roll press

Abstract

The present application relates to a roll press. A roll press and a method of controlling pressing of a composite material are presented. The roll press includes a first portion of a press surface formed of a first material; and a second portion of the press surface formed of a second material having a lower hardness than the first material, wherein the second portion is configured to selectively reduce a press pressure by the second portion of the press surface.

Description

Technical Field

[0001] This disclosure generally relates to the manufacture of composite materials, and more specifically to the pressing of composite materials. Background Technology

[0002] Composite structures are typically formed by placing composite sheet layers or layers onto a forming tool that defines the shape and / or profile of the composite structure. Once placed, the composite material is subsequently reinforced and / or cured to form the composite structure. However, known techniques for transporting the composite material to the forming tool, placing the composite material onto the forming tool, and reinforcing the composite material onto the forming tool can be labor-intensive and time-consuming. Furthermore, depending on the profile and geometry of the composite structure, special treatments can be used to prevent the introduction of wrinkles or other inconsistencies during the transfer and placement of the composite material.

[0003] Therefore, it is desirable to have a method and device that takes into account at least some of the above-mentioned problems, as well as other possible problems. Summary of the Invention

[0004] Embodiments of this disclosure provide a roller press. The roller press includes a first portion of a pressing surface formed of a first material; and a second portion of a pressing surface formed of a second material having a lower hardness than the first material, wherein the second portion is configured to selectively reduce the pressing pressure through the second portion of the pressing surface.

[0005] Another embodiment of this disclosure provides a method for pressing a composite material. A roller press rolls along a pressing path such that the pressing surface of the roller press contacts the composite material. The pressing surface includes a first portion formed of a first material and a second portion formed of a second material having a lower hardness than the first material. A reduced pressing pressure is applied to the composite material through the second portion of the pressing surface.

[0006] Another embodiment of this disclosure provides a method for controlling the pressing pressure of a roller press. A first portion of the pressing surface of the roller press is formed of a first material. A second portion of the pressing surface of the roller press is formed of a second material having a hardness lower than that of the first material.

[0007] The features and functions described herein may be implemented independently in various embodiments of this disclosure, or may be combined in other embodiments, wherein further details can be seen with reference to the following description and accompanying drawings. Attached Figure Description

[0008] The appended claims set forth novel features that are considered to be features of exemplary embodiments. However, the exemplary embodiments, their preferred modes of use, further objects, and features can be best understood by referring to the following detailed description of exemplary embodiments of the present disclosure when read in conjunction with the accompanying drawings, wherein: Figure 1 This is an example of an aircraft according to an exemplary embodiment; Figure 2A and 2B This is an example of a block diagram of a manufacturing environment according to an exemplary embodiment; Figure 3A and 3B This is an example of a block diagram of a manufacturing environment according to an exemplary embodiment; Figure 4 This is an example of an isometric view of a pressing machine according to an exemplary embodiment; Figure 5 This is an example of a cross-sectional view of a press according to an exemplary embodiment; Figure 6 This is an example of an isometric view of a pressing machine according to an exemplary embodiment; Figure 7 This is an example of an isometric view of a pressing machine according to an exemplary embodiment; Figure 8 This is an example of an isometric view of a pressing machine according to an exemplary embodiment; Figure 9 This is an example of a cross-sectional view of an elongated composite member that can be pressed by a press according to an exemplary embodiment; Figure 10 This is an example of a simplified side view of a pressing machine according to an exemplary embodiment; Figure 11 This is a flowchart of a method for pressing composite materials according to an exemplary embodiment; Figure 12 This is a flowchart of a method for controlling the pressing pressure of a roller press according to an exemplary embodiment; Figure 13 This is a flowchart of a method for pressing composite materials according to an exemplary embodiment; Figure 14 This is a flowchart of a method for pressing composite materials according to an exemplary embodiment; Figure 15 This is a flowchart of a method for selectively forming wrinkles in a composite material during forming, according to an exemplary embodiment; Figure 16 This is an example of an aircraft manufacturing and servicing method in block diagram form according to exemplary embodiments; and Figure 17 This is an example of an aircraft in the form of a block diagram that can be implemented as an exemplary embodiment. Detailed Implementation

[0009] The exemplary example acknowledges and considers several factors. The exemplary example recognizes and considers that current manufacturing of elongated composite components involves an operator manually placing the elongated composite component into a forming and curing tool. The exemplary example recognizes and considers that current elongated composite components are pressed against the forming and curing tool using vacuum pressing. The exemplary example recognizes and considers that currently, unique elongated pressing machines are used for each cross-section of the elongated composite component. The exemplary example recognizes and considers that currently, unique elongated pressing machines are used for each elongated composite component.

[0010] The exemplary example recognizes and takes into account that currently used vacuum presses can utilize additional pressure provided by another operator or component. The exemplary example provides a roller-type pressing end actuator for a contour forming sequence. The exemplary example provides a roller-type pressing end actuator configured to provide sufficient continuous pressure during the process. The exemplary example provides a roller-type pressing end actuator that can be used to progressively hold and press an elongated composite member into place.

[0011] Turn now Figure 1 An example of an aircraft is described according to an exemplary embodiment. Wings 102 and 104 of the aircraft 100 are attached to a main body 106. The aircraft 100 includes an engine 108 attached to the wing 102 and an engine 110 attached to the wing 104.

[0012] The main body 106 has a tail section 112. Horizontal stabilizers 114, 116 and 118 are attached to the tail section 112 of the main body 106.

[0013] Aircraft 100 is an example of an aircraft that may have an elongated composite structure pressed using a roller press of an exemplary example. Composite material reinforcements of at least one of wing 102, wing 104, or body 106 may be pressed using a roller press of an exemplary example.

[0014] While exemplary examples have been described with respect to aircraft, exemplary embodiments can be applied to other types of platforms. The platform can be, for example, a mobile platform, a fixed platform, a land-based structure, a water-based structure, or a space-based structure. More specifically, the platform can be a surface vessel, tank, troop carrier, train, spacecraft, space station, satellite, submarine, automobile, power plant, house, manufacturing facility, building, oil refinery, chemical container, fuel tank, cabin, or other suitable platform.

[0015] Turn now Figure 2A and 2B An example of a block diagram of a manufacturing environment is described according to an exemplary embodiment. Figure 1 The composite components of the medium-sized aircraft 100 can be passed through Figure 2A and 2B The roller press 206 is used to press the composite material 254 onto the forming tool 256.

[0016] In this exemplary example, the roller press 206 includes a pressing surface 210 configured to contact the composite material 254. During operation, as the roller press 206 moves along the pressing path, the roller press 206 applies a compressive force to the composite material 254. During operation, the roller press 206 applies a compressive force to the composite material 254 when the pressing surface 210 contacts the composite material 254.

[0017] The roller press 206 includes any desired number of features to provide the desired compression of the composite member 248 and reduce unwanted inconsistencies in the resulting composite structure 246. In some exemplary examples, the roller press 206 includes a multi-material pressing surface 210 to control the application of compressive force. In some exemplary examples, the roller press 206 includes independently movable roller segments 264 to keep the speed 277 constant, while the angular velocity 278 depends on the size and shape of a portion of the roller press 206. In some exemplary examples, the roller press 206 includes grooves 280 in the pressing surface 210 to provide localized relief 260 from the compression 259. Any desired combination of at least one of the different materials forming the pressing surface 210, the grooves 280, or the independently movable roller segments 264 can reduce inconsistencies in the composite member 248. In some exemplary examples, the composite member 248 may be referred to as an elongated composite member.

[0018] In some exemplary examples, the roller press 206 includes a first portion 234 of a pressing surface 210 formed of a first material 226 and a second portion 236 of a pressing surface 210 formed of a second material 228, the second material 228 having a lower hardness than the first material 226. In this exemplary example, the first material 226 has a hardness 227, and the second material 228 has a hardness 229. In this exemplary example, hardness 227 is greater than hardness 229. The second portion 236 is configured to selectively reduce the pressing pressure via the second portion 236 of the roller body 208. By selectively reducing the pressing pressure of the second portion 236, the pressure applied by the first portion 234 is greater than the pressure applied by the second portion 236. In some exemplary examples, the second portion 236 is selected to locally relax the pressing 259 outside the concave radius 251 (concave radius) of the cross-sectional shape 252 of the composite material 254, to strengthen the pressing 259 within the concave radius 251.

[0019] In some exemplary examples, the pressing surface 210 is complementary to the cross-sectional shape 252 of the composite component 248. In some exemplary examples, the pressing surface 210 is complementary to the forming surface 258 of the forming tool 256. In some exemplary examples, the cross-sectional shape 201 of the roller press 206 is complementary to the cross-sectional shape 252 of the composite component 248.

[0020] In some exemplary examples, the second portion 236 is selected to reduce pressing inconsistencies in the composite material 254 pressed by the roller press 206 on the composite material 254. In some exemplary examples, at least one of the second material 228 or the second portion 236 is selected to reduce pressing inconsistencies such as wrinkles, gaps, or bridging.

[0021] In some exemplary examples, a first portion 234 of the pressed surface 210 includes a web forming surface 214, and a second portion 236 of the pressed surface 110 includes a cap forming surface 220 (flange forming surface). In some exemplary examples, the size and shape of the cap forming surface 220 are configured to reduce bridging in the composite member 248.

[0022] In some exemplary examples, the first material 226 and the second material 228 are configured to provide sufficient friction with the pressed composite material 254 to cause the roller press 206 to passively roll about the axis of rotation 272. In these exemplary examples, the end actuator 202 is driven along the pressing path by a manipulator such as an automanipulator 242, such that the pressing surface 210 of the press 204 contacts the composite material 254 of the composite member 248.

