Device for compacting object on rigid tool and roll of material

Abstract

The invention relates to a device for compacting an object on a rigid tool and a roll of material. One embodiment is a method for compressing an object onto a rigid tool. The method includes: placing an object onto a surface of a rigid tool; disposing an end effector over the object; deploying the links of the end effector such that a roll of material between the links is disposed on the top of the object while surrounding the object; and applying a negative pressure to the roll to counteract blow-by between the roll and the object, thereby creating a suction that compresses the object onto the rigid tool.

Description

[0001] This application is a divisional application of Chinese Patent Application No. 202110268891.9, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to the field of manufacturing, and more specifically, to the preparation of composite components. Background Technology

[0003] Composite components, such as carbon fiber parts, are formed by hardening a preform of fiber-reinforced material while maintaining the required pressure and temperature. Preforms that have not yet been hardened into composite components do not exhibit full structural strength. Therefore, before hardening, the "green" preform cannot support itself when stacked on a surface (e.g., a vertical or other non-horizontal surface). This complicates the stacking of large preforms on complex surfaces (e.g., barrel shapes) because of the increased chance of parts of the preform peeling or shifting from the forming tool before completion of stacking. Consequently, accurate placement or positioning of large and / or bulky stacks remains challenging.

[0004] For preforms cured via vacuum bag curing technology, it is difficult to secure the vacuum bag around the preform before it is peeled (relatively displaced) from the corresponding complex surface. The problem is further complicated by the fact that materials such as tape used to secure the vacuum bag to the tool surface are not approved for contact with, and therefore are not permitted to contact, the uncured / unhardened composite material. As a result, the entire stack must be completed before the vacuum bag is applied and attached (via sealant) to the complex surface. Therefore, specifically, when arranging preforms within complex assemblies, it is still desirable to quickly and efficiently secure the preform (and / or other objects) to the complex surface.

[0005] Therefore, it is desirable to have a method and apparatus that takes into account at least some of the problems described above, as well as other possible problems. Summary of the Invention

[0006] The embodiments described herein provide a technique in which a roll of material is rapidly deployed into a preform that has been placed on a mandrel. The roll includes a permeable layer that allows airflow and an impermeable layer extending beyond the boundaries of the permeable layer. During and after the roll is placed, negative pressure is applied via a tape-free pressing process to press the roll into and compress the underlying preform. After pressing is complete, the roll can be quickly removed so that the preform can be vacuum-packed and hardened.

[0007] One embodiment is a method for pressing an object onto a rigid tool. The method includes: placing the object onto the surface of the rigid tool; positioning an end effector above the object; unfolding the links of the end effector so that a roll of material between the links surrounds and rests on top of the object; and applying a negative pressure to the roll to counteract air leakage between the roll and the object, thereby forming a suction that presses the object onto the rigid tool.

[0008] Another embodiment is a non-volatile computer-readable medium including programming instructions that, when executed by a processor, operate to perform a method of pressing an object against a rigid tool. The method includes: placing the object onto the surface of the rigid tool; positioning an end effector above the object; unfolding the links of the end effector such that a roll of material between the links surrounds and rests on top of the object; and applying a negative pressure to the roll to counteract air leakage between the roll and the object, thereby forming a suction that presses the object against the rigid tool.

[0009] Another embodiment is a device for pressing an object onto a rigid tool. The device includes: an end effector configured to move toward the rigid tool; a link coupled to the end effector and configured to pivot relative to the end effector; a shaft coupled to the link and rotatably mounted to the link; and a roll of material stored on the shaft and configured to place the object onto the rigid tool.

[0010] Another embodiment is an apparatus comprising a shaft and a roll of material wound around the shaft. One end of the roll is sealed to the shaft, and the other end of the roll is attached to an object. The material comprises a permeable layer and an impermeable membrane in contact with the permeable layer.

[0011] Another embodiment is a device including at least one rotating shaft. The rotating shaft includes an outer portion, a cavity, and a perforation coupling the cavity to the outer portion. The device also includes a roll of material wound around the rotating shaft. One end of the roll is sealed to the rotating shaft. The material includes a permeable layer and an impermeable membrane in contact with the permeable layer.

[0012] Another embodiment is an apparatus for pressing an object onto a rigid tool. The apparatus includes: a plurality of spindles; and a roll of material stored on the spindles, and configured to perform placement on the object at the rigid tool when the spindles are moved apart from each other.

[0013] Another embodiment is a method for pressing an object placed on the surface of a rigid tool. The method includes: laying out a roll of material over the object, including an impermeable membrane covering a permeable layer and extending beyond the boundary of the permeable layer; and applying a negative pressure to the permeable layer to counteract air leakage between the roll and the object, thereby forming a suction that presses the object onto the rigid tool.

[0014] Another embodiment is a non-volatile computer-readable medium including programming instructions that, when executed by a processor, are operable to perform a method of pressing an object onto a rigid tool. The method includes: laying a roll of material over the object, including an impermeable membrane covering a permeable layer and extending beyond the boundaries of the permeable layer; and applying a negative pressure to the permeable layer to counteract air leakage between the roll and the object, thereby forming a grip that presses the object onto the rigid tool.

[0015] Other illustrative embodiments (e.g., methods and computer-readable media related to the embodiments described above) may be described below. The features, functions, and advantages discussed may be implemented independently in various embodiments, or combined in other embodiments for which further details are set forth with reference to the following description and drawings. Attached Figure Description

[0016] Some embodiments of this disclosure are now described by way of example only and with reference to the accompanying drawings. In all the drawings, the same reference numerals denote the same elements or elements of the same type.

[0017] Figure 1 A volume deployment system in an illustrative implementation is shown.

[0018] Figure 2 This is a flowchart illustrating a method for operating the volume deployment system in the illustrative embodiment.

[0019] Figure 3 An end effector with an undeployed volume in an illustrative implementation is described.

[0020] Figure 4 An end effector with a deployment volume in an illustrative implementation is described.

[0021] Figure 5 This is a cross-sectional view of the roll in the illustrative embodiment.

[0022] Figure 6 It is a scaled view of a portion of a roll including the layers of fiber-reinforced material in the illustrative embodiment.

