Apparatus and method for integrated pick, place, and form of composite loads over complex geometry tools

Abstract

An apparatus for picking up, placing, and forming composite loads over a tool having a complex geometry comprises a first frame, a second frame, and a plurality of dynamic mechanisms. The first frame is formed of a rigid material and includes a first frame member forming at least a rectangular perimeter. The second frame is formed of a flexible material and includes a second frame member forming at least a rectangular perimeter. Each dynamic mechanism is connected to the first frame and the second frame and is positioned along the perimeter of the first frame and the second frame. Each dynamic mechanism includes a variable length component located between the first frame and the second frame, wherein at least a portion of the dynamic mechanisms are configured to change the length of the variable length component for the second frame member to conform to the shape of the tool having a complex geometry.

Description

Technical Field

[0001] Embodiments of the present invention relate to apparatus and methods for forming composite parts with complex geometries. Background Art

[0002] Composite parts can be used in aircraft manufacturing to construct fuselages and other components. One process for forming a composite part begins by retrieving a composite charge, such as a sheet of composite material. The composite charge is placed on the upper surface of a tool shaped similarly to the shape of the composite part. A bag or sheet of flexible material is placed over the composite charge and sealed to the surface of the tool around the edge of the charge. A vacuum is applied between the bag and the tool, which presses the composite charge against the upper surface. Upon release of the vacuum, the flat or planar composite charge now has the shape of the tool upper surface and is a formed composite part.

[0003] Each step of the process is separate and distinct, potentially performed by different teams and / or different equipment. Some steps may be performed manually. The result is a labor-intensive, time-consuming, and inefficient process. Summary of the Invention

[0004] Embodiments of the present invention solve the above problems and provide a single piece of equipment that can pick up a composite load, place it on a tool, and form it into the shape of the tool to produce a formed composite part, thereby making the manufacturing process of the composite part more efficient. The equipment generally includes a manipulator (robotic arm) interface, a first frame, a second frame, and a plurality of dynamic mechanisms. The manipulator interface is configured to be connected to a robot that moves the equipment. The first frame is connected to the manipulator interface. The first frame is formed of a rigid material and includes a first frame member that forms at least a rectangular perimeter. The second frame is formed of a flexible material and includes a second frame member that forms at least a rectangular perimeter. Each dynamic mechanism is connected to the first frame and the second frame and is positioned along the perimeter of the first frame and the second frame. Each dynamic mechanism includes a variable length component located between the first frame and the second frame, wherein at least a portion of the dynamic mechanism is configured to change the length of the variable length component for the second frame member to conform to the shape of the complex geometry tool.

[0005] Another embodiment of the present invention provides an apparatus for picking up, placing, and forming composite loads over a tool with complex geometry. The apparatus includes a robotic arm interface, a first frame, a second frame, a vacuum seal, a plurality of load holders, and a plurality of dynamic mechanisms. The robotic arm interface is configured to be coupled to a robot that moves the apparatus. The first frame is coupled to the robotic arm interface. The first frame is formed of a rigid material and includes a first frame member that defines at least a rectangular perimeter. The second frame is formed of a flexible material and includes a second frame member that defines at least a rectangular perimeter. The vacuum seal is formed of a flexible material and is connected to the lower surface of the second frame. The vacuum seal is configured to form an airtight seal between the second frame and the upper surface of the tool when the vacuum seal is pressed against the tool. Load holders are coupled to the first frame, each configured to contact and hold a composite load using vacuum or suction. Each dynamic mechanism is coupled to the first and second frames and positioned along the perimeters of the first and second frames. Each dynamic mechanism includes a variable-length component positioned between the first and second frames, wherein at least a portion of the dynamic mechanism is configured to change the length of the variable-length component of the second frame member to conform to the shape of the tool with complex geometry.

[0006] Yet another embodiment of the present invention provides a method for picking up, placing, and forming a composite load over a tool having a complex geometry. The method comprises the following steps: lowering an apparatus comprising a plurality of load holders onto the composite load such that the load holders contact and hold the composite load; moving the apparatus and the composite load onto a forming tool; lowering the apparatus and the composite load onto an upper surface of the tool such that a flexible frame of the apparatus contacts and conforms to the shape of the tool and a vacuum seal is pressed against the tool; applying a vacuum through the vacuum seal such that the vacuum bag pulls the composite load against the upper surface of the tool; and releasing the vacuum through the vacuum seal and lifting the apparatus from the tool.