[0023] The multi-material design of the roll press 206, with at least a first material 226 and a second material 228, allows for variable stiffness along the contact profile, thereby allowing for localized reinforcement or relaxation of pressing pressure in different areas. When the composite member 248 includes composite stringers, the variable stiffness enables additional pressing at the web / cap radius to improve quality and reduce or prevent inconsistencies due to bridging / wrinkling. The second material 228, with lower stiffness, will provide a reduced pressing pressure 257. The first material 226, with greater stiffness, will provide a greater pressing pressure—pressing pressure 255.

[0024] The roller press 206, comprising the first material 226 and the second material 228, may include an integrated roller 262 or independently movable roller sections 264. When the roller press 206 is an integrated roller 262, all portions of the pressing surface 210 are connected. When the roller press 206 is an integrated roller 262, all portions of the pressing surface 210 move together about the rotation axis 272. When the roller press 206 includes independently movable roller sections 264, the pressing surface 210 is formed by sections that can move independently of each other.

[0025] In some exemplary examples, the roller press 206 is configured to press composite material 254 and includes a rotating shaft 272, a roller body 208 rotatably supported 273 on the rotating shaft 271, and an auxiliary roller 230 rotatably supported 273 on the rotating shaft 272, such that the auxiliary roller 230 can move independently relative to the roller body 208.

[0026] In some exemplary examples, the roller press 206 further includes a roller bearing 268 between the roller body 208 and the rotating shaft 272. In some exemplary examples, the roller press 206 further includes a bearing 274 between the roller body 208 and the auxiliary roller 230.

[0027] In some exemplary examples, the roller body 208 has a first diameter 237, wherein the auxiliary roller 230 has a first diameter 239 different from the first diameter 237. In some exemplary examples, the first diameter 237 is larger than the first diameter 239.

[0028] In some exemplary examples, the roller press 206 further includes a roller bearing 266 between the auxiliary roller 230 and the rotating shaft 272.

[0029] In some exemplary examples, the roller body 208 and the auxiliary roller 230 are configured to have the same speed 277 at the forming surface, but different angular velocities 278, while maintaining a pressing 259 with the desired level of friction.

[0030] When the roll press 206 includes independently movable roll sections 264, the press 204 is a segmented roll system designed to reduce or prevent frictional effects caused by different rotating surface speeds. The independently movable roll sections 264 reduce the effects caused by different rotating surface speeds. The independently movable roll sections 264 reduce the effects caused by the variable radius in the design profile of the roll press 206. The independently movable roll sections 264 reduce the effects caused by the variable angular velocity 278 during in-plane turning 224 through the curvature 218 of the pressing path. The curvature matches the final profile 250 of the composite member 248. Through the curvature 218, the outer roll (such as one of auxiliary rolls 230 or 232) will have a greater angular velocity 278 than the inner roll (such as the other of auxiliary rolls 230 or 232). In some exemplary examples, the passive rotation of the independently movable roller segment 264 at different angular velocities includes: rotating the independently movable roller segment 264 at different angular velocities due to the in-plane turning 224 of the drive 222 roller press 206 through curvature 218.

[0031] In this exemplary example, each of the independently movable roller segments 264 has its own roller bearing to enable independent rotation on a common axis (rotation axis 272). Bearings (bearings 274 and 276) at the mating interfaces between the roller segments prevent friction / jamming caused by the angular velocity difference 278 between adjacent segments. In some exemplary examples, the bearings at the mating surfaces are needle roller bearings.

[0032] In some exemplary examples, the roller press 206 is configured to press composite material 254 and includes a roller body 208 having a first diameter 237 and an auxiliary roller 230 adjacent to the roller body 208, the auxiliary roller 230 having a first diameter 239 different from the first diameter 237 of the roller body 208 and being movable independently relative to the roller body 208 such that the auxiliary roller 230 can have an angular velocity 278 different from that of the roller body 208.

[0033] In some exemplary examples, the first diameter 239 is smaller than the first diameter 237. In some exemplary examples, the roller body 208 and the auxiliary roller 230 are rotatably mounted 275 to the same axis of rotation (axis of rotation 272).

[0034] In some exemplary examples, the roll press 206 further includes a roll bearing 266 between the auxiliary roll 230 and the rotating shaft 272. In some exemplary examples, the roll press 206 further includes a bearing 274 between the roll body 208 and the auxiliary roll 230. In some exemplary examples, the roll body 208 includes a web forming surface 214 and a cap forming surface 220 for the composite member 248. In some exemplary examples, the auxiliary roll 230 includes a flange forming surface 238.

[0035] In some exemplary examples, the roller press 206 further includes an auxiliary roller 232. In some exemplary examples, the roller press 206 further includes a roller bearing 270 between the auxiliary roller 232 and the rotating shaft 272. In some exemplary examples, the roller press 206 further includes a bearing 276 between the roller body 208 and the auxiliary roller 232. In some exemplary examples, the auxiliary roller 232 includes a flanged forming surface 244.

[0036] In some exemplary examples, grooves 280 along the contour of the roll press 206 allow for compaction relief during continuous rolling pressing. The grooves 280 may be evenly distributed along the circumference of the roll press 206. The width 285 of the grooves 280 may be modified as needed to improve forming quality.

[0037] In some exemplary examples, the roller press 206 includes a pressing surface 210 configured to contact the composite material 254, and a groove 280 extending through at least a portion of the pressing surface 210. In some exemplary examples, the groove 280 is present in the roller body 208.

[0038] In some exemplary examples, the groove 280 extends continuously through the pressing surface 210. In some exemplary examples, the groove 280 is discontinuous on the pressing surface 210. In some exemplary examples, the depth 286 of the groove 280 varies on the pressing surface 210. In some exemplary examples, at least one groove of the groove 280 has a varying depth 286. In some exemplary examples, at least one groove of the groove 280 has a depth 286 different from the other grooves. In some exemplary examples, the depth 286 is selected such that the groove 280 remains depressurized 260 when pressure 259 is applied to the composite material 254. In some exemplary examples, the depth 286 is sufficient to prevent material from the roller press 206 below the groove 280 from contacting the composite material 254.

[0039] In some exemplary examples, the width 285 of the groove 280 varies on the pressing surface 210. In some exemplary examples, at least one groove in the groove 280 has a width 285 different from the other grooves. In some exemplary examples, at least one groove in the groove 280 has a width 285 that varies along the corresponding groove. In some exemplary examples, each groove of the groove 280 has the same width 285.

[0040] In some exemplary examples, the groove 280 is substantially straight. In other exemplary examples, the groove 280 is curved.

[0041] In some exemplary examples, the groove 280 is configured to locally provide pressure relief 260 from the press 259. In some exemplary examples, at least one groove in the groove 280 includes a filler material 281 in the corresponding groove. The filler material 281 includes any desired material with conformability, configured to tailor the pressure applied to the composite material 254. In some exemplary examples, the roller press 206 further includes the filler material 281 within at least one groove in the groove 280, wherein the filler material 281 has a hardness lower than that of the first material 226 of the press surface 210. In some exemplary examples, the filler material 281 is a polymer. In some exemplary examples, the filler material 281 is a siloxane.

[0042] In some exemplary examples, the pressing surface 210 includes a cap-shaped surface 220, a web-shaped surface 214 opposite to the cap-shaped surface 220, and flange-shaped surfaces (flange-shaped surfaces 238 and 244) adjacent to the web-shaped surface 214, wherein a groove 288 or groove 294 extending through at least a portion of the flange-shaped surface has at least one of a different width, a different frequency / distribution density, or a different depth than the groove 280 of the web-shaped surface 214.

[0043] In this exemplary example, the groove 288 in the flange forming surface 238 has a shape 290 including a width 291 and a depth 292. In some exemplary examples, the width 291 and depth 292 are the same as the width 285 and depth 286 of the groove 280. In some exemplary examples, at least one of the width 291 or the depth 292 is different from the width 285 and depth 286 of the groove 280.

[0044] In this exemplary example, the groove 288 in the flange forming surface 238 has a frequency 293. In some exemplary examples, frequency 293 is the same as frequency 282. In some exemplary examples, frequency 293 is different from frequency 282. In some exemplary examples, frequencies 293 and 282 can be described based on angular measurements of the cross-section of the flange forming surface 238. In some exemplary examples, frequencies 293 and 282 can be described based on physical distances through the pressing surface 210. In some exemplary examples, the groove 288 in the flange forming surface 238 includes a filler material 289.

[0045] In some exemplary examples, the groove 280 includes more than one set of grooves, each set of grooves having its own shape. In some exemplary examples, the grooves differ by having different shapes 284, widths 285, depths 286, or paths through the pressing surface 210.

[0046] In this exemplary example, the groove 294 in the flange forming surface 244 has a shape 296 including a width 297 and a depth 298. In some exemplary examples, the width 297 and depth 298 are the same as the width 285 and depth 286 of the groove 280. In some exemplary examples, at least one of the width 297 or depth 298 is different from the width 285 and depth 286 of the groove 280.

[0047] In this exemplary example, the groove 294 in the flange forming surface 244 has a frequency 299. In some exemplary examples, frequency 299 is the same as frequency 282. In some exemplary examples, frequency 299 is different from frequency 282. In some exemplary examples, frequencies 299 and 282 can be described based on angular measurements of the cross-section of the flange forming surface 244. In some exemplary examples, frequencies 299 and 282 can be described based on physical distances through the pressing surface 210. In some exemplary examples, the groove 294 in the flange forming surface 244 includes a filler material 295.

[0048] In some exemplary examples, the groove 280 includes more than one set of grooves, each set of grooves having its own shape. In some exemplary examples, the grooves differ by having different shapes 284, widths 285, depths 286, or paths through the pressing surface 210.

