Continuous moving assembly line for manufacturing composite laminate parts

Abstract

This invention relates to a continuous moving production line for manufacturing composite laminated parts. Specifically, a system for manufacturing composite laminated parts is provided, the system comprising: a plurality of work areas in which operations are performed on parts; a plurality of tools capable of continuous movement along a production line passing through each of the plurality of work areas; a laminator located in at least one of the plurality of work areas and configured to apply composite material onto the tools; and a controller for controlling the movement of the tools and the operation of the laminator.

Description

Technical Field

[0001] This disclosure generally relates to the manufacture of composite laminate parts, and more particularly to systems and methods for manufacturing parts in a continuous moving production line. Background Technology

[0002] Mass production of composite laminated components is typically performed in a fixed location using batch processing. For example, a single laminator (such as an automated fiber layup machine) might be used to lay up a batch of identical components one at a time onto mandrels in a stationary unit within the production facility. This results in inefficient use of production floor space and mandrels. Furthermore, quality control becomes more challenging due to the difficulty and time-consuming process of detecting defective components within a batch.

[0003] Therefore, it is desirable to eliminate the inefficiencies of batch processing of composite laminate components, while promoting improved quality control through the use of continuous production lines.

[0004] The abstract of EP 3653369 A1 describes a manufacturing system comprising a plurality of laminating ends and an end-moving system defining a continuous annular lamination path configured to continuously move the laminating ends along the lamination path. The manufacturing system also includes at least one lamination mandrel positioned along a portion of the lamination path. These laminating ends are configured to dispense a lamination material onto at least one lamination mandrel or onto a lamination material pre-applied to the lamination mandrel as the laminating ends move through one or more revolutions of the lamination path via the end-moving system to lay a composite laminate.

[0005] The abstract of US 2012 / 006475 A1 states: "A method and apparatus for the automated manufacture of an extended composite material part having at least one layer. The method includes the steps of: depositing an assembly having a composite material layer separately attached to a substrate strip on a mold by unfolding it along a mold in a first direction; and forming and compacting a portion of the assembly onto the mold in the first direction. The assembly is partially formed into the shape of the mold, and then the remaining portion of the assembly is formed and compacted in a second direction opposite to the first direction to fully form the shape of the mold. The assembly is then separated by unfolding the substrate strip along the second direction to peel the substrate strip from the composite material layer fixed to the mold." Summary of the Invention

[0006] This disclosure generally relates to the mass production of composite laminate components, and more specifically to continuous moving production lines for producing these components.

[0007] According to one aspect, a system for manufacturing composite laminated parts is provided. The system includes multiple work areas in which operations are performed on the parts. Multiple tools are provided, capable of continuous movement along an assembly line passing through the respective work areas. A laminator is positioned in at least one of the multiple work areas and configured to apply composite material onto the tools. A controller is provided for controlling the movement of the platform and the operation of the laminator.

[0008] According to another aspect, a system for manufacturing composite laminated parts is provided. The system includes: a plurality of mobile platforms; and a mobile production line powertrain configured to cause the mobile platforms to move continuously through various work areas among a plurality of work areas. The system also includes: at least one tool carried on each of the plurality of mobile platforms; and at least one laminator located in each of the plurality of work areas, and configured to apply composite material onto the tool. A controller is configured to coordinate the operation of the laminators relative to each other.

[0009] According to another aspect, a method for manufacturing composite laminated components is provided. The method includes the steps of moving multiple tools along an assembly line passing through various work areas. The method also includes the steps of applying portions of each component of the component onto the tools at each work area using an automated laminator as the tools move along the assembly line through the various work areas.

[0010] According to another aspect, a method for manufacturing a composite laminate component is provided, the method comprising the steps of moving a plurality of tools along an assembly line passing through a plurality of work zones. The method further comprises the steps of laying at least a portion of the component using a laminator located in at least one of the work zones; and performing work on the component in one of the plurality of work zones after the component has been laid.

[0011] One advantage of continuous moving production lines for manufacturing composite laminate components is that they enable higher productivity while increasing the utilization of production equipment such as laminators and mandrels. Another advantage is better utilization of floor space. A further advantage is the ability to detect defective parts more quickly and make adjustments during the manufacturing process, thereby reducing rework and / or scrap.

[0012] These features, functions, and advantages can be implemented independently in different examples of this disclosure, or can be combined in other examples where further details can be seen with reference to the following description and figures.

[0013] This disclosure also includes the following examples:

[0014] 1. A system for manufacturing composite laminate components, the system comprising:

[0015] Multiple work areas, in which operations are performed on the component;

[0016] Multiple tools, which are capable of moving continuously along an assembly line that passes through each of the multiple work areas;

[0017] A laminator, located in at least one of the plurality of work areas, and configured to apply a composite material onto the tool; and

[0018] A controller for controlling the movement of the tool and the operation of the laminator.