[0023] Figure 7 A permeable layer in an illustrative embodiment is described.

[0024] Figure 8 This is a diagram illustrating a vacuum system coupled to a rotating shaft in an illustrative embodiment.

[0025] Figure 9 This is an illustrative implementation method. Figure 8 A cross-sectional view of the pivot.

[0026] Figure 10 It is a flowchart describing a method of applying negative pressure via a rotating shaft in an illustrative embodiment.

[0027] Figure 11 It is a flowchart describing a method for unwinding a roll from a single spool in an illustrative embodiment.

[0028] Figure 12 This is a flowchart illustrating the aircraft manufacturing and maintenance method in an illustrative implementation.

[0029] Figure 13 This is a block diagram illustrating the aircraft in an exemplary embodiment. Detailed Implementation

[0030] The figures and the following description provide specific illustrative embodiments of this disclosure. Therefore, it should be understood that, although not explicitly described or illustrated herein, those skilled in the art will be able to conceive of various arrangements that encompass and are included within the scope of this disclosure. Furthermore, any embodiments described herein are intended to aid in understanding the principles of this disclosure and should be construed as not being limited to the specific embodiments and conditions set forth herein. Therefore, this disclosure is not limited to the specific embodiments or examples described below, but is limited by the technical solutions and their equivalents.

[0031] The roll deployment system described herein can be used to compress preforms of composite components, such as preforms for fuselage sections. Initially, composite components, such as carbon fiber reinforced polymer (CFRP) components, are stacked in multiple layers collectively referred to as preforms. The individual fibers within each layer of the preform are aligned parallel to each other; however, different layers exhibit different fiber orientations to enhance the strength of the synthesized composite component along different dimensions. The preform includes a viscous resin that is cured to harden the preform into a composite component (e.g., for use in aircraft). Carbon fibers impregnated with uncured thermosetting or thermoplastic resins are referred to as “prepreg.” Other types of carbon fibers include “dry fibers” that have not yet been impregnated with thermosetting resin but may include tackifiers or adhesives. Dry fibers are infused with resin prior to curing. For thermosetting resins, curing is a one-way process called hardening, while for thermoplastic resins, if reheated, the resin becomes viscous and can then be solidified into the desired shape and cured. As used herein, the comprehensive term for the process of converting a preform into its final hardened shape (i.e., converting a preform into a composite part) is “hardening,” and this data covers the curing of thermosetting preforms and the forming / curing of thermoplastic preforms into the final desired shape.

[0032] Figure 1A roll deployment system 100 in an illustrative embodiment is shown schematically. The roll deployment system 100 includes any system or device capable of deploying rolls of material (e.g., preforms for a section of an aircraft fuselage mounted on a mandrel) onto an object positioned at a rigid tool and applying negative pressure to uniformly press the object onto the rigid tool. In this embodiment, the roll deployment system 100 includes an end effector 120 configured to move toward (downwards) the rigid tool 110. A link 122 is coupled to the end effector and configured to pivot relative to the end effector. As the link 122 pivots, its distal ends 123 move away from each other. A shaft 124 is coupled to the link and rotatably mounted to the link 122. Further, each shaft 124 stores a portion of a roll 130 of continuous material configured to place an object 140 onto the rigid tool 110. Thus, the shaft 124 carries the roll 130 of material. In one embodiment, roll 130 includes a permeable layer and an impermeable membrane, with the impermeable membrane extending beyond the perimeter of the permeable layer. In a further embodiment, roll 130 also includes one or more layers of fiber reinforcement for pressing onto the object 140.

[0033] The pivoting of link 122 rotates shaft 124 to deploy roll 130 of material from shaft 124. After deployment, roll 130 covers object 140 and extends beyond the boundaries of object 140 (e.g., and circumferentially to the inside and outside of the page). Accordingly, Figure 1 A roll 130 is described in a deployment configuration relative to object 140. In this embodiment, object 140 is a preform comprising multiple layers of fiber-reinforced material (e.g., CFRP), disposed on surface 112 of rigid tool 110, and awaiting hardening into a composite component.

[0034] During and / or after the deployment of roll 130, pump 150 operates to draw air from below roll 130. Specifically, pump 150 draws air from below the impermeable membrane 132 of roll 130 covering object 140 (e.g., a latex sheet or other material that exhibits a high level of elongation while retaining impermeability). Pump 150 draws air via port 152, which penetrates roll 130 at orifice 133, by applying negative pressure via port 152. In this embodiment, port 152 is located at the upper end 182 of roll 130. However, port 152 may be located at other desired portions of roll as needed. Port 152 penetrates impermeable membrane 132 and may be in direct contact with or positioned directly above the permeable layer 134 of roll 130.

[0035] The permeable layer 134 is breathable in both the lateral and vertical directions to allow for the uniform distribution of negative pressure across roll 130. This means that the negative pressure drawn through port 152 is applied evenly to object 140, rather than being localized at port 152. The negative pressure causes the end flaps 136 of the roll to be secured to the rigid tool 110 and forms a loose seal between the end flaps 136 and the rigid tool 110. That is, even if the end flaps 136 do not contain adhesives or other chemical bonding agents, the loose application of negative pressure causes the end flaps to be sealed to the rigid tool 110 by suction, provided that the amount of air drawn through pump 150 is at least equal to the amount of air lost due to leakage between the end flaps 136 and the rigid tool 110. The negative pressure also compresses roll 130 onto object 140 to ensure that object 140 remains in the proper position within the rigid tool 110.

[0036] Pump 150 is a high-flow-rate pump, meaning it can draw in large volumes of air through port 152 without necessarily drawing air at high pressure. In one embodiment, pump 150 creates a vacuum by applying a negative pressure of mercury (in Hg) between twenty-two and twenty-nine inches, but the airflow is at tens of cubic feet per minute (CFM) (e.g., between fifty and two hundred CFM). Thus, pump 150 and port 152 are able to maintain at least one inch of pressure over an impermeable membrane (e.g., the covered area). This can be done using only pump 150 or in combination with other pumps as needed. The amount of pressure applied by pump 150 and the amount of CFM drawn can be varied depending on the total boundary length of roll 130.