[0049] In some exemplary examples, during the molding of composite material 254, pressed regions 253 are formed in composite material 254. In some exemplary examples, in-tolerance wrinkles 207 are located at designated locations 203 between the pressed regions 253 of composite material 254. In some exemplary examples, during the molding of composite material 254, the in-tolerance wrinkles 207 located at designated locations 203 include providing pressure relief 260 from pressing 259 at the designated locations 203. In some exemplary examples, placing the in-tolerance wrinkles 207 at designated locations 203 includes allowing the formation of in-tolerance wrinkles 207 within designated locations 261 at regular intervals between pressed regions 253.

[0050] Figure 2A and 2B The example of manufacturing environment 200 does not imply a physical or structural limitation on how the exemplary embodiments can be implemented. Other components may be used in addition to the illustrated components, or other components may be used in place of the illustrated components. Some components may be unnecessary. Furthermore, boxes exist to illustrate some functional components. When implemented in the exemplary embodiments, one or more of these boxes may be combined, split, or combined and split into different boxes.

[0051] Turn now Figure 3A and 3B An example of a block diagram of a manufacturing environment is described according to an exemplary embodiment. Figure 1 The composite components of the medium-sized aircraft 100 can be passed through Figure 3A and 3B The roller press 306 is used for pressing. In some exemplary examples, the roller press 306 is an example of the roller press 206. The roller press 306 can be used to press the composite material 347 onto the forming tool 379.

[0052] Composite component 348 includes composite material 347 in a “green” state. Composite material 347 is formable because it is uncured or partially cured.

[0053] In this exemplary example, the roller press 306 includes a pressing surface 305 configured to contact the composite material 347. During operation, as the roller press 306 moves along the pressing path 307, the roller press 306 applies compressive force to the composite material 347. The pressing path 307 is followed to press the composite member 348 having a final profile 350. During operation, the roller press 306 applies compressive force to the composite material 347 when the pressing surface 305 contacts it.

[0054] In some exemplary examples, the composite member 348 may take the form of a composite stringer or a composite stiffener. In some exemplary examples, the composite member 348 may be referred to as an elongated composite member. The composite member 348 has a cross-sectional shape 352. In some exemplary examples, the cross-sectional shape 352 may be a cap-shaped cross-section 333. The cap-shaped cross-section 333 includes a cap 354 between a web 356 and flanges (flanges 358 and 360) adjacent to the web 356.

[0055] The roller press 306 is configured to apply a desired amount of pressing pressure to the composite material 347 throughout the entire cross-sectional shape 352 of the composite member 348. The roller press 306 is configured to apply the desired amount of pressing pressure to the composite material 347 as it presses the composite member 348 in the final profile 350. In some exemplary examples, the final profile 350 includes twisting or bending along the length of the composite member 348.

[0056] The roller press 306 includes any desired number of features to provide the desired compression of the composite member 348 and reduce unwanted inconsistencies in the resulting composite structure. In some exemplary examples, the roller press 306 includes a multi-material pressing surface 305 to control the application of compressive force. In some exemplary examples, the roller press 306 includes independently movable roller segments 364 to keep the speed 377 constant, while the angular velocity 378 depends on the size and shape of the portions of the roller press 306. In some exemplary examples, the roller press 306 includes grooves in the pressing surface 305 to provide localized pressure relief from the compression. Any desired combination of at least one of the different materials forming the pressing surface 305, grooves, or independently movable roller segments can reduce inconsistencies in the elongated composite member.

[0057] In some exemplary examples, the roller press 306 includes a first portion of a pressing surface 305 formed of a first material 326 and a second portion of a pressing surface 305 formed of a second material 328, the second material 328 having a lower hardness than the first material 326. The second portion is configured to selectively reduce the pressing pressure through the second portion of the roller body 308.

[0058] In some exemplary examples, the first material 326 may be referred to as a rigid material or a first rigid material 327. The first material 326 has a greater Duroy hardness than the second material 328. In some exemplary examples, the second material 328 refers to a compliant material or a flexible material 329. Although two materials with different Duroy hardnesses are described in this exemplary example, more than two materials may be used in other exemplary examples. In some exemplary examples, the press 304 may include more than two materials with different Duroy hardnesses. In some exemplary examples, the material of the pressing surface 305 may be customized based on the desired pressing and the cross-sectional shape 352 of the composite material 347 to be pressed. In some exemplary examples, the first material 326 has a range of hardnesses. In some exemplary examples, the second material 328 has a different range of hardnesses.

[0059] When the composite component 348 has a cap-shaped cross-section 333, the roll forming machine 306 includes a cap-forming surface 320, a web-forming surface 314, a flange-forming surface 338, and a flange-forming surface 344. In some exemplary examples, the web-forming surface 314 is formed by an angled wall 312. In some exemplary examples, the cap-forming surface 320 includes a planar portion 318 located between an angled wall 316 of the angled wall 312 and an angled wall 317 of the angled wall 313. As shown, the angled wall 316 is connected to the planar portion 318 by a fillet / radius 322. As shown, the angled wall 317 is connected to the planar portion 318 by a fillet / radius 324. The flange-forming surface 344 is connected to the angled wall 317. The flange-forming surface 338 is connected to the angled wall 316.

[0060] In some exemplary examples, the pressing surface 305 is complementary to the cross-sectional shape 352 of the composite member 348. In some exemplary examples, the pressing surface 305 is complementary to the forming surface 383 of the forming tool 379. In this exemplary example, the forming surface 383 is configured to support the composite member 348 having a cross-sectional shape 352 and a final profile 350.

[0061] In some exemplary examples, a second portion is selected to reduce compression inconsistencies in the composite material 347 pressed by a roller press 306 on the composite material 347. In some exemplary examples, at least one of a second material 328 or a second portion is selected to reduce compression inconsistencies such as wrinkles, gaps, or bridging. In some exemplary examples, at least one of the size, shape, and location of the second portion formed by the second material 328 is selected based on the cross-sectional shape 352 of the composite member 348. In some exemplary examples, the second material 328 is selected to tailor the compression pressure to a portion of the cross-sectional shape 352 of the composite member 348.

[0062] In some exemplary examples, a first portion of the pressing surface 305 includes a web-forming surface 314, and a second portion of the pressing surface 305 includes a cap-forming surface 320. In these exemplary examples, the cap-forming surface 320 is more compliant than the web-forming surface 314. In some exemplary examples, the roll press 306 includes a radius between the web-forming surface 314 and the cap-forming surface 320, wherein radii 322 and 324 are formed of a first material 326. In some exemplary examples, the compliance of the cap-forming surface 320 allows radii 322 and 324, formed of the first material 326, to provide increased pressing pressure. In some exemplary examples, the compliance of the cap-forming surface 320 allows the cap-forming surface 320 to provide reduced pressing pressure. In some exemplary examples, the size and shape of the cap-forming surface 320 are configured to reduce bridging in the composite member 348.

[0063] The roller body 308 may include any desired cross-section configured to press the composite member 348 into a cross-sectional shape 352. In some exemplary examples, the roller body 308 includes a trapezoidal cross-section 310, which includes a web forming surface 314 and a cap forming surface 320. In other exemplary examples, the roller body 308 includes multiple curved surfaces. In some exemplary examples, there is no flange forming surface. In some exemplary examples, the cap forming surface 320 is not planar.

[0064] The first material 326 and the second material 328 can be connected in any desired manner. In some exemplary examples, the roller body 308 is 3D printed. In some exemplary examples, the first material 326 and the second material 328 are 3D printed together. In some exemplary examples, the second material 328 can be connected to the first material 326 via an adhesive 357 between the first material 326 and the second material 328. In some exemplary examples, the second material 328 is constrained to the first material 326 by friction 359. In some exemplary examples, a mechanical connector 351 holds the second material 328 to the first material 326. In some exemplary examples, the mechanical connector 351 may be referred to as a mechanical constraint.

[0065] In some exemplary examples, the mechanical connector 351 includes a protrusion 353 formed of a first material 326 and a recess 355 in a second material 328 located above the protrusion 353 to secure the second material 328 to the first material 326. In some exemplary examples, the mechanical connector 351 includes a protrusion 353 formed of the second material 328 and a recess 355 in the first material 326 that receives the protrusion 353 to secure the second material 328 to the first material 326. In some exemplary examples, the mechanical connector 351 includes a combination of a recess 355 and a protrusion 353 formed of the second material 328, configured to interface with the combination of the recess 355 and the protrusion 353 in the first material 326 to secure the second material 328 to the first material 326.

[0066] In some exemplary examples, the first material 326 and the second material 328 are configured to provide sufficient friction with the pressed composite material 347 to cause the roller press 306 to passively roll about the axis of rotation 372. In these exemplary examples, the end actuator 302 is driven along the pressing path 307 by a manipulator such as an automanipulator 375, such that the pressing surface 305 of the press 304 contacts the composite material 347 of the composite member 348. The pressure applied by the end actuator 302 and its movement along the pressing path 307 causes the roller press 306 to move due to friction.

[0067] The multi-material design of the roll press 306, with at least a first material 326 and a second material 328, allows for variable stiffness along the contact profile, thus allowing for localized reinforcement or relaxation of pressing pressure in different areas. When the composite member 348 includes composite stringers, the variable stiffness enables additional pressing at the web / cap radius to improve quality and reduce or prevent inconsistencies due to bridging / wrinkling. The second material 328, with lower stiffness, will provide less pressing pressure. The first material 326, with greater stiffness, will provide greater pressing pressure.

[0068] The roller press 306, comprising a first material 326 and a second material 328, may include an integrated roller 362 or independently movable roller sections 364. When the roller press 306 is an integrated roller 362, all portions of the pressing surface 305 are connected. When the roller press 306 is an integrated roller 362, all portions of the pressing surface 305 move together about a rotation axis 372. When the roller press 306 includes independently movable roller sections 364, the pressing surface 305 is formed by sections that can move independently of each other.

