate mandrel segment 112-2) are not interchangeable. For example, in the exemplary embodiment, the arc length or the number of partial slots 620 at different arcuate mandrel segments 112, or the number of stringer prefabricated pieces 107, may vary depending on the design considerations for receiving the stringer prefabricated pieces 107. In this embodiment, the arcuate mandrel segments 112 have received the stringer prefabricated pieces 107 before being assembled into the combined mandrel 118. The combined mandrel 118 is held together by bolting or otherwise attaching the arcuate mandrel segments 112 to the elements 712 of the frame 710. After the mandrel 118 has been assembled, the slots 620 from the different bow-shaped mandrel segments 112 are merged together to obtain the complete finished slots 622. The stringer prefabricated pieces 107 are then laid into these complete finished slots 622, as shown below. Figure 7B As shown.

[0077] Figures 8A to 8B The illustration depicts the application of a skin layer of fiber-reinforced material 121 onto the composite mandrel 118 in an exemplary embodiment, and corresponds to... Figure 1A Observe arrow 8. In Figure 8A In this configuration, an end effector 123, movably attached to the frame 810 of the laying station 120, is positioned above the IML surface 630. The end effector 123 is adjustably mounted to the frame 810 of the laying station 120 to allow for vertical and lateral dynamic movement (as indicated by the various arrows in the figure) and operation within the laying station 120. The end effector 123 distributes the fiber reinforcement material 121 tow onto the IML surface 630, thereby obtaining… Figure 8B One or more skin plies 830 are shown. Skin plies 830 integrate stringer prefabricated parts 107 from different bow mandrel segments 112, and also integrate stringers or specific bow mandrel segments 112 together. This results in a single integral prefabricated part 122 for the fuselage segment.

[0078] Figures 9A to 9C The illustration shows the laying of the interwoven silk fabric (IWWF) layer 126-1 for the preform 122 and the laying of the pad 134 onto the preform 122 in an exemplary embodiment. The IWWF layer 126-1 facilitates the distribution of electrical energy that can be received by the aircraft. Figures 9A to 9C Corresponding to Figure 1A Observation arrow 9 depicts a setup with one or more workstations (i.e., Figures 1A to 1C IWWF and surface material station 124, Figures 1A to 1C The interlayer 127 of the pad loading station 130. Figure 9AIn this configuration, a first combined mandrel 118 with preform 122 is positioned below the IWWF and surface material station 124, while a second combined mandrel 118 is positioned below the pad loading station 130. Cables 910, driven by actuators at gantry 920, hold the IWWF 126-1, surface material 126-2, and pad 134 above the first and second combined mandrels 118, respectively. In another embodiment, the operation of the IWWF and surface material station 124 is separated among multiple stations, such that the IWWF 126-1 and surface material 126-2 are applied separately. Figure 1A In another embodiment shown, these multiple steps are performed at the same IWWF and surface material station 124. In yet another embodiment, IWWF 126-1, surface material 126-2, and backing plate 134 are all laid out at once in one station. Figure 9B In this process, IWWF 126-1 and surface material 126-2 are lowered (together or separately) until they are balanced above preform 122, and then laid. For example, in one embodiment, IWWF 126-1 is lowered and laid onto mandrel 118, and then surface material 126-2 is lowered and laid onto mandrel 118. Pad 134 is lowered via pad loading station 130 until it is balanced above the previously applied IWWF 126-1 and surface material 126-2, and then laid. Figure 9C The center pad 134, IWWF 126-1 and surface material 126-2 are installed at the corresponding combined mandrel 118 directly below them, and the combined mandrel 118 is each advanced toward the autoclave to the next station, and the new combined mandrel 118 moves to a position below the IWWF and surface material station 124.

[0079] The mezzanine 127, openings 128 and 132 allow IWWF and surface material stations 124 and pad loading station 130 to access the assembly mandrel 118, while also allowing material such as pad 134 to be repeatedly circulated through the mezzanine 127 for readjustment, so that it can be reused within the cleanroom environment 191 after leaving the cleanroom environment 191. The mezzanine 127 thus facilitates the removal of pad 134 (which also performs a vacuum bagging function) from the demolding station 142 back to the mezzanine 127 in the area surrounding the autoclave 136. The pad 134 is removed after the autoclave 136 and then at least partially readjusted on the mezzanine 127 upon transition back to the cleanroom environment 191, thus saving floor space. In another embodiment, the mezzanine 127 utilizes a dedicated crane facility, which helps avoid overloading roof / ceiling crane facilities.