[0019] 2. The system according to Example 1, further comprising:

[0020] Multiple platforms, which are capable of continuous movement along the assembly line passing through various work areas, and

[0021] The tools are respectively hosted on the multiple platforms.

[0022] 3. The system according to Example 1 or 2, wherein the laminator is configured to apply the composite material strip to the tool at different angular orientations.

[0023] 4. The system according to Example 2 or 3, further comprising:

[0024] Multiple laminators are located in adjacent work areas of the multiple work areas, wherein...

[0025] The controller is configured to coordinate the operation of the plurality of laminators such that, as the platform moves between adjacent work areas in the plurality of work areas, the laminators in the adjacent work areas are applying composite material onto one of the tools.

[0026] 5. The system according to any one of Examples 2 to 4, further comprising:

[0027] A guiding device, the guiding device being used to guide the movement of the platform along the assembly line passing through each of the plurality of work areas, wherein,

[0028] The platform is connected to the guiding device.

[0029] 6. The system according to any of Examples 2 to 5, wherein each of the plurality of platforms is an automated guided vehicle.

[0030] 7. The system according to any of the foregoing examples, wherein the laminator comprises:

[0031] A robot manipulator, which is operated by the controller; and

[0032] A material application head is mounted on the robot manipulator and configured to apply the composite material strip onto the tool.

[0033] 8. The system according to Example 7, wherein the robot manipulator is one of an articulated arm robot and a gantry robot.

[0034] 9. The system according to any of Examples 2 to 8, the system further comprising a plurality of sensors located in the plurality of work areas, each sensor being configured to sense movement of one of the plurality of platforms.

[0035] 10. The system according to any one of Examples 2 to 9, further comprising:

[0036] The program is used by the controller to coordinate the movement of the plurality of platforms along the production line and the operation of the plurality of laminators.

[0037] 11. The system according to any of the foregoing examples, wherein the laminators in adjacent work areas of the plurality of work areas are respectively configured to apply the composite material strip to the tool at the same angular orientation.

[0038] 12. A method for manufacturing a composite laminate component, the method comprising the following steps:

[0039] Moving multiple tools along an assembly line that traverses various work areas; and

[0040] As the tool moves along the assembly line through the various work areas, a portion of each component is laid on the tool at each of the various work areas using an automated laminator.

[0041] 13. The method according to Example 12, wherein the step of laying a portion of each of the components comprises: applying a composite material strip at different angular orientations onto the tool using the laminators in different work zones of the plurality of work zones.

[0042] 14. The method according to Example 12 or 13, further comprising the step of:

[0043] The tools are placed on multiple platforms respectively; and

[0044] The platform moves along the assembly line that passes through each of the multiple work areas.

[0045] 15. The method according to Example 14, wherein the step of moving the plurality of tools along the production line is performed continuously, such that the plurality of tools move continuously through the work area.

[0046] 16. The method according to any of Examples 12 to 15, wherein the step of using the automated laminator at each of the plurality of work areas includes:

[0047] Move the material application head above the tool;

[0048] As the tool moves through the work area, the material application head is used to lay the composite material over the tool.

[0049] 17. The method according to any of the examples 12 to 16, wherein the step of laying a portion of each of the components comprises: laying composite material on different components of one of the plurality of tools using a laminator located in the adjacent work areas as the tool moves along a production line between adjacent work areas.

[0050] 18. The method according to any of Examples 12 to 17, wherein the step of laying a portion of each of the components comprises: laying a composite material on the leading edge of the tool at one point within the work area using the laminator; and laying a composite material on the trailing edge of the tool at another point within the work area using the laminator.

[0051] 19. The method according to any of Examples 12 to 18, wherein the step of laying a portion of each of the components comprises:

[0052] Before the leading edge of the tool is passed to the next work area in the production line, a composite material is laid on the tool using a laminator in the work area; and the laying of the composite material continues until the trailing edge of the conveyor tool is reached.

[0053] 20. The method according to any of the examples 14 to 19, wherein the step of moving the platform includes: automatically guiding the platform along the pipeline.

[0054] 21. The method according to any of the examples 12 to 20, wherein the step of moving the plurality of tools along the production line includes: moving the plurality of tools along a U-shaped path.

[0055] 22. The method according to any of the examples 12 to 20, wherein the step of moving the plurality of tools along the production line includes: moving the plurality of tools along a zigzag path.

[0056] 23. The method according to any of the examples 12 to 22, wherein the step of moving the plurality of tools along the production line includes: moving the plurality of tools along a circular path.