[0069] In some exemplary examples, the roller press 306 is configured to press composite material 347 and includes a rotating shaft 372, a roller body 308 rotatably supported on the rotating shaft 372, and an auxiliary roller 330 rotatably supported on the rotating shaft 372, such that the auxiliary roller 330 is movable independently relative to the roller body 308. In some exemplary examples, the roller press 306 further includes an auxiliary roller 332 rotatably supported on the rotating shaft 372, such that the auxiliary roller 332 is movable independently relative to the roller body 308.

[0070] In some exemplary examples, the roller press 306 further includes a roller bearing 368 between the roller body 308 and the rotation shaft 372. The roller bearing 368 enables the roller body 308 to rotate about the rotation shaft 372.

[0071] In some exemplary examples, the roller press 306 further includes a bearing 374 between the roller body 308 and the auxiliary roller 330. In some exemplary examples, the roller press 306 further includes a bearing 376 between the roller body 308 and the auxiliary roller 332. The bearing 374 facilitates independent movement of the auxiliary roller 330 and the roller body 308 relative to each other. The bearing 376 facilitates independent movement of the auxiliary roller 332 and the roller body 308 relative to each other.

[0072] In some exemplary examples, the roller body 308 has a first diameter, while the auxiliary roller 330 has a second diameter different from the first diameter. In some exemplary examples, the roller body 308 has a first diameter, while the auxiliary roller 332 has a second diameter different from the first diameter. In some exemplary examples, the first diameter is larger than the second diameter.

[0073] In some exemplary examples, auxiliary roller 330 includes cylinder 334. In some exemplary examples, auxiliary roller 332 includes cylinder 340.

[0074] The auxiliary roller 330 includes material 336. In some exemplary examples, material 336 may be referred to as rigid material 337. The auxiliary roller 332 includes material 342. In some exemplary examples, material 342 may be referred to as rigid material 343. In some exemplary examples, the pressing surface 305 including the auxiliary rollers 330 and 332 is formed of a first material 326. In this exemplary example, materials 336 and 342 are the same as the first material 326. In some exemplary examples, the pressing surface 305 is formed of more than one material. In some exemplary examples, at least one of material 336 or material 342 is different from the first material 326 of the roller body 308.

[0075] In some exemplary examples, the roller body 308 and the auxiliary roller 330 are configured to have the same speed 377 and different angular velocities 378 at the forming surface 383 while maintaining pressure at a desired level of friction. In some exemplary examples, the roller body 308 and the auxiliary roller 332 are configured to have the same speed 377 and different angular velocities 378 at the forming surface 383 while maintaining pressure at a desired level of friction.

[0076] When the roll press 306 includes independently movable roll sections 364, the press 304 is a segmented roll system used to reduce or prevent frictional effects caused by different rotating surface speeds. The independently movable roll sections 364 reduce the effects caused by different rotating surface speeds. The independently movable roll sections 364 reduce the effects caused by the variable radius in the design profile of the roll press 306. The independently movable roll sections 364 reduce the effects caused by the variable angular velocity 378 during in-plane turning through the curvature of the pressing path 307. Due to the curvature, an outer roll, such as one of auxiliary rolls 330 or 332, will have a greater angular velocity 378 than an inner roll, such as the other of auxiliary rolls 330 or 332.

[0077] In this exemplary example, each of the independently movable roller segments 364 has its own roller bearing to allow independent rotation on a common axis (rotation axis 372). Bearings (bearings 374 and 376) at the mating interfaces between the roller segments prevent friction / jamming caused by the angular velocity difference 378 between adjacent segments. In some exemplary examples, the bearings at the mating surfaces are needle roller bearings.

[0078] In some exemplary examples, the roller press 306 is configured to press composite material 347 and includes a roller body 308 having a first diameter and an auxiliary roller 330 adjacent to the roller body 308, the auxiliary roller 330 having a second diameter different from the first diameter of the roller body 308 and moving independently relative to the roller body 308 such that the auxiliary roller 330 can have an angular velocity 378 different from that of the roller body 308.

[0079] In some exemplary examples, the pressing surface 305 of the roller press 306 having independently movable roller sections 364 comprises one material. In some exemplary examples, the pressing surface 305 of the roller press 306 having independently movable roller sections 364 comprises more than one material for customized pressing.

[0080] In some exemplary examples, grooves 380 along the contour of the roll press 306 allow for pressure relief during continuous roll pressing. The grooves 380 can be evenly distributed along the circumference of the roll press 306. The width 385 of the grooves 380 can be modified as needed to improve forming quality.

[0081] In some exemplary examples, the roller press 306 includes a pressing surface 305 configured to contact the composite material 347, and a groove 380 extending through at least a portion of the pressing surface 305. In some exemplary examples, the groove 380 is present in the roller body 308.

[0082] In some exemplary examples, the groove 380 extends continuously through the pressing surface 305. In some exemplary examples, the groove 380 is discontinuous on the pressing surface 305. In some exemplary examples, the depth 386 of the groove 380 varies on the pressing surface 305. In some exemplary examples, at least one groove of the groove 380 has a varying depth 386. In some exemplary examples, at least one groove of the groove 380 has a depth 386 different from the other grooves.

[0083] In some exemplary examples, the width 385 of the groove 380 varies on the pressing surface 305. In some exemplary examples, at least one groove in the groove 380 has a width 385 different from the other grooves. In some exemplary examples, at least one groove in the groove 380 has a width 385 that varies along the corresponding groove. In some exemplary examples, each groove of the groove 380 has the same width 385.

[0084] In some exemplary examples, the groove 380 is substantially straight. In other exemplary examples, the groove 380 is curved.

[0085] In some exemplary examples, the groove 380 is configured to provide localized pressure relief from the pressing. In some exemplary examples, at least one groove in the groove 380 includes a filler material 381 in the corresponding groove. The filler material 381 includes any desired material with conformability, configured to tailor the pressing applied to the composite material 347. In some exemplary examples, the roller press 306 further includes the filler material 381 within at least one groove in the groove 380, wherein the filler material 381 has a hardness lower than that of the first material 326 of the pressing surface 305. In some exemplary examples, the filler material 381 is a polymer. In some exemplary examples, the filler material 381 is a siloxane.

[0086] In some exemplary examples, the pressing surface 305 includes a cap-forming surface 320, a web-forming surface 314 opposite to the cap-forming surface 320, and flange-forming surfaces (flange-forming surfaces 338 and 344) adjacent to the web-forming surface 314, and wherein a groove 388 or groove 394 extending through at least a portion of the flange-forming surface has at least one of a different width, a different frequency, or a different depth than the groove 380 of the web-forming surface 314.

[0087] In this exemplary example, the groove 388 in the flange forming surface 338 has a shape 390 including a width 391 and a depth 392. In some exemplary examples, the width 391 and depth 392 are the same as the width 385 and depth 386 of the groove 380. In some exemplary examples, at least one of the width 391 or the depth 392 is different from the width 385 and depth 386 of the groove 380.

[0088] In this exemplary example, the groove 388 in the flange forming surface 338 has a frequency 393. In some exemplary examples, frequency 393 is the same as frequency 382. In some exemplary examples, frequency 393 is different from frequency 382. In some exemplary examples, frequencies 393 and 382 can be described based on angular measurements of the cross-section of the flange forming surface 338. In some exemplary examples, frequencies 393 and 382 can be described based on physical distances through the pressing surface 305. In some exemplary examples, the groove 388 in the flange forming surface 338 includes a filler material 389.

[0089] In some exemplary examples, the groove 380 includes more than one set of grooves, each set of grooves having its own shape. In some exemplary examples, at least one of the following is different: the width 385, the depth 386, or the path through the pressing surface 305, by having different shapes 384.

[0090] In this exemplary example, the groove 394 in the flange forming surface 344 has a shape 396 including a width 397 and a depth 398. In some exemplary examples, the width 397 and depth 398 are the same as the width 385 and depth 386 of the groove 380. In some exemplary examples, at least one of the width 397 or depth 398 is different from the width 385 and depth 386 of the groove 380.

[0091] In this exemplary example, the groove 394 in the flange forming surface 344 has a frequency 399. In some exemplary examples, frequency 399 is the same as frequency 382. In some exemplary examples, frequency 399 is different from frequency 382. In some exemplary examples, frequencies 399 and 382 can be described based on angular measurements of the cross-section of the flange forming surface 344. In some exemplary examples, frequencies 399 and 382 can be described based on physical distances through the pressing surface 305. In some exemplary examples, the groove 394 in the flange forming surface 344 includes a filler material 395.

[0092] In some exemplary examples, the groove 380 includes more than one set of grooves, each set of grooves having its own shape. In some exemplary examples, at least one of the following is different: the width 385, the depth 386, or the path through the pressing surface 305, by having different shapes 384.

[0093] In some exemplary examples, the roller press 306 further includes a filler material 381 within at least one recess in the groove 380, wherein the filler material 381 has a hardness lower than that of the first material 326 of the pressing surface 305. In some exemplary examples, the filler material 381 is a polymer. In some exemplary examples, the filler material 381 is a siloxane.

[0094] In some exemplary examples, the groove 380 has a width 385 ranging from 0.05 inches to 0.3 inches. In some exemplary examples, the groove 380 has a width 385 ranging from 0.1 inches to 0.2 inches. In some exemplary examples, the frequency 382 of the groove 380 is such that, in a cross-sectional view perpendicular to the axis of rotation of the roller press 306, one groove is provided approximately every 45 degrees.

[0095] In some exemplary examples, the roller press 306 includes a pressing surface 305 configured to contact the composite material 347 and a groove 380 in at least a portion of the pressing surface 305, wherein the groove 380 is configured to provide partial pressure relief from pressing. Providing pressure relief from pressing can reduce or eliminate inconsistencies in the pressed composite member 348.