[0080] Figures 10A to 10DThe illustration depicts a preform 122 hardened within an autoclave 136 via a plurality of combined mandrels 118 in an exemplary embodiment, and corresponds to Figure 1A Observation arrow 10. That is, the autoclave 136 is sized to hold multiple composite mandrels 118 at a time while hardening the preforms 122 on them. The autoclave 136 includes a body 1020 with a heater 1040 and one or more pumps 1030 pressurizing the interior 1050 of the autoclave 136. The autoclave 136 forms a boundary 1010 between a cleanroom environment 191 and a non-cleanroom environment (e.g., factory workshop 193), such that, in the illustration, travel from right to left, the composite mandrels 118 are moved through the autoclave 136 out of the cleanroom environment 191 and into the non-cleanroom environment.

[0081] exist Figure 10A In the process, the first door 1022 of the autoclave 136 is opened. This exposes the interior 1050 of the autoclave 136 for receiving the combined mandrel 118. Figure 10B In the middle, the combined mandrel 118 is pushed into the inner 1050, and in Figure 10C In the process, the first door 1022 and the second door 1023 are closed, thereby sealing the interior 1050. Heat (Δ) and pressure are applied via arrow 1059 until the preform 122 on the composite mandrel 118 hardens. Then, the second door 1023 is opened and the composite mandrel 118 and the now-hardened composite part 150 proceed to a non-cleanroom environment or factory workshop 193. This process is repeated so that multiple composite mandrels 118 are iteratively circulated through the autoclave 136.

[0082] Figures 10E to 10F The illustration depicts a plurality of preforms 122 hardened on a combined mandrel 118 within an autoclave 136 in an exemplary embodiment, and corresponds to Figure 1A Observe arrow 10. Figures 10E to 10F Depicting Figures 10A to 10DThe alternative embodiment shown. The autoclave 136 does not include a door because the end 1062 of the mandrel 118 is combined with a seal 1070 to seal the preform 122 in place on the mandrel 118 for curing. During operation, the mandrel 118 is inserted into the interior 1050 of the autoclave 136 and the autoclave 136 is sealed to the mandrel 118 to form at least one vacuum chamber 1051. While the mandrel 118 is inserted into the autoclave 136, the mandrel 118 and the autoclave 136, together with the seal 1070, define the vacuum chamber 1051 for the preform 122. That is, the seal 1070 seals the periphery of the mandrel 118 to the inner surface 1053 of the autoclave 136. The seal 1070 may include rigidity or other thermal barriers to seal gaps (G) (e.g., bow gaps) to form the pressure / vacuum chamber 1051 by clamping to the autoclave 136. The seal 1070 may be formed in an arc shape and may include a rigid material segment between the combined mandrel 118 and the autoclave 136.

[0083] The autoclave 136 is sized to complement the composite mandrel 118, thus its dimensions are well-suited for the heating and hardening components 150 (e.g., composite parts 150). Therefore, the vacuum chamber 1051 is smaller than a conventional chamber (and smaller than...). Figures 10A to 10D (The pressure vessel 136). This means that the heat and pressure applied to the vacuum chamber 1051 are applied to a smaller volume than in a conventional pressure vessel, which increases heating efficiency and hardening speed. It also means that the pressure vessel 136 has a smaller thermal mass and that smaller equipment can be used to pressurize the pressure vessel 136 (e.g., using air or nitrogen or other inert fluids).

[0084] The autoclave 136 can be operated according to a desired cycle time (e.g., productivity) to manufacture composite parts. For example, if the desired manufacturing rate for the fuselage section is one piece every eight hours, the autoclave 136 can be operated to harden the preform 122 on two combined mandrels 118 in series every sixteen hours. This, in turn, can specify additional cycle times for other stations in the production line used to manufacture the preform 122 for the hardening and / or post-hardening assembly line.

[0085] Example

[0086] In the following examples, additional processes, systems, and methods are described in the context of an assembly line used to manufacture fuselage section preforms.