[0007] This summary is provided to introduce a selection of concepts in a simplified form, which will be further described in the detailed description below. This summary is neither intended to identify key features or essential features of the claimed subject matter nor to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will become apparent from the following detailed description of the embodiments and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The present invention will be described in detail below with reference to the accompanying drawings, in which:

[0009] Figure 1 is a top perspective view of an apparatus constructed in accordance with at least a first embodiment of the present invention for picking, placing, and forming a composite load over a complex geometry tool to produce a formed composite part, the apparatus generally comprising a first frame, a second frame, and a plurality of actuators;

[0010] Figure 2 is a bottom perspective view of the apparatus, the apparatus further comprising a plurality of load holders and a plurality of heating elements;

[0011] Figure 3 is a bottom perspective view of the apparatus, the apparatus further comprising a vacuum seal and a vacuum bag attached to the second frame;

[0012] Figure 4 is a bottom perspective view of the apparatus showing a composite load held by a load holder;

[0013] Figure 5 is a top perspective view of the apparatus holding a composite load and being lowered onto an upper surface of a forming tool;

[0014] Figure 6 is a top perspective view of the apparatus with the second frame in contact with the upper surface of the tool and the arm of the actuator extended to press the second frame onto the upper surface so that a composite load can be formed;

[0015] Figure 7 is a top perspective view of a formed composite part;

[0016] Figure 8 is an environmental view of a system utilizing a robot to move the device, wherein the device is held by a robotic arm above a stack of composite loads awaiting forming;

[0017] Figure 9 is a view of the environment where the robot lowers the device to pick up a composite load;

[0018] Figure 10 is a view of the environment in which the robot moves the device holding the composite load to the forming tool;

[0019] Figure 11 is an environmental view of the robot lowering the apparatus with the actuator arm extended to press the second frame onto the upper surface to enable formation of the composite load;

[0020] Figure 12 is a top perspective view of a second embodiment of the device, wherein the device includes a plurality of elastic members instead of an actuator;

[0021] Figure 13 is a top perspective view of a second embodiment of the apparatus including a vacuum seal and a vacuum bag;

[0022] Figure 14 is a top perspective view of a second embodiment of the apparatus wherein the second frame is in contact with an upper surface of the tool and the resilient member presses the second frame onto the upper surface to enable formation of a composite load; and

[0023] Figure 15 A listing of at least a portion of the steps of a method for picking, placing, and forming a composite load over a complex geometry tool that produces a formed composite part.

[0024] The drawings do not limit the invention to the specific embodiments disclosed and described herein.The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention. DETAILED DESCRIPTION

[0025] The following detailed description of the present invention refers to the accompanying drawings, which illustrate specific embodiments in which the present invention may be practiced. The embodiments are intended to describe various aspects of the present invention in sufficient detail to enable those skilled in the art to practice the present invention. Other embodiments may be utilized and changes may be made without departing from the scope of the present invention. Therefore, the following detailed description should not be considered restrictive. The scope of the present invention is limited only by the appended claims and the full range of equivalents encompassed by the claims.

[0026] In this specification, relative terms such as "upper," "lower," "upper," "lower," "top," "bottom," "outer," and "inner" may be used. These terms are used with reference to the embodiments of the present invention and their orientations shown in the accompanying drawings. The embodiments of the present invention may be oriented in other ways. Therefore, these terms do not limit the scope of the present invention.

[0027] Figures 1 to 11 Shown is an apparatus 10 constructed in accordance with various embodiments of the present invention for picking, placing, and forming a composite load 12 over a complex geometry tool 14 to produce a formed composite part 16. The apparatus 10 can also interface with a robot 18 to perform the pick and place operation. The apparatus 10 generally includes a robotic arm interface 20, a first frame 22, a second frame 24, a plurality of load holders 26, a plurality of heating elements 28, a plurality of actuators 30, a vacuum seal 32, and a vacuum bag 34.

[0028] Each composite load 12 is a sheet of composite material having a general shape similar to that of the formed composite part 16. In the exemplary embodiment shown in the figures, the composite load 12 has a generally rectangular shape, but other geometries are possible. As is known in the art, composite materials generally include at least two constituent components—a reinforcement material and a matrix material. The reinforcement material generally provides mechanical strengthening properties, such as high tensile strength, to the composite material, while the matrix material acts as a binder, holding the reinforcement material together. The reinforcement material and the matrix material may have additional properties not discussed herein. In addition, composite materials may include additional components not discussed herein.

[0029] Examples of reinforcing materials that can be used with the present invention include, but are not limited to, fiber materials such as carbon fibers, boron fibers, glass fibers, aramid fibers, ceramic fibers, and similar materials without departing from the spirit of the present invention. For fiber-based reinforcing materials, the fibers can be present in one of at least two forms - pre-impregnated (prepreg) or dry fibers, in which the fibers are coated with a matrix material that is uncured and / or requires further heat treatment, such as an uncured resin or thermoplastic polymer, or dry fibers in which no matrix material is added prior to part manufacture. The matrix material can typically be in the form of a thermoplastic polymer, such as polycarbonate, polyamide, polyphenylene sulfide, polyetherimide, polyetheretherketone, polyetherketoneketone, etc. The matrix material can also or alternatively be in the form of a thermosetting polymer resin, such as epoxy resin, bismaleimide, vinyl ester, phenolic resin, polyimide, etc.

