Apparatus and method of manufacturing a composite part and aircraft partition manufactured thereby

Abstract

The invention relates to a device (40) and a method for manufacturing composite parts, such as aircraft partitions (23), wherein a part of the composite is placed on a first mould (11) by a robot device (21), another part of the composite is placed on a second mould (12) by a robot device (22), the second mould (12) has the same surface as the surface of the first mould (11), and the first and second moulds are mounted on a frame in a centrosymmetric arrangement around a centre point of symmetry (15), so that the parts are placed symmetrically on the moulds (11, 12) in order to obtain two identical composite parts simultaneously.

Description

Technical Field

[0001] This invention relates to an apparatus for manufacturing composite parts and a method for manufacturing composite parts. The invention also relates to aircraft bulkheads manufactured by this method. Background Technology

[0002] Aircraft bulkheads are both very large and high-load-bearing components, as they separate pressurized and unpressurized areas. Therefore, the attachment of the bulkhead to the fuselage frame is crucial for transferring the load from the bulkhead to the frame. However, this attachment is bulky and requires a significant amount of work.

[0003] The use of one-piece composite bulkheads to replace composite bulkheads used in aircraft and their assembly with the fuselage has been considered. For example, document US5,062,589 discloses a bulkhead with a structure suitable for smooth integration with the geometry of an aircraft. The bulkhead described in this document is made of fiber-reinforced material. However, the document does not describe an efficient manufacturing apparatus or method for obtaining such a bulkhead.

[0004] Manufacturing costs are closely related to making certain technologies accessible to everyone. Manufacturing costs involve, in part, the space required for machines and operators to manufacture objects. Therefore, any reduction in the space required to manufacture an object will lower its manufacturing cost.

[0005] Furthermore, manufacturing multiple parts using the same equipment typically reduces the manufacturing cost of those parts, especially if the tool provides the opportunity to manufacture multiple parts at once. This is particularly true in high-productivity industries. Summary of the Invention

[0006] The present invention aims to provide a method and apparatus that allow for the manufacture of complex composites in a particularly efficient manner.

[0007] The present invention aims to reduce the cost of manufacturing composite parts.

[0008] The present invention also aims to provide an aircraft bulkhead manufactured by the method of the present invention.

[0009] The present invention also proposes a manufacturing method that provides repeatability for a large number of composite parts.

[0010] This invention provides an apparatus for manufacturing composite parts, the apparatus comprising:

[0011] - A first mold, which is mounted on a frame, and the first mold includes functional surfaces adapted to receive components of a first composite.

[0012] - A first robotic device adapted to place at least a first component of the first composite onto the first mold.

[0013] The device is characterized by comprising:

[0014] -Second mold:

[0015] The second mold is mounted on the same frame as the first mold.

[0016] The second mold includes functional surfaces adapted to receive components of the second composite part, and the functional surfaces of the second mold are the same as those of the first mold.

[0017] The second mold is positioned in a position that is symmetrical about the center point of symmetry relative to the first mold.

[0018] - A second robotic device adapted to place at least a second component of the second composite onto a second mold.

[0019] Throughout the text, the term "functional surface" is used to specify a portion of a mold surface that can be used to place components of a composite to be manufactured on the mold. In practice, it is not necessary to use the entire surface of the mold to form a part, as some portions of the mold can be dedicated to other functions, such as attaching the mold to a frame.

[0020] Throughout the text, when the terms “mold” or “robot device” are used, the described features may apply to either the first mold or the second mold, and correspondingly to either the first robot device or the second robot device.

[0021] Similarly, the first mold and the second mold are mounted in a position that is centrally symmetrical about the center point of symmetry, which means that the first mold and the second mold are mounted such that the functional surfaces of the first mold and the second mold are arranged in a position that is centrally symmetrical about the center point of symmetry.

[0022] The device according to the invention allows for the simultaneous manufacture of two composite parts in a very simple, efficient, and compact manner. This can potentially reduce the cost of manufacturing such parts.

[0023] The frame can be adapted to allow at least the first mold and the second mold to rotate simultaneously about at least one axis.