[0087] Referring more specifically to the accompanying drawings, embodiments of this disclosure may be as follows: Figure 11 The aircraft manufacturing and servicing in method 1100 shown, and such as Figure 12The description is based on the background of the aircraft 1102 shown. Prior to production, method 1100 may include the specification and design 1104 of the aircraft 1102 and material procurement 1106. During production, the manufacturing of components and sub-assemblies of the aircraft 1102 and system integration 1110 are carried out. Thereafter, the aircraft 1102 may be certified and distributed 1112 for service 1114. During service, the customer schedules routine maintenance and upkeep work 1116 for the aircraft 1102 (which may also include modifications, reconfigurations, upgrades, etc.). The devices and methods specifically implemented herein may be used during any one or more suitable production and service phases (e.g., specification and design 1104, material procurement 1106, component and subassembly manufacturing 1108, system integration 1110, certification and distribution 1112, service entry 1114, repair and maintenance 1116) and / or in any suitable component of the aircraft 1102 (e.g., airframe 1118, system 1120, interior 1122, propulsion system 1124, electrical system 1126, hydraulic system 1128, environmental system 1130).

[0088] The various processes of Method 1100 may be performed or completed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator may include (but is not limited to) any number of aircraft manufacturers and main system subcontractors; a third party may include (but is not limited to) any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0089] like Figure 12 As shown, an aircraft 1102 produced by method 1100 may include a fuselage 1118 having multiple systems 1120 and an interior 1122. Examples of systems 1120 include one or more of a propulsion system 1124, an electrical system 1126, a hydraulic system 1128, and an environmental system 1130. 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.

[0090] As mentioned above, the devices and methods specifically implemented herein can be employed during any one or more production and service phases described in method 1100. For example, a component or sub-assembly corresponding to component and sub-assembly manufacturing 1108 can be processed or manufactured in a manner similar to the components or sub-assemblies produced when aircraft 1102 is put into service. Additionally, one or more device embodiments, method embodiments, or combinations thereof can be used during sub-assembly manufacturing 1108 and system integration 1110 (e.g., by significantly accelerating the assembly of aircraft 1102 or reducing the cost of aircraft 1102). Similarly, one or more device embodiments, method embodiments, or combinations thereof can be used when aircraft 1102 is put into service (e.g., but not limited to, during maintenance and repair 1116). Therefore, this disclosure may be used at any stage or in any combination thereof (e.g., specifications and design 1104, material procurement 1106, component and subassembly manufacturing 1108, system integration 1110, certification and distribution 1112, service entry 1114, repair and maintenance 1116) and / or in any suitable component of the aircraft 1102 (e.g., airframe 1118, systems 1120, interior 1122, propulsion system 1124, electrical system 1126, hydraulic system 1128 and / or environmental system 1130).

[0091] In one embodiment, the part comprises a portion of the airframe 1118 and is manufactured during component and subassembly manufacturing 1108. The part can then be assembled into an aircraft in systems integration 1110 and used in service 1114 until wear renders it unusable. Then, in repair and maintenance 1116, the part can be discarded and replaced with a newly manufactured part. The components and methods of the present invention can be used throughout component and subassembly manufacturing 1108 to manufacture new parts.

[0092] 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 a 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 similar terms. 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 referring exclusively to hardware capable of executing software, and may implicitly include (but is not limited to) digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile storage devices, logic, or some other physical hardware component or module.

[0093] Additionally, control elements can be implemented as instructions, which can be executed 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, instructions instruct the processor to perform the functions of the element. Instructions can be stored on a storage device that can be read by the processor. Some examples of storage devices are digital or solid-state memory, magnetic storage media (e.g., hard disks and magnetic tapes), hard disk drives, or optically readable digital data storage media.

[0094] Furthermore, this disclosure includes examples relating to various aspects of this disclosure.

[0095] The first example includes a method 300 for manufacturing a preform 122 for a fuselage section of an aircraft 1102, the method 300 comprising the steps of: advancing a series of bow-shaped mandrel segments 112 in a process direction 199 via an assembly line 100 302; laying stringer preforms 107 306 onto the bow-shaped mandrel segments 112 via a stringer laying station 113; merging the series of bow-shaped mandrel segments 112 308 into a combined mandrel 118; and laying fiber-reinforced material 121 310 onto the combined mandrel 118 and the stringer preforms 107.

[0096] In a first example embodiment, the method further includes laying the additional stringer prefabricated member 107 into the groove 622 formed by the merging of the bow-shaped mandrel section 112.

[0097] In a first example implementation, the method further includes operating the stringer manufacturing line 110 to supply stringer prefabricated parts 107 to the assembly line 100 at cycle times.

[0098] In a first example embodiment, the method further includes: advancing a combined mandrel 118 having fiber reinforcement material 121 below an opening 128 in a sandwich 127; and lowering at least one of an IWWF sheet 126-1, a surface material sheet 126-2, and a pad 134 onto the fiber reinforcement material 121 through the opening 128.