[0096] In some exemplary examples, the roller press 306 with groove 380 includes an integrated roller 362. In some exemplary examples, the roller press 306 with groove 380 includes independently movable roller segments 364. In some exemplary examples, the roller press 306 with groove 380 includes more than one material forming the pressing surface 305.

[0097] Figure 3A and 3BThe example of manufacturing environment 300 does not imply any physical or structural limitation on how the exemplary embodiments can be implemented. Other components may be used in addition to or alternative to the components in the examples. Some components may be unnecessary. Furthermore, boxes exist to illustrate some functional components. When implemented in the exemplary embodiments, one or more of these boxes may be combined, split, or combined and split into different boxes.

[0098] For example, in some exemplary examples, the composite member 348 may have a cross-sectional shape 352 different from the cap-shaped cross-section 333. In some exemplary examples, the pressed surface 305 includes additional shaped surfaces. In some exemplary examples, the pressed surface 305 has fewer shaped surfaces than described.

[0099] Turn now Figure 4 An example of an isometric view of a press is described according to an exemplary embodiment. In manufacturing... Figure 1 When assembling components of the aircraft 100, the press 404 can be used to press composite materials. The press 404 is... Figure 2A and 2B The physical implementation scheme of press 204. Press 404 is... Figure 3A and 3B The physical implementation scheme of the press 304.

[0100] In view 400, a press 404 is connected to an end actuator 402. In this exemplary example, the press 404 includes a roller press 405. The roller press 405 includes independently movable roller sections 403.

[0101] The press 404 includes a roller body 408 rotatably mounted on a rotating shaft 406. In this exemplary example, the press 404 further includes an auxiliary roller 410 adjacent to the roller body 408. In this exemplary example, the press 404 further includes an auxiliary roller 412 adjacent to the roller body 408.

[0102] In this exemplary example, the roller press 405 includes a pressing surface 414 configured to contact the composite material. During operation, as the roller press 405 moves along the pressing path, the roller press 405 applies a compressive force to the composite material. During operation, the roller press 405 applies a compressive force to the composite material when the pressing surface 414 contacts the composite material.

[0103] The roller press 405 includes several features to provide the desired compression of elongated composite components and reduce undesirable inconsistencies in the resulting composite structure. In this exemplary example, the roller press 405 includes a multi-material pressing surface 414 to control the application of compressive force.

[0104] In this exemplary example, the roller press 405 includes a first portion 419 of a pressing surface 414 formed of a first material 418, and a second portion 421 of the pressing surface 414 formed of a second material 420 having a lower hardness than the first material 418. The second portion 421 is configured to selectively reduce the pressing pressure through the second portion 421 of the pressing surface 414. In some exemplary examples, the first material 418 refers to a rigid material. In some exemplary examples, the second material 420 refers to a compliant material.

[0105] In this exemplary example, the roller press 405 includes a pressing surface 414 configured to contact the composite material, and a groove 416 extending through at least a portion of the pressing surface 414. In this exemplary example, the groove 416 extends substantially parallel to the cross-sectional shape of the elongated composite member. In this exemplary example, the groove 416 extends substantially perpendicular to the direction of movement of the roller press 405. In this exemplary example, the groove 416 extends through both the first material 418 and the second material 420. The groove 416 provides selective pressure relief during the pressing of the composite material. In cases of reduced inconsistencies (including reduced wrinkles), the groove 416 provides pressure relief for the composite member.

[0106] In this exemplary example, groove 416 extends continuously through roller body 408. In this exemplary example, groove 416 extends continuously through a portion of pressing surface 414. In this exemplary example, groove 416 is discontinuous on pressing surface 414 because groove 422 in auxiliary roller 410 differs from groove 416 in roller body 408 in at least one of frequency or size. In this exemplary example, grooves 416 and 422 form two sets of grooves with two different frequencies. For example, the distance between grooves 416 in roller body 408 is different from the distance between grooves 422 in auxiliary roller 410. Although grooves 416 and 422 have different frequencies, grooves 416 and 422 can have the same width and the same depth.

[0107] In some exemplary examples, the depth of the groove 416 varies on the pressing surface 414. In some exemplary examples, the depth of the groove 422 varies on the pressing surface 414. Although the width of the groove 416 is continuous on the pressing surface 414, in some exemplary examples, the width of the groove 416 varies on the pressing surface 414. Although the width of the groove 422 is continuous on the pressing surface 414, in some exemplary examples, the width of the groove 422 varies on the pressing surface 414.

[0108] In this exemplary example, groove 416 is substantially linear across the entire pressing surface 414. In this exemplary example, groove 422 is substantially linear across the entire pressing surface 414. However, in other exemplary examples, the groove, such as at least one of grooves 416 or 422, may be curved. In other exemplary examples, the grooves including grooves 416 and 422 may have any desired width, depth, frequency, and angle on the pressing surface 414. In some exemplary examples, the frequency of the groove, such as groove 416, is such that, in a cross-sectional view perpendicular to the axis of rotation 417 of the roller press 405, approximately one groove is provided every 45 degrees.

[0109] In this exemplary example, a roller press 405 configured to press composite materials includes a rotating shaft 406, a roller body 408 rotatably supported on the rotating shaft 406, and an auxiliary roller 410 rotatably supported on the rotating shaft 406, such that the auxiliary roller 410 moves independently relative to the roller body 408. In this exemplary example, the roller press 405 further includes an auxiliary roller 412 rotatably supported on the rotating shaft 406, such that the auxiliary roller 412 moves independently relative to the roller body 408. In this exemplary example, by having independently movable roller sections 403, the roller press 405 can have different angular velocities than the auxiliary roller 410 and the roller body 408, while maintaining a single speed on the composite material. In some exemplary examples, the roller press 405 provides pressing of the composite material to reduce inconsistencies (including wrinkle reduction).

[0110] Turn now Figure 5 An example of a cross-sectional view of a pressing machine is described according to an exemplary embodiment. In manufacturing... Figure 1 When assembling components of the aircraft 100, the press 504 can be used to press composite materials. The press 504 is... Figure 2A and 2B The physical implementation scheme of press 204. Press 504 is... Figure 3A and 3B The physical implementation scheme of the press 304.

[0111] In view 500, a press 504 is connected to an end effector 502. In this exemplary example, the press 504 includes a roller press 505. The roller press 505 includes independently movable roller sections 503.

[0112] In this exemplary example, a roller press 505 configured to press composite materials includes a rotating shaft 506, a roller body 508 rotatably supported on the rotating shaft 506, and an auxiliary roller 510 rotatably supported on the rotating shaft 506, such that the auxiliary roller 510 moves independently relative to the roller body 508. In this exemplary example, by having independently movable roller sections 503, the roller press 505 can have different angular velocities than the auxiliary roller 510 and the roller body 508, while maintaining a single speed for the roller press 505 on the composite material. In some exemplary examples, the roller press 505 provides pressing of the composite material in cases of reducing inconsistencies (including reducing wrinkles).

[0113] In this exemplary example, the roller press 505 includes a first portion 509 of a pressing surface 507 formed of a first material 514, and a second portion 513 of the pressing surface 507 formed of a second material 512, the second material 512 having a lower hardness than the first material 514. The second portion 513 is configured to selectively reduce the pressing pressure by means of the second portion 513 of the pressing surface 507. In some exemplary examples, the first material 514 refers to a rigid material. In some exemplary examples, the second material 512 refers to a compliant material.

[0114] In some exemplary examples, the roller press 505 further includes an adhesive (not shown) between the first material 514 and the second material 512. In some exemplary examples, the second material 512 is constrained by friction against the first material 514.

[0115] In some exemplary examples, the roller press 505 further includes a protrusion 526 formed of a first material 514 and a groove 524 positioned above the protrusion 526 in a second material 512 to secure the second material 512 to the first material 514. The protrusion 526 and the groove 524 may be referred to as mechanical connectors. Although the protrusion 526 is shown as being formed of the first material 514, in other exemplary examples, the second material 512 forms the protrusion, while the first material 515 has the groove. In some exemplary examples, the first material 514 and the second material 512 each have a mixture of protrusions and grooves to constrain the second material 512 onto the first material 514.

[0116] In this exemplary example, the roll press 505 includes a roll body 508 having a trapezoidal cross-section comprising a web forming surface and a cap forming surface. In other exemplary examples, the roll press 505 has any cross-section required to provide pressing of elongated composite members. Furthermore, the roll press 505 includes any desired number of independently movable roll sections.

[0117] In this exemplary example, the roller press 505 further includes a roller bearing 518 between the roller body 508 and the rotating shaft 506. In this exemplary example, the roller press 505 further includes a bearing 520 between the roller body 508 and the auxiliary roller 510.

[0118] In this exemplary example, the auxiliary roller 510 is cylindrical. However, the auxiliary roller 510 can have any desired cross-sectional shape. The auxiliary roller 510 can have any desired size and any desired cross-sectional shape to form a portion of the cross-sectional shape of an elongated composite component.

[0119] In this exemplary example, the roller body 508 includes a trapezoidal cross-section. However, the roller body 508 can have any desired cross-sectional shape. The roller body 508 can have any desired size and any desired cross-sectional shape to form a portion of the cross-sectional shape of an elongated composite member.

[0120] In this exemplary example, the roller press 505 is configured to press composite materials and includes a roller body 508 having a first diameter 519 and an auxiliary roller 510 adjacent to the roller body 508. The auxiliary roller 510 has a second diameter 517 smaller than that of the roller body 508 and is movable independently relative to the roller body 508, such that the auxiliary roller 510 can have a different angular velocity than the roller body 508. In this exemplary example, the roller press 505 further includes a bearing 516 between the auxiliary roller 510 and a rotating shaft 506.

[0121] In this exemplary example, the roller press 505 includes a pressing surface 507 configured to contact the composite material and a groove 522 extending through at least a portion of the pressing surface 507. In this exemplary example, the groove 522 extending through the second material 512 is visible. However, additional grooves (not visible) may be present in the roller press 505.