[0030] like Figure 5 、 Figure 6 and Figures 8 to 11 As shown, tool 14 generally provides the shape of at least one surface that the formed composite part 16 is to have. Tool 14 can be a male or female tool and can have concave or convex curvatures, contours, notches, protrusions, grooves, and other shapes or features. Tool 14 can be of any size, although generally the surface of tool 14 that forms the formed composite part 16 is at least the size of the formed composite part 16. Because tool 14 is utilized to form composite load 12 and to apply force to tool 14, tool 14 is made of a rigid material such as metal, alloys thereof, or other hardened material. In some embodiments where tool 14 includes a groove or a small radius concave curved feature, tool 14 may also include or be capable of receiving a plug or other filler that fits into the groove, which can form an airtight vacuum seal during forming.

[0031] like Figures 8 to 11As shown, the robot 18 generally moves the apparatus 10 from one location to another and provides a force or pressure transmitted to the second frame 24 to form an airtight contact between the vacuum seal 32 and the surface of the tool 14. The robot 18 may include at least one arm coupled to the robot arm interface 20. The arm can extend and retract to move the apparatus 10 from one location to another. Additionally or alternatively, the robot 18 may include one or more translation stages that can move the arm, and thus the apparatus 10, from one location to another. Furthermore, the arm can lift and lower the apparatus 10 along a vertical axis. Furthermore, the robot 18 may include an actuating component that can apply a generally downward force or pressure to the apparatus 10. The robot 18 may include or be implemented by an automated fiber placement (AFP) robotic system. Furthermore, the robot 18 can operate in three-dimensional space, wherein the coordinates are known to a controller that controls the operation and movement of the robot 18 and the apparatus 10. The tool 14 is located within the operating space of the robot 18.

[0032] like Figures 1 to 6 and Figures 8 to 11 As shown, the robot interface 20 generally provides a connection between the device 10 and the robot 18 that moves the device 10. The robot interface 20 may include one or more boards, one or more mechanical connectors, and one or more electrical connectors.

[0033] like Figures 1 to 6 and Figures 8 to 11 As shown, the first frame 22 provides a structure for holding the actuator 30, the load holder 26, and the heating element 28. The first frame 22 is formed from a rigid or reinforced material such as steel or aluminum and includes a first frame member 36 and a plurality of I-beams 38. The first frame member 36 has at least a rectangular outer perimeter shape, but nearly any geometric shape is possible. Typically, the outer perimeter shape of the first frame member 36 is similar to, or varies depending on, the outer perimeter shape of the composite load 12 and / or the shape of the formed composite part 16. The first frame member 36 includes an upper surface and a lower surface. In some embodiments, the first frame member 36 can be formed from a single piece of material including a plurality of openings extending from the upper surface to the lower surface. Alternatively, the sheet of material can be solid and lack openings. In other embodiments, the first frame member 36 can be formed from a plurality of flat beams interconnected to form at least a rectangular outer perimeter shape, although the first frame member 36 may include additional beams connected to opposite sides of the perimeter to provide structural strength.

[0034] An exemplary embodiment of the first frame 22 includes a first I-beam 38 positioned on the upper surface along a forward portion of the central longitudinal axis of the first frame 22 and a second I-beam 38 positioned along a rearward portion of the central longitudinal axis. The I-beam 38 provides structural support for the first frame 22 and connects the first frame 22 to the robot arm interface 20.

[0035] The first frame 22 may also include a hat section 40 attached along the central longitudinal axis to the lower surface of the first frame member 36. The hat section 40 includes a central wall between two side walls that are perpendicular to the hat section 40.

[0036] The first frame 22 may also include first and second rails 42 attached to a lower surface of the first frame member 36 , with each rail 42 spaced apart from the central longitudinal axis.

[0037] like Figures 1 to 6 and Figures 8 to 11 As shown, the second frame 24 generally presses the vacuum seal 32 and the vacuum bag 34 against the surfaces of the tool 14 and the composite load 12. The second frame 24 is formed of a flexible or pliable material including plastic or rubber. An exemplary second frame 24 is formed of Plexiglas. The second frame 24 may include a second frame member having at least a rectangular peripheral shape, but nearly any geometric shape is possible. Typically, the peripheral shape of the second frame member is similar to or varies based on the peripheral shape of the composite load 12 and / or the shape of the formed composite part 16. The second frame member includes an upper surface and a lower surface. In some embodiments, the second frame member can be formed from a single piece of material including a large central opening, leaving only a narrow peripheral edge. In other embodiments, the second frame member can be formed from a plurality of flat beams interconnected to form at least a rectangular peripheral shape.

[0038] like Figures 1 to 3 As shown, the load holders 26 typically hold a single composite load 12 during pick-up, placement, and forming. Each load holder 26 can be implemented by a passive holding device, such as a suction cup, or a similar component that adheres to a surface, or an active holding device, such as a port assembly capable of applying a vacuum to a surface. In some embodiments, the load holders 26 can include both passive and active devices. In addition, each load holder 26 can include or be coupled to an actuation mechanism that can lower and raise the load holder 26 to pick up and place the composite load 12. The load holders 26 are connected to and distributed along the central wall of the cap section 40 of the first frame 22.