[0099] In a first example embodiment, the method further includes: advancing a combined mandrel 118 having fiber reinforcement material 121 below an opening 128 in a sandwich 127; lowering at least one of an IWWF sheet 126-1 and a surface material sheet 126-2 onto the fiber reinforcement material 121 through the opening 128; advancing the combined mandrel 118 having fiber reinforcement material 121 and at least one of an IWWF sheet 126-1 and a surface material sheet 126-2 below a second opening 132 in the sandwich 127; and applying a pad 134 312 onto at least one of the IWWF sheet 126-1 and the surface material sheet 126-2 through the second opening 132.

[0100] In the first example embodiment, the step of laying the stringer prefabricated 107 306 onto the bow mandrel segment 112 includes laying the stringer prefabricated 107 306 during pauses between pulses of the bow mandrel segment 112 along the assembly line 100.

[0101] In the first example embodiment, the step of laying the stringer prefabricated 107 306 onto the bow mandrel segment 112 includes laying the stringer prefabricated 107 306 as the bow mandrel segment 112 moves continuously along the assembly line 100.

[0102] In the first example embodiment, the step of laying the fiber reinforcement material 121 310 onto the combined mandrel 118 and stringer preform 107 includes merging the stringer preform 107 and the fiber reinforcement material 121 into a single preform 122.

[0103] In the implementation of the first example, the advancement steps include enforcing uniform working hours across multiple workstations performing layup, merging, and deployment, thereby allowing for coordinated and synchronized operations across workstations based on a common schedule.

[0104] In the first example implementation, the common timetable is based on the time span of the autoclave heating cycle.

[0105] In the first example embodiment, the step of laying the stringer preform 107 onto the arched mandrel segment 112 includes: laying and trimming a flat sheet 104 of fiber-reinforced material at one or more lamination stations 102; shaping the flat sheet 104 into the stringer preform 107 at one or more forming stations 106; and laying the stringer preform 107 onto the arched mandrel segment 112 at one or more laying stations.

[0106] In the first example embodiment, the laying and forming steps are performed along track 109, and the mandrel 105 for the stringer preform 107 cycles through the lamination station 102 and the forming station 106 multiple times before leaving track 109.

[0107] In the first example embodiment, the step of laying the stringer prefabricated member 107 onto the bow-shaped mandrel segment 112 further includes applying at least one of frame filler, ply pack and barrier ply to the bow-shaped mandrel segment 112 while laying the stringer prefabricated member 107.

[0108] In the first example embodiment, the step of laying the fiber-reinforced material 121 310 onto the composite mandrel 118 and stringer preform 107 includes advancing the composite mandrel 118 through a plurality of laying stations 120 via one or both of continuous or intermittent advance.

[0109] In the first example embodiment, the step of laying the fiber reinforcement material 121 310 onto the composite mandrel 118 and the stringer preform 107 includes simultaneously laying the fiber reinforcement material 121 310 onto the composite mandrel 118 via a plurality of laying stations 120.

[0110] In a first example embodiment, the method further includes: advancing a composite mandrel 118 having at least fiber-reinforced material 121 through a first door 1022 of an autoclave 136; hardening the fiber-reinforced material 121 within the autoclave 136; advancing the composite mandrel 118 and a composite part 150 formed of the fiber-reinforced material 121 through a second door 1023 in the autoclave 136; demolding the composite part 150 from the composite mandrel 118; separating the composite mandrel 118 into an arcuate mandrel segment 112; and cleaning the arcuate mandrel segment 112.

[0111] In the first example embodiment, the step of merging a series of arc-shaped mandrel segments 112 308 includes laying the arc-shaped mandrel segments 112 on the frame 710 such that the arc-shaped mandrel segments 112 are adjacent to each other.

[0112] In the first example embodiment, the step of merging a series of bow-shaped mandrel segments 112 308 includes fastening the bow-shaped mandrel segments 112 to each other while they are chordally adjacent.

[0113] In the first example embodiment, the step of merging a series of bow-shaped mandrel segments 112 308 into a combined mandrel 118 includes merging a series of bow-shaped mandrel segments 112 to form a half-tube fuselage segment.

[0114] In the first example embodiment, the step of merging a series of bow-shaped mandrel segments 112 308 into a combined mandrel includes merging a series of bow-shaped mandrel segments 112 to form a full-bore fuselage segment.