[0122] Turn now Figure 6 An example of an isometric view of a press is described according to an exemplary embodiment. In manufacturing... Figure 1 When assembling components of the aircraft 100, the press 604 can be used to press composite materials. The press 604 is... Figure 2A and 2B The physical implementation scheme of the press 204. Press 604 is... Figure 3A and 3B The physical implementation scheme of the press 304.

[0123] In view 600, end effector 602 includes press 604. In this exemplary example, press 604 is a roller press 609.

[0124] The press 604 includes a pressing surface 607 formed of two different materials. The press 604 includes a pressing surface 607 formed of a first material 618 and a second material 616, wherein the second material 616 has a lower hardness than the first material 618.

[0125] The multi-material design of the press 604 provides variable pressing pressure for localized reinforcement / relaxation in different areas. The pressing of the composite material is improved by varying the compliance of the material on the pressing surface 607. The compliance of the pressing surface 607 can be locally increased or decreased relative to other portions of the pressing surface 607 to locally control pressing and friction. In some exemplary examples, for composite reinforcements such as stringers, additional pressing at the radius connecting the web and cap can improve pressing. In some exemplary examples of composite reinforcements such as stringers, less pressing can be applied at locations outside the radius to customize stringer quality and prevent out-of-tolerance inconsistencies. In some exemplary examples, additional pressing at the radius connecting the web and cap allows for pressing of material in the inner radius / female radius of the stringer cap without bridging. In some exemplary examples, additional pressing can be applied at other locations on the composite reinforcement.

[0126] A press 604 is configured to press a composite material onto a forming tool. In this exemplary example, the press 604 includes a web forming surface 608 of a roll body 603 formed of a first material 618, and a cap forming surface 610 of the roll body 603 formed of a second material 616, the second material 616 having a lower hardness than the first material. In some exemplary examples, the web forming surface 608 refers to an angled wall. In some exemplary examples, the cap forming surface 610 refers to a flat surface.

[0127] The roller body 603 is rotatably mounted to the rotating shaft 606. When the roller body 603 rotates about the rotating shaft 606, the roller body 603 applies pressure to the composite material to compress it.

[0128] In this exemplary example, radii / radiuses exist between the web forming surface 608 and the cap forming surface 610. In this exemplary example, the radii include radii 612 and 614, which are formed by a first material 618. By forming radii 612 and 614 from a first material 618 having a harderness than a second material 616, radii 612 and 614 can apply additional pressure to the composite material at its inner radius within the forming tool.

[0129] In this exemplary example, the press 604 further includes a flange forming surface 620. In this exemplary example, the flange forming surface 620 is formed of a first material 618. However, in other exemplary examples, the flange forming surface 620 may be formed of any desired material based on the desired pressing level.

[0130] In this exemplary example, although two materials with different Duroy hardnesses are described, more than two materials may be used in other exemplary examples. In some exemplary examples, the press 604 may include more than two materials with different Duroy hardnesses. In some exemplary examples, the material of the pressing surface 607 may be customized based on the desired pressing and the cross-sectional shape of the composite material to be pressed. In some exemplary examples, the first material 618 has a range of hardnesses. In some exemplary examples, the second material 616 has a different range of hardnesses.

[0131] Although the first material 618 and the second material 616 have different hardnesses, in some exemplary examples, the first material 618 and the second material 616 are the same material. In some exemplary examples, the first material 618 and the second material 616 are the same substrate with different additives to control hardness. In some exemplary examples, the first material 618 and the second material 616 are the same substrate with different treatments to control hardness. In some exemplary examples, the first material 618 and the second material 616 are different materials.

[0132] The second material 616 can be attached to the first material 618 by any desired method. In some exemplary examples, the roller body 603 is 3D printed. In some exemplary examples, the first material 618 and the second material 616 are 3D printed together. In some exemplary examples, the second material 616 can be attached to the first material 618 by an adhesive between the first material 618 and the second material 616. In some exemplary examples, the second material 616 is constrained by the first material 618 by friction. In some exemplary examples, a mechanical connector holds the second material 616 onto the first material 618. In some exemplary examples, the mechanical connector includes a protrusion formed by the first material 618 and a groove positioned in the second material 616 above the protrusion to secure the second material 606 to the first material 618. In some exemplary examples, the mechanical connector includes a protrusion formed by the second material 616 and a groove in the first material 618 receiving the protrusion to secure the second material 616 to the first material 618.

[0133] In this exemplary example, the press 604 is configured to press an elongated composite member having a cap-shaped cross-section. In this exemplary example, the roller body 603 of the press 604 includes a trapezoidal cross-section 611, which includes a web forming surface 608 and a cap forming surface 610.

[0134] In some exemplary examples, the roller press 609 includes a first portion 619 of a pressing surface 607 formed of a first material 618, and a second portion 621 of a pressing surface 607 formed of a second material 616, the second material 616 having a lower hardness than the first material 618. The second portion 621 is configured to selectively reduce the pressing pressure through the second portion 621 of the pressing surface 607.

[0135] The pressing surface 607 is configured to contact the composite material during pressing. In some exemplary examples, the pressing surface 607 is complementary to the cross-sectional shape of the composite member. In some exemplary examples, the pressing surface 607 is complementary to the forming surface of the forming tool.

[0136] The second portion 621 is selected to reduce pressing inconsistencies in the composite material pressed by the roller press 609 on the composite material. In some exemplary examples, at least one of the second material 616 or the second portion 621 is selected to reduce pressing inconsistencies such as wrinkles, gaps, or bridging.

[0137] In this exemplary example, a first portion 619 of the pressed surface 607 includes a web-forming surface 608, and a second portion 621 of the pressed surface 607 includes a cap-forming surface 610. In some exemplary examples, the size and shape of the cap-forming surface 610 are configured to reduce bridging in composite members, such as elongated composite members. In some exemplary examples, bridging can be reduced by providing a more compliant surface to the cap-forming surface 610. In this exemplary example, a radius exists between the web-forming surface 608 and the cap-forming surface 610, wherein the radius is formed by a first material 618.

[0138] Turn now Figure 7 An example of an isometric view of a press is described according to an exemplary embodiment. In manufacturing... Figure 1 When assembling components for the aircraft 100, the press 704 can be used to press composite materials. The press 704 is... Figure 2A and 2B The physical implementation scheme of the press 204. Press 704 is... Figure 3A and 3B The physical implementation scheme of the press 304.

[0139] In view 700, the end effector 702 includes a press 704. In this exemplary example, the press 704 is a roller press 709. The roller press 709 is rotatably mounted to a rotating shaft 706.

[0140] The roller press 709 includes grooves 716 and 718. In some exemplary examples, at least one of the grooves 716 or 718 is filled or partially filled with a compliant material, such as a siloxane. Grooves 716 and 718 are positioned on the roller press 709 to provide pressing pressure relief. Grooves 716 and 718 facilitate the forming of the composite material. Grooves 716 and 718 facilitate the forming pressure relief achieved by the grooves 716 and 718. In some exemplary examples, grooves 716 and 718 facilitate areas of variation within tolerance corresponding to grooves 716 or 718, rather than wrinkles exceeding tolerance. In some exemplary examples, variations within tolerance can be reduced by autoclaving and curing processes. Variations in grooves 716 and 718 include frequency, width, and path. In some exemplary examples, grooves 718 are arranged at 45-degree intervals across a 360-degree cross-sectional area. In some exemplary examples, the width of the groove 718 is in the range of "0.1 to 0.2".

[0141] The roller press 709 includes a pressing surface 707 configured to contact the composite material, and a groove 716 extending through at least a portion of the pressing surface 707.

[0142] In this exemplary example, the groove 716 extends continuously through the web forming surface 708 and the cap forming surface 710. In this exemplary example, the groove 716 is discontinuous on the pressing surface 707. The groove 716 is linear on the pressing surface 707. In other examples not described, the groove 716 may be curved or have any desired path through the pressing surface 707. In this exemplary example, the groove 716 is distributed around the roller body 712 at a frequency of approximately one every 45 degrees.

[0143] In this exemplary example, the groove 718 extends continuously through the flange-forming surface 714. In this exemplary example, the groove 718 is discontinuous 720 on the pressing surface 707. The groove 718 is linear on the pressing surface 707. In other examples not described, the groove 718 may be curved or have any desired path through the pressing surface 707. In this exemplary example, the groove 718 is distributed around a portion of the roll press 709 having the flange-forming surface 714 at a frequency of approximately one every 90 degrees.

[0144] In some exemplary examples, the depth of the groove is the same throughout the groove. In some exemplary examples, the depth of the groove varies along the groove. In some exemplary examples, the depth of some grooves differs from the depth of others. In some exemplary examples, the depth of groove 718 is configured to provide the desired pressure relief. In some exemplary examples, the depth of groove 718 varies on the pressure surface 707.

[0145] In some exemplary examples, the width of the groove is the same throughout the groove. In some exemplary examples, the width of the groove (such as groove 718 or groove 716) varies along the groove. In some exemplary examples, the width of some grooves (such as groove 718 or groove 716) differs from the width of the other grooves. In some exemplary examples, the width of groove 718 is configured to provide the desired pressure relief. In some exemplary examples, the width of groove 718 varies on the pressure surface 707.

[0146] As described, both grooves 718 and 716 are substantially straight 722. In other undescribed examples, grooves passing through the pressed surface 707 may have alternative paths, such as curved paths.

[0147] As shown in the figure, the pressing surface 707 includes a cap-shaped surface 710, a web-shaped surface 708 opposite to the cap-shaped surface 710, and a flange-shaped surface 714, and a flange-shaped surface 714 adjacent to the web-shaped surface 708, and a groove 718 extending through at least a portion of the flange-shaped surface 714 having at least one of a different width, a different frequency, or a different depth than the groove 716 of the web-shaped surface 708.