[0024] This framework is particularly well-suited for maintaining the first and second dies in their centrally symmetrical relationship at all times. Therefore, the relative positions of the first and second dies are maintained such that operations for forming the composite on the dies can continue in parallel.

[0025] The frame can be adapted to allow the first and second molds to rotate simultaneously about multiple axes.

[0026] The frame may include some engines to cause the first mold and the second mold, as well as mechanical joints, such as pivots or ball joints, to pivot.

[0027] The rotation of the first and second molds can provide an operator or robotic device with access to certain portions of the functional surfaces of the first and second molds, for example, for placing additional parts or for inspecting the mold or composite. The rotation of the first and second molds can also provide a quick and efficient way to add and assemble parts to form a composite; for example, when a robotic device picks up a new part to be added to the composite, the mold can rotate simultaneously to be in an optimal position for the robotic device as it approaches the mold with the new part.

[0028] Furthermore, the size of the frame can be reduced because the weight of the first mold located on the first side of the frame, as well as the pivoting in the first direction, will compensate for the weight of the second mold located on the second opposite side of the frame. Thus, the engine used for pivoting the frame does not need to overcome the weight of a single mold.

[0029] The frame can also be adapted to allow the mold to translate in one or more directions. Therefore, the mold can be displaced from a first assembly station to a second assembly station, enabling the creation of an assembly line for manufacturing the mold.

[0030] The mold can be removed from the frame, allowing it to be handled separately on the production line.

[0031] The first and second robotic devices can be adapted to perform the same operation simultaneously in a relationship of central symmetry about a center point of symmetry.

[0032] The first and second robotic devices are adapted to perform operations in a centrally symmetrical and coordinated manner.

[0033] Therefore, this device allows two composite parts to be manufactured simultaneously on the same frame.

[0034] By mirroring the motion of the first robotic device onto the second robotic device around the center of symmetry, the programming of such robotic devices is expected to be quite simple.

[0035] The apparatus according to the invention is adapted to place a second part on a second mold in the same way as placing a first part on a first mold. In some embodiments, the first robot device and the second robot device can be identical. Thus, two identical parts can be obtained simultaneously.

[0036] The first and second robotic devices can be adapted to move relative to the frame.

[0037] The frame allows the first and second molds to be displaced relative to the first and second robotic devices, but the first and second robotic devices can also move relative to the frame, and therefore relative to the first and second molds. In some embodiments, both the frame and the robotic devices can be movable to ensure rapid and efficient assembly of the composite. Having both a movable frame and a movable robotic device allows the composite component to be placed in each area of ​​the functional surface of the mold, even when these functional areas are complex.

[0038] The first and second robotic devices may each include a composite tape laying device.

[0039] Composite tape laying is a manufacturing method in which the component placed on a mold is a tape of composite material. In this specification, the tape laying method will be considered to also include the so-called "patch placement" method. A complete composite part consists of multiple tapes. For example, the tape can be a resin-impregnated fiber component. The entire composite part can then be cured.

[0040] The first and second robotic devices may each include a robotic arm.

[0041] The robotic arm offers advantages in this invention because it is a highly flexible robotic device that can be easily reprogrammed for different mold shapes and can perform complex movements to pick up parts from multiple locations and place them at different locations on the functional surface of the mold.

[0042] The robotic arm may include one or more interchangeable tools. In particular, a composite tape laying device may be mounted on the robotic arm.

[0043] The first and second robotic devices can be adapted to grasp rigid components and place them onto one of the molds. Thus, composites manufactured using the devices according to the invention can be made from multiple components with different properties. More specifically, the invention allows for the production of complex composites including reinforcing components embedded in composite materials (e.g., CFRP (carbon-reinforced polymer)). This allows for the placement of preforms, such as preforms made of the same or similar material as the reinforcing component, or pre-cured composites suitable for pre-laying materials.

[0044] The first mold and the second mold can have convex functional surfaces.

[0045] The functional surfaces of each mold are advantageously oriented outwards to allow for easy placement of the composite on the mold.

[0046] In some embodiments of the invention that have been identified as particularly advantageous, the first mold and the second mold are adapted to form a composite partition for an aircraft.