[0039] like Figures 1 to 3 、 Figure 5and Figure 6 As shown, heating element 28 generally provides heat to composite load 12 and may include conductive elements, such as wires or cables, that heat up when current flows through them and may be encapsulated in an insulating material. Additionally or alternatively, heating element 28 may include a material that undergoes a chemical reaction to generate heat. A first portion of heating element 28 is held by first rail 42, while a second portion of heating element 28 is held by second rail 42.

[0040] Actuators 30 may be considered "dynamic mechanisms" because they include one or more moving parts that respond to or apply a force. Figures 1 to 6 and Figures 8 to 11 As shown, the actuators 30 generally provide for extension or retraction of the second frame 24 relative to the first frame 22. Each actuator 30 may be implemented by a linear actuation device or mechanism, such as a hydraulic actuator, a pneumatic actuator, an electric actuator, a gas spring, or the like. Thus, each actuator 30 may include a chamber 44 or cylinder, an arm 46, and a semi-rigid element 47, wherein the arm 46 may be extended from and retracted into the chamber 44. The semi-rigid element 47 is coupled to the moving end of the arm 46. Each actuator 30 may also include control circuitry or components that control the distance that the arm 46 extends from the chamber 44, or the amount of force or pressure that the arm 46 can apply.

[0041] In some embodiments, the actuator 30 is configured such that the arm 46 extends from the chamber 44 to its default axial length when no external force acts on the arm 46, but can be forced to retract into the chamber 44 by applying a force to the arm 46. For example, in these embodiments, a cylinder filled with compressed air can be used as the actuator 30. In other embodiments, the arm 46 resists displacement in response to an externally applied force and moves only in response to an actuator drive mechanism. For example, in these embodiments, an electrically driven ball screw actuator can be used as the actuator 30. In some embodiments, the chamber 44 can define a volume capable of holding a fluid such as compressed air or a hydraulic fluid. In other embodiments, the chamber 44 can be unable to hold a fluid and can include one or more orifices and / or can be completely open on one or more sides. The chamber 44 can serve as a structural frame for the actuator 30 to provide guidance for the arm 46 and can limit the movement of the arm 46 to a single axis relative to the chamber 44. Furthermore, in the absence of forces acting on the first frame 22 or the second frame 24 , the arm 46 may remain in a neutral or default longitudinal or axial position.

[0042] The actuators 30 can be positioned and distributed along the periphery of the first frame member 36 such that the chamber 44 of each actuator 30 is coupled to the upper surface of the first frame member 36 and the arms 46 extend through the lower surface to project below and away from the first frame member 36. The chamber 44 of each actuator 30 can be rigidly mounted to the first frame member 36. The arms 46 of the actuators 30 can move in a common direction relative to the first frame member 36.

[0043] A semi-rigid element 47 coupled to the moving end of the arm 46 of each actuator 30 is connected to the upper surface of the second frame 24. Thus, each actuator 30 and arm 46 can move and / or apply force to a section of the second frame 24. Figures 3 to 6 In the exemplary embodiment shown, the semi-rigid element 47 comprises a pivot joint with a U-shaped lug that is rotatably coupled to the movable end of the arm 46 via a pin. The U-shaped lug is also connected to the upper surface of the second frame 24, which allows a portion of the second frame 24 to bend or flex relative to the arm 46. In other embodiments not shown, the semi-rigid element 47 may comprise a relatively short conical spring that allows a small amount of lateral movement between the arm 46 and the second frame 24 to prevent binding as the second frame 24 conforms to the contours of the tool 14. Generally, the semi-rigid element 47 allows limited lateral or rotational movement between the movable end of the arm 46 and a corresponding position on the second frame 24 while still maintaining substantial lateral alignment between the arm 46 and the second frame 24.

[0044] like Figure 3 and Figure 4 As shown, the vacuum seal 32 generally provides an airtight seal or contact between the second frame 24 and the tool 14 during forming. The vacuum seal 32 can be formed of a resilient, flexible material such as silicone, elastomer, fluoroelastomer, and combinations thereof. Like the second frame 24, the vacuum seal 32 can have a shape forming a generally planar rectangular periphery, although other shapes are also possible. The vacuum seal 32 can be formed from multiple sheets of material attached to each other or a single sheet of material. The vacuum seal 32 can include one or more openings through which a vacuum is applied. The vacuum seal 32 is attached to the bottom surface of the second frame 24 using an adhesive or the like.

[0045] like Figure 3 and Figure 6As shown, the vacuum bag 34 generally provides a uniform force or pressure on the composite load 12 during forming. The vacuum bag 34 can be implemented from a flexible film or sheet of polymer material capable of forming an airtight seal. The vacuum bag 34 can have a rectangular shape, although other shapes are possible. The vacuum bag 34 can include a plurality of openings 48 to which the load holders 26 are attached, such that a successive one of the plurality of load holders 26 is attached to each opening 48. The vacuum bag 34 is attached to the vacuum seal 32 such that the outer edge of the vacuum bag 34 is attached to, and may overlap, the inner edge of the vacuum seal 32.

