Pick and place end effector configured to form bend

Abstract

The invention relates to a pickup and placement end effector configured to form a bend. A pick and place end effector is configured to form a bend in a composite laminate. The pick and place end effector includes a vacuum lift face configured to hold the composite laminate and move from a flat configuration to a forming configuration angled in the vacuum lift face to form a bend in the composite laminate; a plurality of motors configured to move the vacuum lift surface between the flat configuration and the formed configuration; and a plurality of limiters configured to clamp portions of the composite laminate on opposite sides of the bend on the vacuum lift face during movement between the flat configuration and the formed configuration.

Description

Technical Field

[0001] The present disclosure relates generally to composite material manufacturing and, more particularly, to forming bends in composite laminates during pick and place operations. Background Art

[0002] Composite materials are strong, lightweight materials produced by combining two or more functional components. For example, a composite material may include reinforcing fibers incorporated into a polymer resin matrix. The fibers may take the form of unidirectional tapes, woven fabrics or fabrics, or braids. The mechanical properties and other material properties of a composite material may be desirable for some implementations.

[0003] Composite fabrication uses different methods than metal working due to the different material properties. Due to complex shapes, especially those with bends or curves, some composite fabrication is done by hand. However, manually forming composite structures is undesirably time consuming.

[0004] Therefore, it is desirable to have a method and apparatus that takes into account at least some of the above-mentioned problems as well as other possible problems.It is desirable to have an automated method of forming a composite material structure having kinks. Summary of the invention

[0005] One embodiment of the present disclosure provides a pick and place end effector configured to form a bend in a composite laminate. The pick and place end effector includes a vacuum lift surface configured to hold the composite laminate and move from a flat configuration to an angled forming configuration in the vacuum lift surface to form the bend in the composite laminate; a plurality of motors configured to move the vacuum lift surface between the flat configuration and the forming configuration; and a plurality of limiters configured to clamp portions of the composite laminate on opposite sides of the bend on the vacuum lift surface during movement between the flat configuration and the forming configuration.

[0006] Another embodiment of the present disclosure provides a method of forming a bend in a composite laminate. Lifting a composite laminate on a vacuum lift surface of a pick and place machine, the vacuum lift surface configured to hold the composite laminate and move from a flat configuration to an angled forming configuration on the vacuum lift surface to form the bend in the composite laminate. Clamping a portion of the composite laminate on the vacuum lift surface. Moving the vacuum lift surface between the flat configuration and the forming configuration while the portion is clamped on the vacuum lift surface to form a bend in the composite laminate, thereby forming a bent composite laminate. Placing the bent composite laminate on a mandrel having a bend.

[0007] Yet another embodiment of the present disclosure provides a pick and place end effector configured to form a bend. The pick and place end effector includes: a vacuum lift surface, the vacuum lift surface including: a fixed central vacuum portion; a first vacuum plate, the first vacuum plate movably connected to the fixed central vacuum portion; and a second vacuum plate movably connected to the fixed central vacuum portion; a plurality of limiters, the plurality of limiters are configured to limit the movement of portions of a composite laminate on opposite sides of the fixed central vacuum portion on the vacuum lift surface; and a plurality of motors, the plurality of motors are configured to move the first vacuum plate and the second vacuum plate relative to the fixed central vacuum portion to bring the vacuum lift surface into an angled forming configuration.

[0008] The features and functions can be achieved independently in various embodiments of the present disclosure or may be combined in yet other embodiments in which further details can be seen with reference to the following description and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The novel features believed to be characteristic of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments and their preferred modes of use, further objects and features thereof will be best understood by reference to the following detailed description of illustrative embodiments of the disclosure when read in conjunction with the accompanying drawings, in which:

[0010] Figure 1 is a diagram of an aircraft according to an illustrative embodiment;

[0011] Figure 2A and Figure 2B is an illustration of a block diagram of a manufacturing environment according to an illustrative embodiment;

[0012] Figure 3 is an illustration of a block diagram of a flow chart for forming a bend using a pick and place end effector in accordance with an illustrative embodiment;

[0013] Figure 4 is an illustration of a side view of a pick and place end effector in a flat configuration with a plurality of restraints in an open configuration in accordance with an illustrative embodiment;

[0014] Figure 5 is an illustration of a side view of a pick and place end effector in a flat configuration with a plurality of restraints in a clamping configuration according to an illustrative embodiment;

[0015] Figure 6 is an illustration of a side view of a pick and place end effector in a forming configuration with a plurality of restraints in a clamping configuration according to an illustrative embodiment;

[0016] Figure 7 is an illustration of a side view of a pick and place end effector in a forming configuration with a plurality of restraints in an open configuration according to an illustrative embodiment;

[0017] Figure 8 is an illustration of a side view of a pick and place end effector in a forming configuration with a plurality of restraints in different configurations according to an illustrative embodiment;

[0018] Fig. 9 is an illustration of a side view of a pick and place end effector with multiple bladders in accordance with an illustrative embodiment;

[0019] Fig.10 is an illustration of an isometric view of a forming mandrel according to an illustrative embodiment;

[0020] Fig.11 is a flow chart of a method of forming a bend in a composite laminate according to an illustrative embodiment;

[0021] Fig.12 is an illustration of an aircraft manufacturing and service method in block diagram form according to an illustrative embodiment; and

[0022] Fig.13 is an illustration of an aircraft in block diagram form in which illustrative embodiments may be implemented. DETAILED DESCRIPTION

[0023] The illustrative examples recognize and take into account one or more considerations. The illustrative examples recognize and take into account that kinks exist in rear wing spars used for aerospace structures and drag reduction. The illustrative examples recognize and take into account that kinks present manufacturing challenges for composite material manufacturing. The illustrative examples recognize and take into account that a wing spar may be made of three or more components.

[0024] The illustrative example allows bending and pick and place of raw spar feedstock without manual labor. The illustrative example maintains full tension throughout the component. The illustrative example moves the neutral axis out of the component. As a result, the component remains in tension and not compressed during the bending operation.

[0025] Now go to Figure 1 , shows an illustration of an aircraft in accordance with an illustrative embodiment. Aircraft 100 has wing 102 and wing 104 attached to fuselage 106. Aircraft 100 includes engine 108 attached to wing 102 and engine 110 attached to wing 104.

[0026] Fuselage 106 has tail section 112 . Horizontal stabilizer 114 , horizontal stabilizer 116 , and vertical stabilizer 118 are attached to tail section 112 of fuselage 106 .

[0027] Aircraft 100 is an example of an aircraft that may have a composite material structure formed using the illustrative examples. For example, the illustrative examples may be used to form a component of at least one of wing 102 or wing 104. In some illustrative examples, the illustrative examples may be used to form a spar of at least one of wing 102 or wing 104.

[0028] Now go to Figure 2A and Figure 2B , an illustration of a block diagram of a manufacturing environment in accordance with an illustrative embodiment is shown. Manufacturing environment 200 is a composite material manufacturing environment. In manufacturing environment 200, composite laminate 202 may be formed into spar 204. A pick and place end effector 206 is present in manufacturing environment 200 to lift and form composite laminate 202.

[0029] The pick and place end effector 206 is configured to form a bend 208 in the composite laminate 202. The pick and place end effector 206 includes a vacuum lift surface 210, a plurality of motors 212, and a plurality of limiters 214. The vacuum lift surface 210 is configured to hold the composite laminate 202 and move from a flat configuration 216 to a forming configuration 218 at an angle 220 in the vacuum lift surface 210 to form the bend 208 in the composite laminate 202. The plurality of motors 212 are configured to move the vacuum lift surface 210 between the flat configuration 216 and the forming configuration 218.