[0037] Controller 160 manages the operation of pump 150 based on inputs from sensors (not shown), such as pressure sensors or flow rate sensors, to ensure that the negative pressure is constant within the required range to overcome leakage along the perimeter of roll 130. The sensors can be located at any suitable location, such as at permeable layer 134, roll 130, port 152, pump 150, etc. In one embodiment, controller 160 increases or decreases the speed or intensity of pumping operation at pump 150 to maintain a constant airflow or a constant negative pressure. For example, controller 160 can be implemented as custom circuitry, a hardware processor executing programmed instructions, or some combination thereof.

[0038] The holding force (F) applied to object 140 by roll 130 H The quantity is based on the volume (VP) drawn per unit time by pump 150, the volume (VL) leaked per unit time through end flap 136 of roll 130, and the difference between the total area covered by roll 130. F can also be adjusted based on the pressure applied by pump 150. HModeling is performed. VL is overcome by VP. Therefore, VP should be equal to or greater than VL. Roll 130 is attached to rigid tool 110 without sealant, adhesive, fasteners, magnetism, etc. However, a vacuum is maintained below roll 130 by pump 150 while air leaks into the system through the perimeter. Thus, a small amount of air leakage may still exist in this configuration because negative pressure is the main (e.g., only) force holding roll 130 to rigid tool 110. Leakage may be caused by folds in the roll 130 that provide airflow channels. However, when roll 130 is not sealed to rigid tool 110, folds are only one cause of leakage because air leaks beyond the edges of roll 130. Even so, VL is still small, and therefore, negative pressure is maintained by venting an equal or greater amount of air lost through leakage between the end flaps 136 of impermeable membrane 132 and rigid tool 110.

[0039] The permeable layer 134 comprises a material that is deformable when force is applied to the impermeable membrane 132, allowing air to be drawn freely across the object 140 while adhering to it for air intake. In other words, the permeable layer 134 can draw air across the object 140 without displacing it. For example, the permeable layer 134 may comprise a conforming double-plane mesh material that facilitates airflow. The permeable layer 134 is a highly fluid material, meaning that it does not sufficiently restrict the rate at which the pump 150 draws air. Therefore, the resistance of the permeable layer 134 to airflow has a negligible effect on the flow rate of the pump 150. In some embodiments, the permeable layer 134 comprises an open-cell foam material. However, in this embodiment, the selected open-cell foam material is stiff enough that it is not collapsed beneath the impermeable membrane 132, and open enough that airflow is not inhibited. Since the airflow from the region below the impermeable membrane 132 is subsequently restricted, the collapse of the impermeable membrane 132 will shut down or restrict the airflow, which is undesirable.

[0040] The impermeable membrane 132 may comprise any suitable, flexible, airtight material. For example, the impermeable membrane 132 may comprise a plastic sheet that prevents air from escaping directly through it. In a further embodiment, for convenience, the impermeable membrane 132 and the permeable layer 134 may be structurally bonded or adhesively connected. In one embodiment, the permeable layer 134 and the impermeable membrane 132 comprise an approved contact material that accepts the use of the bonded carbon fiber composite and does not chemically interact with the resin.

[0041] The implementation of the method (shown as) Figure 2 The operation of the roll deployment system 100 is discussed in illustrative detail in the method 200. For this embodiment, it is assumed that the rigid tool 110 is waiting to place the preform for compression and hardening into a composite component.

[0042] Figure 2 This is a flowchart illustrating a method 200 for operating a volume deployment system in the illustrative embodiment. (See reference) Figure 1 The steps of method 200 are described in the volume deployment system 100 described herein; however, those skilled in the art will recognize that method 200 can be performed in other systems. The steps in the flowchart described herein are not exhaustive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

[0043] In step 202, object 140 is placed onto surface 112 of rigid tool 110. In one embodiment, this includes stacking a preform onto surface 112 via an automated fiber placement (AFP) machine or other tool. In a further embodiment, this includes picking up and placing the preform from another location and placing it onto surface 112.

[0044] Step 204 includes positioning the end effector 120 above the object 140. In one embodiment, this includes moving the end effector 120 on a guide rail, stand, or track (not shown) to align the end effector with the object 140.

[0045] Step 206 includes: unfolding the link 122 of the end effector 120, thereby positioning the roll 130 of material between the links 122 on top of the object 140 while still surrounding the object. In one embodiment, as the end effector 120 descends, the link 122 unfolds due to gravity because the pivot 124 follows the contour of the rigid tool. Simultaneously with unfolding, the link pivots relative to the end effector 120. This causes the link 122 to contact the rigid tool 110 (and / or the object 140) and deflect from the rigid tool 110 (and / or the object 140), thereby swinging outwards. In a further embodiment, the links are electrically driven and actively actuated to separate from each other. As the link 122 unfolds, the pivot 124 coupled to the link rotates. Because the roll 130 is wound around the pivot 124, the rotation of the pivot causes the roll 130 to be distributed, or causes the material at the roll to be spread out / positioned in place. This means that as the link 122 unfolds, the pivot 124 begins to roll in the opposite direction, thereby exposing the roll 130 for deployment. That is, because a portion of the roll 130 is held at the pivot 124 of one link 122, and another portion of the roll is held at the pivot of another link, the unfolding action of the link causes the roll 130 to unroll from the pivot.

[0046] In step 208, roll 130 is unrolled over object 140, roll 130 comprising an impermeable membrane covering the permeable layer and extending beyond the boundary of the permeable layer. In one embodiment, this occurs in response to the unfolding of a link, while in a further embodiment where a link is not used, this includes unrolling roll 130 via any other suitable means.

[0047] In step 210, port 152 applies a negative pressure to roll 130 to counteract air leakage between roll 130 and object 140, thereby creating a suction that presses object 140 against rigid tool 110. The applied negative pressure draws the end flaps 136 of the impermeable membrane 132 of roll 130 into contact with rigid tool 110. The application of negative pressure can be performed by drawing the required volumetric flow rate through pump 150 or by applying a constant pressure via pump 150. Because air is drawn in through port 152, the application of negative pressure causes air to be expelled from beneath roll 130. The negative pressure applies the required force for the desired time period to achieve complete contact with object 140.