[0046] For reference Figures 8 to 11 The pick, place and form process is performed as follows. A plurality of composite loads 12, typically stacked, are positioned on a table 50 adjacent to a tool 14. In some embodiments, the table 50 and tool 14 may be part of the same structure or may be positioned adjacent to each other. Figure 8 As shown, the robot 18 may align the apparatus 10 above the stacked composite loads 12 and then lower the apparatus 10 onto the composite loads 12 until the load holder 26 contacts the top composite load 12, as shown. Figure 9 A vacuum and / or some downward force may be applied to the load holder 26 so that the load holder 26 holds or retains the composite load 12 . Figure 4 , a composite load 12 held by the apparatus 10 is shown viewed from below the apparatus 10. When the composite load 12 is held by the load holder 26, the upper surface of the composite load 12 is in contact with the lower surface of the vacuum seal 32.

[0047] With the load holder 26 holding the composite load 12, the robot 18 then picks up the device 10 and composite load 12 and moves them over and into alignment with the tool 14, as shown. Figure 5 and Figure 10As shown, the robot 18 lowers the apparatus 10 to place the composite load 12 onto the top surface of the tool 14. As the apparatus 10 is lowered, the various sections of the second frame 24 gradually contact the upper surface of the tool 14. The actuator 30 can retract and / or extend its arm 46 to change the shape of the second frame 24 by raising and / or lowering the various sections of the second frame 24, depending on the position of the actuator 30 and the contact position of the relevant sections of the second frame 24 on the tool 14. For example, an actuator 30 coupled to the second frame 24 in a position contacting a lower, or recessed, area of ​​the tool 14 can extend its arm 46 to push the relevant section of the second frame 24 downward, thereby engaging the upper surface of the tool 14. An actuator 30 coupled to the second frame 24 in a position contacting a higher, or elevated area of ​​the tool 14 can retract its arm 46 to raise the relevant section of the second frame 24 upward, thereby engaging the upper surface of the tool 14. Alternatively, the actuators 30 coupled to the second frame 24 at locations where they contact one or more highest points of the tool 14 may not extend or retract their arms 46 at all, while all other actuators 30 extend their arms 46 an appropriate amount to push downward on the associated sections of the second frame 24 to engage the upper surface of the tool 14. Figure 6 and Figure 11 The apparatus 10 is shown in its lowest position with its second frame 24 in full contact with the tool 14 .

[0048] In other embodiments, the arms 46 of the actuator 30 may passively respond to compressive forces originating from the robot 18 to lower the apparatus 10 onto the tool 14. Higher points on the tool 14 push the arms 46 into the chambers 44 to a greater extent than lower points on the tool 14, while the second frame 24 flexes and bends to conform to the shape of the upper surface of the tool 14. Thus, once the apparatus 10 is fully lowered, it is possible that none of the arms 46 extend from their neutral longitudinal length, and some or all of the arms 46 are retracted into their chambers 44 at varying lengths.

[0049] As described below, at some point after the load holder 26 has picked up the composite load 12 and before vacuum is applied for the forming process, the heating element 28 can be activated to warm the composite load 12. The heating element 28 can warm the composite load 12, making it less rigid and more pliable and loose.

[0050] The actuator 30 is adjusted (the arms 46 are extended and / or retracted an appropriate amount) or set (the arms 46 are appropriately responsive to the compressive force) so that the second frame 24 contacts and conforms to the upper surface of the tool 14 and the vacuum seal 32 is also pressed against the upper surface of the tool 14 to form an airtight seal between the vacuum bag 34 and the upper surface of the tool 14. In embodiments where the tool 14 includes a groove or a small radius concave curved feature, a plug can be inserted into the groove to complete the airtight seal. A vacuum is applied through a port in the opening of the vacuum seal 32. The vacuum applied by the vacuum seal 32 pulls the vacuum bag 34 against the composite load 12 and presses the composite load 12 into the upper surface of the tool 14 so that the load 12 conforms to the shape of the tool 14. After a period of time, the vacuum is no longer applied. Figure 7 As shown, formed composite part 16 is completed.

[0051] In some embodiments, suction or vacuum may still be applied to load holder 26, and robot 18 may lift apparatus 10 and formed composite part 16 and move the combination to a position where formed composite part 16 is released. Robot 18 may then transport apparatus 10 back to the composite load 12 stacking position to begin the pick, place, and form process again.

[0052] In other embodiments, suction or vacuum is no longer applied to load grippers 26, and apparatus 10 can be lifted and transported back to the composite load 12 stacking location by robot 18 to begin the pick, place, and form process again. Formed composite part 16 can be retrieved from tool 14 by a technician or a second robot, who can move the formed composite part 16 to another location.

[0053] A second embodiment of the device 100 is as follows Figures 12 to 14 As shown, apparatus 100 includes a robotic arm interface 120, a first frame 122, a second frame 124, a plurality of load holders 126, a plurality of heating elements 128, a vacuum seal 132, and a vacuum bag 134. The listed components of apparatus 100 are substantially similar in structure, function, and operation to the like-named components of apparatus 10. However, apparatus 100 has the following exceptions. Instead of actuator 30 that actively applies force to second frame 124, apparatus 100 includes a plurality of resilient members 130 that passively apply force to second frame 124.