[0047] The first and second molds can be adapted to form the bulkhead for the aircraft fuselage.

[0048] Furthermore, in the device according to the invention:

[0049] - The functional surface of the first mold may have a circumferential portion, the radius of curvature of which is smaller than the radius of curvature of the central portion.

[0050] - The frame and the first robotic device can be adapted to circumferentially lay the composite belt on the circumferential portion of the first mold.

[0051] In a symmetrical way,

[0052] - The functional surface of the second mold has a circumferential portion, the radius of curvature of which is smaller than the radius of curvature of the central portion.

[0053] - The frame and the second robot device are adapted to lay the composite tape circumferentially on the circumferential portion of the second mold.

[0054] The robotic device and frame are adapted to lay composite strips radially and / or circumferentially and / or in any combination of circumferential and radial directions on a mold having a generally rotationally symmetrical shape. In this particular case, it is emphasized that the device according to the invention allows the strip to be laid circumferentially about the rotational symmetry axis of the mold, that is, circumferentially "around" said axis of symmetry. This characteristic of the device allows for appropriate reinforcement of the outer edge of the one-piece partition, which has a small radius of curvature (high curvature), to allow for attachment to the fuselage with as few intermediate pieces as possible.

[0055] The first and second robot devices are suitable for laying composite strips with a width between 0.7 cm and 7 cm.

[0056] More specifically, the first and second robotic devices are suitable for laying composite strips with a width between 1.5 cm and 5 cm.

[0057] This width of the composite tape (or composite tow) allows for the manufacture of composite parts with small radii of curvature. In particular, this width allows the composite tape to be placed in the circumferential portion of the mold.

[0058] The first and second robot devices can be adapted to lay the composite tape onto the first and second molds respectively, then lay at least one reinforcing member with properties different from the composite tape onto the first and second molds respectively, and then lay the composite tape onto the first and second molds respectively in such a way that it at least partially covers the at least one reinforcing member.

[0059] The first and second robotic devices are particularly well-suited for switching from a laying device to another tool type for laying reinforcing components. Therefore, the reinforcing components can be embedded between the two composite laminates to form a single, integrated composite.

[0060] Reinforcing components can have different properties than composite components. In particular, reinforcing components can be made of rigid or semi-rigid plastics or metal alloys.

[0061] The apparatus according to the invention allows for the placement of an inner layer composite strip around the circumference of a mold, followed by the placement of a plurality of separate reinforcing members around the circumference of the mold, and then the placement of an outer layer composite strip in such a manner that it at least partially covers the reinforcing members.

[0062] The apparatus and method according to the invention allow for the manufacture of one-piece bulkheads for aircraft fuselages. In fact, manufacturing the bulkhead directly on the mold by automatically placing components not only allows for the manufacture of a convex central portion of the bulkhead with a high radius of curvature (making the bulkhead as flat as possible), but also allows for the manufacture of flanges with a smaller radius of curvature to connect the bulkhead to the fuselage. Rotating the mold and / or the robotic device allows for the placement of all components of the composite bulkhead around the functional surface to obtain a one-piece bulkhead. Manufacturing such a one-piece bulkhead using the method of the invention is relatively fast. Furthermore, using a one-piece composite bulkhead instead of a bulkhead produced by assembling multiple components such as gusset plates, annular frames, a central portion of the bulkhead, etc., allows for minimizing the manufacturing time of the bulkhead.

[0063] Furthermore, since the device according to the invention limits the manufacturing cost of such composite partitions, two symmetrical and identical composite partitions can be manufactured simultaneously on the same frame.

[0064] The present invention also extends to a method for manufacturing composite parts, the method comprising:

[0065] - Placing a first component of a first composite onto a first mold using a first robotic device, characterized in that the method further includes:

[0066] -The second component of the second composite is placed on the second mold by the second robotic device:

[0067] The second mold has the same functional surfaces as the first mold, and both the first and second molds are mounted on the same frame in a centrally symmetrical arrangement about a center point of symmetry.

