Method and system for making a wing panel for an aircraft

Abstract

The present application provides methods and systems for making a wing panel of an aircraft. The method includes loading a wing skin preform onto a profile of an outer mold line (OML) tool, applying a stringer preform to a slot of an inner mold line (IML) tool, aligning the OML tool with the IML tool, and assembling the IML tool and the OML tool into a box that molds a wing panel preform including the wing skin preform and the stringer preform. The method further includes inserting the box into a press and hardening the wing panel preform into a composite part while the box is present in the press.

Description

Technical Field

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

[0002] Currently, composite wing panels for aircraft are manufactured using vacuum bagging. During vacuum bagging, a membrane sheet is placed over the stringer preform of the wing panel preform, the vacuum bag itself is sealed in place over the wing panel preform, leaks are checked, and the preform is cured into the composite part. While vacuum bagging is suitable for large composite parts, there are issues related to whether the synthesized composite part conforms to the desired profile. Specifically, vacuum bagging can lead to markings, bowing, resin pooling, and other problems that cause the composite part to deviate from the desired profile. To address these deviations, the composite wing panel may require filling and / or machining to meet desired tolerances, a time-consuming and costly process.

[0003] Therefore, it is desirable to have methods and devices that take into account at least some of the aforementioned problems, as well as other possible problems. Summary of the Invention

[0004] The embodiments described herein provide box-based molding of wing panels, wherein a rigid inner mold line (IML) tool and a corresponding outer mold line (OML) tool together form a single box. To achieve box-based molding, individual wing panel preforms are laid on the box and held in shape by the tooling of the box. Each individual box receives a preform, is inserted into a press, heated to harden the preform into a composite part, removed, and their composite part is demolded. Using removable boxes in this press process allows the demolding and laying processes to be performed at the box itself rather than at the press. Therefore, while the first composite part is laid or demolded, the press can continue operating to harden another composite part. This extends the overall press runtime. Furthermore, because the box used by the press includes rigid tools on both the IML and OML sides of the composite part, the synthesized composite part requires less time-consuming reprocessing.

[0005] One embodiment is a method for manufacturing a wing panel of an aircraft. The method includes: loading a wing skin preform onto the profile of an outer mold line (OML) tool; applying a stringer preform into a groove of an inner mold line (IML) tool; aligning the OML tool with the IML tool; and assembling the IML tool and the OML tool into a cassette, the cassette molding a wing panel preform including the wing skin preform and the stringer preform. The method further includes: inserting the cassette into a press; and hardening the wing panel preform into a composite part while the cassette is present in the press.

[0006] Another embodiment is a system for manufacturing wing panels. The system includes: a plurality of boxes, each including an outer mold line (OML) tool and an inner mold line (IML) tool for wing panel preforms; and a press sized to receive the boxes. The press includes: a positioning plate that clamps the boxes in the middle; a pressure plate that applies pressure to the boxes while they are clamped by the positioning plate; and a heater that heats the boxes while the pressure plate applies pressure.

[0007] Another embodiment is a method for hardening wing panels. The method includes: opening a press; inserting a box including a wing panel preform into the press; hardening the wing panel preform into a composite component by applying heat and pressure while the box is in the press; removing the box from the press; inserting another box including another wing panel preform into the press; and demolding the composite component from the box while other wing panel preforms in other boxes are hardened into composite components at the press.

[0008] Other exemplary embodiments (e.g., methods and computer-readable media relating to the foregoing embodiments) may be described below. The features, functions, and advantages already discussed may be implemented independently in various embodiments or may be combined in other embodiments, further details of which may be seen with reference to the following description and accompanying drawings. Attached Figure Description

[0009] Some embodiments of this disclosure, which are merely examples, will now be described with reference to the accompanying drawings. Throughout the drawings, the same reference numerals denote the same elements or elements of the same type.

[0010] Figure 1 An aircraft in an exemplary embodiment is shown.

[0011] Figure 2 The wings of an aircraft in an exemplary embodiment are shown.

[0012] Figure 3 The illustration shows a wing skin preform laid at an OML tool in an exemplary embodiment.

[0013] Figure 4 An IML tool in an exemplary embodiment is shown.

[0014] Figure 5 This is an exploded view of a box including a wing panel preform in an exemplary embodiment.

[0015] Figure 6 In the exemplary embodiment Figure 5 An unexploded view of the box.

[0016] Figure 7 This is a cross-sectional view of the box in an exemplary embodiment.

[0017] Figure 8 The illustration depicts inserting a box into a press in an exemplary embodiment.

[0018] Figures 9 to 10 A press for a sealing box is depicted in an exemplary embodiment.

[0019] Figures 11 to 13 This is a cross-sectional view of the press with the sealed box in an exemplary embodiment.

[0020] Figure 14 This is a cross-sectional view of a steam-heated press in an exemplary embodiment.

[0021] Figure 15 The exemplary embodiment depicts the demolding of the composite component from the box.

[0022] Figure 16 A factory layout for box molding is depicted in an exemplary embodiment.

[0023] Figure 17 A resin injection performed at the cartridge is depicted in an exemplary embodiment.

[0024] Figure 18 This is a flowchart illustrating a method for box molding for wing panels in an exemplary embodiment.

[0025] Figure 19 This is a flowchart illustrating another method for box molding for wing panels in an exemplary embodiment.

[0026] Figure 20 This is a block diagram of a box molding system in an exemplary embodiment.

[0027] Figure 21 This is a flowchart of an exemplary embodiment of an aircraft production and maintenance method.