[0115] In the first example embodiment, the step of laying the fiber-reinforced material 121 310 onto the composite mandrel 118 and the stringer preform 107 includes at least one of the following: operating at least one end effector 123 to distribute the fiber-reinforced material 121 filaments onto the composite mandrel 118; and laying the fiber-reinforced wide fabric sheet onto the composite mandrel 118.

[0116] The second example includes a system for manufacturing a preform 122 for a fuselage section of an aircraft 1102, the system comprising: a series of bow-shaped mandrel segments 112 advanced in a process direction 199 via an assembly line 100; at least one stringer laying station 113 operable to lay stringer preforms 107 onto the bow-shaped mandrel segments 112; at least one mandrel assembly station 116 operable to combine the series of bow-shaped mandrel segments 112 into a combined mandrel 118; and at least one laying station 120 operable to lay fiber-reinforced material 121 onto the combined mandrel 118 and the stringer preforms 107.

[0117] In the second example embodiment, at least one stringer laying station 113 is operable to lay stringer prefabricated members 107 into grooves 622 formed by the merging of bow-shaped mandrel segments 112.

[0118] In a second example embodiment, the system also includes at least one stringer manufacturing line 110 capable of operating to supply stringer prefabricated parts 107 to assembly line 100 at takt times.

[0119] In a second example embodiment, the system further includes a sandwich 127 comprising a first opening 128, the sandwich 127 being operable to lower at least one of the IWWF sheet 126-1, the surface material sheet 126-2, and the pad 134 through the opening 128 onto the fiber reinforcement material 121 on the combined mandrel 118.

[0120] In a second example embodiment, the system further includes a sandwich 127 comprising a first opening 128 and a second opening 132, the sandwich 127 being operable to lower at least one of the IWWF sheet 126-1 and the surface material sheet 126-2 through the first opening 128 onto the fiber reinforcement material 121 on the combined mandrel 118, and also operable to lower a pad 134 through the second opening 132 onto said at least one of the IWWF sheet 126-1 and the surface material sheet 126-2.

[0121] In the second example embodiment, at least one stringer laying station 113 is operable to lay stringer preforms 107 onto the bow mandrel section 112 during pauses between pulses along the assembly line 100.

[0122] In the second example embodiment, at least one stringer laying station 113 is operable to lay stringer preforms 107 onto the bow mandrel segments 112 as the bow mandrel segments 112 move continuously along the assembly line 100.

[0123] In the second example embodiment, at least one laying station 120 is operable to lay fiber reinforcement material 121, such that stringer preform 107 and fiber reinforcement material 121 are combined into a single preform 122.

[0124] In a second example embodiment, the system further includes: at least one lamination station 102 configured to lay and trim a flat sheet 104 of fiber-reinforced material; at least one forming station 106 configured to shape the flat sheet 104 into a stringer preform 107; and at least one laying station configured to lay the stringer preform 107 onto a bow-shaped mandrel 112.

[0125] In a second example embodiment, the system further includes a mandrel 105 for forming the stringer preform 107.

[0126] In a second example embodiment, the system also includes a track 109, and a mandrel 105 for the stringer preform 107 is operable to cycle through at least one lamination station 102 and at least one molding station 106 multiple times before leaving the track 109.

[0127] In the second example embodiment, at least one laying station is operable to apply at least one of the frame filler, ply package, and barrier ply to the bow mandrel 112 while laying the stringer prefabricated member 107.

[0128] In the second example embodiment, the advancement of a series of bow-shaped mandrels 112 in the process direction 199 includes one or both of continuous advancement and pulsating advancement.

[0129] In the second example embodiment, at least one mandrel assembly station 116 includes a frame 710, and at least one mandrel assembly station 116 is operable to merge a series of arc-shaped mandrel segments 112 by laying arc-shaped mandrel segments 112 onto the frame 710 such that the arc-shaped mandrel segments 112 are adjacent to each other.

[0130] In the second example embodiment, at least one mandrel assembly station 116 is operable to merge a series of bow-shaped mandrel segments 112 by fastening the bow-shaped mandrel segments 112 together while they are chordally adjacent.

[0131] In the second example embodiment, at least one mandrel assembly station 116 is operable to combine a series of bow-shaped mandrel segments 112 to form a semi-cylinder body segment.

[0132] In the second example embodiment, at least one mandrel assembly station 116 is operable to combine a series of bow-shaped mandrel segments 112 to form a full-bore fuselage segment.

[0133] In a second example embodiment, at least one laying station 120 includes at least one end effector 123, which is operable to distribute fiber reinforcement material 121 filaments to the composite mandrel 118.