[0068] • The second component of the second composite is placed on the second mold in a manner symmetrical about the center point of symmetry and about the first component applied to the first mold.

[0069] The mold, the first robot device, and the second robot device can move simultaneously and / or in a sequential manner.

[0070] In the apparatus and method according to the invention, the component placed on the mold can be adhesive. This facilitates the application of the component to the mold because, in subsequent steps, such as placing other components, the component may not move from its position already placed on the mold. The adhesiveness of the component can be:

[0071] The inherent properties of some components, such as pre-impregnated CFRP components, are sticky.

[0072] It is obtained by applying a certain adhesive to the functional surface of the component or mold before placing the component.

[0073] In some cases, not every component needs to be adhesive. In fact, if one or more adhesive components, such as the pre-impregnated CFRP component in the example above, have been previously placed on the mold, the subsequent component does not need to be adhesive because the surface formed by the previous component and the surface on which the subsequent component will be placed is already adhesive.

[0074] The first component placed on the first mold by the first robot device and the second component placed on the second mold by the second robot device simultaneously can be the same.

[0075] Specifically, the first component, placed on the first mold by the first robotic device, and the second component, placed simultaneously on the second mold by the second robotic device, are identical. Therefore, the two composite components can be manufactured simultaneously, identically, and in a coordinated manner.

[0076] The second robot device can be programmed to mirror the actions of the first robot device about a center of symmetry, so that the second component is placed on the second mold in a centrally symmetrical arrangement about the center of symmetry with respect to the first robot device applying the first component on the first mold.

[0077] Alternatively, the second robotic unit can be arranged in a manner symmetrical about the center of symmetry of the first robotic unit, such that each robotic unit can be controlled by the same program. For example, if the first robotic unit is mounted on the ground, the second robotic unit can be mounted upside down on the ceiling.

[0078] In other embodiments, the first and second robotic devices can each place specific types of components of the composite. Thus, the first robotic device can place one or more components of a first type onto a first mold, while the second robotic device applies one or more components of a second type onto a second mold. The mold is then rotated such that the first robotic device can thus place one or more components of the first type onto the second mold, and / or the second robotic device can place one or more components of the second type onto the second mold.

[0079] The method of the present invention can be a method for manufacturing an integral bulkhead for the fuselage of an aircraft.

[0080] The inventors have determined that this method is particularly advantageous for manufacturing composite aircraft bulkheads, especially one-piece bulkheads, which require far fewer intermediate components for attachment to the fuselage. In fact, such composites can be manufactured using the method of this invention because they have a generally convex shape, which is particularly suitable for mounting two molds in a centrally symmetrical relationship about a pivot or other type of joint.

[0081] Therefore, the present invention also extends to aircraft bulkheads obtained by the method of the present invention.

[0082] The invention also extends to other possible combinations of the features described above and below with respect to the accompanying drawings. In particular, the invention extends to methods for manufacturing composites and aircraft partitions, the method including the features described with respect to an apparatus for manufacturing composites; the invention extends to an apparatus for manufacturing composites, the apparatus including the features described with respect to a method for manufacturing composites; and the invention extends to aircraft partitions, the aircraft partition including the features described with respect to an apparatus for manufacturing composites and the features described with respect to a method for manufacturing composites. Attached Figure Description

[0083] In the following description, some specific exemplary embodiments and aspects of the invention are described with reference to the accompanying drawings.

[0084] Figure 1 This is a schematic representation of a side view of an embodiment of an apparatus for manufacturing composite parts according to the present invention.

[0085] Figure 2 yes Figure 1 A schematic representation of a perspective view of the device shown.

[0086] Figure 3 This is a schematic exploded view of a partition for an aircraft that can be manufactured using the apparatus and / or method of the present invention.

[0087] Figure 4 This is a schematic representation of the method according to the present invention.

[0088] Figure 5a This is a schematic representation of a cross-sectional view of a one-piece partition that can be obtained by the method of the present invention.

[0089] Figure 5b yes Figure 5a A schematic representation of the details of the partitions being attached to the aircraft fuselage.

[0090] Figure 6a It is a schematic representation of a cross-sectional view of a partition in the prior art.