[0028] Figure 22 This is a block diagram of an aircraft in an exemplary embodiment. Detailed Implementation

[0029] The accompanying drawings and the following description provide specific exemplary embodiments of this disclosure. Therefore, it should be understood that those skilled in the art will be able to design various arrangements that, although not expressly described or shown herein, embody the principles of this disclosure and are included within its scope. Furthermore, any examples described herein are intended to aid in understanding the principles of this disclosure and are to be construed as not being limited to the instances and conditions of such specific statements. Therefore, this disclosure is not limited to the specific embodiments or examples described below, but is defined by the claims and their equivalents.

[0030] Composite components, such as carbon fiber reinforced polymer (CFRP) parts, are initially laid out in multiple layers, collectively referred to as preforms. Individual fibers within each layer of a preform are aligned parallel to each other, but different layers exhibit different fiber orientations to increase the strength of the synthesized composite component along different dimensions. Preforms include a tackifying resin that cures to harden the preform into a composite component (e.g., used in aircraft). Carbon fibers already impregnated with uncured thermosetting or thermoplastic resins are called “prepreg.” Other types of carbon fibers include “dry fibers” that are not impregnated with thermosetting resins but may include tackifiers or adhesives. Dry fibers are impregnated with resin before curing. For thermosetting resins, curing is a unidirectional process called hardening, while for thermoplastic resins, if the resin is reheated, it reaches a tack form, after which it can solidify into the desired shape and cure. As used herein, the comprehensive term for the process of transforming a preform into its final hardened shape (i.e., transforming a preform into a composite part) is “hardening,” and the term includes both the curing of thermosetting preforms and the shaping / curing of thermoplastic preforms into their final desired shape.

[0031] For reference Figure 1 The illustration depicts an aircraft 10 that can implement the manufacturing system and methods described herein. In this exemplary example, the aircraft 10 includes wings 15 and 16 attached to a body 28 having a nose 92. The aircraft 10 includes an engine 93 attached to the wing 15 and an engine 14 attached to the wing 16. A tail section 18 is also attached to the body 28. A horizontal stabilizer 20, a horizontal stabilizer 21, and a vertical stabilizer 22 are attached to the tail section 18 of the body 28.

[0032] Figure 2 The wing 16 of the aircraft 10 in the exemplary embodiment is shown, and corresponds to Figure 1 View arrow 2. In this embodiment, the wing 16 includes a wing panel 200 made of a fiber-reinforced material 210 such as CFRP. The wing panel includes an outer mold line (OML) 202 that receives airflow, and an inner mold line (IML) 204 that is inside the wing 16 and hidden from view. The OML defines the outward-facing portion of the composite component when fully assembled. For example, the OML of an aircraft wing panel may define the top or bottom surface of the wing. The IML defines the inward-facing portion of the composite component when fully assembled. For example, the IML of an aircraft wing panel may define the surface of an internal fuel tank within the wing.

[0033] Figures 3-14 Various techniques for manufacturing composite components such as wing panels 200 via a box molding process are described. Specifically, Figure 3An OML tool 300 for laying out a wing skin preform 330 is illustrated in an exemplary embodiment. The wing skin preform 330 is laid out over a contour 320 defined by the body 310 of the OML tool 300. Contour 320 corresponds to the desired OML of the wing panel. In this embodiment, the OML tool 300 has been precisely machined (e.g., machined to within five-thousandths of an inch along contour 320) such that the OML tool 300 imparts a precisely defined shape onto the wing skin preform 330. Due to this precision, the composite wing panel 200 already fabricated using the OML tool 300 may not require infilling, as the tolerances of the wing panel 200 may be precise enough to eliminate the need for infilling. In this embodiment, the OML tool 300 also includes indexing features 350, such as cups complementary to cones at inner mold line (IML) tools (such as IML tool 400 below).

[0034] OML tool 300 is made of a suitable rigid material with a low coefficient of thermal expansion (CTE). For example, OML tool 300 may be made of nickel-iron alloy 340 (such as invariant steel). OML tool 300 may be manufactured by welding, casting, and / or numerical control (NC) machining to achieve the desired shape with the desired tolerances (e.g., 0.5 inch). OML tool 300 for wing panel 200 may have a length of 60 feet or more and a weight of 30 to 40 tons or more.

[0035] Figure 4 An IML tool 400 in an exemplary embodiment is shown. The body 410 of the IML tool 400 includes a surface 420 and a ridge 432 defining a groove 430 in which a stringer preform of the wing panel 200 is placed and molded. The surface 420 defines the IML for the wing panel. The body 410 can define any suitable number of grooves 430 depending on the design of the wing panel 200. In this embodiment, the grooves 430 are sized to receive and hold a cap-shaped stringer preform; however, in another embodiment, the grooves 430 are sized to support stringers of other shapes. In this embodiment, the IML tool 400 also includes an indexing feature 450, such as a cone complementary to a cup at the OML tool 300.

[0036] In this embodiment, the IML tool 400 has been precisely machined (e.g., machined to within five-thousandths of an inch along surface 420) such that the IML tool 400 imparts a precisely defined shape to the wing skin preform 330 and any stringer preforms attached to the wing skin preform. Due to this precision, the composite wing panel 200 produced using the IML tool 400 may not require infill, as the tolerances of the wing panel 200 may be so precise that infill is unnecessary. The IML tool 400 used for the wing panel 200 may have a length of 60 feet or more and a weight of 30 to 40 tons or more.

[0037] IML tool 400 is made of a suitable rigid material with a low coefficient of thermal expansion. For example, IML tool 400 may be made of a nickel-iron alloy (such as invariant steel). IML tool 400 may be manufactured by welding, casting and / or NC machining to achieve the desired shape with the desired tolerance (e.g., five-thousandths of an inch).