[0134] In a second example embodiment, at least one laying station 120 includes at least one end effector 123, which is operable to lay fiber-reinforced wide silk sheet onto the composite mandrel 118.

[0135] In a second example implementation, the system also includes a controller 190 that is operable to enforce uniform working hours among at least one stringer laying station 113, at least one mandrel assembly station 116, and at least one laying station 120, so that laying, merging, and laying are coordinated and synchronized according to a common schedule.

[0136] In the second example implementation, the common timeline is based on the time span of the autoclave 136 heating cycle.

[0137] In a second example embodiment, the system further includes: at least one lamination station 102 configured to lay and trim a flatbed of fiber-reinforced material 104; and at least one forming station 106 configured to shape the flatbed 104 into a stringer preform 107. The controller 190 is also operable to coordinate and synchronize the operations of at least one lamination station 102, at least one forming station 106, and at least one stringer laying station 113 according to a common schedule.

[0138] The third example includes a method 300 for manufacturing a preform 122 for a fuselage section of an aircraft 1102, the method comprising the steps of: advancing a series of bow-shaped mandrel segments 112 in a process direction 199 through an assembly line 100 302; laying stringer preforms 107 306 onto the bow-shaped mandrel segments 112 via a stringer laying station 113; merging the series of bow-shaped mandrel segments 112 308 into a combined mandrel 118; and laying fiber reinforcement material 121 310 onto the combined mandrel 118 and the stringer preforms. 107; a composite mandrel 118 having at least fiber-reinforced material 121 is pushed through a first door 1022 of an autoclave 136; the fiber-reinforced material 121 is hardened within the autoclave 136; the composite mandrel 118 and a composite part 150 formed of fiber-reinforced material 121 are pushed through a second door 1023 to exit the autoclave 136; the composite part 150 is demolded from the composite mandrel 118; the composite mandrel 118 is separated into an arc-shaped mandrel segment 112; and the arc-shaped mandrel segment 112 is cleaned.

[0139] In the third example embodiment, the step of laying the stringer prefabricated 107 306 onto the bow-shaped mandrel section 112 includes laying a batch of stringer prefabricated 107 306 onto the bow-shaped mandrel section 112 at a time.

[0140] In the third example embodiment, at least one stringer laying station 113 is operable to lay batches of stringer prefabricated pieces 107 306 onto the bow-shaped mandrel section 112.

[0141] 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.

Claims

1. A method (300) for manufacturing a preform (122) for a fuselage section of an aircraft (1102), the method (300) comprising the following steps: In the advancing step, a series of bow-shaped mandrel segments (112) are advanced through the assembly line (100) in the process direction (199); In the laying step, the stringer prefabricated component (107) is laid on the bow-shaped mandrel section (112) via the stringer laying station (113); The merging step combines the series of bow-shaped mandrel segments (112) into a combined mandrel (118); The laying step involves laying the fiber-reinforced material (121) onto the combined mandrel (118) and the stringer precast (107); and In the splicing step, the fiber-reinforced material (121) laid on the bow-shaped mandrel segment (112) is spliced, wherein: - The step of laying the stringer prefabricated component (107) onto the bow-shaped mandrel segment (112) includes laying the stringer prefabricated component (107) during pauses between pulsations of the bow-shaped mandrel segment (112) along the assembly line (100); or - The step of laying the stringer prefabricated component (107) onto the bow-shaped mandrel segment (112) includes laying the stringer prefabricated component (107) as the bow-shaped mandrel segment (112) moves continuously along the assembly line (100).

2. The method (300) according to claim 1, further comprising one or more of the following: - Lay the additional stringer precast member (107) into the groove (622) formed by the confluence of the bow-shaped mandrel section (112); and / or - Operate the stringer manufacturing line (110) to supply stringer prefabricated parts (107) to the assembly line (100) at cycle times.

3. The method (300) according to any one of claims 1 to 2, wherein the method (300) further comprises: - The combined mandrel (118) having the fiber-reinforced material (121) is advanced below the opening (128) in the interlayer (127); and The method (300) further includes the following steps: -At least one of the interwoven silk fabric sheet (126-1), the surface material sheet (126-2), and the pad (134) is lowered onto the fiber-reinforced material (121) through the opening (128); or: - At least one of the interwoven silk fabric sheet (126-1) and the surface material sheet (126-2) is lowered onto the fiber reinforcement material (121) through the orifice (128); and -The combined mandrel (118) having at least one of the fiber reinforcement material (121), and the interwoven filament sheet (126-1) and the surface material sheet (126-2) is advanced below the second opening (132) in the interlayer (127); and - Apply (312) the pad (134) through the second port (132) to at least one of the interwoven silk fabric sheet (126-1) and the surface material sheet (126-2).