[0091] Figure 6b It is based on Figure 6a A schematic representation of the details of the existing technology of attaching the bulkhead to the aircraft fuselage. Detailed Implementation

[0092] exist Figure 1 and Figure 2 The image illustrates an embodiment of the device 40 according to the invention. The device 40 includes a first mold 11 and a second mold 12. The first mold 11 and the second mold 12 are mounted on a pivot of a frame 13. The pivot has an axis 14 passing between the first mold 11 and the second mold 12. The first mold 11 and the second mold 12 have identical shapes. More specifically, the functional surface 17 of the first mold 11 is identical to the functional surface of the second mold 12. Figure 1 and Figure 2 In the embodiment shown, the functional surfaces 17 and 18 of the first mold 11 and the second mold 12 correspond to the external convex surfaces of the first mold 11 and the second mold 12. The first mold 11 and the second mold 12 are placed in a centrally symmetrical relationship about a center point 15.

[0093] In this embodiment, the first mold 11 and the second mold 12 are adapted to form a partition for the aircraft. For example, this could be a partition separating the rear fuselage of a commercial aircraft from the fuselage section for receiving cargo and / or passengers.

[0094] In addition, the device includes a first robot device 21 and a second robot device 22.

[0095] The first robot device 21 and the second robot device 22 are fixed at one end to the same reference plane as the frame 13. In this embodiment, the reference plane can be a solid ground surface. The first robot device 21 is positioned on one side of the first mold 11 relative to the pivot axis 14. The second robot device 22 is positioned on one side of the second mold 12 relative to the pivot axis 14. More specifically, the first robot device 21 and the second robot device 22 are positioned such that the first robot device 21 and the second robot device 22 can respectively place the composite element on the functional surface 17 of the first mold 11 and the functional surface 18 of the second mold 12.

[0096] Additionally, pivot 14 allows the first mold 11 and the second mold 12 to rotate so that the first mold 11 is positioned in a position suitable for the second robot device 22 to place the part on the functional surface 17 of the first mold 11, and the second mold 12 is positioned in a position suitable for the first robot device 21 to place the part on the functional surface 18 of the second mold 12; that is, the positions of the first mold and the second mold are inverted relative to the plane passing between the molds.

[0097] In this embodiment, the first robot device 21 and the second robot device 22 are industrial robotic arms, such as 6-axis articulated robotic arms. Each of the first robot device 21 and the second robot device 22 is equipped with a composite tape laying device as a tool at its functional end point. Therefore, each of the first robot device 21 and the second robot device 22 is adapted to lay composite tape on the first mold 11 and the second mold 12.

[0098] The first robot device 21 and the second robot device 22 are programmed to simultaneously place composite elements, such as composite strips, on the first mold 11 and the second mold 12. More specifically, the first robot device 21 and the second robot device 22 are programmed and controlled to simultaneously place the same composite components on the first mold 11 and the second mold 12 at positions symmetrical about a center point 15.

[0099] This device allows for the simultaneous manufacture of two identical aircraft bulkheads in a highly efficient and reproducible manner.

[0100] In an alternative embodiment of the invention, the first mold 11 and the second mold 12 can be rotated around... Figure 1 and Figure 2The first mold 11 and the second mold 12 are pivotally mounted on the frame 13 along a different axis from the pivot axis 14. The first mold 11 and the second mold 12 can be pivotally mounted about an axis parallel to or collinear with the axis of rotational symmetry 35 of the first mold 11 and the second mold 12. This pivot axis will be orthogonal to the plane passing between the first mold 11 and the second mold 12. Therefore, any section of the first mold 11 and the second mold 12 can be positioned at a low, high, or lateral point of the assembly by a simple rotation about this pivot axis. This also allows for the placement of continuous strips manually or by a robotic device around the circumference of the molds 11 and 12, or in a spiral manner on the molds 11 and 12.