[0057] 24. The method according to any of the examples 14 to 23, wherein:

[0058] The steps of moving the platform include: guiding the platform along the production line; and

[0059] The step of laying a portion of each of the plurality of components includes: coordinating the operation of the laminator with the movement of the plurality of platforms along the production line.

[0060] 25. The method according to any of the examples 14 to 23, wherein: the step of moving the plurality of platforms along the production line is performed continuously, such that the plurality of platforms move continuously along the production line through the work area.

[0061] 26. A system for manufacturing composite laminate components, the system comprising:

[0062] Multiple mobile platforms;

[0063] A mobile assembly line powertrain is configured to enable the plurality of mobile platforms to move continuously through various work areas in a plurality of work areas;

[0064] At least one tool, said at least one tool being carried on each of the plurality of mobile platforms;

[0065] At least one laminator, located in each of the plurality of work areas, and configured to apply composite material onto a tool; and

[0066] A controller configured to coordinate the operation of the plurality of laminators relative to each other.

[0067] 27. The system according to Example 26, wherein the controller is configured to coordinate the operation of the mobile production line powertrain with the operation of the plurality of laminators.

[0068] 28. The system according to Example 26 or 27, wherein each of the plurality of mobile platforms is an automated guided vehicle.

[0069] 29. The system according to any of the examples 26 to 28, the system further comprising at least one sensor configured to sense the position of at least one of the plurality of mobile platforms.

[0070] 30. A method for manufacturing a composite laminate component, the method comprising the following steps:

[0071] Multiple tools are moved along an assembly line that passes through multiple work areas;

[0072] As the tool moves through the plurality of work areas, at least a portion of the component is laid using a laminator located in one of the plurality of work areas; and

[0073] After the component has been laid, the work is performed on the component in one of the multiple work areas.

[0074] 31. The method according to Example 30, the method comprising the steps of: placing the plurality of tools on a plurality of platforms respectively, wherein the step of moving the plurality of tools comprises: moving the plurality of platforms along the assembly line passing through the plurality of work areas.

[0075] 32. The method according to Example 30 or 31, wherein the step of applying the at least portion of the component using the laminator includes: moving a material application head above the tool as the tool moves through the work area.

[0076] 33. The method according to any one of Examples 30 to 32, the method further comprising the step of:

[0077] At least a portion of the component is laid using a laminator located in one of the plurality of work areas, while another portion of the component is being laid using a laminator in another adjacent work area of ​​the plurality of work areas.

[0078] 34. The method according to any of the examples 30 to 33, wherein laminators in adjacent work areas of the plurality of work areas lay composite material strips on tools with different orientations.

[0079] 35. The method according to any of the examples 30 to 34, wherein the step of performing a task on the component includes at least one of the following:

[0080] Debulking the component.

[0081] Press the component firmly.

[0082] Molding the component,

[0083] The component is cured.

[0084] Repair the components.

[0085] Inspect the components.

[0086] Rework the aforementioned components, and

[0087] The surface of the component is processed. Attached Figure Description

[0088] The novel features of the illustrative examples are set forth in the appended claims. However, the illustrative examples, preferred modes of use, further objects, and features will be best understood by referring to the following detailed description of the illustrative examples of this disclosure when read in conjunction with the accompanying drawings, wherein:

[0089] Figure 1 This is an exemplary block diagram illustrating a continuously moving production line used to manufacture composite laminate components.

[0090] Figures 2 to 4 These are illustrative diagrams of different layouts of a continuous moving production line.

[0091] Figure 5 This is an illustrative perspective view of an example of a work area along a continuously moving assembly line that uses an articulated robot for material laying.

[0092] Figure 6 This is an illustrative perspective view of another example of a work area along a continuously moving assembly line that uses a gantry robot for material laying.

[0093] Figures 7 to 11 This is a schematic plan view illustrating the flow of three adjacent work zones performing a lamination operation, showing the progressive movement of components through the work zones.

[0094] Figure 12 This is an exemplary block diagram showing the control components of a continuously moving production line.

[0095] Figure 13 This is an exemplary block diagram of another example of a continuously moving production line.

[0096] Figure 14 This is an exemplary flowchart of an example of a method for manufacturing composite laminate components using a continuous moving production line.

[0097] Figure 15 This is an exemplary flowchart of another example of a method for manufacturing composite laminate components using a continuous moving production line.

[0098] Figure 16 It is an illustrative flowchart of aircraft manufacturing and maintenance methods.