[0030] A plurality of restraints 214 are configured to restrain the movement of the end portion, first portion 205, and second portion 222 of composite laminate 202 on vacuum lift surface 210. In some illustrative examples, a plurality of restraints 214 are configured to clamp composite laminate 202 on vacuum lift surface 210 during movement between flat configuration 216 and forming configuration 218. A plurality of restraints 214 are configured to clamp composite laminate 202 within a desired distance from a location where bend 208 is to be formed in composite laminate 202. In some illustrative examples, composite laminate 202 is long compared to the size of bend 208. In some illustrative examples, a plurality of restraints 214 are configured to clamp portions of composite laminate 202 on opposite sides of central vacuum portion 213 on vacuum lift surface 210 during movement between flat configuration 216 and forming configuration 218. In some illustrative examples, number of restraints 214 is configured to clamp the ends of composite laminate 202 on vacuum lift surface 210 during movement between flat configuration 216 and formed configuration 218 .

[0031] The plurality of restraints 214 are configured to clamp the first portion 205 and the second portion 222 of the composite laminate 202 on the vacuum lifting surface 210. In some illustrative examples, the plurality of restraints 214 include a first clamping plate 224 and a second clamping plate 226. The first clamping plate 224 is configured to clamp the first portion 205 of the composite laminate 202 on the vacuum lifting surface 210. The first clamping plate 224 is configured to clamp the entire width 207 of the composite laminate 202 against the first vacuum plate 215 in the clamping configuration 253. The second clamping plate 226 is configured to clamp the second portion 222 of the composite laminate 202 on the vacuum lifting surface 210. The second clamping plate 226 is configured to clamp the entire width 207 of the composite laminate 202 against the second vacuum plate 217 in the clamping configuration 257.

[0032] In some illustrative examples, first clamping plate 224 is formed of metal 223. In some illustrative examples, metal 223 takes the form of aluminum 225. In some illustrative examples, second clamping plate 226 is formed of metal 227. In some illustrative examples, metal 227 takes the form of aluminum 229.

[0033] The vacuum lifting surface 210 includes a fixed 211 central vacuum section 213, a first vacuum plate 215 movably connected to the central vacuum section 213, and a second vacuum plate 217 movably connected to the central vacuum section 213, so that the central vacuum section 213 is located between the first vacuum plate 215 and the second vacuum plate 217. The first vacuum plate 215 has a vacuum profile 219 that provides vacuum to control the lifting of the composite laminate 202. The vacuum profile 219 takes any desired form. The vacuum profile of the vacuum lifting surface 210 includes at least one of the material of the vacuum lifting surface, vacuum channels, or vacuum cups.

[0034] In some illustrative examples, vacuum profile 219 includes material 228. Material 228 may be porous to distribute vacuum. In some illustrative examples, vacuum profile 219 includes vacuum channels 230. Vacuum channels 230 may be formed into the material to direct the vacuum in first vacuum plate 215. In some illustrative examples, vacuum profile 219 includes vacuum cups 231.

[0035] Second vacuum plate 217 has vacuum profile 221 that provides vacuum to control the lifting of composite laminate 202. Vacuum profile 221 takes any desired form. In some illustrative examples, vacuum profile 219 and vacuum profile 221 are the same. In some illustrative examples, vacuum profile 219 and vacuum profile 221 are different from each other.

[0036] In some illustrative examples, vacuum profile 221 includes material 232. Material 232 may be porous to distribute vacuum. In some illustrative examples, vacuum profile 221 includes vacuum channels 233. Vacuum channels 233 may be formed into the material to direct the vacuum in second vacuum plate 217. In some illustrative examples, vacuum profile 221 includes vacuum cups 234.

[0037] The vacuum provided to the vacuum lift surface 210 is used to lift the composite laminate 202. The vacuum supplied to the vacuum lift surface 210 is controlled for a pick and place operation of the pick and place end effector 206. In order to form the bend 208 in the composite laminate 202, a plurality of restraints 214 provide a clamping force to the composite laminate 202. The step of forming the bend 208 in the composite laminate 202 is performed while the pick and place end effector 206 holds the composite laminate 202 and before the composite laminate 202 is placed on the mandrel 282.

[0038] The plurality of restraints 214 operate to provide tension in the composite laminate 202. The thickness of the vacuum lift surface 210 is such that when bent, the neutral axis of the combination of the vacuum lift surface 210 and the composite laminate 202 is located outside the composite laminate 202. The neutral axis of the combination of the vacuum lift surface 210 and the composite laminate 202 is near the interface of the vacuum lift surface 210 and the composite laminate 202. The neutral axis located outside the composite laminate 202 places the entire composite laminate 202 in tension and prevents or reduces the formation of wrinkles during the formation of the bend 208 in the composite laminate 202. A vacuum is maintained between the vacuum lift surface 210 and the composite laminate 202 to cause the combination of the vacuum lift surface 210 and the composite laminate 202 to bend as a unit.

[0039] In some illustrative examples, the first clamping plate 224 is movably connected to the first vacuum plate 215. As shown, the first clamping plate 224 is movably connected to the first vacuum plate 215 by a hinge 236. The hinge 236 has an open channel 237 to control a distance 238 between the first clamping plate 224 and the first vacuum plate 215. The open channel 237 is configured to set the distance 238 between the first clamping plate 224 and the first vacuum plate 215. Based on the position of the first clamping plate 224 in the open channel 237 of the hinge 236, the distance 238 is variable.

[0040] Mechanical limiter 240 is configured to hold first clamping plate 224 relative to vacuum lift surface 210. In this illustrative example, mechanical limiter 240 includes clamp 241. Mechanical limiter 240 includes any desired limiter to maintain a desired value for distance 238 and a desired compression.

[0041] In some illustrative examples, the second clamping plate 226 is movably connected to the second vacuum plate 217. As shown, the second clamping plate 226 is movably connected to the second vacuum plate 217 via a hinge 242. The hinge 242 has an open channel 243 to control a distance 244 between the second clamping plate 226 and the second vacuum plate 217. Based on the position of the second clamping plate 226 in the open channel 243 of the hinge 242, the distance 244 is variable.

[0042] Mechanical limiter 246 is configured to hold second clamping plate 226 relative to vacuum lift surface 210. In this illustrative example, mechanical limiter 246 includes clamp 247. Mechanical limiter 246 includes any desired limiter to maintain a desired value for distance 244 and a desired compression.

[0043] First clamping plate 224 and second clamping plate 226 each include clamping teeth configured to clamp composite laminate 202. In some illustrative examples, first clamping plate 224 includes mechanical teeth 250 configured to prevent or reduce composite laminate 202 from sliding relative to first clamping plate 224. In some illustrative examples, mechanical teeth 250 are referred to as clamping teeth. In some illustrative examples, second clamping plate 226 includes mechanical teeth 252 configured to prevent or reduce composite laminate 202 from sliding relative to second clamping plate 226.

[0044] The first clamping plate 224 is configured to move between an open configuration 251 and a clamping configuration 253. In the open configuration 251, the first vacuum plate 215 is not obscured by the first clamping plate 224. In the clamping configuration 253, the first clamping plate 224 is constrained at a distance 238 relative to the first vacuum plate 215. When an open channel 237 is present in the hinge 236, the distance 238 is variable. In some illustrative examples, the first clamping plate 224 is connected to the first motor 258 when in the open configuration 251. The first clamping plate 224 is fixed using a mechanical limiter 240 when in the clamping configuration 253.

[0045] The plurality of motors 212 are configured to move the first vacuum plate 215 and the second vacuum plate 217 relative to the fixed 211 central vacuum section 213 to place the vacuum lifting surface 210 in a forming configuration 218 having an angle 220. The plurality of motors 212 include a first motor 258 connected to the first vacuum plate 215 at an end 261 opposite the central vacuum section 213 and a second motor 259 connected to the second vacuum plate 217 at an end 263 opposite the central vacuum section 213. The motors can provide the desired level of precision without the need for additional metering. In some illustrative examples, the first motor 258 includes an electric motor. In some illustrative examples, the second motor 259 includes an electric motor. In some illustrative examples, the plurality of motors 212 include a first motor connected to the first clamping plate 224 and a second motor connected to the second clamping plate 226.