[0101] exist Figure 3 The diagram schematically illustrates an exploded view of an exemplary embodiment of an aircraft partition 23 that can be manufactured by the apparatus and method according to the invention. The partition 23 includes an inner first composite layer 19, a reinforcing member 16, and an outer second composite layer 20. The first composite layer 19 and the second composite layer 20 are laminates made of a composite material, such as CFRP. The first composite layer 19 and the second composite layer 20 are obtained by successively applying multiple composite strips using a first robotic device and / or a second robotic device.

[0102] In the first step of the method according to the invention, the first robot device and the second robot device may place the composite component on the first mold and the second mold (molds not shown) to form at least the first composite layer 19.

[0103] In the second step, the first robot device 21 and the second robot device 22 and / or one or more operators can place one or more reinforcing members 16 on the first composite layer 19. Figure 3 In the example, the reinforcing member 16 is placed in the peripheral edge 27 and transition zone 28 of the bulkhead. The transition zone 28 corresponds to the area of ​​the bulkhead located between the central region 29 and the peripheral edge 27, and in this region, the radius of curvature of the bulkhead is small (high curvature). The transition zone 28 bears the load during the use of the bulkhead because this part transfers the load between the central region 29 of the bulkhead and the peripheral edge 27 of the bulkhead 23, which is used to attach the bulkhead to the fuselage, thereby replacing multiple assemblies.

[0104] In the third step, the first and second robotic devices can place the composite component on the first and second molds—in fact, on the reinforcing component 16 and / or the first composite layer—to form the second composite layer 20. This encapsulates the reinforcing component 16 between the first composite layer 19 and the second composite layer 20, making the partition a single, integral piece.

[0105] The second and third steps can then be repeated to form multiple composite layers, wherein reinforcing elements are inserted between successive composite layers.

[0106] The composite component, which in this example is a partition, can then be cured.

[0107] The partition 23 includes a peripheral edge 27 located on its outer periphery. The peripheral edge 27 is generally cylindrical or conical. The partition 23 also includes a flat or high-radius convex central region 29 about its center of symmetry. Furthermore, the method and apparatus according to the invention allow such a partition 23 to be manufactured as a single piece, and the partition 23 has a transition zone 28 with a small radius of curvature (high curvature) between the central region 29 and the peripheral edge 27.

[0108] Figure 4 The manufacturing process according to the invention is shown in further detail.

[0109] In step 1, the frame supporting the first mold 11 and the second mold 12 rotates around the center point of symmetry to a predetermined position.

[0110] In steps 2A and 2B—which can advantageously be performed simultaneously—the first robot device 21 and the second robot device 22 each place the composite component, such as a pre-impregnated CFRP strip, onto the first mold 11 and the second mold 12, respectively.

[0111] In step 3, the number of composite components placed on the first mold and the second mold is compared with a predetermined value. If the first predetermined number of composite components to be placed is not reached, steps 1, 2A, 2B and 3 are repeated.

[0112] This first stage, which includes multiple iterations of steps 1, 2A, 2B, and 3, allows the creation of a first composite layer 19 on the first mold 11 and the second mold 12. During this first stage, if necessary, the first mold 11 and the second mold 12 can be rotated to new positions each time step 1 is repeated.

[0113] Once a first predetermined number of composite components have been placed on the first mold 11 and the second mold 12, the process continues to the second stage, which includes steps 4, 5A, 5B and 6.

[0114] In step 4, the frame supporting the first mold 11 and the second mold 12 rotates about the center point of symmetry 15 to a predetermined position. This position allows the first robot device 21 and the second robot device 22, or an operator, to place the reinforcing member 16 on the composite layer 19.

[0115] In steps 5A and 5B—which may be performed simultaneously or not simultaneously—the reinforcing member 16 is placed on the first mold 11, and the same reinforcing member 16 is placed on the second mold 12 in a symmetrical manner about the center point 15.

[0116] In step 6, the number of reinforcing components 16 placed on the first mold 11 and the second mold 12 is compared with a predetermined value. If the predetermined number of reinforcing components 16 to be placed is not reached, steps 4, 5A, 5B and 6 are repeated.

[0117] This second stage, which includes multiple repetitions of steps 4, 5A, 5B, and 6, allows multiple reinforcing components 16 to be placed on the first composite layer 19 to form a composite assembly. In this second stage, if necessary, the first mold 11 and the second mold 12 can be rotated to new positions each time step 4 is repeated.