[0099] Figure 17 This is an example block diagram of an aircraft. Detailed Implementation

[0100] First, refer to Figure 1 A production system 20 is used to manufacture composite laminated components, which typically comprise multiple layers (not shown) of fiber-reinforced polymers, such as, but not limited to, carbon fiber reinforced epoxy. The production system 20 includes multiple work zones 22 arranged sequentially along a continuous moving assembly line 28. In this example, each of these work zones 22 includes a laminator 36 coupled to a robotic manipulator 38, which may be, for example, but not limited to, an articulated robot, or a gantry robot that controls the movement of the laminator 36 within the work zone 22. As will be discussed below, in some examples, one or more of these work zones 22 may employ multiple laminators 36 that operate collaboratively with each other within the same work zone 22 for the same or different components. Furthermore, the operation of the laminators 36 in adjacent work zones 22 can also be coordinated so that they can lay portions of the same component approximately simultaneously as the component moves between adjacent work zones 22.

[0101] Multiple platforms 30 form part of a continuous moving assembly line 28 that passes through various work areas in n work areas 22. Each platform 30 may include any suitable structure capable of moving and supporting tools 32 (such as a lamination mandrel). In one example described later, each platform 30 may be a self-propelled and automatically guided vehicle, while in another example, the platform 30 is mounted along a path such as track 52 (…). Figure 5Such a guide device moves and drives the tool. Each component in component 34 may include a multilayer fiber-reinforced polymer liner, which is laid on the tool 32 by a laminator 36 as the tool 32 moves along the continuous moving assembly line 28 through work zones 22. In one example, the laminators 36 in adjacent work zones 22 may be configured to apply composite strips to the tool 32 at the same angular orientation.

[0102] Production system 20 may include a loading area 24 in which tools 32 are loaded onto one of the platforms 30 for movement through work areas 22. Tools 32 carrying finished parts 34 can be removed from the platforms 30 in an unloading area 26 at the end of a continuous moving assembly line 28. Coating material can be delivered in a just-in-time (JIT) manner to the respective work areas 22 via corresponding associated coating material feeder lines 25.

[0103] exist Figure 1 In the example shown, work area 22 is arranged along a generally straight line, and thus the continuously moving assembly line 28 is also straight. However, other geometric arrangements of work area 22 are also possible. For example, work area 22 could be arranged along... Figure 2 The U-shaped path 40 shown, or as... Figure 3 The zigzag path shown is 42, or as shown in the image. Figure 4 The circular path 44 shown is configured. Figures 2 to 4 The path layout shown concentrates work area 22, thus connecting with... Figure 1 The linear path layout of work areas 22 shown reduces ground space requirements. Additional work areas 22 can be added as needed to increase production capacity and / or work density. Alternatively, depending on the application, one or more work areas 22 can be deactivated as needed. Figure 2 In the example shown, loading area 24 is positioned at the beginning 29 of the continuous moving assembly line 28, while unloading area 26 is positioned at the end 31 of the continuous moving assembly line 28. A tool 32, such as a lamination mandrel, can be used... Figure 1 The tool can be loaded onto one of the platforms 30 within the loading area 24 and can be removed from the platform 30 in the unloading area 26.

[0104] Similarly, in Figure 3 In the zigzag path example shown, the continuous moving pipeline 28 also has: a loading area 24 at the beginning 29 of the continuous moving pipeline 28, and an unloading area 26 at the end 31 of the continuous moving pipeline 28, where the tool 32 is loaded and unloaded in the unloading area 26. Figure 4In the illustrated circular path configuration 44, the loading area 24 and unloading area 26 can be positioned anywhere around the continuously moving production line 28, and the loading and unloading of tools 32 can be performed within the same work area 22. For example, when platform 30 enters one of these work areas 22, a tool 32 with a completed lamination can be removed from platform 30, and another tool 32 can be loaded onto the same platform 30 for subsequent lamination operations. Figure 4 In the example shown, the circular path configuration 44 is rectangular; however, depending on the application, it can have any other shape, which may be regular or irregular. It should also be noted here that in some examples, the movement of the continuous moving assembly line 28 can be reversed, causing the platform 30 to move backward. For example, once part 34 has been processed in one or more of these work areas 22, the platform 30 can move backward to perform additional processing or return to the loading area 24.

[0105] In some examples, it might be desirable to move the platform backward to the previous work area 22 because the previous work area 22 contains specialized equipment and / or is otherwise more suitable for performing a specific lamination operation. Positioning the loading area 24 and unloading area 26 along... Figure 4 The ability to handle any point in the continuously moving assembly line 28 configuration shown allows for greater processing flexibility and can increase job density while reducing footprint requirements. This continuous assembly line configuration is feasible and well-suited for laying long components. For example, two sets of parallel work zones 22 can be used to lay long components, wherein after the component layer moves in one direction through one set of work zones 22, the component layer is moved laterally rather than rotated to a second set of work zones 22, where the component layer moves in the opposite direction. Work can also be performed on the component layer as the component moves in the opposite direction through the second set of work zones 22. In the example mentioned later, as the component layer moves through the first set of work zones 22, the front portion of the component layer becomes the rear portion of the component layer as it moves through the second set of work zones 22.