[0046] The pick and place end effector 206 also includes a backing plate 260 that connects the first motor 258 and the second motor 259. The pick and place end effector 206 also includes a solid backing plate 262 that connects the central vacuum section 213 to the backing plate 260.

[0047] As shown, first vacuum panel 215 is connected to solid backing plate 262 via hinge 264. Hinge 264 allows controlled movement of first vacuum panel 215 relative to central vacuum section 213. In some illustrative examples, hinge 264 may limit the range of movement of first vacuum panel 215 relative to central vacuum section 213.

[0048] As shown, second vacuum panel 217 is connected to solid backing plate 262 via hinge 265. Hinge 265 allows controlled movement of second vacuum panel 217 relative to central vacuum section 213. In some illustrative examples, hinge 265 may limit the range of movement of second vacuum panel 217 relative to central vacuum section 213.

[0049] The Z motor 294 is connected to other components of the pick and place end effector 206 so that the Z motor 294 can adjust the positioning of the vacuum lift surface 210 independently of the robot arm 296 and the gantry 298. The Z motor 294 is configured to move the components of the pick and place end effector 206 in the Z direction with a desired accuracy. The Z motor 294 is configured to move the first vacuum plate 215 and the second vacuum plate 217 in the Z direction independently of the robot arm 296 and the gantry 298.

[0050] The pick and place end effector 206 is connected to one of the robotic arm 296, the gantry 298, or any other desired large range motion system. The pick and place end effector 206 lifts the composite laminate 202 from the flat laminate tool. When lifted, the composite laminate 202 takes the form of a flat uncured composite laminate 278. The composite laminate 202 includes a plurality of composite plies 266. The plurality of composite plies 266 includes a plurality of zero degree plies 268. The plurality of zero degree plies 268 includes cuts 270 that discontinuous 269 the plurality of zero degree plies 268. The plurality of zero degree plies 268 includes cuts 270 in the width direction so that the plurality of zero degree plies 268 are discontinuous 269 in the longitudinal direction. The plurality of zero degree plies 268 are discontinuous 269, thereby extending across the vacuum lift surface 210 in a direction from the first vacuum plate 215 toward the second vacuum plate 217.

[0051] Cutouts 270 are present in plurality of zero degree plies 268 to reduce or prevent wrinkles in spar 204 having bend 292. Cutouts 270 are a desired distance 272 from bend 208 to be formed in composite laminate 202. In some illustrative examples, cutouts 270 are placed through the thickness of composite laminate 202 in a staggered pattern 273. By being placed in staggered pattern 273, cutouts 270 include a plurality of distances 274 from bend 208. By being placed in staggered pattern 273, cutouts 270 are within a desired distance 272 of bend 208 on both sides of bend 208.

[0052] In some illustrative examples, the composite laminate 202 optionally includes an extended zero-degree ply 276. When present, the extended zero-degree ply 276 is continuous. When present, the extended zero-degree ply 276 extends through the plurality of composite plies 266 in the longitudinal direction. When present, the extended zero-degree ply 276 may be held to apply tension. In some illustrative examples, the extended zero-degree ply 276 is clamped or otherwise constrained on the back side of the first vacuum plate 215 and the second vacuum plate 217. In some illustrative examples, the extended zero-degree ply 276 may be constrained by a plurality of rollers 299. The extended zero-degree ply 276 may initially be held by the plurality of rollers 299 by vacuum, mechanical clamps, adhesives, or any other initial fixation. After initially holding the ends of the extended zero-degree ply 276 on the plurality of rollers 299, the ends of the extended zero-degree ply 276 are wound onto the plurality of rollers 299. In some illustrative examples, winding extended zero degree ply 276 onto number of rollers 299 applies tension. In some illustrative examples, after winding extended zero degree ply 276 onto number of rollers 299, movement of number of rollers 299 applies tension.

[0053] After lifting composite laminate 202, first portion 205 and second portion 222 are clamped on vacuum lifting surface 210. In some illustrative examples, plurality of bladders 254 may be used to apply a compressive force to composite laminate 202. After lifting composite laminate 202, first clamping plate 224 is placed in clamping configuration 253 to clamp first portion 205 of composite laminate 202 on first vacuum plate 215. In some illustrative examples, plurality of first bladders 255 may optionally be used to apply a set compressive force to first portion 205.

[0054] After lifting composite laminate 202, second clamping plate 226 is placed in clamping configuration 257 to clamp second portion 222 of composite laminate 202 onto second vacuum plate 217. In some illustrative examples, plurality of second bladders 256 may optionally be used to apply a set compressive force to second portion 222.

[0055] After clamping first portion 205 and second portion 222, vacuum lift surface 210 moves from flat configuration 216 to forming configuration 218. The transition between flat configuration 216 and forming configuration 218 may be performed at any effective speed. A speed is selected for the transition that will allow resin flow within composite laminate 202. In some illustrative examples, the transition between flat configuration 216 and forming configuration 218 is performed substantially continuously. In some illustrative examples, the transition between flat configuration 216 and forming configuration 218 may be performed in a pulsed manner, wherein there is a pause between incremental movements of vacuum lift surface 210.

[0056] In some illustrative examples, first motor 258 and second motor 259 operate in the same manner, such as the same speed and the same motion pattern. In some illustrative examples, first motor 258 and second motor 259 operate in different modes.

[0057] With the vacuum lift surface 210 in the forming configuration 218, the pick and place end effector 206 has bent the composite laminate 202 to form the bend 208. The composite laminate 202 having the bend 208 is referred to as a bent composite laminate 280. The pick and place end effector 206 lifts the flat, uncured composite laminate 278 and introduces the bend 208 in mid-air to form the bent composite laminate 280 before being placed on the mandrel 282.

[0058] After vacuum lift surface 210 is placed in forming configuration 218, first clamping plate 224 is placed in open configuration 251 and second clamping plate 226 is placed in open configuration 203. Curved composite laminate 280 is placed in contact with web surface 285 of mandrel 282. In some illustrative examples, the Z position of composite laminate 202 is adjusted using Z motor 294 of pick and place end effector 206 to place curved composite laminate 280 in contact with mandrel 282. The vacuum to vacuum lift surface 210 is stopped, and curved composite laminate 280 is left on mandrel 282.

[0059] As the composite laminate 202 is placed onto the mandrel 282, the pick and place end effector 206 may apply additional pressure to the composite laminate 202. After the composite laminate 202 is released from the pick and place end effector 206 and mated with the mandrel 282, the pick and place end effector 206 may apply additional pressure to the composite laminate 202 over the bend 284 in the web surface 285 to reduce or eliminate the gap condition.

[0060] The mandrel 282 has a web surface 285 with bends 284 that match the bends 208 in the composite laminate 202. The bends 284 form angles between portions of the web surface 285. The bends 284 form angles between portions of the web surface 285 on the longitudinal square 283 of the mandrel 282.

[0061] The bent composite laminate 280 on the mandrel 282 is introduced into a spar forming assembly 288 for further processing of the bent composite laminate 280. The spar forming assembly 288 forms the bent composite laminate 280 against a side 286 of the mandrel 282 to form the spar 204.

[0062] The spar 204 includes a web 290 and a flange 291. A bend 292 in the spar 204 is perpendicular to a longitudinal direction 293. The bend 292 in the spar 204 forms an angle between two portions of the web 290 in the longitudinal direction 293.

[0063] The flange 291 is formed by forming the composite laminate 202 against the flange forming surface 287 of the mandrel 282. The flange forming surface 287 is a portion of the side 286 of the mandrel 282. The web 290 having the bend 284 is at least partially formed by the pick and place end effector 206. During the formation of the flange 291 in the spar forming assembly 288, the web 290 having the bend 292 is held against the web surface 285 of the mandrel 282. The bend 292 is substantially the same as the bend 208 in the curved composite laminate 280.

[0064] Figure 2A and Figure 2B The illustration of manufacturing environment 200 in FIG. 1 is not meant to imply physical or architectural limitations on the manner in which the illustrative embodiments may be implemented. Other components in addition to or in place of the components shown may be used. Some components may be unnecessary. In addition, these blocks are provided to illustrate some functional components. When implemented in the illustrative embodiments, one or more of these blocks may be combined, divided, or combined and divided into different blocks.

