System and method for laying up a composite cylindrical structure

Abstract

Systems and methods for laying up a composite cylindrical structure. A composite barrel is laid up on a rotatable mandrel using a lamination machine that applies composite material to the mandrel. The lamination machine is arranged on opposite sides of the mandrel and applies composite material to a first zone of the mandrel while the mandrel is held stationary in a first rotational position. While the lamination machine applies composite material to a second zone of the mandrel to complete the layup, the mandrel is rotated to a second rotational position at which the mandrel is held stationary. During the layup process, the layers in the first and second zones are spliced together.

Description

Technical Field

[0001] This disclosure generally relates to processes and equipment for producing composite structures, and more specifically to systems and methods for laying composite cylindrical structures (e.g., sections of an aircraft fuselage). Background Technology

[0002] Cylindrical aircraft fuselages can be manufactured in sections by using multiple laminators to lay composite materials onto cylindrical mandrels. Each laminator contains a CNC fiber placement head that moves along the mandrel, laying different portions of the cylindrical section. To increase production speed, the mandrel is rotated while the placement head moves, requiring coordination between the two movements.

[0003] Coordinating laminator operation with mandrel rotation requires sophisticated drive, sensing, and control equipment to precisely synchronize the movement of the laying head with the rotation of the mandrel. This precision requirement increases the cost and complexity of the equipment. Furthermore, some of the equipment required to rotate the mandrel in this manner is large and bulky, making it more difficult to move the mandrel through narrow spaces (such as into an autoclave). In addition, the above techniques are not entirely efficient, because when using two laminators to lay tube sections, one laminator typically experiences near 100% utilization, while the second laminator depends on the progress of the first laminator and therefore idles for a portion of the time.

[0004] Therefore, it is desirable to provide a system and method for laying composite cylinders that overcomes the aforementioned disadvantages by using simplified, low-cost equipment, while improving laying efficiency and productivity. Summary of the Invention

[0005] This disclosure generally relates to the manufacture of composite structures, and more specifically to methods and apparatus for laying cylindrical structures (e.g., sections of an aircraft fuselage).

[0006] According to one aspect, a method is provided for laying a composite cylinder on a mandrel. The method includes rotating the mandrel to at least a first rotational position and at least a second rotational position, and holding the mandrel stationary at each of the first and second rotational positions to prevent rotation. The method further includes laying a composite layer on a first region of the mandrel while the mandrel is stationary at the first position, and laying a composite layer on a second region of the mandrel while the mandrel is stationary at the second position. The method also includes forming a splice between the layer in the second region and the layer in the first region.

[0007] According to another aspect, a method for laying a composite cylinder onto a mandrel is provided. The method includes arranging a first laminator and a second laminator, respectively, on opposite sides of the mandrel, and rotating the mandrel to a first rotational position that presents a first section and a second section on the mandrel, respectively, within the reach of the first and second laminators. The method includes holding the mandrel stationary in the first rotational position to prevent rotation, and while the mandrel is stationary in its first rotational position, using the first and second laminators to lay a composite layer onto the mandrel in at least one of the first and second sections, respectively. The method further includes rotating the mandrel to a second rotational position that presents a third section and a fourth section on the mandrel, respectively, within the reach of each of the first and second laminators. The method further includes holding the mandrel stationary in the first rotational position to prevent rotation, and while the mandrel is stationary in its second rotational position, using the first and second laminators to lay a composite layer onto at least one of the third and fourth sections on the mandrel, respectively.

[0008] According to another aspect, a system for laying composite cylinders is provided. The system includes a generally cylindrical mandrel configured to rotate about a central axis. The system includes a first laminator and a second laminator respectively arranged on opposite sides of a housing, wherein each of the first and second laminators has an access range and includes a laminating head configured to apply composite material to the mandrel within its access range. The system also includes a driver configured to rotate the mandrel about the central axis to at least a first and a second rotational position, and to hold the mandrel stationary at the first and second rotational positions. The system further includes a controller configured to control the operation of the driver and the first and second laminators, such that the laminating head moves on the mandrel and applies composite material to the mandrel while the mandrel remains stationary at each of the first and second rotational positions.

[0009] One advantage of the disclosed method and apparatus is that it allows for the more efficient laying of composite cylinder sections using simpler, lower-cost equipment. Another advantage is that the drive system for rotating the mandrel (on which the cylinder sections are laid) is smaller and can be arranged in a straight line with the mandrel. Another advantage is that the automated laminator for laying the cylinder sections has higher utilization. Another advantage is that the number and / or frequency of mandrel rotations can be reduced, thus contributing to higher productivity. Furthermore, precise synchronization between mandrel rotation and laminator operation is not required. Another advantage is that the drive system for rotating the mandrel can be entirely located outside the mandrel, allowing greater flexibility in drive design. Another advantage is that the drive system can be configured more compactly to reduce floor space requirements and better facilitate the movement of the mandrel along the production line into confined spaces (e.g., autoclaves).