[0106] Now, focus your attention on Figure 5 The diagram illustrates a typical work area 22 for performing component lamination. A platform 30 is mounted on a guide device 50 (such as a track 52 on the factory floor 35) for moving through work area 22 at a controlled rate. At least one sensor 46 senses the position of the platform 30 along a continuously moving assembly line 28. The position sensor 46 generates a position signal, which is then controlled by a controller 66, discussed later. Figure 12This is used to coordinate the operation of the laminator 36 and the movement of the laminator and component 34. In this example, the laminator 36 includes a material application head 54 mounted on an articulated robot 48. The material application head 54 lays a composite material strip, such as a composite tape or tows (not shown), onto a tool 32, such as a mandrel. As used herein, the term "applying or laying a composite material on the tool 32" includes laying a composite material on a lower sheet that has already been laid on the tool 32. As will be discussed in more detail below, the laminator 36 may lay an entire sheet on the tool 32. Alternatively, the laminator 36 may lay only a portion of the sheet. Moreover, the laminator 36 may lay a portion of the sheet while another portion of the same sheet is laid by the laminator 36 in an adjoining work area 22 in a continuously moving production line 28. The composite material strip may have different angular orientations.

[0107] Once the laminator 36 has laid part or all of the laminate onto tool 32, it can return to its starting position at the beginning (leading edge) of its work area 22 within a sufficient time to begin laying the composite material onto the next inline tool 32. Once the laminator 36 has returned to its starting position, it can begin laying a portion of the laminate onto the next inline tool 32, which has arrived within the laminator's work area 22 or is in a process transitioning from an adjacent work area 22. As will be discussed in more detail below, the operation of the laminator 36 is coordinated or synchronized with the movement of the platform 30 along the continuous moving production line 28. Furthermore, the operation of the laminators 36 in adjacent work areas 22 is also coordinated to prevent adjacent laminators 36 from colliding with each other or otherwise interfering with each other.

[0108] Figure 6 An example of a work area 22 is shown, in which a laminator 36 includes a material application head 54 mounted on a gantry robot 56. The material application head 54 moves vertically and laterally on the gantry 56. The gantry 56 is mounted to move longitudinally on an overhead rail 60, which is in turn mounted on laterally spaced supports 58. In this example, the platform 30 of the support 34 moves continuously below the material application head 54 along a track 52 or similar guide 50. As the platform 30 moves continuously along the track 52 through the laminator 36, the material application head 54 lays the composite material on a tool 32, while... Figure 12 The controller 66 shown coordinates the movement of the platform 30 with the movement of the material application head 54, and also coordinates the operation of the laminators relative to each other. (As shown in...) Figure 5 In the examples shown, in some implementations, Figure 6The laminator 36 shown can lay all or only part of the sheet, while a similar laminator 36 in an adjacent work area lays another part of the same sheet at the same time.

[0109] Now, focus your attention on Figures 7 to 11 These figures illustrate how to manufacture composite laminated parts 34 using a continuous moving production line 28 and multiple laminators 36 arranged in adjacent work areas 22 to improve production efficiency. Three exemplary adjacent work areas 22a, 22b, and 22c are shown, each containing three laminators 36a, 36b, and 36c. The laminators 36a, 36b, and 36c each include composite material application heads 54a, 54b, and 54c mounted on gantry robots 56, which can move along tracks 60 within their respective work areas 22. Each laminator in the laminators 36a, 36b, and 36c lays all or part of the laminates on the parts 34a that pass through these work areas on the continuous moving production line 28. For simplicity, Figures 7 to 11 The platform 30, which supports the component 34a, is not shown in the diagram. Figures 7 to 11 In the present example, work areas 22a, 22b, and 22c are approximately equal in length; however, in other examples, these work areas within work area 22 may not have equal lengths with other work areas. Furthermore, platform 30 ( Figures 7 to 11 (Not shown) The platform 30 may not move at a constant rate along the continuous moving assembly line 28. Instead, the rate at which the platform 30 moves through the work area 22 can be varied. For example, the platform 30 may transport the component 34 through the work area 22b at a faster rate than it would transport the component 34 through the work area 22a, while the platform 30 may transport the component 34 through the work area 22c at a slower rate than it would transport the component 34 through the work area 22a.