[0065] For example, while number of zero degree plies 268 includes cutouts 270, in some illustrative examples, one or more additional zero degree plies that are not cut may be present in composite laminate 202. In some illustrative examples, one or more continuous zero degree plies are present in composite laminate 202 to prevent undesired stretching of composite laminate 202.

[0066] As another example, heat may be applied to composite laminate 202 in the area of ​​bend 208. Heat may be applied in the area of ​​bend 208 in the form of convection, conduction, or radiation to accelerate the forming process. In some illustrative examples, heat may also be applied in localized areas to control ply slippage. In some illustrative examples, heating system 209 may be connected to pick and place end effector 206 as part of pick and place end effector 206. In other illustrative examples, a separate heating system may be moved to apply heat to composite laminate 202 on pick and place end effector 206. Heating system 209 may be optional.

[0067] As another example, while one pick and place end effector is discussed, multiple pick and place end effectors may be used to lift and form composite laminate 202. In some illustrative examples, composite laminate 202 may have multiple bends formed by multiple pick and place end effectors, including bend 208 formed by pick and place end effector 206. In these illustrative examples, the movement of the multiple pick and place end effectors will be coordinated to form the multiple bends and place composite laminate 202 having the multiple bends on mandrel 282.

[0068] Additionally, while pick and place end effector 206 is depicted as forming a single bend, bend 208, pick and place end effector 206 may be used to form multiple bends in composite laminate 202. In some illustrative examples, the width of central vacuum section 213 may be increased to form two separate bends: a first bend at the intersection of first vacuum plate 215 and central vacuum section 213, and a second bend at the intersection of second vacuum plate 217 and central vacuum section 213. In other illustrative examples, vacuum lift surface 210 may include additional portions in addition to first vacuum plate 215, central vacuum section 213, and second vacuum plate 217 to form additional bends in composite laminate 202.

[0069] Now go to Figure 3 , shows an illustration of a block diagram of a flow chart of forming a bend using a pick and place end effector according to an illustrative embodiment. In method 300, a pick and place end effector 302 is used to lift a flat uncured composite laminate 312 and form a bend. The pick and place end effector 302 may be used with Figure 2A and Figure 2B The pick and place end effector 302 is the same as the pick and place end effector 206 of FIG. The pick and place end effector 302 includes a vacuum lift surface 304, a plurality of restrictors 306, and a plurality of motors 307. The vacuum lift surface 304 is configured to hold a composite laminate and form a bend in the composite laminate. The plurality of restrictors 306 are configured to clamp portions of the composite laminate on the vacuum lift surface 304 during movement. The plurality of motors 307 are configured to move the vacuum lift surface to form a bend in the composite laminate.

[0070] Flat, uncured composite laminate 312 resides on flat layup tool 314. In some illustrative examples, flat, uncured composite laminate 312 is laid up on flat layup tool 314. In some illustrative examples, flat, uncured composite laminate 312 may be laid up on a different tool and then placed on flat layup tool 314 for lifting by pick and place end effector 302.

[0071] Flat uncured composite laminate 312 is formed from plurality of plies 313. Plurality of plies 313 includes plurality of zero degree plies 316. Plurality of zero degree plies 316 are cut 318 to allow for the formation of flat uncured composite laminate 312. In some illustrative examples, plurality of plies 313 includes one or more additional zero degree plies in addition to plurality of zero degree plies 316.

[0072] Prior to lifting 320 the flat, uncured composite laminate 312, the vacuum lift surface 304 of the pick and place end effector 302 is in a flat configuration 308. In the flat configuration 308, the vacuum lift surface 304 may be placed in contact with the flat, uncured composite laminate 312. When the vacuum lift surface 304 is in contact with the flat, uncured composite laminate 312, a vacuum is applied by the vacuum lift surface 304 to hold the flat, uncured composite laminate 312. Prior to lifting 320 the flat, uncured composite laminate 312, the plurality of restrictors 306 are in an open configuration 310 to allow access to the vacuum lift surface 304.

[0073] The pick and place end effector 302 performs a lift 320 to remove the flat, uncured composite laminate 312 from the flat layup tool 314. After the flat, uncured composite laminate 312 is lifted 320 from the flat layup tool 314, the plurality of restraints 306 are placed in a clamping configuration 322. In the clamping configuration, the plurality of restraints 306 clamp a portion of the flat, uncured composite laminate 312 on the vacuum lift surface 304. By clamping the portion of the flat, uncured composite laminate 312, tension in the neutral axis of the flat composite laminate is maintained during forming 324.

[0074] The pick and place end effector 302 forms a curved composite laminate 328 by forming 324 a bend 330 in the flat, uncured composite laminate 312. During forming 324, the vacuum lift surface 304 holds the flat, uncured composite laminate 312 and moves from the flat configuration 308 to the forming configuration 326. In the forming configuration 326, an angle 331 exists in the vacuum lift surface 304 to form the bend 330 in the curved composite laminate 328. The plurality of motors 307 moves the vacuum lift surface 304 between the flat configuration 308 and the forming configuration 326. During the movement between the flat configuration 308 and the forming configuration 326, the plurality of restraints 306 remain in the clamping configuration 322 and continue to clamp the portion of the curved composite laminate 328.

[0075] During placing 332 of the curved composite laminate 328 onto the mandrel 334, the pick and place end effector 302 is maintained in the forming configuration 326 with an angle 331 in the vacuum lift surface 304. The angle 331 in the vacuum lift surface 304 matches the bend 336 in the mandrel 334. The curved composite laminate 328 is placed onto the mandrel 334 by the pick and place end effector 302. During placing 332 of the curved composite laminate 328 onto the mandrel 334, a plurality of restraints are in the open configuration 310 to allow the curved composite laminate 328 to contact the mandrel 334.

[0076] Now go to Figure 4, shows an illustration of a side view of a pick and place end effector in a flat configuration with a plurality of restraints in an open configuration according to an illustrative embodiment. The pick and place end effector 400 may be used to manufacture Figure 1 The pick and place end effector 400 is a composite component of the aircraft 100. Figure 2A and Figure 2B The pick and place end effector 206 may be a physical implementation of the pick and place end effector 206. The pick and place end effector 400 may be Figure 3 The pick and place end effector 302 is a physical implementation of the pick and place end effector 302. The pick and place end effector 400 can perform lifting 320, forming 324, and placement 332 of the composite laminate.

[0077] The pick and place end effector 400 includes a vacuum lift surface 402, a plurality of motors 404, and a plurality of restraints 406. As shown in view 401, the plurality of restraints 406 are in an open configuration 407. With the plurality of restraints 406 in the open configuration 407, the vacuum lift surface 402 may be used to contact the composite laminate.

[0078] The vacuum lift surface 402 includes a first vacuum panel 408, a fixed central vacuum section 410, and a second vacuum panel 412. The first vacuum panel 408 is movably connected to the central vacuum section 410. The second vacuum panel 412 is movably connected to the central vacuum section 410 such that the central vacuum section 410 is located between the first vacuum panel 408 and the second vacuum panel 412. The vacuum lift surface 402 is in a flat configuration 403 to receive the composite laminate. The flat configuration 403 may be Figure 3 Physical realization of the flat structure 308.

[0079] The plurality of motors 404 are configured to move the vacuum lift surface 402. The plurality of motors 404 include a first motor 414 and a second motor 416. The first motor 414 is connected to the first vacuum plate 408. The first motor 414 is configured to move the first vacuum plate 408 relative to the central vacuum portion 410. In order to move the first vacuum plate 408 to a forming configuration, for example Figure 3 In the formed configuration 326 , the first motor 414 may be retracted.