[0010] Features, functions, and advantages may be implemented independently or combined in various examples of this disclosure, with further details to be seen in the following description and figures. Attached Figure Description

[0011] The appended claims set forth novel features that are considered illustrative examples. However, the exemplary examples, preferred modes of use, and further objects and advantages will be best understood when read in conjunction with the accompanying drawings and by referring to the following detailed description of exemplary examples of this disclosure, wherein:

[0012] Figure 1 It is a perspective view of an airplane.

[0013] Figure 2 It is formed Figure 1 A perspective view of the fuselage section of the aircraft shown.

[0014] Figure 3 It is a perspective view of the composite cylinder section laid on the mandrel;

[0015] Figure 4 yes Figure 3 The illustration shows a portion of the layup, demonstrating how a layer can contain multiple individual segments;

[0016] Figure 5 It is a perspective view of a device used to lay composite cylinder sections on a mandrel;

[0017] Figure 6 This is a schematic end view of a rotatable mandrel, showing the extent of the laminator's accessibility on the side of the mandrel, depicting the mandrel in its first rotational position.

[0018] Figure 7 It is similar to Figure 6 The diagram illustrates how to strategically divide the circumference of the mandrel into zones and sections.

[0019] Figure 8 It is similar to Figure 6 and Figure 7 The diagram illustrates the first laying sequence performed when the mandrel remains stationary in the first rotational position;

[0020] Figures 9-13 It is similar to Figure 8 The diagram illustrates the additional laying sequence performed sequentially when the mandrel is in its first rotational position; the laminator is not shown for clarity.

[0021] Figure 13A yes Figure 13 Designated as " Figure 13A A diagram of the area marked "".

[0022] Figure 14 It is similar to Figure 13 The diagram shows that its central axis has been rotated 180 degrees to its second rotational position;

[0023] Figure 14A yes Figure 14 Designated as " Figure 14A A diagram of the area marked "".

[0024] Figure 15 This is a diagram illustrating a method of laying composite cylinders on a rotatable mandrel;

[0025] Figure 16 Another illustration shows a method for laying composite cylinders on a rotatable mandrel;

[0026] Figure 17 It is a diagram of a combination frame and schematic side view of a rotatable mandrel and associated drive mounted on an automated guided vehicle;

[0027] Figure 18 This is a schematic diagram of a part of the locking mechanism, showing the locking pin in the released position;

[0028] Figure 19 It is similar to Figure 18 The illustration shows the locking pin in the locked position;

[0029] Figure 20 It is a diagram illustrating a position sensor associated with a feature on the mandrel or in the laying;

[0030] Figure 21 It is an illustration of a combination frame and a schematic side view of a rotatable mandrel mounted on a mobile platform coupled to a tugboat;

[0031] Figure 22 It has already been dragged into the autoclave. Figure 21 A schematic end view of the mandrel shown;

[0032] Figure 23 This is a block diagram that provides a general overview of the components of a system for laying composite cylinders on a rotatable mandrel.

[0033] Figure 24 It is a flowchart illustrating the methods of aircraft production and use; and

[0034] Figure 25 It is a diagram of an aircraft block diagram. Detailed Implementation

[0035] First refer to Figure 1The aircraft 30 includes a fuselage 32, wings 34, a horizontal stabilizer 36, and a vertical stabilizer 38. In the illustrated example, the cross-section of the fuselage 32 is substantially cylindrical; however, in other examples it may be elliptical or have other similar shapes. The fuselage 32 is formed of composite components (including a composite outer skin 44) and typically has multiple openings 42, such as hatches or windows. The outer skin 44 is a composite laminated material, such as carbon fiber reinforced polymer (CFRP).

[0036] like Figure 2 As shown, the fuselage 32 may include several composite cylindrical sections 40 connected end-to-end. Each cylindrical section 40 includes an outer composite skin 44, longitudinally extending longitudinal beams 50, and longitudinally spaced, circumferentially extending ribs 52. In the illustrated example, the outer composite skin 44 includes an upper skin 46 and a lower skin 48 connected together along a waistline 45. However, in other examples, the outer skin 44 may comprise a single-piece cylindrical section.

[0037] refer to Figure 3 and Figure 4 The composite skin 44 comprises multiple composite material layers 94, which are laid on the cylindrical mandrel 54 according to a predetermined layer arrangement that will be unique for a specific application. Each of the layers 94 may comprise a complete layer, or as... Figure 4 The diagram may contain one or more segments 58, thereby forming local features (e.g., doublers or tear bands).