[0048] After compression is complete, the connecting rod 122 retracts, thereby pulling the roll 130 upward from the preform. In embodiments where the roll 130 comprises one or more layers of fiber reinforcement material, the compression process secures the fiber reinforcement material to the object 140. Thus, when the roll 130 retracts, these layers of fiber reinforcement material remain at the object 140, while the permeable layer 134 and the impermeable membrane 132 retract. After the roll 130 is removed, it can be cleaned, reloaded with additional layers of fiber reinforcement material, and / or replaced by another cleaned spindle and loaded with the desired material.

[0049] Method 200 offers technological advantages over existing technologies because it enables rapid deployment of a tapeless compaction system via an end effector that occupies a relatively small space. It also allows for the deployment of individual layers of fiber reinforcement material as part of the compaction process. This increases production speed and reduces labor costs.

[0050] Figure 3 An end effector 300 with an undeployed roll as shown in an illustrative embodiment is described. In this embodiment, the end effector 300 includes a frame 330 and a base 332 from which a link 334 extends. An actuator 336 is disposed at the link 334 and, after clamping is complete, facilitates the retraction of the link 334 by rolling it upward along a spindle 310 via a pivot 338. In one embodiment, the actuator 336 includes a motor with a slip clutch that, after clamping is complete, causes the pivot 338 to move upward and backward. In this embodiment, the end effector 300 deploys a roll of material from the pivot 338 into a preform 320 placed on the spindle 310.

[0051] Figure 4 Described Figure 3 The diagram shows the deployment volume 400 with an end effector 300 as illustrated in the embodiment. For example... Figure 4 As shown, the spindle 338 has been moved to the deployment roll 400 so that the roll 400 covers the entire preform 320. The pump 420 applies negative pressure during the deployment of the roll 400 using the vacuum port 410, and is also used to press the preform 320 into place after deployment.

[0052] Figure 5 This is a cross-sectional view of volume 400 in the illustrative embodiment and is related to... Figure 3 This corresponds to arrow 5 in the diagram. Roll 400 is wound around pivot 338, and as link 334 unfolds outward, pivots 338 roll apart. This exposes roll 500 of roll 400 for deployment.

[0053] Figure 6 It is a scaled view of a portion of a roll including the fiber-reinforced materials of each layer in the illustrative embodiment and is related to Figure 5 It corresponds to region 6 in the text. Figure 6 The roll 400 is shown to include multiple layers. In this embodiment, the roll 400 includes one or more layers 621 of fiber reinforcement material. When the roll 400 is deployed, the layers 621 are in direct contact with the object below and can form an outer mold line (OML) or inner mold line (IML) stack of the composite component. As described above, the permeable layer 614 is after the layer 612 and is able to apply a negative pressure uniformly distributed along the underside of the roll 400 during deployment. In embodiments where the roll 400 does not include individual layers of fiber reinforcement material, the permeable layer 614 is positioned to be in direct contact with the object below. An impermeable layer 616 is after the permeable layer 614 and prevents airflow from crossing when the roll is deployed. When flattened, the roll 400 includes only one group 610 of layers 612, the permeable layer 614, and the impermeable layer 616. However, the roll 400 is wound around a pivot such that the group 610 is visible multiple times along the diameter of the pivot.

[0054] Figure 7A permeable layer, illustratively described, is air-permeable in both the vertical and horizontal directions. Specifically, air 710 can flow freely through and across the gaps 720 in the permeable layer 700. This is possible because the permeable layer 700 is a double-planar mesh. The first layer 730 of the double-planar mesh includes structural elements 732 arranged parallel to each other, and the second layer 740 of the double-planar mesh includes structural elements 742 arranged parallel to each other, but in a different direction from the first layer 730. The first layer 730 allows air to flow horizontally in a first direction, and the second layer 740 allows air to flow horizontally in a second direction. Simultaneously, both layers allow air to flow freely in the vertical direction. Thus, if a negative pressure is applied to a portion of the permeable layer 700, the negative pressure can cause air to be drawn uniformly across the entire permeable layer 700. The permeable layer 700 allows airflow to be free and does not interfere with the pump's suction of air. That is, the permeable layer 700 does not limit the pump's CFM rate. The permeable layer 700 may include polyethylene, polypropylene, nylon, etc. In one embodiment, the permeable layer 700 is selected as an "approved contact" material that does not chemically interact with the adhesive of the cured resin at the object being fixed. For example, the permeable layer 700 may be made of a silicone-free material that does not mark the object 140 below.

[0055] The aforementioned apparatus and method involve the use of a pair of opposing rollers and a vacuum port configured to apply a vacuum through a hole in the material. However, in other embodiments, further configurations are possible. For example, in a further embodiment, the material is rolled on a single roller, rather than on a pair of opposing rollers, and / or a vacuum is applied via the end of the roller shaft, via a cavity in the shaft, and through a perforation in the shaft. To illustrate these configurations, Figures 8 to 11 Embodiments of vacuum systems including these configurations and methods of utilizing such systems are shown and described below.

[0056] Figure 8 Figure 800 illustrates a vacuum system 870 coupled to a rotating shaft 840 in an illustrative embodiment. Figure 8 As shown, the rotating shaft 840 includes a cavity 842 having a plurality of through holes 844 leading to the outside 846. The cavity 842 is in communication with a vacuum port 850, that is, when the vacuum system 870 vents air from the vacuum port 850, the air in the cavity 842 is removed.

[0057] A roll 838 of material 830 is wound around a spindle 840 and covers the lower preform 860 for use in composite parts or any other suitable objects. The ends of the roll 838 are sealed to the spindle 840 around a perforation 844, such that suction applied via a vacuum port 850 generates a negative pressure evenly distributed through the roll 838. Figure 9Further details of the arrangement are provided in the document.