[0038] Figure 5 This is an exploded view of a box 500 including a wing panel preform 590 in an exemplary embodiment. In this embodiment, the wing panel preform 590 includes a wing skin preform 330 and a plurality of stringer preforms 520. The wing panel preform 590 includes a surface 530 conforming to the profile 320 of an OML tool 300 (e.g., defining the OML of the wing panel preform 590). The wing panel preform 590 also includes a surface 540 conforming to the surface 420 of an IML tool 400 (e.g., defining the IML of the wing panel preform 590), such that the stringer preforms 520 are positioned within a slot 430 of the IML tool 400.

[0039] While the wing panel preform 590 is being cured, the housing 500 surrounds and defines the shape of the wing panel preform 590. The housing 500 includes both an IML tool 400 and an OML tool 300, which surround the wing panel preform 590 to achieve the desired net shape while curing continues. In this way, the wing panel preform 590 is clamped between the OML tool 300 and the IML tool 400. The housing 500 is sized for removable insertion into a press.

[0040] In this embodiment, the body 310 of the OML tool 300 includes ribs 560 defining a volume 550 for receiving a heater at the press, and the body 410 of the IML tool 400 includes ribs 580 defining a volume 570 for receiving a heater at the press. For clarity, only a subset of ribs 580 is shown. While in this embodiment, ribs 560 and 580 extend perpendicular to the length L of the housing 500, in other embodiments, rib 560 extends in any suitable direction (such as parallel to the length L). Furthermore, while in this embodiment, volumes 550 and 570 are accessible from the outside of the housing 500, in other embodiments, these volumes 550 and 570 are partially or completely enclosed within their respective tools. In another embodiment, volumes 550 and 570 are sized to receive steam from the press. Although steam is described as a heating medium for the purposes of this figure, any fluid, including gases and / or liquids, can be used. For example, the fluid may include steam, oil, ethylene glycol, or other fluids.

[0041] Because the box 500 is a "two-tool" (i.e., a tool with rigidity and precision machining at either end), it exhibits technical benefits by resulting in a significant reduction in deviations from the desired shape compared to vacuum bagging systems (e.g., caused by markings, resin bowing, resin pooling, flashing edges, sealant removal, etc.). This is because vacuum bags themselves lack sufficient rigidity to perfectly implement the desired shape on preforms, particularly wing panel preforms 590, which may be 60 feet long and may require high levels of tolerance to avoid infill. Even when vacuum bags force the desired shape to fall within 30 or 40 millimeter ranges, infill may still be necessary when assembling the wing panel with the wing spars and ribs.

[0042] Figure 6 In the exemplary embodiment Figure 5 An unexploded view of the box 500. Therefore, the IML tool 400 and OML tool 300 surround the no longer visible wing panel preform 590. An end plate 600 is attached to the end 510 of the box to seal the end 510. The end plate 600 includes a bladder (e.g., within the stringer preform 520 at the wing panel preform 590) for sealing the end 510. Figure 7 The sac-like structure 710) has an inflatable port 610.

[0043] Figure 7 This is a cross-sectional view of box 500 in an exemplary embodiment, and corresponds to Figure 6 Arrow 7 in the view. Figure 7 It is not drawn to scale to enhance the visibility of the capsule 710 and other internal components. Figure 7In this configuration, a capsule 710 is disposed within the stringer preform 520 of the wing panel preform 590. The stringer preform 520 is embedded within a groove 430 of the IML tool 400 and is positioned below the interface 720 between the OML tool 300 and the IML tool 400. The capsule 710 is connected via a port 610 to a pressure source 750 (e.g., a compressor, a reservoir for shop floor air, etc.) outside the housing 500. The port 610 is sealed to the end plate 600 via a seal 730 (e.g., an O-ring), and the end plate 600 is sealed to the housing 500 via a seal 740 (e.g., a silicone or rubber seal extending along the length of the housing 500). During the curing process, the capsule 710 is pressurized by the pressure source 750 to ensure that the stringer preform 520 does not collapse and maintains the desired shape.

[0044] Figure 8 An exemplary embodiment depicts the insertion of a cassette 500 into a press 800. The press 800 is sized to receive one cassette 500 at a time. In this embodiment, the press 800 includes positioning plates 810 and 870 connected together via engaging members 840 and 860. Positioning plates 810 and 870 can be opened by the action of a hydraulic piston 850. When positioning plates 810 and 870 are open, the cassette 500 is placed between them. Positioning plates 810 and 870 can then be closed and locked in place. After positioning plates 810 and 870 are locked, a pressure plate 820 attached to positioning plate 810 is driven into the cassette 500 to apply pressure. That is, while the cassette 500 is clamped between positioning plates 810 and 870, the pressure plate 820 applies pressure to the cassette 500.

[0045] Heater 830 extends from pressure plate 820 and is sized to insert into volume 550 of box 500 when box 500 is placed into press 800. Heater 880 of positioning plate 870 is sized to insert into volume 570 of box 500. Heaters 830 and 880 heat box 500 while pressure is applied by pressure plate 820. Furthermore, in this embodiment, heaters 830 and 880 are embedded within box 500 when box 500 is located at press 800.

[0046] Heaters 830 and 880 may be implemented as radiant heating elements, resistance heating elements, smart sensors, or other components via other technologies as discussed in U.S. Patent 5,728,309. For example, heaters 830 and 880 may be made of a sensor material 832 (e.g., a metal alloy or a metal-containing alloy) designed to have a hardening temperature at or near the Curie temperature for use in a press. In this way, sensor material 832 is heated in response to an applied electromagnetic field until it reaches the Curie temperature, at which point sensor material 832 transforms into a nonmagnetic phase.

[0047] After the box 500 has been heated to transform the wing panel preform 590 into a composite part, the hydraulic piston 850 is operated to open the press 800 and remove the box 500.