[0110] exist Figure 7 As can be seen, the laminator 36a is in the process of laying composite material on the component 34a as it moves from left to right through the work area 22a. The laminator 36a can begin laying composite material on the component 34a as it begins to enter the work area 22a, or at any point when the component 34a is within the work area 22a, or when the component 34a transitions from the work area 22a to the work area 22b. Therefore, as... Figure 7As shown, transitioning to the next work area 22 involves the coordinated movement of material application heads 54a and 54b laying material on component 34. This coordination also involves avoiding any interference, such as collisions between adjacent material application heads 54a and 54b. As material application head 54b begins a new layer at the leading edge, material application head 54a may begin the last layer at the leading edge before material application head 54b progresses toward the trailing edge. In another example, material application head 54a may lay material on the rear of the top of component 34a, while material application head 54b lays material forward from the joint. Other types of lamination placement between material application heads 54a and 54b and component 34 are also possible.

[0111] Figure 8 The diagram shows component 34a advancing along a continuous moving assembly line 28, traversing a portion of work zone 22a and a portion of work zone 22b. As component 34a is transferred from work zone 22a to work zone 22b, laminator 36b begins laying composite material on component 34a, while laminator 36a also lays composite material on component 34a. Thus, laminator 36a in work zone 22 can lay composite material on a portion of a component, while laminator 36b in adjacent work zone 22 can lay composite material on another portion of the component. In some applications, laminator 36b can lay a portion of the next layer, while in other applications, laminator 36b can complete the laying of a layer partially laid by laminator 36a. The orientation of the laminate being laid can differ from work zone 22 to work zone 22b. Therefore, for example, the orientation of the material applied in work zone 22a can be 0 degrees, and in work zone 22b, the orientation can be 45 degrees, while in work zone 22c, the orientation can be 90 degrees. The orientation of the composite material being applied can have any angle orientation in any of these work zones 22. In other words, the laminators 36 in different work zones 22 can apply the composite material strip onto the tool with different angle orientations. As previously shown, the operation and movement of the laminators 36 are coordinated so that they can simultaneously lay the composite material on the same component 34 without interfering with or colliding with each other.

[0112] Figure 9 The diagram shows component 34a advancing further from left to right into work area 22b, where laminator 36b completes the application of composite material to component 34a. Simultaneously, a second component 34b enters work area 22a, where laminator 36a begins applying composite material to component 34b.

[0113] exist Figure 10In this process, components 34a and 34b have both moved from left to right along the continuous moving assembly line 28, and component 34a has been partially transitioned into work zone 22c, where laminator 36c begins laying composite material on component 34a, while laminator 36b is completing the laying of composite material on component 34a. Laminator 36a may begin laying composite material on component 34b before component 34b enters work zone 22a, or at any point while component 34b is in work zone 22a, or when component 34b transitions from work zone 22a to work zone 22b. Therefore, it can be seen again that the transition to the next work zone 22 involves the coordinated movement of material application heads 54b and 54c laying material on component 34a. As material application head 54c begins a new layer at the leading edge, material application head 54b may begin the final layer at the leading edge before material application head 54c progresses toward the trailing edge. In another example, material application head 54b can apply material to the rear of the top of component 34a, while material application head 54c applies material forward from the joint. Other types of lamination placement between material application heads 54b and 54c and component 34a are also possible. When laminator 36b has finished laying composite material on component 34a, laminator 36b returns to the beginning of work area 22b to lay composite material on the next component 34b in the line.

[0114] exist Figure 11 As can be seen, component 34a has fully entered work area 22c, while component 34b has partially entered work area 22b. At this time, laminators 36a and 36b are both laying composite material on component 34b. This sequence continues as additional components move continuously through work areas 22a, 22b, and 22c, and the operation of laminators 36a, 36b, and 36c is coordinated in such a way that two adjacent laminators 36a and 36b are allowed to combine above each other. Figure 8 and Figure 10 The method of discussion involves simultaneously laying composite material on the same component 34. In various cases, laminators 36a, 36b, and 36c return to their starting position at the beginning (leftmost) of work area 22 to begin laying composite material on the next line component 34.

[0115] Now, focus your attention on Figure 12 The diagram roughly illustrates production system 20 ( Figure 1The controller 66 coordinates and controls the operation of the laminator 36 and the movement of the platform 30 along the continuous moving production line 28. In an example where a portion of a sheet is applied by the laminator 36 in one work area 22 and another portion of the same sheet is applied by the laminator 36 in an adjacent work area 22, the controller 66 also coordinates the operation of the laminator 36. The controller 66 may include a computer 68 coupled to a suitable memory 70 and a control program 72. In one example, the platform 30 may be driven along the continuous moving production line 28 by a moving line powertrain 74 controlled by the controller 66. In this example, the platform 30 may include a suitable utility connection 84 (such as a commercially available quick connection 83) connecting the platform 30 to an external utility source 82, which may include electrical, pneumatic, and hydraulic quick-disconnect connections. In other examples, as previously mentioned, platform 30 may include an automated guided vehicle (AGV) that may have onboard utilities, as well as a global positioning system (GPS) and an automated guidance system 86. Still in other examples, a laser tracker 88 may be used to control the movement of platform 30. Appropriate position and / or motion sensors 46, coupled to controller 66, are used to determine the position of platform 30 and the moving assembly line powertrain 74.