[0038] Figure 5 The illustration depicts an apparatus for laying a cylindrical section 40 onto a mandrel 54. The mandrel 54 includes a pair of shafts 108 mounted on a pair of supports 60 for rotation. One of the supports 60 may include a driver, discussed later, that rotates or "clocks" the mandrel 54 to one or more predetermined rotational positions. A first laminator 62 and a second laminator 64 are arranged on opposite sides of the mandrel 54 and mounted for longitudinal movement along a guide rail 66. Although only two laminators 62, 64 are used in the illustrated example, the use of more than two laminators is possible in other examples. The laminators 62, 64 include laminator heads 72, 74 that serve as end effectors on articulated arm robots 68, 70. The use of other types of robot manipulators is possible.

[0039] Each of the laminator heads 72, 74 is movable along multiple axes to allow the composite material to be placed at a desired location and orientation on the mandrel 54. As used herein, the phrase “applying composite material to mandrel 54” means applying the composite material directly to mandrel 54 or to a composite material layer already laid on mandrel 54. As will be discussed in more detail later, the operation of robots 68, 70 and laminator heads 72, 74 is controlled by one or more controllers, which may be NC (numerical control) or CNC (computer numerical control) controllers 146. Figure 23 The controller 146 controls and coordinates the rotation of the mandrel 54, the operation of the robots 68 and 70, and the operation of the laminating heads 72 and 74 according to one or more sets of program instructions (e.g., software programs). Figure 23 While the mandrel 54 remains stationary in a preselected rotational position, the controller 146 controls the movement of the laminating heads 72, 74 on the mandrel 54. Each of the laminating heads 72, 74 can be any of several types that apply and compact composite or split tapes on the mandrel 54.

[0040] Figure 6 and Figure 7 The mandrel 54 and laminators 62, 64 are schematically illustrated, with the mandrel 54 depicted in a first stationary position 82 of rotation, sometimes referred to as "position A" below. To illustrate an example where the cylinder is a cylindrical section 40 of an aircraft fuselage, the mandrel 54 is divided into two 180-degree halves, with the upper skin 46 and lower skin 48 laid on these two 180-degree halves respectively. Robots 68, 70 ( Figure 5 The laminator heads 72 and 74 are provided with circumferential motion ranges, or "accessible ranges," 76 and 78, respectively. In the illustrated example, each of the circumferential motion ranges or "accessible ranges" 76 and 78 is approximately 120 degrees; however, other ranges are possible, including ranges greater than 180 degrees. The mounting of the robots 68 and 70 on the track 66 extends the circumferential access ranges 76 and 78 of the laminator heads 72 and 74 to the entire length of the mandrel 54. Figure 6 It can be seen that the two motion ranges 76 and 78 overlap each other at the overlapping area 80 between the upper skin 46 and the lower skin 48.

[0041] refer to Figure 7 Lamination efficiency can be maximized using a lamination strategy that divides the circumference of mandrel 54 into zones and partitions within each zone. In the illustrated example, when mandrel 54 is in position A, the combined circumferential reach of laminators 72 and 74 is 76 and 78 (…). Figure 6The first zone 100 of the mandrel 54 is covered. The laminator 72 has independent access range 76 for partitions 86 within the covered zone 100, and the laminator 78 has independent access range for partitions 88 within the covered zone 100. With the mandrel 54 stationary in position A, the two laminators 72 and 74 lay one or more layers in each of the two partitions 86 and 88, respectively. As will be discussed in more detail below, multiple layers are laid in each partition 86 and 88, and these multiple layers may overlap each other within the overlapping area 80.

[0042] After the required number of layers are laid in the first zone 100, the mandrel 54 is rotated 180 degrees to a second rotational position, sometimes referred to below as "position B," which results in the formation of a second zone 102 within the reach of the laminators 72, 74. The laminators 72, 74 then lay the required number of layers 94 in the two partitions 90, 92 within zone 102, respectively, thus completing the skin layup 56. As will be discussed below, the layers 94 are laid in the two (or more) zones 102, 104 in a manner that forms a joint 97 between the layers of the two zones 102, 104. The joint 97 is created by splices 98 between the layers 94, which are circumferentially offset from each other to maximize skin strength.

[0043] Figures 8-14A A more detailed illustration shows an example of the laying sequence used for laying the composite tube section 40, where, as shown in the diagram... Figure 6 The two laminators 62 and 64 shown lay layer 94 of the composite skin 44 onto mandrel 54. In this example, mandrel 54 is rotated only once, from position A 82 ( Figures 8-13 Rotate 180 degrees to position B 84 ( Figure 14 ). refer to Figure 8 With the mandrel 54 in position A, laminators 62 and 64 lay layers 94a and 94b respectively, which can be stacked on top of each other in the overlapping area 80.