[0048] The use of multiple interchangeable instances of the box at press 800 provides technical benefits because it eliminates the need for extensive demolding, cleaning, or preparation at press 800, which extends press 800 uptime.

[0049] Figures 9 to 10 A press for a sealed box in an exemplary embodiment is described. Specifically, in Figure 9 In the middle, box 500 descends along direction 900 into press 800, and... Figure 10 In the middle, the press 800 is closed by the rotation of the positioning plate 810 in the direction 1000.

[0050] Figures 1 to 13 This is a cross-sectional view of the press with the sealed box in an exemplary embodiment. Specifically, Figure 11 Corresponding to Figure 10 View arrow 11, Figure 12 Corresponding to Figure 11 Area 12, and Figure 13 Corresponding to Figure 11 Area 13.

[0051] exist Figure 11The press 800 also includes pressure hoses 1120 (e.g., fire hoses with a diameter of 4 inches) positioned between the press plate 820 and the positioning plate 810. The desired shape is achieved on the wing panel preform 590 by inflating the pressure hoses 1120 to a desired pressure (e.g., 100 pounds per square inch (PSI) applied via a pressure source 750 such as a workshop air source), which is then applied via the press plate 820 to the OML tool 300 and IML tool 400. A seal 1130 is positioned at the interface 720 between the OML tool 300 and the IML tool 400 at the periphery 1132 of the wing panel preform 590, and this seal prevents resin leakage by sealing the space between the OML tool 300 and the IML tool 400. In one embodiment, each seal 1130 includes a large O-ring that completely surrounds the periphery 1132 of the wing panel preform 590. The latch 1140 is locked in place to hold the positioning plate 810 in the locked position 1150 relative to the positioning plate 870. Figure 12 In the diagram, a linear portion of the seal 1130 is depicted between the IML tool 400 and the OML tool 300, this linear portion being positioned to extend beyond the boundary 1210 of the wing panel preform 590. Figure 13 During the curing process, the inflation of the bladder 710 is depicted, thereby creating a pressurized volume 1300 within the bladder 710, which helps to implement the desired shape on the stringer preform 520.

[0052] Figure 14 This is a cross-sectional view of a steam-heated press 800 in an exemplary embodiment. Figure 14 As shown, the box 500 includes a volume 1420 defined by rib 1421 of the OML tool 300, sized to receive heated steam, and a volume 1422 defined by rib 1423 of the IML tool 400, for receiving steam. Volumes 1420 and 1422 are sealed within their respective tools, and these volumes include inlet and outlet ports 1430 for distributing steam. Thus, when steam is applied to volumes 1420 and 1422 (e.g., at 350 degrees Fahrenheit, 120 PSI), the IML tool 400 and the OML tool 300 are rapidly heated. Figure 14 It is also shown that the latch 1140 is locked in place by rotation of the latch 1140 about axis 1440, and the latch 1140 is placed on the retaining element 1450 of the positioning plate 870.

[0053] Figure 15A composite component 1500 demolded from a box 500 is shown in an exemplary embodiment. In this embodiment, the composite component 1500 includes a composite component for the wing panel 200, and the composite component has IML 1504 and OML 1502; however, in other embodiments, any suitable composite component can be manufactured via the box molding techniques discussed herein. The demolding process can be performed after the box 500 has been removed from the press 800, meaning that the press 800 can be operated to heat and pressurize another box while demolding the first box.

[0054] Figure 16 A factory layout 1600 for box molding in an exemplary embodiment is depicted. For example... Figure 16 As shown, the factory layout 1600 includes a laying area 1620, which includes boxes 1610, 1611, 1612, and 1613. Box 1613 includes a wing panel preform 1653 for curing into a composite component. The boxes are conveyed along a conveyor to a preparation area 1630, which currently holds boxes 1614, 1615, 1616, and 1617. Box 1617 holds the composite component 1657 being demolded. The preparation area 1630 can be used for assembling boxes, sealing boxes, or performing other tasks. The boxes are then conveyed between the preparation area 1630 and a press 800 via an overhead machinery (OHME) 1640. Currently, the press 800 holds box 1618, which holds the wing panel preform 1658. After demolding, the box can be cleaned and returned to the laying area 1620 to receive another wing panel preform 1659. The use of a large number of boxes that can be removed from the press 800 ensures that the press can operate for a longer part of the day, resulting in greater productivity.

[0055] Figure 17 Another embodiment is depicted, wherein resin injection is performed at cartridge 500 in an exemplary embodiment. In this embodiment, the IML tool 400 includes ports 1710 for injecting resin 1730 (i.e., liquid resin) via channel 1720 and nozzle 1732 into a preform 1740 of the wing panel (e.g., a dry fibrous embodiment of wing panel preform 590), thereby impregnating the preform 1740 with resin. Ports 1710 may include quick-connect couplings for easy use and simple attachment to resin delivery lines (not shown). By sealing the wing panel preform 590 in place at cartridge 500 and then injecting resin under pressure via port 1710, the preform can be rapidly impregnated with resin in a repeatable manner.

[0056] In embodiments where the preform 1740 is pre-impregnated with resin, the cartridge 500 can be used for rapid injection of 0.5% to 2% resin to “fill” the tool in a low-pressure area (e.g., via the same qualified resin transfer molding (SQRTM) process). In embodiments where the preform 1740 is made of dry fibers, a longer injection of 35%-40% (by volume) resin can be applied to impregnate all fibers in the preform (e.g., via resin transfer molding (RTM) process). Regardless of the embodiments, in all cases, a vacuum is applied prior to any resin infusion, thus requiring an airtight seal in the tool. Any air, vapor, and / or gas present during the injection process will interfere with the injection process, resulting in voids and porosity. Therefore, sealing and vacuum application are used before resin infusion to prevent this undesirable consequence.