[0118] Once a predetermined number of reinforcing components are placed on the first mold 11 and the second mold 12, the process continues to the third stage, which includes steps 7, 8A, 8B and 9, which are similar to steps 1, 2a, 2B and 3.

[0119] In step 7, the frame supporting the first mold 11 and the second mold 12 rotates around the center point of symmetry to a predetermined position.

[0120] In steps 8A and 8B—which can advantageously be performed simultaneously—the first robot device 21 and the second robot device 22 each place the composite component, such as a pre-impregnated CFRP strip, onto the first mold 11 and the second mold 12, respectively.

[0121] In step 9, the number of composite components placed on the first and second molds is compared with a predetermined value. Steps 7, 8A, 8B, and 9 are repeated as long as the second predetermined number of composite components to be placed has not been reached.

[0122] This third stage, which includes multiple repetitions of steps 7, 8A, 8B, and 9, allows for the creation of a second composite layer 20 on the reinforcing member 16 and the first composite layer 19. In this third stage, if necessary, the first mold 11 and the second mold 12 can be rotated to new positions each time step 7 is repeated.

[0123] Once the second predetermined number of composite components have been placed on the composite assembly, the process continues to step 10.

[0124] In a further step 10, the composite component can be cured to provide mechanical cohesion to the composite component.

[0125] Figure 5a and Figure 5b It is an expression used to understand the benefits obtained by manufacturing a one-piece bulkhead for an aircraft using the manufacturing method and apparatus according to the invention.

[0126] exist Figure 5a In the diagram, a side view schematically shows a bulkhead 23 installed in the fuselage 24 of the aircraft in its final assembly position. This bulkhead 23 is capable of [accessing the aircraft via...]. Figure 4 The described method obtains, for example, through Figure 1 and Figure 2 Obtained by performing the method on the device, and having Figure 3 The component. Because this partition 23 is manufactured on a single mold, it has a small radius between its peripheral edge and center, and can be accessed and assembled as a single piece by rotating the molds 11, 12 about the center point 15 of symmetry. Furthermore, due to the use of a robotic arm, the partition 23 can be directly assembled to the fuselage 24 of the aircraft without intermediate parts or with only a very limited number of intermediate parts. Thus, the present invention provides significant improvements in manufacturing time and complexity, and provides more internal space in the aircraft cabin (located on the concave side of the partition 23, on the pressure side).

[0127] Figure 5b This is a detailed view of how a one-piece partition 23 can be attached to the frame 25 and skin 26 of the fuselage 24 via its peripheral edge 27. The load applied to the central region of the partition by the pressure difference between the concave and convex sides of the partition is transferred to the peripheral edge 27 of the partition via the transition zone 28, and thus to the fuselage frame 25.

[0128] Figure 6a and Figure 6b This is a representation of a partition in the prior art, shown here to provide a comparative view with a one-piece partition.

[0129] exist Figure 6a The diagram schematically shows a bulkhead 30, mounted within the fuselage 24 of an aircraft, in a side view. Existing bulkheads 30 consist only of a high-radius curvature (small curvature) portion. This bulkhead 30 is attached to the fuselage via long gusset plates 31, which are discretely distributed around the fuselage 24. These gusset plates serve as a transition between the high-radius bulkhead 30 and the tapered fuselage 24. Such gusset plate arrangements are long and complex. Furthermore, the weight ratio of the gusset plates 31 is... Figure 3 , Figure 5a and Figure 5bThe peripheral edge 27 and transition zone 28 of the partition shown have a much higher weight.

[0130] Figure 6b This is a detailed view of the prior art, showing how the partition 30 can be attached to the frame 32 and skin 33 of the fuselage 24 via the gusset plate 31. Figure 5b Compared to frame 25, frame 32 is larger and protrudes more inward into the fuselage. Additionally, an attachment called a strap 34 may be needed to connect the gusset plates 31 to frame 32. Thus, the load of this partition 30 is transferred to the fuselage 24 via multiple gusset plates 31.