[0044] Next, in Figure 9 In the process, laminator 62 lays the second layer 94c on top of layer 94a, but laminator 64 does not lay any more layers in this sequence. Figure 10 In the sequence shown, layers 94d and 94e are laid by laminators 62 and 64, respectively. Next, as... Figure 11 As shown, the two additional layers 94f and 94g are laid by laminators 62 and 64, and according to... Figure 12 As shown in the subsequent sequence, the other two layers 94i and 94j are laid on top of layers 94f and 94g by laminators 62 and 64, respectively. The next laying sequence is then shown. Figure 13In the middle, layer 94j is laid by laminator 62, while the complete layer 94k is laid by laminator 64. Although layers 94 within the two partitions 86 and 88 are shown as overlapping at the overlapping area 80 (see... Figure 13A However, in other examples, layers from these two zones can form butt joints (not shown). Layers 94 can be laid such that their ends are staggered or offset to facilitate the formation of joints 97 between layers 94 in the first zone 100 and layers 94 in the second zone 102. The process of laying layers 94 sequentially on the mandrel 54 continues until all layers according to the desired layer arrangement have been laid for the tube section 40 within the first zone 100.

[0045] Now for reference Figure 14 and Figure 14A In the first zone 100 of the spindle 54 Figure 7 After layers 94a-94k in the laminar flow 74 have been laid, the mandrel 54 is rotated to position B, which in this example involves a 180-degree rotation. With the mandrel 54 in position B, the second zone 102 of the mandrel 54 is presented within the reach of the laminators 62, 64. Specifically, zone 92 is within the reach 76 of the laminator 72, and zone 90 is within the reach 78 of the laminator 74. With the mandrel 54 stationary in position B, layers are laid in the second zone 102 to complete the skin 44, which is partially laid in zone 100 as previously described. Each of the layers 94 laid in the second zone 102 can be an extension of the corresponding layer laid in zone 100. For example, as Figure 14 As shown, laminators 72 and 74 lay layers 94l and 94m in zones 92 and 90 respectively, overlapping the ends of layers 94a and 94b in the first zone 100 to form a stepped splice 98 (see...). Figure 14A ).exist Figure 14A In the example shown, layers 94 in splice 98 are offset from each other by an equal distance; however, in other examples, the offset distances may not be equal. In other examples, joint 97 can be formed by overlapping some layers 96 in the two regions 100, 102.

[0046] As mentioned earlier, the tubular section 40 can be a single piece or it can comprise two pieces, namely the upper skin 46 and the lower skin 48 connected together along the waistline 45. Figure 2In the example of a one-piece tube section 40, the ply 56 is removed from the mandrel 54 by disassembling or collapsing the mandrel 54. In the example of a two-piece tube section 40, the two halves of the ply (upper skin and lower skin 46, 48) can be removed from the mandrel 54 by cutting through the ply 56 at the overlapping area 80 and then separating and removing the two halves from the mandrel 54. Alternatively, the mandrel 54 can be disassembled or collapsed to allow the removal of the one-piece ply 56, which can then be cut in half at the overlapping area 80.

[0047] Follow us now Figure 15 The diagram schematically illustrates the steps of a method for laying a composite cylinder segment 40 onto a mandrel 54. Starting at 110, the mandrel 54 is rotated to at least a first rotational position 82 and a second rotational position 84. At 112, the mandrel 54 is held stationary at each of the first and second rotational positions 82, 84 to prevent rotation. At 114, when the mandrel is held stationary in its first position, a composite layer 94 is laid onto the mandrel 54 in a first region of the mandrel, and when the mandrel is held stationary in the second rotational position, a composite layer is laid onto the mandrel in a second region. The laying involves forming a joint between the layer in the second region and the layer in the first region.

[0048] Figure 16 The illustration shows another method of laying the composite cylinder section 40 onto the mandrel 54. At 116, the first laminator and the second laminators 62, 64 are positioned on opposite sides of the mandrel 54. At 118, the mandrel 54 is rotated to a first rotational position 82, which presents a first zone 100 on the mandrel 54 within the accessible ranges 76, 78 of each of the first and second laminators 62, 64. At 120, with the mandrel 54 stationary in its first rotational position 82, the composite layer 94 is laid onto the first zone 100 of the mandrel 54 using the first and second laminators 62, 64. At 122, the mandrel 54 is rotated to a second rotational position 84, which presents a second zone 102 on the mandrel 54 within the accessible ranges 76, 78 of each of the first and second laminators 62, 64. At position 124, when mandrel 54 remains stationary in its second rotational position 84, the composite material is laid on the second zone 102 of mandrel 54 using a first laminator and a second laminator 62, 64.