[0057] Figure 17 Box 500 offers technical benefits by advantageously reducing or eliminating the need for the use of "prepreg" material during installation. Furthermore, any markings at the location of nozzle 1732 can be disregarded because they are not located at component interfaces or aerodynamic surfaces. That is, any markings at the location of nozzle 1732 are not intentionally placed where the wing panel will be attached to another fuselage component, nor are they intentionally placed in areas experiencing airflow.

[0058] Reference Figure 18 Exemplary details of the operation of the discussion box 500 and the press 800 are provided. For this embodiment, it is assumed that the clean versions of the OML tool 300 and IML tool 400 are ready to be laid.

[0059] Figure 18 This is a flowchart illustrating a method 1800 for box molding for a wing panel in an exemplary embodiment. (See reference...) Figure 8 The steps of method 1800 are described in the description of press 800, but those skilled in the art will recognize that method 1800 can be performed in other systems. The steps in the flowcharts described herein are not exhaustive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0060] Method 1800 includes step 1802, loading (e.g., laying or placing) the wing skin preform 330 onto the profile 320 of the OML tool 300. This can include manual laying, laying via an Automated Tape Laying Machine (ATLM) or an Advanced Fiber Laying (AFP) machine, etc. The loading step 1802 can be performed within the laying area 1620, in a clean room environment.

[0061] Method 1800 further includes step 1804, applying the stringer preform 520 to the slot 430 of the IML tool 400. In one embodiment, this includes picking up and placing the stringer preform 520 (including any pockets 710 therein) into the slot 430. In another embodiment, this includes directly fabricating the stringer preform 520 at the slot 430. The application step 1804 can be performed within the laying area 1620, in a clean room environment.

[0062] Method 1800 further includes step 1806, aligning the OML tool 300 with the IML tool 400, for example by reversing the OML tool 300 and placing it on the IML tool 400. This may include operating overhead machinery 1640 or other heavy equipment to place the OML tool 300 or the IML tool 400 in place. In one embodiment, this alignment is facilitated by using complementary indexing features at the OML tool 300 and the IML tool 400.

[0063] Method 1800 further includes step 1808, assembling the IML tool 400 and OML tool 300 into a cassette 500, which is molded to include a wing panel preform 590 comprising a wing skin preform 330 and a stringer preform 520. In one embodiment, this includes lowering the IML tool 400 onto the OML tool 300 while aligning, and vice versa. This step may also include applying one or more end plates 600 to seal multiple ends 510 of the cassette 500. Assembly 1808 may be performed within a preparation area 1630. That is, after assembly step 1808, the IML tool 400 may be sealed to the OML tool 300 at the cassette 500 by applying the end plates 600 to the ends 510 of the cassette 500. Sealing provides the technical benefit of preventing resin seepage. In another embodiment, after the assembly of the box 500, method 1800 further includes injecting resin 1730 into the wing panel preform 590 via port 1710 at the IML tool 400 before the wing panel preform 590 is hardened.

[0064] Method 1800 further includes step 1810, inserting the cartridge 500 into the compressor 800. In one embodiment, this includes operating the overhead mechanical device 1640 to position the cartridge 500 above the compressor 800, and then lowering the cartridge 500 into place. In another embodiment, this includes aligning volumes 550 and 570 with heaters 830 and 880 at the compressor 800. In yet another embodiment, this includes supplying steam to a vapor reservoir (e.g., via a pressure line 1020). Figure 20 The steam storage device 2010 is attached to the housing 500, and / or the pressure source 750 is attached to port 610 at the housing 500.

[0065] Method 1800 also includes step 1812, hardening the wing panel preform 590 into the composite component 1500 while the cartridge 500 is present in the press 800. This includes applying heat and pressure (e.g., 100 PSI at 350 degrees Fahrenheit) for an extended period of time at the press 800 to cure a thermosetting resin or to solidify a thermoplastic resin within the wing panel preform 590. In one embodiment, hardening the wing panel preform 590 includes activating heaters 830 and 880 of the press 800 embedded within the cartridge 500 as the cartridge 500 is inserted into the press 800. Utilizing heaters 830 and 880 in the press 800 provides a technical advantage because it increases the efficiency and ease of heating the wing panel preform 590 after insertion of the cartridge 500. In another embodiment, hardening the wing panel preform 590 includes driving steam through the IML tool 400 and OML tool 300 as the housing 500 is inserted into the press 800. Driving steam provides the technical benefit of significantly increasing the rate of heating and cooling at the housing 500. During the hardening process, the bladder 710 within the stringer preform 520 is inflated. Inflating the bladder 710 provides the technical benefit of ensuring that the stringer preform 520 maintains the desired shape while hardening.

[0066] Method 1800 also includes step 1814, removing box 500 from press 800, which can be performed via OHME 1640. Thus, in one embodiment, OHME 1640 removes box 500 from press 800. The removed box 500 can be conveyed to preparation area 1630 for demolding. Following step 1814, step 1816 can be used to demold composite component 1500 from box 500, while another wing panel preform 590 of another box 500 hardens into composite component 1500 at press 800. Box 500 can continue to be cleaned and returned to laying area 1620. Therefore, method 1800 can also include step 1802 after demolding, loading (e.g., laying) another wing skin preform 330 onto contour 320 of OML tool 300. This provides a technical benefit by increasing the repeatability of tooling for wing panel preform 590.

[0067] The loading, demolding and hardening steps can be performed simultaneously for different boxes, so that while box 1610 is being laid, box 1614 undergoes demolding, and box 1618 is hardening in press 800.