[0148] In this exemplary example, there are more than one set of grooves. In this exemplary example, each set of grooves (groove 716 and groove 718) has its own shape. In this exemplary example, the path of groove 716 is different from the path of groove 718. In some exemplary examples, groove 716 has the same width and depth as groove 718. In other exemplary examples, the width and depth of groove 716 may be different from those of groove 718.

[0149] In some exemplary examples, a filler material (not shown) is present within at least one groove of groove 718. In these exemplary examples, the filler material has a lower hardness than the first material of the pressed surface.

[0150] Turn now Figure 8 An example of an isometric view of a press is described according to an exemplary embodiment. In manufacturing... Figure 1 When assembling components of the aircraft 100, the press 804 can be used to press composite materials. The press 804 is... Figure 2A and 2B The physical implementation scheme of the press 204. Press 804 is... Figure 3A and 3B The physical implementation scheme of the press 304.

[0151] In view 800, end effector 802 includes press 804. In this exemplary example, press 804 is roller press 809. Roller press 809 includes a rotating shaft 812. Roller bodies 806 of roller press 809 are rotatably mounted to rotating shaft 812.

[0152] The roller press 809 is designed to maintain a constant rotational speed at the point of contact with the composite material being pressed. The roller press 809 is designed to press the composite material without undesirable levels of friction. The roller press 809 is segmented to form independently movable roller segments, such that larger diameter roller segments can rotate more slowly than smaller diameter roller segments. In this exemplary example, the center of the roller body 806 rotates more slowly than smaller diameter segments (such as auxiliary rollers 808). The equation that can be used to estimate the rotation of the roller segments is V = AV × radius (where V is the velocity of the forming surface, AV is the angular velocity, and R is the radius). The velocity will be the same for all different diameters / radii.

[0153] The roller press 809 is passively driven by a frictional connection between the pressing surface and the composite material being pressed. Each independently movable roller segment has an independent stimulus during rolling. Depending on the design and direction of rotation of each independently movable roller segment, each segment can have a different stimulus. For example, turning to the right causes the right flange roller, such as auxiliary roller 810, to travel a shorter distance than the left flange roller, such as auxiliary roller 808. Bearings between the independently movable roller segments allow each segment to rotate independently.

[0154] In this exemplary example, the roller press 809 is configured to press composite materials, and the roller press 809 includes a rotating shaft 812, a roller body 806 rotatably supported on the rotating shaft 812, and an auxiliary roller 808 rotatably supported on the rotating shaft 812, such that the auxiliary roller 808 is independently movable relative to the roller body 806. In this exemplary example, the roller press 809 further includes an auxiliary roller 810 rotatably supported on the rotating shaft 812, such that the auxiliary roller 810 is independently movable relative to the roller body 806.

[0155] A roller bearing (not shown) is located between the roller body 806 and the rotating shaft 812. The roller bearing (not shown) between the roller body 806 and the rotating shaft 812 enables the roller body 806 to rotate about the rotating shaft 812.

[0156] A roller bearing (not shown) is present between the auxiliary roller 808 and the rotating shaft 812. The roller bearing (not shown) between the auxiliary roller 808 and the rotating shaft 812 enables the auxiliary roller 808 to rotate about the rotating shaft 812.

[0157] A roller bearing (not shown) is present between the auxiliary roller 810 and the rotating shaft 812. The roller bearing (not shown) between the auxiliary roller 810 and the rotating shaft 812 enables the auxiliary roller 810 to rotate about the rotating shaft 812.

[0158] In some exemplary examples, the roller press 809 further includes a bearing (not shown) between the roller body 806 and the auxiliary roller 808. In some exemplary examples, the roller press 809 further includes a bearing (not shown) between the roller body 806 and the auxiliary roller 810.

[0159] In this exemplary example, the roller body 806 has a first diameter, and the auxiliary roller 808 has a second diameter different from the first diameter. In this exemplary example, the first diameter is larger than the second diameter.

[0160] In this exemplary example, the roller body 806 has a first diameter, and the auxiliary roller 810 has a third diameter different from the first diameter. In this exemplary example, the first diameter is larger than the third diameter.

[0161] Roller body 806 and auxiliary roller 808 are configured to have different angular velocities and the same velocity at the forming surface, while maintaining a pressing pressure with the desired level of friction. Roller body 806 and auxiliary roller 810 are configured to have the same velocity and different angular velocities at the forming surface, while maintaining a pressing pressure with the desired level of friction.

[0162] In this exemplary example, auxiliary roller 808 is cylindrical. In this exemplary example, auxiliary roller 810 is cylindrical. In this exemplary example, roller body 806 includes a trapezoidal cross-section. In this exemplary example, roller body 806 includes a web forming surface and a cap forming surface. In this exemplary example, auxiliary roller 808 includes a flange forming surface. In this exemplary example, auxiliary roller 810 includes a flange forming surface.

[0163] Turn now Figure 9 According to an exemplary embodiment, an example cross-sectional view of an elongated composite member that can be pressed by a press is described. In view 900, composite material 904 is shown on the forming surface of forming tool 902. In this exemplary example, composite material 904 has not yet been pressed.

[0164] In some exemplary examples, composite material 904 can be pressed onto forming tool 902 to manufacture Figure 1The components of the aircraft 100. In some exemplary examples, composite material 904 may be an embodiment of composite material 254, which may be made of Figure 2A and 2B The material is pressed by a press 204. In some exemplary examples, composite material 904 may be an embodiment of composite material 347, which may be made of... Figure 3A and 3B The 304 is pressed using a press. In some exemplary examples, the composite material 904 can be pressed using a press. Figure 4 The press 404 is pressed onto the forming tool 902. In some exemplary examples, the composite material 904 can be pressed by... Figure 5 The press 504 presses the composite material onto the forming tool 902. In some exemplary examples, the composite material 904 can be pressed by... Figure 6 The press 604 presses the composite material onto the forming tool 902. In some exemplary examples, the composite material 904 can be pressed by... Figure 7 The press 704 presses the composite material onto the forming tool 902. In some exemplary examples, the composite material 904 can be pressed by... Figure 8 The press 804 presses the material onto the forming tool 902.

[0165] In view 900, composite material 904 is present on forming tool 902. In this exemplary example, forming tool 902 includes a cavity to receive composite material 904 and to shape composite material 904 against an inner mold line.

[0166] The elongated composite member 905 has a trapezoidal cross-sectional shape 907. In this exemplary example, the elongated composite member 905 has a flange 906, a web 908, and a cap 910. In this exemplary example, the composite material 904 of the elongated composite member 905 does not fully contact the forming tool 902. In this exemplary example, a gap 916 exists in the region of the flange 906. In this exemplary example, a bridging 912 exists in the radius 914 of the forming tool 902.

[0167] The pressing pressure used to press the composite material 904 can be customized to apply a desired level of pressing pressure to radius 914 to reduce or eliminate bridging 912. The pressing pressure used to press the composite material 904 can be customized to apply a desired level of pressing pressure to flange 906 to reduce or eliminate gap 916. An exemplary roller press can be used to reduce or eliminate at least one of bridging 912 or gap 916. An exemplary roller press can press the composite material 904 against forming tool 902 without introducing further inconsistencies. An exemplary roller press can press the composite material 904 against forming tool 902 with minimal or no wrinkling.

[0168] Turn now Figure 10 An example of a simplified side view of a pressing machine is described according to an exemplary embodiment. In manufacturing... Figure 1 When assembling components of the aircraft 100, the press 1002 can be used to press composite materials. The press 1002 is... Figure 2A and 2B The physical implementation scheme of the press 204. The press 1002 is... Figure 3A and 3B The physical implementation scheme of the press 304.

[0169] In view 1000, end effector 1001 includes press 1002. In this exemplary example, press 1002 is a roller press. Press 1002 includes a rotating shaft 1004. Press 1002 includes a cross-sectional shape 1003 configured to complement the forming surface 1005 of forming tool 1006. In this exemplary example, cross-sectional shape 1003 is formed by a first portion 1008 having a diameter smaller than that of a second portion 1010 of press 1002. In this exemplary example, the center of press 1002 has a smaller diameter than that of the outer portion of press 1002.

[0170] The press 1002 includes desired design options for improving the pressing quality of the composite material. In this exemplary example, a first portion 1008 is formed of a first material, while a second portion 1010 is formed of a second material. In some exemplary examples, grooves are present in the press 1002. In some exemplary examples, the press 1002 includes a plurality of independently movable roller sections.

[0171] In this exemplary example, the press 1002 is configured to press a composite member onto a protruding portion of the forming surface 1005. However, the press of this exemplary example can have any desired cross-sectional shape configured to be complementary to the forming surface of the corresponding forming tool. A roller press can include any desired cross-section configured to press the composite member. In some exemplary examples, the press can have any desired combination of at least one of angled portions, flat portions, or curved portions. In some exemplary examples, the press can have any desired number of roller segments. In some exemplary examples, the press includes any desired material.

[0172] Turn now Figure 11 A flowchart of a method for pressing composite materials is described according to an exemplary embodiment. Method 1100 can be performed to form Figure 1 The composite reinforcement of aircraft 100. Method 1100 can be used. Figure 2A and 2B The roller press 206 is used. Method 1100 can be used. Figure 3A and 3B The roller press 306 is used. Method 1100 can be used. Figure 4 The press 404 is executed. Method 1100 can be used. Figure 5 The pressing machine 504 is executed. Method 1100 can be used. Figure 6 The press 604 is executed. Method 1100 can be executed to press... Figure 9 Composite material 904. Method 1100 can be used. Figure 10 The pressing machine 1002 is in operation.