[0116] In the previous example, work area 22 was dedicated to lamination operations; however, the principle of the continuous moving production line diagram 28 described herein can include other types of operations typically required in the production of composite laminate components. Figure 13 An example of a continuous moving assembly line 28 is illustrated, which incorporates a variety of operations that may be required in the production of composite laminated parts. For example, work area 22 may include: tool preparation 90 involving cleaning or coating a tool 32, after which the tool 32 is transported on platform 30 to one or more work areas 22, where a lamination operation 92 is formed. The fully laid part 34 can then be delivered on the continuous moving assembly line 28 to a downstream work area 22, where compaction 94 and clamping 96 of the part layout are performed.

[0117] Compaction 94 of component 34 can be performed using, for example, but not limited to, vacuum compaction with a vacuum bag. Compaction 96 of component 34 can also be performed using vacuum compaction with a vacuum bag or a vacuum bag and a pressure equalizing cover plate. Furthermore, component 34 can be processed in an additional work area, where molding 98, curing 100, trimming 102, inspection 104, rework 106, and / or surface treatment 108 can be performed. Molding 98 of component 34 can be performed using pre-curing forming, and / or a molding combination between one side of tool 32, and / or a molding combination between one side of tool 32 and a pressure equalizing cover plate on the other side of tool 32. Curing 100 of component 34 can be performed using an autoclave or autoclave external treatment. Post-curing finishing 102 of the cured component 34 can be performed before or after the component 34 is removed from the tool 32. In some applications, the finishing process may involve a type of quality finishing of the component 34 before curing, followed by more specific finishing after the component 34 has cured. Inspection 104 of the component 34 may include visual inspection as well as inspection using NDI (non-destructive testing) equipment. Although reworking the component 34 (106) along the continuous moving assembly line 28 is feasible, in some cases the component 34 may not require rework. At 108, any of a variety of techniques can be used to treat one or more surfaces of the component 34. For example, surface treatment may involve sealing the finished edges and / or painting one or more surface areas of the component 34.

[0118] Figure 14 The steps of a method for manufacturing composite laminate components using a continuous moving production line 28 are roughly illustrated. Starting at 110, tools 32 are placed on various platforms among a plurality of platforms 30. At 112, the platforms 30 are moved along the continuous moving production line that runs through the various work areas 22. At 114, as the platforms 30 move along the continuous moving production line that runs through the various work areas 22, portions of the components 34 are laid on the tools 32 at the various work areas 22 using an automated laminator 36.

[0119] Figure 15The steps of another method for manufacturing composite laminate components using a continuous moving assembly line are roughly illustrated. At 116, tool 32 is placed on platform 30. At 118, platform 30 is moved along a continuous moving assembly line that runs through multiple work zones 22. At 120, a portion of component 34 is laid using a laminator 36 located in an adjacent work zone within these work zones 22. At 122, after component 34 has been laid, a work is performed on component 34 in one of these work zones 22. This work may include: Figure 13 One or more operations or procedures following the installation of component 34 in the operation or procedure shown.

[0120] The examples disclosed herein can be used in a variety of potential applications, particularly in the transportation industry (including aerospace, marine, and automotive applications) and other applications where composite laminated components can be used. Therefore, reference is now made to... Figure 16 and Figure 17 Examples of this disclosure can be found in, for example, Figure 16 The aircraft manufacturing and maintenance methods 124 shown, and as such Figure 17 This is used in the context of the aircraft 126 shown. The disclosed example aircraft applications may include a variety of composite components and structures formed from laminated sheets of fiber-reinforced polymers. During pre-production, exemplary method 124 may include the specification and design 128 of the aircraft 126 and material procurement 130. During production, the manufacturing 132 of components and sub-assemblies of the aircraft 126 and system integration 134 may be performed. Thereafter, the aircraft 126 may undergo certification and delivery 136 for use 138. When used by a customer, routine maintenance and servicing 138 are scheduled for the aircraft 126, which may also include modifications, reconfigurations, refurbishments, etc. The disclosed systems and methods can be used to generate... Figure 16 The processes shown in 132 and 134, as well as in Figure 17 The composite laminate component used in the frame 142 that forms the components of the aircraft shown.