[0049] In the example described above, the mandrel 54 is rotated only once from position 82 to position 84. However, in other examples, the mandrel 54 can be rotated multiple times to any of a plurality of stationary rotational positions to lay the tube section 40, depending on the requirements of a particular layer arrangement. However, in each example, when the laminators 62, 64 lay layers in zones 100, 102 of the mandrel 54 (zones 100, 102 are within the reach 76 of the laminators 62, 64), the mandrel 54 remains stationary in one of the rotational positions, and the layers in the two zones are joined together during the laying process. Therefore, coordination between the movement of the laminator heads 72, 74 and the simultaneous rotation of the mandrel 54 is unnecessary. Furthermore, because the mandrel 54 only needs to be rotated to a pre-selected fixed rotational position, the disclosed method results in a reduction in the complexity of the equipment required to rotate the mandrel 54.

[0050] refer to Figure 17 The spindle 54 can be mounted using a simple bearing 120 for rotational movement, which is supported on a strut 60 mounted on an automated guided vehicle (AGV) or similar vehicle 112. The vehicle 112 can transport the spindle 54 along a surface 122 (e.g., a factory floor) in any desired direction 124. The spindle 54 is rotated by any suitable drive 114 (e.g., a servo motor). Although not explicitly stated... Figure 17 The figure shows a servo motor, but the servo motor includes an electric motor operated by control circuitry and has an output drive shaft 130 connected to spindle 54. Although not shown in the figure, the driver 114 may include suitable reduction gears and / or other transmission components.

[0051] The drive 114 is located outside the spindle 54 and can be aligned in a straight line with the spindle 54, resulting in a narrow profile that allows the AGV 112 to transport the spindle 54 through narrow spaces (e.g., into the autoclave 136). Figure 22 Depending on the size of the mandrel 54 and the type of drive 114 used, a locking mechanism 116 can be employed to lock the mandrel 54 in the desired rotational position before the lamination operation is performed. In one example, such as Figure 18 and Figure 19 As shown, the locking mechanism may comprise a simple locking pin 132 that is displaced into an opening 134 in a portion of the spindle 54. In other examples, the locking mechanism 116 may be electronic circuitry (not shown) integrated into a servo motor forming part of the drive 114 to precisely position and hold the spindle 54 in the desired rotational position. See also... Figure 20 One or more sensors 144 may be provided for sensing one or more features 135 on the mandrel 54 or the layup 56 in order to place the mandrel 54, the layup 56 and the laminators 62, 64 in a common coordinate system.

[0052] refer to Figure 21 The spindle 54 can be mounted on a non-powered mobile platform 112 with wheels 138, which allow the mobile platform 112 to be pushed or pulled on the surface 122 by a tugboat 126 or a similar powered vehicle. In this example, a drive 114 is mounted on top of the tugboat 126 and rotates the spindle 54 via a drive shaft 130.

[0053] Follow us now Figure 22 The illustration shows an autoclave 136 for curing the layup 56 on a mandrel 54. In this example, the mandrel 54 and the actuator 114 are mounted in a configuration similar to... Figure 17 and Figure 21 On the moving platform 112 shown. Because the drive 114 is aligned with the spindle 54, the combination of the spindle 54 and the drive 131 presents a narrow profile, which allows them to be dragged or pushed together into the autoclave 136 along the production line (not shown).

[0054] Figure 23 The diagram schematically illustrates the operation and control components of a system for laying composite cylinder section 40 onto mandrel 54. In this example, cylinder section 40 is laid onto mandrel 54 mounted on a moving platform 112. Laminators 62, 64, arranged on the opposite side of mandrel 54, are operated by controller 146, which, as previously described, can be an NC or CNC controller employing one or more software programs 148. Controller 146 also controls drive 114 and, optionally, lock 116 and brake 142. As previously described, lock 116 can be in electronics forming part of a servo motor. Depending on the application, mandrel 54 may have a relatively large mass, which can make slowing down the rotation of mandrel 54 challenging. Therefore, mechanical or electronic brake 142 is provided as needed to slow down the rotation of mandrel 54. Slowing down the rotation of mandrel 54 may be necessary to allow the mandrel to be precisely positioned at the desired rotational position. In those examples where the mobile platform 112 is an AGV, a control station 150 can be provided to wirelessly control the AGV and the operation of the controller 146.

[0055] The examples disclosed herein can be used in a variety of potential applications, particularly in the transportation industry, including, for example, aerospace, marine, automotive applications, and other applications where composite cylindrical structures can be used. Therefore, reference is now made to... Figure 24 and Figure 25 Examples of this disclosure can be found in, for example, Figure 24 The aircraft manufacturing and usage methods shown in Figure 152 and as follows Figure 25Used in the context of the aircraft 154 shown. The aircraft applications disclosed in the examples may include various cylindrical structures, such as fuselages. During pre-production, exemplary method 152 may include the specification and design 156 of the aircraft 154 and material procurement 158. During production, the manufacturing 160 of components and sub-assemblies of the aircraft 154 and system integration 162 are performed. Thereafter, the aircraft 154 may be certified and delivered 164 for use 166. During customer service, the aircraft 154 is scheduled for routine maintenance and repair 168, which may also include modifications, reconfigurations, refurbishments, etc.