[0058] The other end 836 of the material 830 of the roll 838 is attached to the surface 812 of the mandrel 810 via tape 820. In a further embodiment, the end 836 is attached to the mandrel 810 by applying negative pressure to the roll 838. The material 830 comprises multiple layers, including at least one impermeable membrane 832 and a permeable layer 834 (e.g., a double-planar mesh) disposed beneath the impermeable membrane 832. The permeable layer 834 is in fluid communication with a cavity 842 within the shaft 840. (Refer to below...) Figure 9 Further details of the layer arrangement of Material 830 were discussed.

[0059] The hollow shaft 840 and / or the coupling of the vacuum port 850 to the hollow portion of the shaft 840 provide multiple benefits by enabling a single component (i.e., the shaft) to perform multiple functions, facilitating not only the spreading of material but also the clamping of the underlying preform 860. In a further embodiment, multiple shafts (such as...) Figure 3 and Figure 4 The shaft described herein (e.g., the rotating shaft) is implemented as a hollow rotating shaft with a cavity and a vacuum port to apply negative pressure. In this embodiment, the vacuum ports of different rotating shafts can be provided on the same side of each rotating shaft, on different sides of the rotating shaft, or on both sides of the rotating shaft, as needed.

[0060] Figure 9 This is an illustrative implementation method. Figure 8 A cross-sectional view of the rotating shaft 840 is shown in Figure 900. Figure 9 The scale in the middle is adjusted to better show the relationship with Figure 8 The other components described herein relate to shaft 840, and therefore, the scales of these figures do not correspond. As indicated by the arrows, Figure 9 This illustrates how airflow moves from material 830 to shaft 840 when suction is applied. (As shown) Figure 9 As shown, the permeable layer 834 extends to contact and thus is in fluid communication with the perforation 844. Further, the perforation 844 is located between the end 936 of the roll and the position 938 of the shaft 840. The permeable layer 834 is defined by a first impermeable membrane 832 forming an upper boundary on the top of the preform 860 and further defined by a second impermeable membrane 910 forming a lower boundary. The impermeable membrane contacts the permeable layer and thus contains the airflow within the permeable layer 834.

[0061] The first impermeable membrane 832 terminates after the permeable layer 834, and the second impermeable membrane 910 terminates before reaching the preform 860. The second impermeable membrane 910 prevents pressure loss in the permeable layer 834 during and after the layup process by providing a direct current path to the cavity 842 of the spindle 840. In a further embodiment, such as discussed above, the roll 838 is wound around the second spindle, and the end 836 of the roll is sealed to the second spindle in a manner similar to that described above with respect to the end 936.

[0062] Figure 10 This is a flowchart illustrating a method 1000 for applying negative pressure via a rotating shaft in an illustrative embodiment. Step 1002 includes: positioning the rotating shaft 840 on top of an object, such as a preform for a composite component. This may include: physically placing the rotating shaft 840 on the object or on a mandrel 810 on which objects are already stacked. Step 1004 includes: spreading a roll 838 of material 830 from the rotating shaft 840 onto the object, thereby covering the object with material. In some embodiments, the spreading action causes the permeable layer to come into direct contact with the object.

[0063] Step 1006 includes applying negative pressure to a permeable layer 834 in a material 830 in fluid communication with a cavity 842 within the shaft 840. In one embodiment, the application of negative pressure is performed via a vacuum port 850 in fluid communication with the cavity 842 and via a plurality of perforations 844 at the shaft 840 connecting the cavity 842 to the permeable layer 834. The negative pressure is distributed across the impermeable membrane via the permeable layer to ensure that the impermeable membrane does not “pinch off” or self-seale in response to negative pressure at undesirable locations. Step 1008 includes forming a suction that draws the impermeable membrane of the material into contact with an object in response to the negative pressure. The suction is naturally formed due to the distribution of negative pressure across the impermeable membrane. At locations where the permeable layer 834 terminates and the impermeable membrane 832 extends, the negative pressure causes the impermeable membrane to seal itself to the underlying mandrel 810.

[0064] Figure 11 This is a flowchart illustrating a method 1100 for unwinding a roll from a single spool in an illustrative embodiment. Method 1100 includes: in step 1102, positioning a spool 840 on top of an object located at a mandrel 810. Step 1104 includes: attaching the end 836 of a roll 838 of material at the spool 840 to the mandrel 810. In one embodiment, attaching the end 836 of the roll includes: adhering the end 836 of the roll 838 to the mandrel 810. As described above, for method 1000, in a further embodiment, attaching the end of the roll includes: forming a suction between an impermeable membrane of the material and the mandrel. Thus, as long as there is substantially no air leakage, activating the vacuum system 870 can be used to attach the end 836.

[0065] Step 1106 includes applying negative pressure to the permeable layer in the material, thereby forming a suction that positions the material in contact with an object. This can be done in a manner similar to step 1008 in method 1000 discussed above. In one embodiment, the application of negative pressure is performed via a plurality of perforations 844 at the shaft where the cavity of the shaft is connected to the permeable layer. The permeable layer 834 distributes negative pressure across the impermeable membrane of the material.

[0066] Step 1108 includes: unwinding the roll while applying negative pressure. In one embodiment, unwinding the roll includes: covering the preform for the composite component. Unwinding the roll allows the permeable layer to be placed in direct contact with the object. Further, because the ends 836 of the roll 838 are attached in place, the roll does not warp or change position as the placement process continues. This allows the entire roll (the entire covered object) to be unwound as needed. In a further embodiment, the method further includes: compressing the object via suction. This can include: increasing the negative pressure until the object is securely pressed into the mandrel at the desired level of pressure.

[0067] although Figures 8 to 11 The description includes a single roller, a vacuum device for the application tube, and related methods; however, in further embodiments, the various aspects and features mentioned herein are applied to various systems. For example, these can be... Figures 8 to 11 The arrangement of the cavity and vacuum system described herein is applied to Figure 1 and Figures 3 to 5 The two-roller implementation described herein, except for the vacuum applied via one or more ends of one or two rotating shafts. In a further embodiment, in these... Figures 8 to 11 The single-roller implementation described herein can be accessed via reference. Figure 1 and Figures 3 to 5 The material being discussed has pores that are then subjected to a vacuum.

[0068] Example

[0069] In the following embodiments, additional processes, systems, and methods are described in the context of a roll deployment system for pressing preforms onto a rigid tool (e.g., a mandrel).