[0080] As shown, the plurality of motors 404 includes a first motor 414 connected to the first vacuum plate 408 at an end 409 opposite the central vacuum portion 410. As shown, the plurality of motors 404 includes a second motor 416 connected to the second vacuum plate 412 at an end 413 opposite the central vacuum portion 410. It can be seen that the plurality of motors 404 are connected to the faces of the first vacuum plate 408 and the second vacuum plate 412 opposite the vacuum lifting face 402. The opposite faces can be referred to as the back faces of the first vacuum plate 408 and the second vacuum plate 412.

[0081] The second motor 416 is configured to move the second vacuum plate 412 relative to the central vacuum section 410. To move the second vacuum plate 412 to the forming configuration, the second motor 416 may be retracted.

[0082] Plurality of restraints 406 includes first clamping plate 418 and second clamping plate 420. First clamping plate 418 is configured to clamp a portion of the composite laminate to first vacuum plate 408. Second clamping plate 420 is configured to clamp a second portion of the composite laminate to second vacuum plate 412. In some illustrative examples, the first portion and the second portion may be ends of the composite laminate. These portions are within a desired distance of central vacuum section 410 to maintain tension in the composite laminate.

[0083] The first motor 414 and the second motor 416 are connected to a backing plate 422. The backing plate 422 connects the components of the pick and place end effector 400 to the Z motor 426. The Z motor 426 moves the vacuum lifting surface 402, the plurality of motors 404, and the plurality of limiters 406 to position the composite laminate held by the vacuum lifting surface 402 to a desired accuracy. The central vacuum section 410 is rigidly connected to a solid backing plate 424. The solid backing plate 424 maintains the position of the central vacuum section 410.

[0084] In this illustrative example, in the open configuration 407, the second clamping plate 420 is connected to the second motor 416 at a connection point 428. In this illustrative example, in the open configuration 407, the first clamping plate 418 is connected to the first motor 414 at a connection point 430.

[0085] Now go to Figure 5 , shows an illustration of a side view of a pick and place end effector in a flat configuration with a plurality of restraints in a clamping configuration in accordance with an illustrative embodiment. View 500 is a side view of the pick and place end effector 400 with the vacuum lift surface 402 in the flat configuration 403 and the plurality of restraints 406 in the clamping configuration 502. In the clamping configuration 502, the first clamping plate 418 has been released from the first motor 414. By clamping portions of the flat composite laminate, tension is maintained in the flat composite laminate during forming.

[0086] In the clamped configuration 502, the first clamping plate 418 is held by a mechanical restraint 504. The mechanical restraint 504 includes a clamp 506. The clamp 506 maintains a set distance between the first clamping plate 418 and the first vacuum plate 408.

[0087] The mechanical limiter 504 includes a clamp 508. The clamp 508 maintains a set distance between the second clamping plate 420 and the second vacuum plate 412.

[0088] First clamping plate 418 moves relative to first vacuum plate 408 using hinge 510. Hinge 510 includes an open channel to allow adjustment of the distance between first clamping plate 418 and first vacuum plate 408. In some illustrative examples, the distance between first clamping plate 418 and first vacuum plate 408 may be adjusted based on the thickness of the composite laminate to be lifted. In some illustrative examples, the distance between first clamping plate 418 and first vacuum plate 408 may be adjusted based on a desired amount of compaction to be applied to the composite laminate.

[0089] Second clamping plate 420 moves relative to second vacuum plate 412 using hinge 512. Hinge 512 includes an open channel to allow adjustment of the distance between second clamping plate 420 and second vacuum plate 412. In some illustrative examples, the distance between second clamping plate 420 and second vacuum plate 412 may be adjusted based on the thickness of the composite laminate to be lifted. In some illustrative examples, the distance between second clamping plate 420 and second vacuum plate 412 may be adjusted based on the desired amount of compaction to be applied to the composite laminate.

[0090] The pick and place end effector 400 may have the vacuum lift surface 402 in a flat configuration 403 and the plurality of restraints 406 in a clamping configuration 502, as may be present in view 500 after lifting 320 and before forming 324. After the composite laminate is clamped by the plurality of restraints 406, the pick and place end effector 400 may be used to form a bend in the composite laminate.

[0091] Now go to Figure 6 , shows an illustration of a side view of a pick and place end effector in a forming configuration with a plurality of restraints in a gripping configuration in accordance with an illustrative embodiment. In view 600, the vacuum lift surface 402 has transitioned between the flat configuration 403 and the forming configuration 602. In the forming configuration 602, the vacuum lift surface 402 has an angle 603. In view 600, the plurality of restraints 406 are in the gripping configuration 502. Views 500 and 600 show two different distances between the plurality of restraints 406 and the vacuum lift surface 402.

[0092] Pick and place end effector 400 may move between flat configuration 403 and formed configuration 602 in any desired manner. In some illustrative examples, pick and place end effector 400 may move from flat configuration 403 to formed configuration 602 at a continuous rate. In some illustrative examples, pick and place end effector 400 may move from flat configuration 403 to formed configuration 602 in a series of incremental changes.

[0093] Mechanical teeth 604 of first clamping plate 418 are visible in view 600. Mechanical teeth 606 of second clamping plate 420 are visible in view 600. Mechanical teeth 604 and mechanical teeth 606 are present to reduce or prevent slippage between the composite laminate and first clamping plate 418 and second clamping plate 420. In some illustrative examples, mechanical teeth may also be referred to as clamping teeth.

[0094] Now go to Figure 7 , shows an illustration of a side view of a pick and place end effector in a forming configuration according to an illustrative embodiment, wherein the plurality of restraints are in an open configuration. In view 700, the plurality of restraints have transitioned back to the open configuration 407. In the open configuration 407, the vacuum lift surface 402 is visible. With the plurality of restraints 406 in the open configuration 407 and the vacuum lift surface 402 in the forming configuration 602, a composite laminate may be placed onto a forming mandrel, for example, by the pick and place end effector 400. Fig.10 Forming mandrel 1000.

[0095] Now go to Figure 8 , shows a bottom view of a pick and place end effector in a forming configuration according to an illustrative embodiment, wherein a plurality of restrictors are in different configurations. In view 800, the vacuum lift surface 402 is visible. In view 800, a vacuum port 802 extending through the vacuum lift surface 402 is visible. The vacuum port 802 provides vacuum to a vacuum profile 804 in the vacuum lift surface 402. As shown, the vacuum profile 804 includes a plurality of channels in the vacuum lift surface 402. Any desired design and components of the vacuum profile 804 may be provided to lift and place composite laminates.

[0096] As can be seen in view 800, the plurality of restrictors 406 including the first clamping plate 418 are configured to clamp the entire width of the composite feedstock. For example, the width 806 of the first clamping plate 418 is sufficient to clamp the entire width of the composite feedstock held on the vacuum lift surface 402. The width 806 of the first clamping plate 418 extends completely across the width of the first vacuum plate 408.

[0097] Although pick and place end effector 400 is depicted as forming a single bend, pick and place end effector 400 may be used to form multiple bends in a composite laminate. In some illustrative examples, the width of central vacuum section 410 may be increased to form two separate bends: a first bend at the intersection of first vacuum plate 408 and central vacuum section 410, and a second bend at the intersection of second vacuum plate 412 and central vacuum section 410. In other illustrative examples, vacuum lift surface 402 may include additional portions in addition to first vacuum plate 408, central vacuum section 410, and second vacuum plate 412 to form additional bends in the composite laminate.

[0098] Now go to Fig. 9 , shows an illustration of a side view of a pick and place end effector with a plurality of bladders according to an illustrative embodiment. In view 900, a plurality of bladders 902 are provided to apply a compressive force to a composite laminate held on the pick and place end effector 400. In this illustrative example, the plurality of bladders 902 are located between the plurality of restrainers 406 and the composite laminate (not shown). The plurality of bladders 902 include a first bladder 904 between the first clamping plate 418 and the first vacuum plate 408 and a second bladder 906 between the second clamping plate 420 and the second vacuum plate 412. The first bladder 904 will apply a compressive force to a first end of the composite laminate (not shown). The second bladder 906 will apply a compressive force to a second portion of the composite laminate (not shown).