[0068] Figure 19This is a flowchart illustrating another method 1900 for box molding of wing panel 200 in an exemplary embodiment. Method 1900 includes: step 1902, opening press 800 (e.g., by the action of hydraulic piston 850); and step 1904, inserting box 500 including wing panel preform 590 into press 800. Insertion 1904 can be performed via operation of OHME 1640.

[0069] Method 1900 further includes: step 1906, hardening the wing panel preform 590 into the composite component 1500 by applying heat and pressure while the box 500 is present in the press 800; and step 1908, removing the box 500 from the press 800. In one embodiment, heat and pressure are applied via heaters 830 and / or heaters 880 at the press 800. In another embodiment, by the following Figure 20 The fluid 2012 is subjected to heat and pressure. In one embodiment, heat is continuously applied to the press 800, and the press 800 remains heated while the press is used to harden multiple wing panel preforms 590 in a series of boxes 500. For example, the heater 830 may remain on, or it may be controlled to maintain the press 800 at the hardening temperature of the resin in the box 500, even when the box 500 is removed and replaced by another box. In another embodiment, for each box 500, the press 800 is heated and then cooled to facilitate the loading and unloading process of the box 500.

[0070] Method 1900 further includes: step 1910, inserting another box 1610, including another wing panel preform 1653, into press 800; and step 1912, demolding the composite component 1500 from box 500 while the other wing panel preforms 1653 in the other boxes 1610 are hardened into composite component 1500 at press 800. Method 1900 provides technical benefits by increasing the production volume of wing panel manufacturing because it increases the speed at which hardening can be performed on wing panel preforms 590.

[0071] In another embodiment, each box 500 includes an OML tool 300 and an IML tool 400, and the method further includes separating the OML tool 300 from the IML tool 400 after curing 1906.

[0072] Figure 20This is a block diagram of a box molding system 2000 according to an exemplary embodiment. In this embodiment, the box molding system 2000 includes a press 800, which includes a positioning plate 810, a pressure plate 820, a heater 830, a connecting member 840, a hydraulic piston 850, a connecting member 860, a positioning plate 870, and a heater 880. A latch 1040 holds the positioning plates 810 and 870 together. When the pressure tube 1020 is inflated, pressure is applied via the pressure plate 820.

[0073] Box 500 is held within press 800. Box 500 includes OML tool 300 having volume 550 and rib 560, and IML tool 400 having ridge 432 defined by slot 430, rib 580 and volume 570. Wing panel preform 590 is disposed between IML tool 400 and OML tool 300, and the wing panel preform includes wing skin preform 330 and stringer preform 520.

[0074] A bladder 710 is provided within the stringer preform 520. The bladder 710 is inflated via a pressure pipe 1020, which is connected to a pressure source 750 (the pressure pipe is omitted for clarity). Volumes 550 and 570 of the box 500 are filled with steam 2012 via a steam reservoir 2010.

[0075] The controller 2020 manages various operations of the components discussed herein, such as adjusting the pressure and temperature applied to the wing panel preform 590 according to the numerical control (NC) program 2022, guiding the opening and closing of the press 800, or controlling the OHME 1640. In one embodiment, the controller 2020 is implemented as custom circuitry, as a hardware processor executing programmed instructions stored in memory, or some combination thereof.

[0076] Example

[0077] In the following examples, additional processes, systems, and methods are described in the context of an aircraft manufacturing system.

[0078] Referring more specifically to the accompanying drawings, embodiments of this disclosure can be described in the context of aircraft manufacturing and maintenance. Figure 21 The method shown is 2100 and Figure 22The aircraft 2102 is shown. During the pre-production phase, method 2100 may include the specification and design 2104 of the aircraft 2102 and the procurement of materials 2106. During production, the manufacturing of components and sub-assemblies of the aircraft 2102 and system integration 2110 are carried out. Thereafter, the aircraft 2102 can be certified and delivered 2112 for entry into service 2114. When used by the customer, routine work (which may also include modifications, changes in shape, refurbishment, etc.) is performed on the aircraft 2102 for maintenance and repair 2116. The equipment and methods presented herein can be applied during any one or more suitable phases of manufacturing and maintenance described in method 2100 (e.g., specification and design 2104, material procurement 2106, component and sub-assembly manufacturing 2108, system integration 2110, certification and delivery 2112, commissioning 2114, repair and maintenance 2116) and / or any suitable component of aircraft 2102 (e.g., fuselage 2118, system 2120, interior 2122, propulsion system 2124, electrical system 2126, hydraulic system 2128, environment 2130).

[0079] Each process of Method 2100 may be performed or conducted by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0080] like Figure 22 As shown, an aircraft 2102 produced by method 2100 may include a fuselage 2118 having an interior 2122 and multiple systems 2120. Examples of systems 2120 include one or more of a propulsion system 2124, an electrical system 2126, a hydraulic system 2128, and an environmental system 2130. Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention can be applied to other industries, such as the automotive industry.

[0081] As mentioned above, the equipment and methods implemented herein can be employed during any one or more phases of the manufacturing and maintenance described in method 2100. For example, components or sub-assemblies corresponding to manufacturing process 2108 can be made or manufactured in a manner similar to that in which components and sub-assemblies are produced when aircraft 2102 is put into service. Furthermore, one or more equipment embodiments, method embodiments, or combinations thereof can be utilized during sub-assembly manufacturing 2108 and system integration 2110, for example, by significantly accelerating the assembly of aircraft 2102 or reducing the cost of the aircraft. Similarly, one or more equipment embodiments, method embodiments, or combinations thereof can be utilized during aircraft 2102 service (e.g., but not limited to, during repair and maintenance 2116). Therefore, the present invention can be used in any stage or any combination thereof discussed herein, such as specifications and design 2104, material procurement 2106, component and sub-component manufacturing 2108, system integration 2110, certification and delivery 2112, commissioning 2114, repair and maintenance 2116, and / or any suitable component of aircraft 2102 (e.g., fuselage 2118, systems 2120, interior 2122, propulsion system 2124, electrical system 2126, hydraulic system 2128 and / or environment 2130).