[0070] More specifically, referring to the attached diagram, in Figure 12 The method 1200 shown is... Figure 9Embodiments of this disclosure are described in the context of aircraft manufacturing and maintenance of the illustrated aircraft 1202. During pre-production, method 1200 may include the specification and design 1204 of the aircraft 1202 and material procurement 1206. During production, the manufacturing of components and sub-assemblies of the aircraft 1202 and system integration 1210 are performed. Subsequently, the aircraft 1202 may be certified and delivered 1212 for operation 1214. When in customer use, routine maintenance and upkeep 1216 of the aircraft 1202 are scheduled (which may also include modifications, reconfigurations, refurbishments, etc.). The apparatus and methods covered herein may be employed in any one or more suitable stages of the production and maintenance (e.g., specifications and design 1204, material procurement 1206, component and sub-component manufacturing 1208, system integration 1210, certification and delivery 1212, operation 1214, maintenance and upkeep 1216) and / or any suitable component of the aircraft 1202 (e.g., fuselage 1218, system 1220, interior 1222, propulsion system 1224, electrical system 1226, hydraulic system 1228, environmental system 1230) as described in method 1200.

[0071] The various processes of method 1200 can be performed or completed by system integrators, third parties, and / or operators (e.g., customers). For the purposes of this description, system integrators may include, but are not limited to, any number of aircraft manufacturers and main system subcontractors; third parties may include, but are not limited to, any number of retailers, subcontractors, and suppliers; and operators may be airlines, leasing companies, military entities, service organizations, etc.

[0072] like Figure 13 As shown, the aircraft 1202 produced by method 1200 may include a fuselage 1218 having multiple systems 1220 and an interior 1222. Embodiments of system 1220 include one or more of a propulsion system 1224, an electrical system 1226, a hydraulic system 1228, and an environmental system 1230. Any number of other systems may be included. Although an aerospace embodiment is shown, the principles of the invention can be applied to other industries such as the automotive industry.

[0073] As mentioned above, the apparatus and methods covered herein can be employed in any one or more stages of the production and maintenance described in method 1200. For example, a component or sub-assembly corresponding to component and sub-assembly manufacturing 1208 can be prepared or manufactured in a manner similar to that used for components or sub-assemblies produced when aircraft 1202 is put into operation. Furthermore, for example, during sub-assembly manufacturing 1208 and system integration 1210, one or more apparatus embodiments, method embodiments, or combinations thereof can be utilized to significantly accelerate the assembly of aircraft 1202 or reduce costs. Similarly, during the operation of aircraft 1202, such as, but not limited to, maintenance and upkeep 1216, one or more apparatus embodiments, method embodiments, or combinations thereof can be utilized. Therefore, the invention can be used in any stage or combination thereof discussed herein, such as the specifications and design 1204 of the aircraft 1202, material procurement 1206, component and sub-component manufacturing 1208, system integration 1210, certification and delivery 1212, operation 1214, maintenance and upkeep 1216, and / or any suitable components (e.g., fuselage 1218, system 1220, interior 1222, propulsion system 1224, electrical system 1226, hydraulic system 1228, and / or environmental system 1230).

[0074] In one embodiment, the component includes a portion of the fuselage 1218 and is manufactured during the component and subassembly manufacturing process 1208. The component can then be assembled into an aircraft in system integration 1210, and then put into operation 1214 until wear renders the component unusable. Therefore, during maintenance 1216, the component can be discarded and replaced with a newly manufactured component. Throughout component and subassembly manufacturing 1208, the inventive components and methods can be used to manufacture new components.

[0075] Any of the various control elements (e.g., electrical or electronic components) shown in the figures or described herein can be implemented as hardware, processor-implemented software, processor-implemented firmware, or some combination thereof. For example, an element can be implemented as dedicated hardware. A dedicated hardware element may be referred to as a “processor,” a “controller,” or a similar term. When provided via a processor, functionality may be provided via a single dedicated processor, via a single shared processor, or via multiple independent processors (some of which may be shared). Moreover, the explicit use of the terms “processor” or “controller” should not be construed as exclusively referring to hardware capable of executing software and may implicitly include, but is not limited to, digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs), or other circuitry, field-programmable gate arrays (FPGAs), read-only memory (ROM) for storing software, random access memory (RAM), non-volatile memory, logic, or some other physical hardware component or module.

[0076] Furthermore, control elements can be implemented as instructions executed by a processor or computer to perform the functions of the element. Some embodiments of these instructions are software, program code, and firmware. When executed by a processor, the instructions are operable to instruct the processor to perform the functions of the element. The instructions can be stored on a processor-readable storage device. Some embodiments of the storage device are digital or solid-state memory, magnetic storage media such as disks and magnetic tapes, hard drives, or optically readable digital data storage media.

[0077] This disclosure includes exemplary implementations according to the following provisions: Article 1. A method for clamping an object placed on the surface of a rigid tool, the method comprising: A roll of material (208) is laid out over the object, comprising an impermeable membrane covering the permeable layer and extending beyond the boundary of the permeable layer; and A negative pressure is applied to the permeable layer that counteracts air leakage between the roll and the object, thereby forming a grip that presses the object firmly onto the rigid tool (210).

[0078] Section 2. The method described in Section 1 further includes: Place the end effector above the object (204); and Unfold the link of the end effector so that the roll of material is positioned on top of the object while surrounding it (206).

[0079] Section 3. According to the method described in Section 2, wherein: Applying negative pressure includes applying negative pressure through pores in the material.

[0080] Section 4. According to the method described in Section 2 or Section 3, wherein: Applying negative pressure includes applying negative pressure to a permeable layer in the material, wherein the permeable layer is in fluid communication with a cavity within the shaft of the bearing roll.

[0081] Article 5. The method according to any one of Articles 2 to 4, wherein: The link that unfolds the end effector causes the shaft coupled to the link and storing the roll to rotate, thereby distributing the roll.

[0082] Article 6. The method according to any one of paragraphs 2 to 5 further comprises: After being compressed, the connecting rod retracts, thereby pulling the object upwards.