[0099] The plurality of bladders 902 may have any desired size and shape. The plurality of bladders 902 are configured to apply a compressive force to the entire width of the composite laminate. The plurality of bladders 902 are filled to a known pressure so that the clamping pressure applied to the feed is known. The surfaces of the plurality of bladders 902 are configured to reduce or prevent slippage between the plurality of bladders and the composite laminate. In this illustrative example, the plurality of restrictors 406 do not contact the composite laminate. In this illustrative example, mechanical teeth may not be present on the plurality of restrictors 406.

[0100] Now go to Fig.10 , shows an isometric view of a forming mandrel according to an illustrative embodiment. Mandrel 1000 may be used to form Figure 1 The composite structure of the aircraft 100. The mandrel 1000 may be Figure 2A and Figure 2B The physical implementation of the mandrel 282. The mandrel 1000 may be Figure 3 Physical implementation of spindle 334. Figures 4 to 8 The pick and place end effector 400 may be used to place the composite laminate onto the mandrel 1000 .

[0101] Mandrel 1000 includes a web surface 1002 having a bend 1004 and a flange surface 1006. Web surface 1002 is configured to shape a web portion of a spar. Flange surface 1006 is configured to shape a flange portion of a spar.

[0102] The composite laminate held by the pick and place end effector 400 in the forming configuration 602 may be placed on the mandrel 1000. The angle 603 is configured to match the bend 1004 in the web surface 1002.

[0103] Now go to Fig.11 , a flow chart of a method for forming a bend in a composite laminate according to an illustrative embodiment is shown. The method 1100 may be used to form Figure 1 A composite portion of the aircraft 100. Figure 2A and Figure 2B The method 1100 can be performed using the pick and place end effector 206. Figure 3 The method 1100 can be performed using a pick and place end effector 302. Figures 4 to 9 The method 1100 may be performed using a pick and place end effector 400. The method 1100 may be performed to place a composite laminate on a Fig.10 On the spindle 1000.

[0104] Method 1100 lifts a composite laminate on a vacuum lift surface of a pick and place machine, the vacuum lift surface configured to hold the composite laminate and move from a flat configuration to a formed configuration having an angle in the vacuum lift surface to form a bend in the composite laminate (operation 1102). Method 1100 clamps a portion of the composite laminate on the vacuum lift surface (operation 1104). Method 1100 moves the vacuum lift surface between a flat configuration and a formed configuration to form a bend in the composite laminate while the portion is clamped on the vacuum lift surface, thereby forming a bent composite laminate (operation 1106). Method 1100 places the bent composite laminate on a mandrel having the bend (operation 1108). Thereafter, method 1100 ends.

[0105] In some illustrative examples, lifting the composite laminate on the vacuum lifting surface includes drawing a vacuum through a first vacuum plate and a second vacuum plate of the vacuum lifting surface (operation 1110). In some illustrative examples, lifting the composite laminate includes moving a pick and place end effector using one of a robotic arm or a gantry (operation 1112).

[0106] In some illustrative examples, clamping the portion of the composite laminate on the vacuum lift surface includes clamping a first portion of the composite laminate to a first vacuum plate and clamping a second portion of the composite laminate to a second vacuum plate (operation 1114). In some illustrative examples, the clamping is performed within a set distance from a bend to be formed in the composite laminate. In some illustrative examples, the portion of the composite laminate is supported by a vacuum or another support system.

[0107] In some illustrative examples, clamping the first portion of the composite laminate to the first vacuum plate includes rotating the first clamping plate relative to the first vacuum plate and securing the first clamping plate relative to the first vacuum plate (operation 1116 ).

[0108] In some illustrative examples, moving the vacuum lift surface between the flat configuration and the formed configuration to form the bend includes rotating the first vacuum plate and the second vacuum plate about a central vacuum portion connected to the first vacuum plate and the second vacuum plate away from the composite laminate to form the bend in the composite laminate (operation 1118).

[0109] In some illustrative examples, rotating the first vacuum plate away from the composite laminate includes retracting a first motor connected to the first vacuum plate (operation 1120). In some illustrative examples, placing the curved composite laminate on the mandrel includes adjusting a Z position of the composite laminate using a Z motor of the pick and place end effector (operation 1122).

[0110] As used herein, the phrase "at least one of...", when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one of each item in the list may be required. For example, "at least one of item A, item B, or item C" may include, but is not limited to: item A; item A and item B; or item B. This example may also include; item A, item B, and item C; or item B and item C. Of course, any combination of these items may exist. In other examples, "at least one of..." may be, for example, but not limited to: two of item A, one of item B, and ten of item C; four of item B and seven of item C; or other suitable combinations. Items may be specific objects, things, or categories. In other words, "at least one of..." means: any combination of items and number of items in the list may be used, but not all items in the list are required.

[0111] As used herein, "plurality" when used with reference to items means one or more items.

[0112] The flowcharts and block diagrams in the different described embodiments illustrate the architecture, functionality, and operation of some possible implementations of the devices and methods in the illustrative embodiments. In this regard, each box in the flowchart or block diagram may represent at least one of the following: a module; a segment; a function; or a part of an operation or step.

[0113] In some alternative implementations of the illustrative embodiments, one or more functions indicated in the blocks may not occur in the order indicated in the figure. For example, in some cases, two blocks shown in succession may be performed substantially simultaneously, or the blocks may sometimes be performed in reverse order, depending on the functions involved. In addition, in addition to the blocks shown in the flow chart or block diagram, other blocks may be added. Some blocks may be optional. For example, operations 1110 to 1122 may be optional.

[0114] You can Fig.12 Aircraft manufacturing and service method 1200 is shown and described below. Fig.13 Illustrative embodiments of the present disclosure are described in the context of aircraft 1300 as shown. Fig.12 , a diagram of an aircraft manufacturing and service method is shown in block diagram form in accordance with an illustrative embodiment. During pre-production, aircraft manufacturing and service method 1200 may include Fig.13 Specification and design 1202 of the aircraft 1300 and material procurement 1204.

[0115] During production, component and subassembly manufacturing 1206 and system integration 1208 of the aircraft 1300 occurs. Thereafter, the aircraft 1300 may be certified and delivered 1210 for placement into service 1212. When placed into service 1212 by a customer, the aircraft 1300 is scheduled for routine maintenance and repair 1214, which may include modification, reconfiguration, refurbishment, or other maintenance and repair.

[0116] Each of the processes of aircraft manufacturing and service method 1200 may be performed or carried out by a system integrator, a third party, and / or an operator. In these examples, the operator may be a customer. For purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0117] Reference now Fig.13 , shows, in block diagram form, a diagram of an aircraft in which an illustrative embodiment may be implemented. In this example, aircraft 1300 is Fig.12Aircraft manufacturing and service method 1200 is produced and may include airframe 1302 having plurality of systems 1304 and interior 1306. Examples of systems 1304 include one or more of propulsion system 1308, electrical system 1310, hydraulic system 1312, and environmental system 1314. Any number of other systems may be included.

[0118] Apparatus and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method 1200. Fig.12 One or more illustrative embodiments are manufactured or used during at least one of component and subassembly manufacturing 1206 , system integration 1208 , service 1212 , or maintenance and repair 1214 .

[0119] An illustrative example provides an end effector with articulated vacuum plates suspended from a robot or gantry. The vacuum plates pick up a flat, unmachined spar feed, grip portions of the composite feed on opposite sides of the intended bend using gripper plates to hold them fully tensioned, and then impart the desired bend by bending one / both vacuum plates.

[0120] The illustrative examples provide a novel method of maintaining a composite full stack in tension during forming bends to reduce or prevent wrinkle formation and undesirable damage to structural integrity. A method of forming and a pick and place end effector maintains a composite full stack in full tension during forming.