[0056] Each step in Method 152 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 specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major systems subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service provider, etc.

[0057] like Figure 25 As shown, an aircraft 154 produced by exemplary method 152 may include an aircraft frame 180 having multiple systems 182 and an interior 184. Examples of advanced systems 182 include one or more of a propulsion system 186, an electrical system 188, a hydraulic system 190, and an environmental system 192. 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.

[0058] The systems and methods embodied herein can be employed during any one or more phases of the aircraft manufacturing and use method 152. For example, a component or sub-assembly corresponding to production process 160 can be manufactured or produced in a manner similar to that of a component or sub-assembly produced when the aircraft 154 is in service. Furthermore, one or more apparatus examples, method examples, or combinations thereof can be utilized during production processes 160 and 162, for example, by significantly accelerating the assembly of the aircraft 154 or reducing the cost of the aircraft 154. Similarly, one or more apparatus examples, method examples, or combinations thereof can be utilized during the aircraft's service life, for example, but not limited to maintenance and repair 168.

[0059] As used in this article, the phrase "at least one of" when used with a list of items means that different combinations of one or more of the listed items can be used and that only one of each item in the list may be required. For example, "at least one of items A, B, and C" can include, but is not limited to, items A, B, and A, or B. This example could also include items A, B, and C, or B and C. Items can be specific objects, things, or categories. In other words, "at least one of" means that any combination and any number of items can be used from the list, but not all items in the list are required.

[0060] Furthermore, this disclosure includes embodiments pursuant to the following provisions:

[0061] Clause 1. A method of laying a composite cylinder (40) on a mandrel (54), comprising:

[0062] Rotate the spindle (54) (110) to at least each of the first rotation position and the second rotation position (82, 84);

[0063] The spindle (54) is kept stationary at each of the at least first and second rotational positions (82, 84) to prevent rotation; and

[0064] When the mandrel (54) remains stationary at the first rotational position (82), the composite material layer (94) is laid (114) in the first region (100) of the mandrel (54); and

[0065] When the mandrel (54) remains stationary at the second rotation position (84), the composite material layer (94) is laid (124) in the second region (102) of the mandrel (54), including forming (114) splices (98) between the layer (94) in the second region (102) and the layer (94) in the first region (100).

[0066] Clause 2. The method described in Clause 1, wherein forming (114) splices (98) includes offsetting the splices (98) from one another.

[0067] Clause 3. The method according to Clause 1, wherein the laying of the composite layer (94) is performed using an automatically controlled laminator (62), each having a laminator head (72, 74), including moving the laminator head (76, 78) on the mandrel (54) while the mandrel (54) remains stationary at each of the first and second rotational positions (82, 84).

[0068] Clause 4. The method according to Clause 3, wherein laying the layer (94) includes arranging (116) the first automatic control laminator and the second automatic control laminator (62, 64) on opposite sides of the mandrel (54) such that the laminators (62, 64) have a combined reachable range (76, 78) extending over a first region (100) of the mandrel (54) when the mandrel (54) is in a first rotational position (82), and a combined reachable range (76, 78) extending over a second region (102) of the mandrel (54) when the mandrel (54) is in a second rotational position (84).

[0069] Clause 5. The method described in Clause 4, wherein the laying layer (94) comprises:

[0070] Using the first laminator (62), a layer (94) is laid in the first section (86) within the first zone (100); and

[0071] At the same time, a second laminator (64) is used to lay a layer (94) in the second section (88) within the first zone (100).

[0072] Clause 6. The method described pursuant to Clause 1 further includes:

[0073] When the spindle (54) is rotated to each of the at least first and second positions (82, 84) of spindle rotation, the rotation of the spindle (54) is braked (142); and

[0074] Lock the spindle (54) (116) in each of the first rotational position and the second rotational position (82, 84).

[0075] Clause 7. The method according to Clause 1, wherein rotating the mandrel (54) from the first rotational position (82) to the second rotational position (84) comprises rotating the mandrel (54) by 180 degrees.

[0076] Clause 8. The method according to Clause 1, wherein laying the composite material layer (94) includes an overlap (80) layer between the first and second zones (100, 102) of the mandrel (54).

[0077] Clause 9. A method of laying a composite cylinder (40) on a mandrel (54), comprising:

[0078] The first laminator and the second laminator (62, 64) are respectively arranged (116) on opposite sides of the mandrel (54);

[0079] Rotate the mandrel (54) (118) to a first rotational position (82) of the mandrel (54), which presents a first partition and a second partition (86, 88) on the mandrel (54) within the reach (76, 78) of the first laminator and the second laminator (62, 64), respectively.