4. The method (300) according to any one of claims 1 to 2, wherein: - The step of laying the fiber-reinforced material (121) onto the combined mandrel (118) and the stringer preform (107) includes merging the stringer preform (107) and the fiber-reinforced material (121) into a single preform (122); and / or - The advancement step includes forcing a uniform working time among multiple workstations performing the laying step, the merging step, and the laying step, thereby allowing coordinated and synchronized operation among the workstations according to a common schedule; and / or - The step of laying the precast stringer (107) onto the arched mandrel segment (112) includes: - Laying and trimming the fiber-reinforced material flat pack (104) at one or more lamination stations (102); - The flat stock (104) is formed into stringer preforms (107) at one or more forming stations (106); and - Lay the stringer precast (107) onto the bow-shaped mandrel section (112) at one or more laying stations; and / or - The laying and forming steps are performed along the track (109), and the mandrel (105) for the stringer preform (107) circulates multiple times through the lamination station (102) and the forming station (106) before leaving the track (109); and / or - The step of laying the stringer prefabricated component (107) onto the arched mandrel segment (112) further includes applying at least one of frame filler, ply pack, and barrier ply to the arched mandrel segment (112) while laying the stringer prefabricated component (107); and / or - The step of laying the fiber-reinforced material (121) onto the composite mandrel (118) and the stringer preform (107) includes advancing the composite mandrel (118) through a plurality of laying stations (120) via one or both of continuous or intermittent advance; and / or The step of laying fiber-reinforced material (121) onto the composite mandrel (118) and the stringer preform (107) includes laying fiber-reinforced material (121) onto the composite mandrel (118) simultaneously via multiple laying stations (120).

5. The method (300) according to claim 4, wherein, The common timeline is based on the time span of the autoclave heating cycle.

6. The method (300) according to any one of claims 1 to 2, further comprising the step of: The combined mandrel (118) having at least the fiber-reinforced material (121) is pushed through the first door (1022) of the autoclave (136); The fiber-reinforced material (121) is hardened (314) in the autoclave (136); The combined mandrel (118) and the composite part (15) formed of the fiber-reinforced material (121) are pushed through the second door (1023) in the autoclave (136); The composite part (150) is demolded (316) from the combined mandrel (118); The combined mandrel (118) is separated (318) into an arc-shaped mandrel segment (112); and Clean the bow-shaped mandrel section (112).

7. The method (300) according to any one of claims 1 to 2, wherein, The steps of merging the series of bow-shaped mandrel segments (112) include: - Lay the arc-shaped mandrel segments (112) onto the frame (710) such that the arc-shaped mandrel segments (112) are adjacent to each other; and / or - Secure the bow-shaped mandrel segments (112) together while they are chordally adjacent; and / or - The series of bow-shaped mandrel segments (112) are combined to form a half-cylinder fuselage segment or the series of bow-shaped mandrel segments (112) are combined to form a full-cylinder fuselage segment.

8. The method (300) according to any one of claims 1 to 2, wherein, The step of laying the fiber-reinforced material (121) onto the composite mandrel (118) and the stringer preform (107) includes at least one of the following: Operate at least one end effector (123) to distribute the fiber-reinforced material (121) filaments onto the combined mandrel (118); as well as The fiber-reinforced wide silk sheet is laid on the composite mandrel (118). And / or the step of laying the stringer prefabricated pieces (107) onto the bow-shaped mandrel section (112) includes laying a batch of stringer prefabricated pieces (107) onto the bow-shaped mandrel section (112) at one time.

9. A system for manufacturing a preform (122) for a fuselage section of an aircraft (1102), the system comprising: A series of bow-shaped mandrel segments (112) are advanced through the assembly line (100) in the process direction (199); At least one stringer laying station (113) is operable to lay stringer prefabricated components (107) onto the bow-shaped mandrel section (112); At least one mandrel assembly station (116) operable to combine the series of arc-shaped mandrel segments (112) into a combined mandrel (118); and At least one laying station (120) operable to lay fiber-reinforced material (121) onto the composite mandrel (118) and the stringer prefabrication (107) and splice the fiber-reinforced material (121) laid onto the bow-shaped mandrel segment (112); and The at least one stringer laying station (113) is operable to lay stringer prefabricated pieces (107) onto the bow-shaped mandrel segment (112) during pauses between pulsations along the assembly line (100); or The at least one stringer laying station (113) is operable to lay stringer prefabricated pieces (107) onto the bow-shaped mandrel section (112) as the bow-shaped mandrel section (112) moves continuously along the assembly line (100).