[0121] An illustrative example provides an end effector that can be mounted on a robot or gantry system. In the illustrative example, a flat, unmachined spar feed is delivered into a workspace / cell. The end effector locates the spar feed and moves to a position above the spar feed. The end effector moves downward and draws a vacuum to pick up the spar feed. The motor of the end effector moves / pulses to bend the spar feed in the center. The feed with the bend is placed on a mandrel to receive additional forming and processing. The illustrative example allows for the pick and place and bending of unmachined spar feed without the need for manual labor.

[0122] The neutral axis of the combined vacuum panel and composite laminate is outside the composite laminate, at the interface between the two or slightly within the vacuum panel. In the illustrative example, the composite laminate is held in place on the vacuum panel by a combination of vacuum and a plurality of restraints that clamp the composite laminate, place the vacuum panel in compression and hold the entire composite laminate in tension to prevent wrinkles from forming.

[0123] Picking up a spar with a vacuum and placing it down has been shown by previous end effectors, but the illustrative example allows for more work to be done on the composite feedstock before placement on the mandrel than just picking and placing. The composite feedstock is bent in mid-air by a motor attached to a vacuum plate. The illustrative example automates multiple processes that are currently performed manually.

[0124] The illustrative examples address the high buy-in cost of conventional spar installation processes. The illustrative examples reduce the number of processes to form a spar with a bend. The illustrative examples reduce part movement to completion. The illustrative examples reduce time lost to re-indexing parts. The illustrative examples reduce manual installation and can reduce undesirable ergonomic operations.

[0125] Illustrative, non-exclusive examples of inventive subject matter according to the present disclosure are described in the following enumerated paragraphs:

[0126] A1. A pick and place end effector (206, 400) configured to form a bend (208) in a composite laminate (202), the pick and place end effector (206, 400) comprising:

[0127] a vacuum lift surface (210, 402) configured to hold the composite laminate (202) and move from a flat configuration (216, 403) to a forming configuration (218, 602) at an angle (220, 603) within the vacuum lift surface (210, 402) to form the bend (208) in the composite laminate (202);

[0128] a plurality of motors (212, 404) configured to move the vacuum lift surface (210, 402) between the flat configuration (216, 403) and the forming configuration (218, 602); and

[0129] A plurality of restraints (214, 406) configured to clamp portions (205, 222) of the composite laminate (202) on opposite sides of the bend (208) to the vacuum lifting surface (210, 402) during movement between the flat configuration (216, 403) and the formed configuration (218, 602).

[0130] A2. The pick and place end effector (206, 400) of paragraph A1, wherein the vacuum lifting surface (210, 402) comprises:

[0131] a fixed (211) central vacuum section (213, 410);

[0132] a first vacuum panel (215, 408) movably connected to the central vacuum section (213, 410); and

[0133] A second vacuum plate (217, 412) is movably connected to the central vacuum section (213, 410) such that the central vacuum section (213, 410) is between the first vacuum plate (215, 408) and the second vacuum plate (217, 412).

[0134] A3. A pick and place end effector (206, 400) according to paragraph A2, wherein the plurality of motors (212, 404) include a first motor (258, 414) connected to the first vacuum plate (215, 408) at an end (261) opposite to the central vacuum portion (213, 410) and a second motor (259, 416) connected to the second vacuum plate (217, 412) at an end (263) opposite to the central vacuum portion (213, 410).

[0135] A4. The pick-and-place end effector (206, 400) of paragraph A3, wherein the pick-and-place end effector comprises:

[0136] a back plate (260, 422) connecting the first motor (258, 414) and the second motor (259, 416); and

[0137] A solid back plate (262, 424) connects the central vacuum section (213, 410) to the back plate (260, 422).

[0138] A5. The pick-and-place end effector (206, 400) of paragraph A2, comprising:

[0139] A Z motor (294, 426) configured to move the first vacuum plate (215, 408) and the second vacuum plate (217, 412) in a Z direction independently of a gantry (298) or robot arm (296) connected to the pick and place end effector (206, 400).

[0140] A6. A pick and place end effector (206, 400) according to any one of paragraphs A2 to A5, wherein the plurality of limiters (214, 406) include: a first clamping plate (224, 418) movably connected to the first vacuum plate (215, 408); and a mechanical limiter (240, 504) configured to hold the first clamping plate (224, 418) relative to the vacuum lifting surface (210, 402).

[0141] A7. The pick-and-place end effector (206, 400) of paragraph A6, wherein the first clamping plate (224, 418) includes clamping teeth (250, 604) configured to clamp the composite laminate (202).

[0142] A8. A pick and place end effector (206, 400) according to paragraph A6, wherein the first clamping plate (224, 418) is configured to move between an open configuration (251, 407) and a clamping configuration (253, 257, 502), wherein, when in the open configuration (251, 407), the first clamping plate (224, 418) is connected to a first motor (258, 414), and wherein the mechanical limiter (240, 504) is used to fix the first clamping plate (224, 418) in the clamping configuration (253, 257, 502).

[0143] B1. A method (1100) of forming a bend (208) in a composite laminate (202), the method comprising:

[0144] lifting (1102) a composite laminate (202) on a vacuum lift surface (210, 402) of a pick and place end effector (206, 400), the vacuum lift surface (210, 402) configured to hold the composite laminate (202) and move from a flat configuration (216, 403) to a formed configuration (218, 602) at an angle (220, 603) within the vacuum lift surface (210, 402) to form the bend (208) in the composite laminate (202);

[0145] clamping (1104) a portion (205, 222) of the composite laminate (202) on the vacuum lifting surface (210, 402);

[0146] while clamping the portion (205, 222) on the vacuum lift surface (210, 402), moving (1106) the vacuum lift surface (210, 402) between the flat configuration (216, 403) and the formed configuration (218, 602) to form a bend (208) in the composite laminate (202), thereby forming a curved composite laminate (280); and

[0147] The curved composite laminate (280) is placed (1008) on a mandrel (282, 1000) having a bend (284).

[0148] B2. The method of paragraph B1, wherein lifting the composite laminate (202) on the vacuum lifting surface (210, 402) comprises: drawing a vacuum through a first vacuum plate (215, 408) and a second vacuum plate (217, 412) of the vacuum lifting surface (210, 402).

[0149] B3. A method according to paragraph B2, wherein clamping a portion (205, 222) of the composite laminate (202) on the vacuum lifting surface (210, 402) includes: clamping a first portion of the composite laminate (202) to the first vacuum plate (215, 408) and clamping a second portion of the composite laminate (202) to the second vacuum plate (217, 412).

[0150] B4. A method according to paragraph B3, wherein clamping the first portion (205) of the composite laminate (202) to the first vacuum plate (215, 408) includes: rotating the first clamping plate (224, 418) relative to the first vacuum plate (215, 408); and fixing the first clamping plate (224, 418) relative to the first vacuum plate (215, 408).

[0151] B5. The method of paragraph B2, wherein moving the vacuum lift surface (210, 402) between the flat configuration (216, 403) and the formed configuration (218, 602) to form the bend (208) comprises:

[0152] The first vacuum plate (215, 408) and the second vacuum plate (217, 412) are rotated away from the composite laminate (202) about a central vacuum portion (213, 410) connected to the first vacuum plate (215, 408) and the second vacuum plate (217, 412) to form the bend (208) in the composite laminate (202).

[0153] B6. The method of paragraph B5, wherein rotating the first vacuum plate (215, 408) away from the composite laminate (202) includes retracting a first motor (258, 414) connected to the first vacuum plate (215, 408).

[0154] B7. The method of any of paragraphs B1 to B6, wherein lifting the composite laminate (202) comprises moving the pick and place end effector (206, 400) using one of a robotic arm (296) or a gantry (298).

[0155] B8. A method according to any one of paragraphs B1 to B6, wherein placing the curved composite laminate (280) on the mandrel (282, 1000) includes: adjusting the Z position of the composite laminate (202) using a Z motor (294, 426) of the pick and place end effector (206, 400).