[0054] The resilient members 130 can be considered "dynamic mechanisms" because they include one or more moving parts that respond to a force or the application of a force. Each resilient member 130 can include a spring 144 or a coil wrapped around a central rod 146, such that the central rod 146 is positioned along the central longitudinal axis of the spring 144. A first end of the spring 144 of each resilient member 130 is rigidly attached to the first frame 122, while a second, opposite end of the spring 144 is rigidly attached to the second frame 124. A first end of the central rod 146 of each resilient member 130 is rigidly attached to the second frame 124, while a second, opposite end of the central rod 146 includes a bolt or similar fastener such that the second end of the central rod 146 is free to move relative to the first frame 122, but cannot be pulled from the upper surface of the first frame 122 to the lower surface. This structure allows the central rod 146 and the bolts, rather than the springs 144, to support the weight of the second frame 124 when the device 100 is raised. When the elastic member 130 is connected between the first frame 122 and the second frame 124, the elastic member 130 generally applies a force to resist the displacement of the second frame 124 relative to the first frame 122, wherein the force generally corresponds to, is proportional to, or varies according to the amount of displacement.

[0055] In some embodiments, the first end of the center rod 146 of each resilient member 130 can be pivotally attached to the second frame 124. In some embodiments, the first end of the center rod 146 of each resilient member 130 can be coupled to the second frame 124 by means of a semi-rigid element (not shown), allowing limited lateral movement between the first end of the center rod 146 and a corresponding position on the second frame 124. The semi-rigid element can be a relatively short conical spring. Allowing a small amount of lateral movement between the center rod 146 and the second frame 124 can prevent sticking when the second frame 124 conforms to the contour of the tool 14. In some embodiments, an intermediate frame (not shown) can be interposed between the first frame 122 and the second frame 124. The first end of the center rod 146 can be attached to one side of the intermediate frame, and the semi-rigid element can be attached to the other side of the intermediate frame.

[0056] When the apparatus 100 is positioned to place the composite load 12 for forming, the robot 18 lowers the apparatus 100 onto the tool 14, with the various sections of the second frame 124 contacting the upper surface of the tool 14. As this occurs, those sections of the second frame 124 shift upward. In response, the elastic members 130 in these sections apply a downward force to counteract the displacement. The robot 18 continues to lower the apparatus 100 until all sections of the second frame 124 contact the upper surface of the tool 14. The robot 18 may apply additional downward force to ensure that the vacuum seal 132 forms an airtight bond (connection) with the upper surface of the tool 14. Given that some areas of the upper surface of the tool 14 have a higher elevation than other areas, the elastic members 130 in the corresponding sections of the second frame 124 may experience greater displacement. The springs 144 of the elastic members in these sections may be selected to have a smaller spring constant to balance the amount of downward force applied to the upper surface of the tool 14 by all elastic members 130.

[0057] Figure 15 A list of at least a portion of the steps of an exemplary method 200 for picking, placing, and forming a composite load 12 over a complex geometry tool 14 is depicted. The steps may be as follows: Figure 15 The steps may be performed in the order shown, or in a different order. In addition, some steps may be performed simultaneously, rather than in order. In addition, some steps may be optional or not performed.

[0058] Referring to step 201, the apparatus 10, 100, including a plurality of load holders 26, 126, is lowered onto the composite load 12, such that the load holders 26, 126 contact and hold the composite load 12. The composite load 12 may reside on the stack of composite loads 12 placed on the table 50. The apparatus 10, 100 may also include a robotic arm interface 20, 120, a first frame 22, 122, a second frame 24, 124, a plurality of heating elements 28, 128, a vacuum seal 32, 132, and a vacuum bag 34, 134. These components have the structure, function, and operation described above. As also described above, in some embodiments, the apparatus 10 includes a plurality of actuators 30, while in other embodiments, the apparatus 100 includes a plurality of elastic members 130. Furthermore, the apparatus 10, 100 docks with the robot 18, which lowers the apparatus 10, 100 onto the composite load 12.

[0059] Referring to step 202, the apparatus 10, 100 and held composite load 12 are moved to the tool 14 for forming. The robot 18 lifts the apparatus 10, 100 and composite load 12 from the stack of composite loads 12 and moves the combination to align with and position over the tool 14.

[0060] Referring to step 203, the apparatus 10, 100 and composite load 12 are lowered onto the upper surface of the tool 14 such that the second frame 24, 124 conforms to the shape of the tool 14 and the vacuum seal 32, 132 is pressed against the tool 14. The vacuum seal 32, 132 is attached to the bottom surface of the second frame 24, 124. Pressing the vacuum seal 32, 132 against the tool 14 also forms an airtight seal between the vacuum bag 34 and the upper surface of the tool 14. In embodiments where the tool 14 includes a groove or a small radius concave curved feature, a plug may be inserted into the groove to complete the airtight seal.