[0082] In one embodiment, the component comprises a portion of the fuselage 2118 and is produced during component and subassembly manufacturing 2108. The component can then be assembled into the aircraft in systems integration 2110 and then put into service 2114 until wear renders it unusable. The component can then be discarded and replaced with a newly manufactured component during repair and maintenance 2116. Throughout the component and subassembly manufacturing 2108, ingenious components and methods can be utilized to produce new components.

[0083] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein may be implemented as hardware, processor-implemented software, processor-implemented firmware, or a combination of these. For example, an element may be implemented as dedicated hardware. A dedicated hardware element may be referred to as a “processor,” a “controller,” or similar terms. When set by a processor, functionality may be set by a single dedicated processor, a single shared processor, or multiple separate processors, some of which may be shared. Furthermore, the explicit use of the terms “processor” or “controller” should not be construed as exclusively referring to hardware capable of executing software, and may implicitly include, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic, or some other physical hardware component or module.

[0084] Furthermore, control elements can be implemented to execute instructions via a processor or computer to perform the function of the element. Some examples of instructions are software, program code, and firmware. Instructions, when executed by a processor, are operable to instruct the processor to perform the function of the element. Instructions can be stored on processor-readable storage devices. Some examples of storage devices are digital or solid-state memories, magnetic storage media such as disks and tapes, hard disk drives, or optically readable digital data storage media.

[0085] This disclosure includes exemplary implementations according to the following provisions:

[0086] Clause 1. A method for manufacturing a wing panel of an aircraft, the method comprising:

[0087] Step (1802): The wing skin preform (330) is loaded onto the contour (320) of the outer mold line (OML) tool (300);

[0088] Step (1804) involves applying the stringer preform (520) to the slot (430) of the inner mold line (IML) tool (400);

[0089] Step (1806): Align the outer mold line tool (300) with the inner mold line tool (400);

[0090] Step (1808) assemble the outer mold line tool (300) and the inner mold line tool (400) into a box (500) which molds a wing panel preform (590) including a wing skin preform (330) and a stringer preform (520);

[0091] Step (1810): Insert the box (500) into the press (800); and

[0092] Step (1812) involves hardening the wing panel preform (590) into a composite component (1500) while the box (500) is in the press (800).

[0093] Clause 2. The method pursuant to Clause 1 also includes:

[0094] Step (1814), remove the box (500) from the press (800); and

[0095] In step (1816), while demolding the composite component (1500) from the box (500), another wing panel preform (1653) in another box (1610) is hardened into the composite component (1500) at the press (800).

[0096] Clause 3. The method pursuant to Clause 2 also includes:

[0097] After the demolding step (1816), another wing skin preform (1659) is mounted onto the contour (320) of the OML tool (300).

[0098] Clause 4. The method according to any one of Clauses 1 to 3, wherein:

[0099] The step (1812) of hardening the wing panel preform (590) includes:

[0100] As the box (500) is inserted into the press (800), the heaters (830, 880) of the press (800) embedded in the box (500) are activated.

[0101] Clause 5. The method according to any one of Clauses 1 to 4, wherein:

[0102] The step (1812) of hardening the wing panel preform (590) includes:

[0103] As the cartridge (500) is inserted into the press (800), the driving fluid (2012) passes through the OML tool (300) and the IML tool (400).

[0104] Clause 6. The method pursuant to any one of Clauses 1 to 5 further includes:

[0105] While the wing panel preform (590) is being hardened (1812), the bladder (710) inside the stringer preform (520) is being inflated.

[0106] Clause 7. The method pursuant to any one of Clauses 1 to 6 further includes:

[0107] The IML tool (400) is sealed to the OML tool (300) at the box (500) by applying the end plate (600) to the end (510) of the box (500).

[0108] Clause 8. The method pursuant to any one of Clauses 1 to 7 further includes:

[0109] Step (1812) involves injecting resin into the wing panel preform (590) via the port of the IML tool (400) before the wing panel preform (590) is hardened.

[0110] Clause 9. A system for manufacturing wing panels, the system comprising:

[0111] Multiple boxes (500, 1610-1617), each box including an outer mold line (OML) tool (300) and an inner mold line (IML) tool (400) for the wing panel preform (590); and

[0112] A press (800), the size of which is designed to be the size of a receiving box (500), the press (800) includes:

[0113] Positioning plates (810, 870) sandwich the box (500) in the middle;

[0114] The pressure plate (820) applies pressure to the box (500) while the box (500) is clamped in the middle by the positioning plates (810, 870); and

[0115] The heater (830, 880) heats the box (500) while the pressure plate (820) applies pressure.

[0116] Clause 10. The system pursuant to Clause 9, wherein:

[0117] The OML tool (300) includes a body (310) that defines the outline (320) of the OML (1502) of the wing panel preform (590), and the IML tool (400) includes a body (410) that includes a surface (420) defining the IML (1504) of the wing panel preform (590).

[0118] Clause 11. According to Clause 9 or 10, the system shall include:

[0119] While the housing (500) is present at the press (800), the heaters (830, 880) are embedded inside the housing (500).

[0120] Clause 12. A system pursuant to any one of Clauses 9 to 11, wherein:

[0121] The heaters (830, 880) are made of sensor material (832).

[0122] Clause 13. A system pursuant to any one of Clauses 9 to 12, wherein:

[0123] The IML tool (400) includes a slot (430) sized to hold the stringer preform (520) of the wing panel preform (590).