[0080] In the first rotational position (82), the spindle (54) is kept stationary to prevent rotation;

[0081] When the mandrel (54) remains stationary in its first rotational position (82), a composite material layer (94) is laid (120) on the mandrel (54) in at least one of the first and second sections (86, 88) using a first laminator and a second laminator (62, 64);

[0082] Rotate the mandrel (54) (122) to a second rotational position (84) of the mandrel (54), which presents a third and a fourth section (90, 92) on the mandrel (54) within the reach (76, 78) of each of the first and second laminators (62, 64);

[0083] In the first rotational position (82), the spindle (54) is kept stationary to prevent rotation; and

[0084] When the mandrel (54) remains stationary in its second rotational position (84), the composite material layer (94) is laid (124) on at least one of the third and fourth sections (90, 92) on the mandrel (54) using the first laminator and the second laminator (62, 64), respectively.

[0085] Clause 10. The method according to Clause 9, wherein the laying layer (94) includes overlapping (80) layers (94) between at least two of the partitions (86, 88, 90, 92).

[0086] Clause 11. The method according to Clause 9, wherein the layup layer (94) comprises:

[0087] A (144) splice (98) is formed between layers (94) in partitions (86, 88, 90, 92); and

[0088] Make the splices (98) offset from each other.

[0089] Clause 12. The method according to Clause 9, wherein rotating the mandrel (54) to its second position (84) comprises rotating the mandrel (54) 180 degrees from the first position (82) of the mandrel (54).

[0090] Clause 13. The method according to Clause 9, wherein the rotation of the spindle (54) is performed using a drive (114) located outside the spindle (54).

[0091] Clause 14. The method described pursuant to Clause 9 further comprises:

[0092] When the mandrel (54) is stationary in at least one of its first rotational position and each of its second rotational positions (82, 84), the reference feature (135) is placed on the mandrel (54); and

[0093] Use reference features to lay the layer (94) at the desired location on the mandrel (54).

[0094] Clause 15. A system for laying composite cylinders (40), comprising:

[0095] The spindle (54) is configured to rotate about a central axis and is generally cylindrical;

[0096] A first laminator and a second laminator (62, 64) are arranged on opposite sides of a mandrel (54), each of the first laminator and the second laminator (62, 64) having an access range (76, 78) and including a laminator head (76, 78) configured to apply composite material (94) to the mandrel (54) within the access range (76, 78) of the first laminator and the second laminator (62, 64);

[0097] A driver (114) configured to rotate the spindle (54) about a central axis to at least a first rotational position and a second rotational position (82, 84), and to keep the spindle (54) stationary at each of the first and second rotational positions (82, 84); and

[0098] A controller (146) is configured to control the operation of the driver (114) and the operation of the first and second laminators (62, 64) such that the laminator head (76, 78) moves on the mandrel (54) and applies composite material (94) to the mandrel (54) while the mandrel (54) remains stationary at each of its first and second rotational positions (82, 4).

[0099] Clause 16. The system according to Clause 15, wherein the driver (114) is located outside the spindle (54) and is generally aligned with the central axis of the spindle (54).

[0100] Clause 17. The system according to Clause 15, wherein the driver (114) includes a servo motor configured to rotate the spindle to each of its first rotational position and second rotational position (82, 84).

[0101] Clause 18. The system described in Clause 15 further includes:

[0102] Sensor (144), configured to sense the rotational position of spindle (54); and

[0103] A lock (116) is configured to lock the spindle (54) to prevent rotation when the spindle (54) has been rotated to each of its first and second rotational positions (82, 84).

[0104] Clause 19. The system described in Clause 15 further includes:

[0105] A brake (142) coupled to a spindle (54) for slowing down and stopping the rotation of the spindle (54) at each of a first rotational position and a second rotational position (82, 84) of the spindle (54).

[0106] Clause 20. The system described in Clause 15 further includes:

[0107] A mobile platform (112) is configured to move on a surface (122);

[0108] A driver (114) for rotating a spindle (54); and

[0109] Its spindle (54) and drive (114) are mounted on a moving platform (112) for movement along the surface (122).

[0110] Various illustrative examples have been presented for purposes of explanation and description, and are not intended to be exhaustive or limiting of the examples in the disclosed forms. 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. The selected examples were chosen and described in order to best explain the principles and practical applications of the examples, and to enable others skilled in the art to understand the disclosure of various examples with various modifications to suit the intended particular purpose.