[0061] The robot 18 lowers the device 10, 100 and the composite load 12 onto the upper surface of the tool 14, such that the second frame 24, 124 contacts the tool 14. The robot 18 then maintains at least the position of the device 10, 100. Since the second frame 24, 124 is formed from a flexible material, it can conform to the shape of the upper surface of the tool 14. In some embodiments, the second frame 24 is coupled to the rigid first frame 22 via actuators 30, such that the arms 46 of each actuator 30 can extend from the chamber 44 and change the shape of the second frame 24. In addition, the extension of the arms 46 also applies one or more forces to the second frame 24. In other embodiments, the second frame 124 is coupled to the rigid first frame 122 via a resilient member 130, which generally applies a force to resist displacement of the second frame 124 relative to the first frame 122.

[0062] In the following steps, at some point after the load holder 26, 126 has picked up the composite load 12 and before vacuum is applied for the forming process, the heating elements 28, 128 may be activated to warm the composite load 12. The heating elements 28, 128 may warm the composite load 12, making it less rigid and more pliable and loose.

[0063] Referring to step 204, a vacuum is applied through the vacuum seals 32, 132, causing the vacuum bag 34, 134 to pull the composite load 12 against the upper surface of the tool 14. The vacuum applied through the vacuum seals 32, 132 pulls the vacuum bag 34, 134 against the composite load 12, which in turn presses the composite load 12 into the upper surface of the tool 14, causing the load 12 to conform to the shape of the tool 14.

[0064] Referring to step 205, vacuum is no longer applied through the vacuum seal 32. Figure 7 As shown, formed composite part 16 is completed.

[0065] In some embodiments, suction or vacuum may still be applied to load holder 26, and robot 18 may lift apparatus 10 and formed composite part 16 and move the combination to a position where formed composite part 16 is released. Robot 18 may then transport apparatus 10 back to the composite load 12 stacking position to begin the pick, place, and form process again.

[0066] In other embodiments, suction or vacuum is no longer applied to load grippers 26, and apparatus 10 can be lifted and transported back to the composite load 12 stacking location by robot 18 to begin the pick, place, and form process again. Formed composite part 16 can be retrieved from tool 14 by a technician or a second robot, who can move the formed composite part 16 to another location.

[0067] Other considerations

[0068] In this specification, reference to "one embodiment," "an embodiment," or "an embodiment" means that the referenced feature or features are included in at least one embodiment of the present technology. Separate references to "one embodiment," "an embodiment," or "an embodiment" in this specification do not necessarily refer to the same embodiment, and are not mutually exclusive unless so stated and / or unless obvious to a person skilled in the art from this specification. For example, features, structures, acts, etc. described in one embodiment may also be included in other embodiments, but are not required to be included. Therefore, the present invention can include various combinations and / or integrations of the embodiments described herein.

[0069] Although this application sets forth a detailed description of many different embodiments, it should be understood that the legal scope of this description is defined by the words and equivalents of the claims recited at the end of this patent. The detailed description is to be interpreted as exemplary only and does not describe every possible embodiment, as describing every possible embodiment would be impractical. Numerous alternative embodiments can be implemented using current technology or technology developed after the filing date of this patent, which still fall within the scope of the claims.

[0070] In this specification, multiple instances can implement the components, operations or structures described as single instances. Although the individual operations of one or more methods are shown and described as separate operations, one or more individual operations can be performed simultaneously and do not need to be performed in the order shown. The structure and functionality presented as separate components in the example configuration can be implemented as a combined structure or component. Similarly, the structure and functionality presented as a single piece component can be implemented as multiple independent components. These and other variations, modifications, additions and improvements all fall within the scope of this paper's theme.

[0071] As used herein, the terms "comprises," "including," "comprising," "includes," "having," "having" or any further variations thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0072] Unless conventional means-plus-function terminology is explicitly recited, such as "means for" or "step for" terminology, the patent claims at the end of this patent application are not intended to be construed under 35 U.S.C. §112(f) unless explicitly recited in the claims.

[0073] While the present technology has been described with reference to the embodiments illustrated in the drawings, it should be noted that equivalents may be used herein and substitutions may be made without departing from the scope of the present technology as recited in the claims.

[0074] Having thus described various embodiments of the present technology, what is claimed as new and desired protected by Letters Patent includes that set forth in the following claims.

Claims

1. An apparatus for picking, placing, and forming composite loads over a complex geometry tool, the apparatus comprising: a robotic arm interface configured to couple to a robot that moves the device; a first frame coupled to the robotic arm interface, the first frame formed of a rigid material and including a first frame member defining at least a rectangular perimeter; a second frame formed of a flexible material and including a second frame member defining at least a rectangular perimeter; as well as A plurality of dynamic mechanisms, each connected to the first frame and the second frame and positioned along the periphery of the first frame and the second frame, each dynamic mechanism including a variable length member positioned between the first frame and the second frame, at least a portion of the dynamic mechanism being configured to change the length of the variable length member for the second frame member to conform to the shape of the complex geometry tool.