[0121] Each of the processes in Method 124 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0122] like Figure 17As shown, an aircraft 126 produced according to exemplary method 124 may include a frame 142 having multiple systems 144 and an interior 146. Examples of the advanced systems 144 include one or more of the following: a propulsion system 148, an electrical system 150, a hydraulic system 152, and an environmental system 154. 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 marine and automotive industries.

[0123] During any or more of these stages of the aircraft manufacturing and maintenance method 124, the systems and methods specifically implemented herein may be employed. For example, the parts or sub-assemblies corresponding to production process 132 may be made or manufactured in a manner similar to those produced when the aircraft 126 is in use. Moreover, during production processes 132 and 134, one or more equipment examples, method examples, or combinations thereof may be utilized, for example, by significantly accelerating the assembly of the aircraft 126 or reducing the cost of the aircraft. Similarly, when the aircraft 126 is in use, one or more of the equipment examples, method examples, or combinations thereof may be used to perform maintenance and servicing 140, for example and without limitation.

[0124] As used in this article, the phrase "at least one of..." when used with list items means that different combinations of one or more of the listed items can be used, and only one of each item in the list may be required. For example, "at least one of item A, item B, and item C" can include, but is not limited to: item A, item A and item B, or item B. This example could also include item A, item B, and item C, or item B and item C. The item can be a specific object, thing, or category. In other words, "at least one of..." means any combination of items, and the number of items can be used according to the list, but not all items in the list are required.

[0125] Various illustrative examples have been presented for purposes of illustration and description, and are not intended to be exclusive or limited to these examples as disclosed. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different illustrative examples may offer different advantages compared to other illustrative examples. A selection of several examples has been chosen and described in order to best illustrate the principles and practical applications of the example, and to enable those skilled in the art to understand this disclosure with respect to various examples having various modifications as suited to the intended particular purpose.

Claims

1. A system for manufacturing composite laminate components, the system comprising: Multiple work areas, in which operations are performed on the component; Multiple platforms, which are capable of continuous movement along an assembly line that passes through various work areas. Multiple tools are capable of continuous movement along an assembly line passing through various work areas, wherein the multiple tools are respectively carried on multiple platforms; A plurality of laminators, each located in an adjacent work area of ​​a plurality of work zones, and configured to apply a composite material onto the tool; and A controller is provided for controlling the movement of the tools and the operation of the laminators, wherein the controller is configured to coordinate the operation of the plurality of laminators such that, as the platform moves between adjacent work areas in the plurality of work areas, the laminators in the adjacent work areas are applying composite material to one of the plurality of tools, wherein a first laminator located in the first work area is used when the trailing edge of the tool is in the first work area of ​​the adjacent work area, and a second laminator located in the next work area is used when the leading edge of the tool is in the next work area of ​​the adjacent work area.

2. The system of claim 1, wherein, The laminator is configured to apply composite material strips to the tool at different angular orientations.

3. The system according to claim 1 or 2, further comprising: A guiding device for moving the assembly line guide platform along the various work areas of the plurality of work areas. The platform is connected to the guiding device.

4. The system of claim 1 or 2, wherein, Each of the multiple platforms is an automated guided vehicle.

5. The system of claim 1 or 2, wherein, The laminator includes: A robot manipulator, which is operated by the controller; and A material application head is mounted on the robot manipulator and configured to apply a composite material strip onto the tool.

6. The system of claim 5, wherein, The robot manipulator is one of an articulated arm robot and a gantry robot.

7. The system according to claim 1 or 2, further comprising a plurality of sensors located in the plurality of work areas, and each sensor being configured to sense movement of one of the plurality of platforms.

8. The system according to claim 1 or 2, further comprising: The program is used by the controller to coordinate the movement of the plurality of platforms along the production line and the operation of the plurality of laminators.

9. The system of claim 1, wherein, The laminators in adjacent work areas of the plurality of work areas are respectively configured to apply composite material strips to the tool at the same angular orientation.

10. A method for manufacturing a composite laminate component using the system according to any one of the preceding claims, the method comprising the steps of: Multiple tools are moved along an assembly line that passes through various work areas; as well as As the tool moves along the assembly line through the various work areas, a portion of each component is laid on the tool at each of the various work areas using an automated laminator.

11. The method of claim 10, wherein, The step of laying a portion of each of the components includes: applying composite material strips at different angular orientations onto the tool using the laminators in different work zones of the plurality of work zones.

12. The method according to claim 10 or 11, further comprising the step of: The tools are placed on multiple platforms respectively; as well as The platform moves along the assembly line that passes through each of the multiple work areas.

13. The method of claim 12, wherein, The step of continuously moving the plurality of tools along the production line is performed, so that the plurality of tools continuously move through the work area.

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