[0156] C1. A pick and place end effector (206, 400) configured to form a bend (208), the pick and place end effector (206, 400) comprising:

[0157] A vacuum lifting surface (210, 402) comprising: a fixed (211) central vacuum section (213, 410); a first vacuum plate (215, 408) movably connected to the fixed (211) central vacuum section (213, 410); and a second vacuum plate (217, 412) movably connected to the fixed (211) central vacuum section;

[0158] a plurality of limiters (214, 406) configured to limit movement of portions (205, 222) of a composite laminate (202) on opposite sides of the fixed (211) central vacuum portion (213, 410) on the vacuum lifting surface (210, 402); and

[0159] A plurality of motors (212, 404) configured to move the first vacuum plate (215, 408) and the second vacuum plate (217, 412) relative to the fixed (211) central vacuum section (213, 410) to bring the vacuum lifting surface (210, 402) into a forming configuration (218, 602) having an angle (220, 603).

[0160] C2. The pick and place end effector (206, 400) of paragraph C1, wherein the plurality of limiters (214, 406) include:

[0161] a first clamping plate (224, 418) configured to clamp the entire width (207) of the composite laminate (202) against the first vacuum plate (215, 408) in a clamping configuration (253, 257, 502); and

[0162] A second clamping plate (226, 420) configured to clamp the entire width (207) of the composite laminate (202) against the second vacuum plate (217, 412) in a clamping configuration (253, 257, 502).

[0163] C3. A pick and place end effector (206, 400) according to paragraph C2, wherein the first clamping plate (224, 418) is movably connected to the first vacuum plate (215, 408) by a hinge (236, 510) having an open channel (237), and the open channel (237) is configured to set a distance (238) between the first clamping plate (224, 418) and the first vacuum plate (215, 408).

[0164] C4. A pick and place end effector (206, 400) according to paragraph C2, wherein the plurality of motors (212, 404) include a first motor (414) connected to the first clamping plate (224, 418) and a second motor (416) connected to the second clamping plate (226, 420).

[0165] C5. The pick-and-place end effector (206, 400) of paragraph C2, wherein the first clamping plate (224, 418) and the second clamping plate (226, 420) are formed of metal (223, 227).

[0166] C6. A pick and place end effector (206, 400) according to any one of paragraphs C1 to C5, wherein the vacuum distribution of the vacuum lifting surface (210, 402) includes at least one of a vacuum channel (230, 233), a vacuum cup (231, 234), or a material (228, 232) of the vacuum lifting surface (210, 402).

[0167] Descriptions of different illustrative embodiments have been given for purposes of illustration and description, and these descriptions are not intended to be exhaustive or limited to the embodiments of the disclosed forms. Many modifications and variations are apparent to those of ordinary skill in the art. In addition, different illustrative embodiments may provide different features compared to other illustrative embodiments. One or more selected embodiments are selected and described in order to best explain the principles of the embodiments, practical applications, and to enable other persons of ordinary skill in the art to understand the disclosure of various embodiments with various modifications suitable for the intended specific use.

[0168] CROSS-REFERENCE TO RELATED APPLICATIONS

[0169] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 590,262, filed on October 13, 2023, entitled “PICK-AND-PLACE END EFFECTOR CONFIGURED TO FORM A BEND,” the entire contents of which are incorporated herein by reference.

Claims

1. A pick and place end effector (206, 400) configured to form a bend (208) in a composite laminate (202), the pick and place end effector (206, 400) comprising: a vacuum lift surface (210, 402) configured to hold the composite laminate (202) and move from a flat configuration (216, 403) to a forming configuration (218, 602) at an angle (220, 603) within the vacuum lift surface (210, 402) to form the bend (208) in the composite laminate (202); a plurality of motors (212, 404) configured to move the vacuum lift surface (210, 402) between the flat configuration (216, 403) and the forming configuration (218, 602); as well as A plurality of restraints (214, 406) configured to clamp portions (205, 222) of the composite laminate (202) on opposite sides of the bend (208) to the vacuum lifting surface (210, 402) during movement between the flat configuration (216, 403) and the formed configuration (218, 602).

2. The pick and place end effector (206, 400) of claim 1, wherein: The vacuum lifting surface (210, 402) comprises: a fixed (211) central vacuum section (213, 410); a first vacuum panel (215, 408) movably connected to the central vacuum section (213, 410); and A second vacuum plate (217, 412) is movably connected to the central vacuum section (213, 410) such that the central vacuum section (213, 410) is between the first vacuum plate (215, 408) and the second vacuum plate (217, 412).

3. The pick and place end effector (206, 400) of claim 2, wherein: The plurality of motors (212, 404) include a first motor (258, 414) connected to the first vacuum plate (215, 408) at an end (261) opposite the central vacuum section (213, 410) and a second motor (259, 416) connected to the second vacuum plate (217, 412) at an end (263) opposite the central vacuum section (213, 410).

4. The pick and place end effector (206, 400) of claim 3, comprising: a back plate (260, 422) connected to the first motor (258, 414) and the second motor (259, 416); as well as A solid back plate (262, 424) connects the central vacuum section (213, 410) to the back plate (260, 422).

5. A method (1100) of forming a bend (208) in a composite laminate (202), the method comprising: lifting (1102) a composite laminate (202) on a vacuum lift surface (210, 402) of a pick and place end effector (206, 400), the vacuum lift surface (210, 402) configured to hold the composite laminate (202) and move from a flat configuration (216, 403) to a formed configuration (218, 602) at an angle (220, 603) within the vacuum lift surface (210, 402) to form the bend (208) in the composite laminate (202); clamping (1104) a portion (205, 222) of the composite laminate (202) on the vacuum lifting surface (210, 402); while clamping the portion (205, 222) on the vacuum lift surface (210, 402), moving (1106) the vacuum lift surface (210, 402) between the flat configuration (216, 403) and the formed configuration (218, 602) to form a bend (208) in the composite laminate (202), thereby forming a curved composite laminate (280); and The curved composite laminate (280) is placed (1008) on a mandrel (282, 1000) having a bend (284).

6. The method according to claim 5, wherein: Lifting the composite laminate (202) on the vacuum lifting surface (210, 402) includes drawing a vacuum through a first vacuum plate (215, 408) and a second vacuum plate (217, 412) of the vacuum lifting surface (210, 402).

7. The method according to claim 6, wherein: Clamping a portion (205, 222) of the composite laminate (202) on the vacuum lifting surface (210, 402) includes: clamping a first portion of the composite laminate (202) to the first vacuum plate (215, 408) and clamping a second portion of the composite laminate (202) to the second vacuum plate (217, 412).

8. The method according to claim 7, wherein: Clamping the first portion (205) of the composite laminate (202) to the first vacuum plate (215, 408) includes: rotating a first clamping plate (224, 418) relative to the first vacuum plate (215, 408); and fixing the first clamping plate (224, 418) relative to the first vacuum plate (215, 408).

9. A pick and place end effector (206, 400) configured to form a bend (208), the pick and place end effector (206, 400) comprising: A vacuum lifting surface (210, 402) comprising: a fixed (211) central vacuum section (213, 410); a first vacuum plate (215, 408) movably connected to the fixed (211) central vacuum section (213, 410); and a second vacuum plate (217, 412) movably connected to the fixed (211) central vacuum section; a plurality of limiters (214, 406) configured to limit movement of portions (205, 222) of a composite laminate (202) on opposite sides of the fixed (211) central vacuum portion (213, 410) on the vacuum lifting surface (210, 402); and A plurality of motors (212, 404) configured to move the first vacuum plate (215, 408) and the second vacuum plate (217, 412) relative to the fixed (211) central vacuum section (213, 410) to bring the vacuum lifting surface (210, 402) into a forming configuration (218, 602) having an angle (220, 603).

10. The pick and place end effector (206, 400) of claim 9, wherein: The plurality of limiters (214, 406) include: a first clamping plate (224, 418) configured to clamp the entire width (207) of the composite laminate (202) against the first vacuum plate (215, 408) in a clamping configuration (253, 257, 502); and A second clamping plate (226, 420) configured to clamp the entire width (207) of the composite laminate (202) against the second vacuum plate (217, 412) in a clamping configuration (253, 257, 502).

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