[0083] Article 7. The method according to any one of Articles 2 to 6, wherein: The extension of the link is performed by driving the end effector toward a rigid tool.

[0084] Article 8. The method according to any one of Articles 2 to 7, wherein: The link for deploying the end effector includes: pivoting the link relative to the end effector.

[0085] Article 9. The method according to any one of Articles 1 to 8, wherein: Applying negative pressure includes expelling air from below the roll.

[0086] Article 10. The method according to any one of Articles 1 to 9, wherein: Applying negative pressure causes the flap of the impermeable membrane of the roll of material to come into contact with a rigid tool.

[0087] Article 11. The method according to any one of paragraphs 1 to 10 further comprises: Before being laid out, the spool containing the material is placed on top of the object. Applying negative pressure includes applying negative pressure to a permeable layer in a material that is in fluid communication with the cavity inside the shaft.

[0088] Article 12. The method according to any one of Articles 1 to 11, wherein: Negative pressure is applied via multiple perforations at the point where the shaft cavity is connected to the permeable layer.

[0089] Article 13. According to the method described in Article 12, wherein: The negative pressure is applied via a vacuum port that is in fluid communication with the cavity.

[0090] Article 14. The method according to any one of paragraphs 1 to 13 further comprises: Negative pressure is distributed across the impermeable membrane via the permeable layer.

[0091] Article 15. The method according to any one of Articles 1 to 14, wherein: Unrolling the material includes covering a preform for the composite component.

[0092] Article 16. The method according to any one of paragraphs 1 to 15 further comprises: The object is pressed firmly by suction.

[0093] Article 17. The method according to any one of paragraphs 1 to 16 further comprises: During the laying process, the permeable layer is placed in direct contact with the object.

[0094] Article 18. The method according to any one of paragraphs 1 to 17 further comprises: Attach the end of the roll of material to a rigid tool.

[0095] Article 19. According to the method described in Article 18, wherein: The attachment roll end includes: attaching the roll end to a rigid tool.

[0096] Article 20. A non-volatile computer-readable medium comprising programming instructions, which, when executed by a processor, operate to perform a method of clamping an object placed on the surface of a rigid tool, the method comprising: A roll of material (208) is laid out over the object, comprising an impermeable membrane covering the permeable layer and extending beyond the boundary of the permeable layer; and A negative pressure is applied to the permeable layer that counteracts air leakage between the roll and the object, thereby forming a grip that presses the object firmly onto the rigid tool (210).

[0097] Article 21. The medium according to Article 20, wherein the method further comprises: Place the end effector above the object (204); and Unfold the link of the end effector so that the roll of material is positioned on top of the object while surrounding it (206).

[0098] Article 22. The medium according to Article 21, wherein: Applying negative pressure includes applying negative pressure through pores in the material.

[0099] Article 23. The medium according to Article 21 or Article 22, wherein: Applying negative pressure includes applying negative pressure to a permeable layer in the material, wherein the permeable layer is in fluid communication with a cavity within the shaft of the bearing roll.

[0100] Article 24. The medium according to any one of Articles 21 to 23, wherein: The link that unfolds the end effector causes the shaft coupled to the link and storing the roll to rotate, thereby distributing the roll.

[0101] Article 25. The medium according to any one of Articles 21 to 24, wherein the method further comprises: After being compressed, the connecting rod retracts, thereby pulling the object upwards.

[0102] Article 26. The medium according to any one of Articles 21 to 25, wherein: The extension of the link is performed by driving the end effector toward a rigid tool.

[0103] Article 27. The medium according to any one of Articles 21 to 26, wherein: The link for deploying the end effector includes: pivoting the link relative to the end effector.

[0104] Article 28. The medium according to any one of Articles 20 to 27, wherein: Applying negative pressure includes expelling air from below the roll.

[0105] Article 29. The medium according to any one of Articles 20 to 28, wherein: Applying negative pressure causes the flap of the impermeable membrane of the roll of material to come into contact with a rigid tool.

[0106] Article 30. The medium according to any one of Articles 20 to 29, wherein the method further comprises: Before being laid out, the spool containing the material is placed on top of the object. Applying negative pressure includes applying negative pressure to a permeable layer in a material that is in fluid communication with the cavity inside the shaft.

[0107] Article 31. The medium according to any one of Articles 20 to 30, wherein: Negative pressure is applied via multiple perforations at the point where the shaft cavity is connected to the permeable layer.

[0108] Article 32. The medium according to any one of Articles 20 to 31, wherein: The negative pressure is applied via a vacuum port that is in fluid communication with the cavity.

[0109] Article 33. The medium according to any one of Articles 20 to 32, wherein the method further comprises: Negative pressure is distributed across the impermeable membrane via the permeable layer.

[0110] Article 34. The medium according to any one of Articles 20 to 33, wherein: Unrolling the material includes covering a preform for the composite component.

[0111] Article 35. The medium according to any one of Articles 20 to 34, wherein the method further comprises: The object is pressed firmly by suction.

[0112] Article 36. The medium according to any one of Articles 20 to 35, wherein the method further comprises: During the laying process, the permeable layer is placed in direct contact with the object.

[0113] Article 37. A device for pressing an object against a rigid tool, the device comprising: Multiple spindles (124); and A roll (130) of material (830) is stored on a spindle and is configured to be placed on an object (140) at a rigid tool (110) when the spindles are moved apart.

[0114] Article 38. The apparatus according to Article 37 further comprises: The end effector (120) is configured to move toward the rigid tool; and Link (122) is coupled to the end effector and configured to pivot relative to the end effector; The rotating shaft is coupled to the connecting rod and rotatably mounted to the connecting rod.

[0115] Article 39. The apparatus according to Article 37 or Article 38, wherein: The roll includes a permeable layer (134) and an impermeable membrane (132); and The impermeable membrane extends beyond the perimeter of the permeable layer.

[0116] Article 40. The apparatus according to any one of Articles 37 to 39, wherein: Rigid tools include mandrels (310) for sections of the aircraft fuselage.

[0117] Article 41. The apparatus according to any one of Articles 37 to 40 further comprises: Port (850), penetrates into the volume; and Pump (150) applies negative pressure through port.