Claims

1. A method for laying a composite cylinder (40) on a mandrel (54), comprising: The first laminator and the second laminator (62, 64) are respectively arranged (116) on opposite sides of the mandrel (54); Rotate the mandrel (54) (118) to a first rotational position (82) of the mandrel (54), thereby presenting a first section and a second section (86, 88) in a first region on the mandrel (54) within the circumferential reach (76, 78) of the first laminator and the second laminator (62, 64), respectively. The spindle (54) is kept stationary in the first rotational position (82) to prevent rotation; When the mandrel (54) remains stationary in its first rotational position (82), the first laminator and the second laminator (62, 64) are used to lay (120) the composite material layer (94) on the mandrel (54) in a sequential order in at least one of the first and second sections (86, 88) of the mandrel; Rotate the mandrel (54) (122) to a second rotational position (84) of the mandrel (54) to present a third and a fourth section (90, 92) in the second region on the mandrel (54) within the circumferential reach (76, 78) of each of the first and second laminators (62, 64), respectively. In the second rotation position (84), the mandrel (54) is kept stationary to prevent rotation; as well as When the mandrel (54) remains stationary in its second rotational position (84), the first laminator and the second laminator (62, 64) are used to lay (124) composite material layers (94) on the mandrel (54) in a sequential order in at least one of the third and fourth sections (90, 92) of the mandrel (54); The laying of the composite material layer (94) includes overlapping (80) the composite material layer (94) between at least two of the partitions (86, 88, 90, 92) and within the first and second regions of the mandrel; and The first laminator has an independent circumferential reachable range covering the first partition within the first region and the fourth partition within the second region, the second laminator has an independent circumferential reachable range covering the second partition within the first region and the third partition within the second region, and the positions of the first partition, the second partition, the fourth partition and the third partition are successively arranged to form a complete circumference of the mandrel.

2. The method according to claim 1, wherein laying the composite material layer (94) comprises: A splice (98) is formed between the composite material layers (94) in the partitions (86, 88, 90, 92); as well as The splices (98) are offset from each other.

3. The method according to claim 1, wherein rotating the mandrel (54) to its second rotation position (84) comprises rotating the mandrel (54) 180 degrees from the first rotation position (82) of the mandrel (54).

4. The method of claim 1, wherein rotating the mandrel (54) is performed using a driver (114) located outside the mandrel (54).

5. The method according to any one of claims 1-4, further comprising: When the mandrel (54) is stationary in at least each of the first rotational position and the second rotational position (82, 84), the reference feature (135) is placed on the mandrel (54); and The reference feature is used to lay the composite material layer (94) at the desired location on the mandrel (54).

6. A system for laying composite cylinders (40), comprising: A spindle (54) is configured to rotate about a central axis, and the spindle (54) is generally cylindrical; A first laminator and a second laminator (62, 64) are respectively arranged on opposite sides of the mandrel (54), each of the first laminator and the second laminator (62, 64) having a circumferential reach (76, 78) and including a laminating head, the laminating head being configured to apply a composite material layer (94) onto the mandrel (54) in a sequential manner within the circumferential reach (76, 78) of the first laminator and the second laminator when the mandrel is held stationary; A driver (114) is configured to rotate the spindle (54) about the central axis to at least a first rotational position and a second rotational position (82, 84), and to keep the spindle (54) stationary at each of the first rotational position and the second rotational position (82, 84); as well as A controller (146) is configured to control the operation of the driver (114) and the operation of the first laminator and the second laminator (62, 64) such that the laminating head moves on the mandrel (54) and applies the composite material layer (94) to the mandrel (54) while the mandrel (54) remains stationary at each of its first rotational position and the second rotational position (82, 84), and overlaps the composite material layer in the first and second regions of the mandrel and between at least two of the first, second, third and fourth partitions in the first and second regions of the mandrel; The first laminator has an independent circumferential reachable range covering the first partition within the first region and the fourth partition within the second region, the second laminator has an independent circumferential reachable range covering the second partition within the first region and the third partition within the second region, and the positions of the first partition, the second partition, the fourth partition and the third partition are successively arranged to form a complete circumference of the mandrel.

7. The system of claim 6, wherein the driver (114) is located outside the mandrel (54) and is substantially aligned with the central axis of the mandrel (54).

8. The system of claim 6, wherein the driver (114) includes a servo motor configured to rotate the spindle to each of its first rotational position and second rotational position (82, 84).

9. The system according to claim 6, further comprising: Sensor (144), configured to sense the first rotational position and the second rotational position of the spindle (54); and A lock (116) is configured to lock the spindle (54) to prevent rotation when the spindle (54) has been rotated to each of its first rotational position and second rotational position (82, 84).

10. The system according to claim 6, further comprising: A brake (142) coupled to the spindle (54) for slowing down and stopping the rotation of the spindle (54) at each of the first and second rotational positions (82, 84) of the spindle (54).

11. The system according to any one of claims 6-10, further comprising: A mobile platform configured to move on a surface (122); A driver (114) for rotating the spindle (54); and The mandrel (54) and the drive (114) are mounted on the moving platform for movement along the surface (122).

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