[0131] This invention is not limited to the specific embodiments disclosed herein as examples. The invention also includes other embodiments not explicitly described herein, which may include various combinations of the features described herein. In particular, although the invention arose in the context of manufacturing one-piece bulkheads for aircraft, the apparatus and methods of the invention can be applied to the manufacture of many other composite components.

Claims

1. An apparatus (40) for manufacturing composite parts, the apparatus (40) comprising: - A first mold (11) is mounted on a frame (13) and includes a functional surface (17) adapted to receive a component of the first composite. - A first robot device (21), the first robot device (21) being adapted to place at least a first component of the first composite onto the first mold (11), The device (40) is characterized in that it comprises: -Second mold (12): • The second mold (12) is mounted on the same frame (13) as the first mold (11). • The second mold (12) includes a functional surface (18) adapted to receive a component of the second composite, the functional surface (18) of the second mold (12) being identical to the functional surface (17) of the first mold (11). • The second mold (12) is arranged in a position that is symmetrical about the center point (15) relative to the first mold (11). - A second robot device (22), the second robot device (22) being adapted to place at least a second component of the second composite onto the second mold (12); The first robot device (21) and the second robot device (22) are adapted to perform the same operation simultaneously in a relationship of central symmetry about the center point (15).

2. The apparatus according to claim 1, characterized in that, The frame (13) is adapted to allow at least the first mold (11) and the second mold (12) to rotate simultaneously about at least one axis (14).

3. The apparatus according to claim 1 or 2, characterized in that, The first robot device (21) and the second robot device (22) are adapted to move relative to the frame (13).

4. The apparatus according to claim 1 or 2, characterized in that, The first robot device (21) and the second robot device (22) each include a composite tape laying device.

5. The apparatus according to claim 1 or 2, characterized in that, The first robot device (21) and the second robot device (22) each include a robotic arm.

6. The apparatus according to claim 1 or 2, characterized in that, The first mold (11) and the second mold (12) have convex functional surfaces (17, 18).

7. The apparatus according to claim 1 or 2, characterized in that, The first mold (11) and the second mold (12) are adapted to form a partition (23) for the fuselage (24) of the aircraft.

8. The apparatus according to claim 1 or 2, characterized in that: - The functional surface (17) of the first mold (11) has a circumferential portion (28) with a radius of curvature smaller than that of the central portion (29). - The frame (13) and the first robot device (21) are adapted to lay the composite tape circumferentially on the circumferential portion (28) of the first mold (11).

9. The apparatus according to claim 1 or 2, characterized in that, The first robot device (21) and the second robot device (22) are adapted to lay composite strips with a width between 0.7 cm and 7 cm.

10. The apparatus according to claim 1 or 2, characterized in that, The first robot device (21) and the second robot device (22) are adapted to lay the composite tape on the first mold (11) and the second mold (12) respectively, then lay at least one reinforcing member with properties different from the composite tape on the first mold (11) and the second mold (12) respectively, and then lay the composite tape on the first mold (11) and the second mold (12) respectively in such a way as to at least partially cover the at least one reinforcing member.

11. A method for manufacturing a composite part, the method comprising: -The first component of the first composite is placed on the first mold (11) by the first robot device (21). The method is characterized in that it further includes: -The second component of the second composite is placed on the second mold (12) by the second robot device (22): • The second mold (12) has the same functional surface (18) as the first mold (11) (17), and the first mold (11) and the second mold (12) are mounted on the same frame (13) in a centrally symmetrical arrangement about a center point (15). • The second component of the second composite is placed on the second mold (12) in a manner symmetrical about the center point of symmetry (15) and about the first component applied on the first mold (11).

12. The method according to claim 11, characterized in that, The first component placed on the first mold (11) by the first robot device (21) and the second component placed on the second mold (12) by the second robot device (22) at the same time are the same.

13. The method according to claim 12, characterized in that, The method is a method for manufacturing an integral bulkhead (23) for the fuselage (24) of an aircraft.

14. A spacecraft partition (23) obtained by means of the method according to any one of claims 11 to 13.

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