2. The device according to claim 1, wherein Each dynamic mechanism includes an actuator, the actuator including a chamber, an arm, and a semi-rigid element, the arm being configured to retract into and extend from the chamber, the semi-rigid element being coupled to a moving end of the arm, the chamber of the actuator being connected to a continuous section of the first frame, and the semi-rigid element of the actuator being connected to a continuous section of the second frame, such that at least a portion of the actuator changes the length of its arm to change the shape of the second frame.

3. The device according to claim 2, characterized in that The semi-rigid element of the actuator allows lateral or rotational movement between the arm and a corresponding position on the second frame.

4. The device according to claim 1, wherein Each dynamic mechanism includes a resilient member comprising a spring, a first end of each of the springs being attached to the first frame and an opposite second end of each of the springs being attached to the second frame, such that each spring is configured to apply a force opposing the displacement of a continuous section of the second frame when the second frame is in contact with the tool.

5. The device according to claim 1, wherein The apparatus also includes a vacuum seal formed of a pliable material and coupled to a lower surface of the second frame, the vacuum seal configured to form an airtight seal between the second frame and an upper surface of the tool when the vacuum seal is pressed against the tool.

6. The device according to claim 5, characterized in that The vacuum seal is sized to overlap an edge of the composite load when the composite load is placed on the tool.

7. The device according to claim 5, characterized in that The apparatus also includes a vacuum bag formed from a single sheet of flexible material and connected to the vacuum seal, the vacuum bag being configured to press the composite load against the tool when a vacuum is applied through the vacuum seal.

8. The device according to claim 7, characterized in that The vacuum bag comprises a plurality of openings to which load holders are attached such that each opening is attached to a consecutive one of the plurality of load holders.

9. The device according to claim 1, wherein The apparatus also includes a plurality of load holders coupled to the first frame, each load holder configured to contact and hold the composite load using vacuum or suction.

10. The device according to claim 1, wherein The apparatus also includes at least one heating element coupled to the first frame and configured to heat the composite load.

11. An apparatus for picking, placing, and forming composite loads over a complex geometry tool, the apparatus comprising: a robotic arm interface configured to couple to a robot that moves the device; a first frame coupled to the robotic arm interface, the first frame formed of a rigid material and including a first frame member defining at least a rectangular perimeter; a second frame formed of a flexible material and including a second frame member defining at least a rectangular perimeter; a vacuum seal formed of a pliable material and coupled to a lower surface of the second frame, the vacuum seal configured to form an airtight seal between the second frame and an upper surface of the tool when the vacuum seal is pressed against the tool; a plurality of load holders coupled to the first frame, each load holder configured to contact and hold the composite load using vacuum or suction; as well as A plurality of dynamic mechanisms, each connected to the first frame and the second frame and positioned along the periphery of the first frame and the second frame, each dynamic mechanism including a variable length member positioned between the first frame and the second frame, at least a portion of the dynamic mechanism being configured to change the length of the variable length member for the second frame member to conform to the shape of the complex geometry tool.

12. The device according to claim 11, wherein Each elastic member further comprises a central rod positioned along a central longitudinal axis of the spring, a first end of the central rod being attached to the second frame, and an opposite second end of the central rod comprising a bolt such that the second end of the central rod is free to move relative to the first frame.

13. The device according to claim 11, wherein The apparatus also includes a vacuum seal formed of a pliable material and connected to a lower surface of the second frame, the vacuum seal configured to form an airtight seal between the second frame and an upper surface of the tool when the vacuum seal is pressed against the tool, and the vacuum seal sized to overlap an edge of the composite load when the composite load is placed on the tool.

14. The device according to claim 13, wherein The apparatus also includes a vacuum bag formed from a single sheet of pliable material and connected to the vacuum seal, the vacuum bag configured to press the composite load against the tool when a vacuum is applied through the vacuum seal, and the vacuum bag including a plurality of openings to which the load holders are coupled such that each opening is attached to a successive one of the plurality of load holders.

15. The device according to claim 11, wherein The apparatus also includes a plurality of load holders coupled to the first frame, each load holder configured to contact and hold the composite load using vacuum or suction.

16. The device according to claim 11, wherein The apparatus also includes at least one heating element coupled to the first frame and configured to heat the composite load.

17. A method for picking, placing, and forming a composite load over a complex geometry tool, the method comprising: lowering an apparatus comprising a plurality of load holders onto the composite load such that the load holders contact and hold the composite load; moving the apparatus and the composite load to a forming tool; lowering the apparatus and the composite load onto the upper surface of the tool such that the flexible frame of the apparatus contacts and conforms to the shape of the tool and presses the vacuum seal against the tool; applying a vacuum through the vacuum seal so that the vacuum bag pulls the composite load against the upper surface of the tool; and Release the vacuum through the vacuum seal and lift the device from the tool, The method further includes extending or retracting a plurality of actuator arms connected to the rigid frame to change the shape of the flexible frame.

18. The method according to claim 17, wherein The method also includes heating the composite load prior to applying the vacuum.

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