[0118] Article 42. The apparatus according to any one of Articles 37 to 41, wherein: The roll extends beyond the object.

[0119] Article 43. The apparatus according to any one of Articles 37 to 42, wherein: The roll includes at least one layer of fiber-reinforced material.

[0120] Article 44. An apparatus comprising: At least one rotating shaft (124) further includes: External (846); cavity (842); and Perforation (844) allows the cavity to be coupled to the outside; and A roll (838) of material (830) is wound around a shaft, wherein one end (836) of the roll is sealed to the shaft, and wherein the material comprises: Permeable layer (834); and An impermeable membrane (832) is in contact with a permeable layer.

[0121] Article 45. The apparatus according to Article 44, wherein: The cavity is coupled to the vacuum system (870).

[0122] Article 46. The apparatus according to Article 45 further comprises: The vacuum port (850) is in fluid communication with the cavity at the point where the shaft is coupled to the vacuum system.

[0123] Article 47. The apparatus according to any one of Articles 44 to 46, wherein: The permeable layer consists of a biplane mesh.

[0124] Article 48. The apparatus according to any one of Articles 44 to 47, wherein: The material further includes a second impermeable membrane (910) in contact with the permeable layer.

[0125] Article 49. The apparatus according to any one of Articles 44 to 48, wherein: At least one spool includes two spools, wherein a roll is wound around each of the two spools and the end (836) of the roll is sealed to the two spools.

[0126] Article 50. The apparatus according to any one of Articles 44 to 49, wherein: The preform is positioned between the points where the ends of the roll are sealed to the spool.

[0127] Section 51. A method comprising: Set the pivot on top of the object located at the center axis (1102).

[0128] The end of the roll of material at the pivot is attached to the mandrel (1104). A negative pressure is applied to the permeable layer in the material, thereby forming an adhesion that places the material in contact with the object (1106); and Unroll the roll while applying negative pressure (1108).

[0129] Section 52. According to the method described in Section 51, wherein: The end of the attachment roll includes: attaching the end of the roll to the mandrel.

[0130] Section 53. According to the method described in Section 51 or Section 52, wherein: The end of the attachment roll includes: forming an adhesion between the impermeable membrane of the material and the mandrel.

[0131] Article 54. The method according to any one of Articles 51 to 53, wherein: Negative pressure is applied via multiple perforations at the point where the shaft cavity is connected to the permeable layer.

[0132] Article 55. The method according to any one of Articles 51 to 54, wherein: Unwinding includes: covering a preform for composite components.

[0133] Article 56. The method according to any one of Articles 51 to 55 further comprises: The object is pressed firmly by suction.

[0134] Article 57. The method according to any one of Articles 51 to 56 further comprises: Negative pressure is distributed across the impermeable membrane via the permeable layer.

[0135] Article 58. The method according to any one of Articles 51 to 57 further comprises: During the laying process, the permeable layer is placed in direct contact with the object.

[0136] Although specific embodiments have been described herein, the scope of this disclosure is not limited to these specific embodiments. The scope of this disclosure is defined by the following technical solutions and their equivalents.

Claims

1. A device for clamping an object onto a rigid tool, the device comprising: Multiple spindles; as well as A roll of material, stored on the spools, is configured to be placed on an object at a rigid tool when the spools are moved apart, wherein the roll of material comprises a permeable layer and an impermeable membrane, and wherein the impermeable membrane extends beyond the perimeter of the permeable layer.

2. The apparatus according to claim 1, further comprising: An end effector is configured to move toward the rigid tool; as well as A connecting rod, coupled to the end effector and configured to pivot relative to the end effector. The rotating shaft is coupled to the connecting rod and is rotatably mounted to the connecting rod.

3. The apparatus according to claim 1, wherein: The rigid tool includes a mandrel for a section of the aircraft fuselage.

4. The apparatus according to claim 1, further comprising: The port penetrates into a roll of material that is in fluid communication with the permeable layer.

5. The apparatus according to claim 1, wherein: The roll of material extends beyond the object.

6. The apparatus according to claim 1, wherein: The roll of the material comprises at least one layer of fiber-reinforced material.

7. The apparatus according to claim 4, further comprising: The pump applies negative pressure through the port.

8. The apparatus according to claim 1, wherein: The permeable layer comprises a double-plane mesh.

9. An apparatus comprising: At least one rotating shaft, including: external; cavity; and Perforation to couple the cavity to the outside; and A roll of material is wound around the outside of the rotating shaft, wherein one end of the roll of material is sealed to the rotating shaft, and wherein the roll of material comprises: A permeable layer, in fluid communication with the cavity through the perforations; and An impermeable membrane is in contact with the permeable layer.

10. The apparatus of claim 9, further comprising: A vacuum system is coupled to the cavity.

11. The apparatus of claim 10, further comprising: A vacuum port is in fluid communication with the cavity at the point where the shaft couples the shaft to the vacuum system.

12. The apparatus according to claim 9, wherein: The permeable layer comprises a double-plane mesh.

13. The apparatus according to claim 9, wherein: The roll of the material further includes a second impermeable membrane in contact with the permeable layer.

14. The apparatus according to claim 9, wherein: The at least one spool includes two spools, wherein a roll of material is wound around each of the two spools and the end of the roll of material is sealed to the two spools.

15. The apparatus according to claim 9, wherein: The perforation is provided therein between the position where the end of the roll of material is sealed to the shaft.

16. A roll of material configured to perform placement on an object at a rigid tool, the roll of material comprising: Permeable layer; as well as An impermeable membrane, wherein the impermeable membrane extends beyond the perimeter of the permeable layer.

17. The roll of material according to claim 16, wherein: The roll of material is configured to extend beyond the object.

18. The roll of material according to claim 16, further comprising: At least one layer of fiber-reinforced material.

19. The roll of material according to claim 16, wherein: The permeable layer comprises a double-plane mesh.

20. The roll of material according to claim 16, further comprising: A port, penetrating into a roll of material in fluid communication with the permeable layer, wherein the port is configured to be coupled to a pump that applies negative pressure via the port.

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