10. The system according to claim 9, wherein, At least one stringer laying station (113) is operable to lay stringer preforms (107) into the groove (622) formed by the combined passage through the bow-shaped mandrel section (112), and / or wherein the system further includes at least one stringer manufacturing line (110) operable to supply stringer preforms (107) to the assembly line (100) at cycle times.

11. The system according to any one of claims 9 to 10, further comprising: -Including a sandwich (127) having a first opening (128) through which at least one of the interwoven filament sheet (126-1), the surface material sheet (126-2), and the pad (134) is lowered through the opening (128) onto the fiber reinforcement material (121) on the combined mandrel (118); or - Includes a sandwich (127) having a first opening (128) and a second opening (132) through it, the sandwich (127) being operable to lower at least one of the interwoven fabric sheet (126-1) and the surface material sheet (126-2) through the first opening (128) onto the fiber reinforcement material (121) on the combined mandrel (118), and also operable to lower a pad (134) through the second opening (132) onto at least one of the interwoven fabric sheet (126-1) and the surface material sheet (126-2).

12. The system according to any one of claims 9 to 10, wherein, The at least one laying station (120) is operable to lay the fiber-reinforced material (121) such that the stringer preform (107) and the fiber-reinforced material (121) are combined into a single preform (122). and / or The system also includes: At least one lamination station (102) configured to lay and trim a flat sheet of fiber-reinforced material (104); At least one forming station (106) configured to form the flat material (104) into a stringer preform (107); and At least one laying station is configured to lay the stringer prefabricated component (107) onto the bow-shaped mandrel segment (112).

13. The system according to any one of claims 9 to 10, further comprising one or more of the following: - Mandrel (105) for forming the stringer prefabricated member (107); and / or - Track (109), the mandrel (105) for the stringer preform (107) is operable to cycle through the at least one lamination station (102) and the at least one molding station (106) multiple times before leaving the track (109).

14. The system according to any one of claims 9 to 10, wherein: - wherein the at least one laying station is operable to apply at least one of frame filler, ply package and barrier ply to the bow mandrel segment (112) while laying the stringer precast member (107); and / or - wherein the advancement of the series of bow-shaped mandrel segments (112) in the process direction (199) includes one or both of continuous advancement and pulsating advancement; and / or - wherein the at least one mandrel assembly station (116) includes a frame (710), the at least one mandrel assembly station (116) being operable to combine the series of arcuate mandrel segments (112) by laying the arcuate mandrel segments (112) onto the frame (710) such that the arcuate mandrel segments (112) are adjacent to each other; and / or - wherein the at least one mandrel assembly station (116) is operable to merge the series of arc-shaped mandrel segments (112) by fastening the arc-shaped mandrel segments (112) together while they are chordally adjacent; and / or - wherein the at least one mandrel assembly station (116) is operable to combine the series of bow-shaped mandrel segments (112) to form a semi-cylinder body segment or a full-cylinder body segment; and / or - wherein the at least one laying station (120) includes at least one end effector (123) operable to distribute fiber-reinforced material (121) bundles onto the combined mandrel (118); and / or - wherein the at least one laying station (120) includes at least one end effector (123) operable to lay fiber-reinforced wide fabric sheets onto the composite mandrel (118); and / or -At least one stringer laying station (113) is operable to lay batches of stringer prefabricated parts (107) onto the bow-shaped mandrel section (112).

15. The system according to any one of claims 9 to 10, further comprising a controller (190) operable to enforce uniform working hours among the at least one stringer laying station (113), the at least one mandrel assembly station (116), and the at least one laying station (120), such that the laying, the merging, and the laying are coordinated and synchronized according to a common schedule.

16. The system according to claim 15, wherein, The common timeline is based on the time span of the autoclave (136) heating cycle.

17. The system of claim 15, further comprising: At least one lamination station (102) configured to lay and trim a flat sheet of fiber-reinforced material (104); as well as The controller (190) is configured to form the flat material (104) into a stringer preform (107) at least one forming station (106), and is also operable to coordinate and synchronize the operation of the at least one laminating station (102), the at least one forming station (106) and the at least one stringer laying station (113) according to the common schedule.

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