[0124] Clause 14. A system pursuant to any one of Clauses 9 to 13, wherein:

[0125] The IML tool (400) includes a port (1710) through which resin (1730) is injected into the wing panel preform (590).

[0126] Clause 15. The system pursuant to any one of Clauses 9 to 14 also includes:

[0127] Overhead mechanical equipment (OHME) (1640) removes box (500) from press (800).

[0128] Clause 16. A system pursuant to any one of Clauses 9 to 15, wherein:

[0129] The press (800) includes a latch (1140) that holds the positioning plates (810, 870) in a locked position (1150).

[0130] Clause 17. A method comprising:

[0131] Step (1902), turn on the press (800);

[0132] Step (1904): Insert the box (500) including the wing panel preform (590) into the press (800);

[0133] Step (1906): While the box (500) is in the press (800), the wing panel preform (590) is hardened into a composite component (1500) by applying heat and pressure.

[0134] Step (1908): Remove the box (500) from the press (800);

[0135] Step (1910) involves inserting another box (1610) containing another wing panel preform (1653) into the press (800); and

[0136] In step (1912), while demolding the composite component (1500) from the box (500), other wing panel preforms (1653) in other boxes (1610) are hardened into composite components (1500) at the press (800).

[0137] Clause 18. The method pursuant to Clause 17, wherein:

[0138] Each box (500) includes an OML tool (300) and an IML tool (400), and the method further includes separating the OML tool (300) from the IML tool (400) after the hardening step (1906).

[0139] Clause 19. The method described pursuant to Clause 17 or 18, wherein:

[0140] Heat and pressure are applied via heaters (830, 880) at the press (800).

[0141] Article 20. The method pursuant to any one of Articles 17 to 19, wherein:

[0142] Heat and pressure are applied via fluid (2012).

[0143] While specific embodiments have been described herein, the scope of this disclosure is not limited to those specific embodiments. The scope of this disclosure is defined by the appended claims and any equivalents thereof.

Claims

1. A method for manufacturing wing panels for an aircraft, wherein, The method includes: In the loading step (1802), the wing skin preform (330) is loaded onto the contour (320) of the outer mold line tool (300); In step (1804), the stringer preform (520) is applied to the slot (430) of the inner mold line tool (400). Alignment step (1806): Align the outer mold line tool (300) with the inner mold line tool (400); Assembly step (1808): The outer mold line tool (300) and the inner mold line tool (400) are assembled into the box (500), the box molding includes the wing panel preform (590) of the wing skin preform (330) and the stringer preform (520). Insertion step (1810): Insert the box (500) into the press (800); and The hardening step (1812) involves hardening the wing panel preform (590) into a composite component (1500) while the box (500) is in the press (800), wherein the hardening step (1812) for hardening the wing panel preform (590) includes activating heaters (830, 880) of the press (800) embedded in the box (500) while the box (500) is inserted into the press (800).

2. The method according to claim 1, further comprising: In the removal step (1814), the box (500) is removed from the press (800). as well as In the demolding step (1816), while demolding the composite component (1500) from the box (500), another wing panel preform in another box (1610) is hardened into the composite component (1500) at the press (800).

3. The method according to claim 2, further comprising: After the demolding step (1816), another wing skin preform is loaded onto the contour (320) of the outer mold line tool (300).

4. The method according to any one of claims 1 to 3, wherein: The hardening step (1812) for hardening the wing panel preform (590) includes: As the box (500) is inserted into the press (800), the driving fluid (2012) passes through the outer mold line tool (300) and the inner mold line tool (400).

5. The method according to any one of claims 1 to 3, further comprising: During the hardening step (1812) of hardening the wing panel preform (590), the bladder (710) inside the stringer preform (520) is inflated.

6. The method according to any one of claims 1 to 3, further comprising: The inner mold line tool (400) is sealed to the outer mold line tool (300) at the box (500) by applying an end plate (600) to the end (510) of the box (500).

7. The method according to any one of claims 1 to 3, further comprising: Before the hardening step (1812) that hardens the wing panel preform (590), resin is injected into the wing panel preform (590) via the port at the inner mold line tool (400).

8. A method for hardening wing panels, the method comprising: Assemble the box using the following steps: Loading step (1802): Loading the wing skin preform (330) onto the contour (320) of the outer mold line tool (300); Applying step (1804): Applying the stringer preform (520) into the groove (430) of the inner mold line tool (400); Alignment step (1806): Aligning the outer mold line tool (300) with the inner mold line tool (400); Assembly step (1808): Assembling the outer mold line tool (300) and the inner mold line tool (400) into a box (500), the box molding comprising the wing panel preform (590) of the wing skin preform (330) and the stringer preform (520). Open step (1902), open the press (800); In the insertion step (1904), the box (500) including the wing panel preform (590) is inserted into the press (800); The hardening step (1906) involves hardening the wing panel preform (590) into a composite component (1500) by applying heat and pressure while the box (500) is in the press (800), wherein the hardening step (1812) for hardening the wing panel preform (590) includes activating heaters (830, 880) of the press (800) embedded in the box (500) while the box (500) is inserted into the press (800); Removal step (1908): Remove the box (500) from the press (800); Assemble another box; The insertion step involves inserting the other box into the press (800); and In the demolding step, the composite component (1500) is demolded from the box (500) while the other box is inserted into the press (800).

9. The method according to claim 8, wherein: Each of the boxes (500) includes an outer mold line tool (300) and an inner mold line tool (400), and the method further includes separating the outer mold line tool (300) from the inner mold line tool (400) after the hardening step (1906).

10. The method according to claim 8 or 9, wherein: Heat and pressure are applied via heaters (830, 880) at the press (800).

11. The method according to claim 8 or 9, wherein: Heat and pressure are applied via fluid (2012).

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