[0173] Method 1100 involves rolling a roller press along a pressing path, causing the pressing surface of the roller press to contact the composite material. The pressing surface comprises a first portion formed of a first material and a second portion formed of a second material having a lower hardness than the first material (operation 1102). Method 1100 applies a reduced pressing pressure to the composite material through the second portion of the pressing surface (operation 1104). Method 1100 then terminates.

[0174] In some exemplary examples, applying reduced compressive pressure to the composite material includes applying reduced compressive pressure between radii of the cross-sectional shape of the composite material (operation 1106). In some exemplary examples, by applying reduced compressive pressure between radii, the composite material in the radii is sufficiently compressed, while reducing or eliminating inconsistencies such as bridging. In some exemplary examples, by applying reduced compressive pressure between radii, the composite material in the radii receives sufficient compressive pressure to push the composite material into the radii.

[0175] In some exemplary examples, method 1100 identifies a first region of the cross-sectional shape of the elongated composite member to receive higher pressing pressure (operation 1108). In some exemplary examples, method 1100 forms a first portion of a pressing surface configured to contact the first region of the cross-sectional shape made of a first material (operation 1110).

[0176] In some exemplary examples, method 1100 identifies a second region of the cross-sectional shape of the elongated composite member to receive reduced pressing pressure (operation 1112). In some exemplary examples, method 1100 uses a second material to form a second portion of the pressing surface, wherein the second portion of the pressing surface is configured to contact the second region of the cross-sectional shape (operation 1114). In some exemplary examples, the second material refers to a compliant material. In some exemplary examples, the compliant material is the second portion of the pressing surface, which is configured to apply a lower pressing force to the second region. In these exemplary examples, the first portion has a greater pressing force to adequately press a portion of the composite material.

[0177] Turn now Figure 12 A flowchart illustrating a method for controlling the pressing pressure of a roller press, according to an exemplary embodiment, is described. Method 1200 can be performed to form a material for pressing. Figure 1 A roller press for the composite reinforcement of the aircraft 100. Method 1200 can be performed to form... Figure 2A and 2B The roller press 206. Method 1200 can be performed to form Figure 3A and 3B The roller press 306. Method 1200 can be performed to form Figure 4 The press 404. Method 1200 can be performed to form Figure 5 The press 504. Method 1200 can be performed to form Figure 6 The press 604. Method 1200 can be performed to form a roller press to press. Figure 9 The composite material 904. Method 1200 can be used. Figure 10 The pressing machine 1002 is in operation.

[0178] Method 1200 forms a first portion of the pressing surface of a roller press from a first material (operation 1202). Method 1200 forms a second portion of the pressing surface of the roller press from a second material having a lower hardness than the first material (operation 1204). Method 1200 then terminates.

[0179] In some exemplary examples, method 1200 uses a roller press to press an elongated composite member, wherein pressing includes applying pressing pressure through a first material and applying reduced pressing pressure through a second material (operation 1206). In some exemplary examples, the second material applies a reduced pressing pressure compared to the first material, based on the increased compliance of the second material compared to the first material.

[0180] In some exemplary examples, the second portion of forming the pressed surface includes applying a second material onto the first material (operation 1208). In some exemplary examples, friction between the first and second materials holds the second material onto the first material. In some exemplary examples, the second portion of forming the pressed surface further includes bonding the second material to the first material using an adhesive (operation 1210).

[0181] In some exemplary examples, the second portion forming the pressed surface further includes forming a mechanical connection (operation 1212) between a mechanical connector of the first material and the second material. In some exemplary examples, the mechanical connector includes a protrusion and an internal groove.

[0182] In some exemplary examples, the first portion forming the pressed surface includes a first portion of the pressed surface of the 3D-printed first material (operation 1214), and the second portion forming the pressed surface includes a second portion of the pressed surface of the 3D-printed second material (operation 1216). In some exemplary examples, the second material is 3D-printed separately from the first material. In some exemplary examples, the second material may be bonded to the first material after the second portion is 3D-printed.

[0183] Turn now Figure 13 A flowchart of a method for pressing composite materials is described according to an exemplary embodiment. Method 1300 can be performed to form a composite material for pressing. Figure 1 A roller press for the composite reinforcement of the medium-sized aircraft 100. Method 1300 can be performed to form... Figure 2A and 2B The roller press 206. Method 1300 can be performed to form Figure 3A and 3B The roller press 306. Method 1300 can be performed to form Figure 4 The press 404. Method 1300 can be performed to form Figure 5 The press 504. Method 1300 can be performed to form Figure 8 The press 804. Method 1300 can be performed to form a roller press for pressing. Figure 9 904 composite material.

[0184] Method 1300 drives a roller press having independently movable roller sections along a pressing path at a certain speed to press a composite material. The roller press includes a rotating shaft, and the independently movable roller sections are rotatably supported on the rotating shaft independently of each other (operation 1302). When the roller press contacts the composite material, method 1300 passively rotates the independently movable roller sections independently of each other (operation 1304). Method 1300 then terminates.

[0185] In some exemplary examples, the independently movable roller section includes a roller body rotatably supported on a rotation axis and an auxiliary roller rotatably supported on the rotation axis independently of the roller body (operation 1306). In some exemplary examples, the independently movable roller section further includes a second auxiliary roller, wherein the roller body is positioned between the auxiliary rollers. In some exemplary examples, the auxiliary roller includes a flanged forming surface.

[0186] In some exemplary examples, passively rotating an individually movable roller segment includes passively rotating the individually movable roller segment at different angular velocities (operation 1308). In some exemplary examples, passively rotating an individually movable roller segment at different angular velocities includes rotating the individually movable roller segment at different angular velocities due to different radii (operation 1310). In some exemplary examples, a roller segment with a smaller radius has a higher angular velocity.

[0187] In some exemplary examples, passively rotating independently movable roller segments at different angular velocities includes rotating the independently movable roller segments at different angular velocities due to in-plane turning of the drive roller press through curvature (operation 1312). In some exemplary examples, the roller segments of the independently movable roller segments in the direction of curvature have lower angular velocities.

[0188] Turn now Figure 14 A flowchart of a method for pressing composite materials is described according to an exemplary embodiment. Method 1400 can be performed to form a composite material for pressing. Figure 1 A roller press for the composite reinforcement of aircraft 100. Method 1400 can be performed to form... Figure 2A and 2B The roller press 206. Method 1400 can be performed to form Figure 3A and 3B The roller press 306. Method 1400 can be performed to form Figure 4 The press 404. Method 1400 can be performed to form Figure 5 The press 504. Method 1400 can be performed to form Figure 7 The press 704. Method 1400 can be performed to form a roller press for pressing. Figure 9 904 composite material.

[0189] Method 1400 rolls the pressing surface of a roller press onto the composite material to press the composite material into a forming tool (operation 1402). Method 1400 provides pressure relief during forming by periodically rolling grooves in the pressing surface onto the composite material (operation 1404). Method 1400 then terminates.

[0190] In some exemplary examples, method 1400 forms the pressing surface of a roller press, wherein the grooves are positioned approximately every 45 degrees (operation 1406). In some exemplary examples, the grooves are positioned approximately every 90 degrees. In some exemplary examples, the distribution frequency of the grooves is configured to provide the desired pressure relief to the composite material.

[0191] In some exemplary examples, method 1400 forms a pressing surface of a roller press, wherein the width of the grooves ranges from approximately 0.1 inches to approximately 0.2 inches (operation 1408). In some exemplary examples, each groove has a substantially constant width. In some exemplary examples, at least one groove has a variable width. In some exemplary examples, each groove has the same width. In some exemplary examples, grooves of different widths are present in the pressing surface.

[0192] In some exemplary examples, method 1400 forms a pressing surface of a roller press with grooves, wherein the grooves are continuous across the pressing surface (operation 1410). In some exemplary examples, the grooves extend continuously across the pressing surface in a direction parallel to the axis of rotation of the pressing surface. In some exemplary examples, the grooves extend continuously from a first edge to a second edge on the pressing surface. In other exemplary examples, at least one groove is discontinuous on the pressing surface. In other exemplary examples, at least one groove extends partially into the pressing surface from one edge and terminates before reaching an opposite edge of the pressing surface.

[0193] In some exemplary examples, method 1400 forms a pressed surface with a filler material within the groove, the filler material having a hardness lower than that of a first material of the pressed surface (operation 1412). In some exemplary examples, the filler material completely fills the groove. In some exemplary examples, the filler material only partially fills the groove. In some exemplary examples, the filler material is a polymer material. In some exemplary examples, the filler material is a siloxane.

[0194] Turn now Figure 15 A flowchart of a method for selectively forming wrinkles in a composite material during molding is described according to an exemplary embodiment. Method 1500 can be performed to press... Figure 1 The composite structure of the medium-sized aircraft 100. Method 1500 can be executed to suppress... Figure 2A and 2B Composite material 254. Method 1500 can be performed to press... Figure 3A and 3B Composite material 347. In some exemplary examples, method 1500 may use Figure 4 The pressing machine 404 is used to perform the operation. Method 1500 can be used. Figure 5 The pressing machine 504 is used to perform this. Method 1500 can be used... Figure 7 The press 704 is used to execute this. Method 1500 can be executed to press... Figure 9 The composite material 904. Method 1500 can be used. Figure 10 The pressing machine 1002 is used to perform the operation.

[0195] Method 1500 forms pressed regions in the composite material during the molding process (operation 1502). Method 1500 positions tolerance-compliant wrinkles at designated locations between the pressed regions of the composite material (operation 1504). Method 1500 then terminates.

[0196] In some exemplary examples, positioning the tolerance-inclusive wrinkles in a designated location includes providing pressure relief from pressing at the designated location during composite molding (operation 1506). In some exemplary examples, positioning the tolerance-inclusive wrinkles in a designated location includes allowing the formation of tolerance-inclusive wrinkles within designated locations at regular intervals between pressing areas (operation 1508).

[0197] As used herein, when used with a list of items, the phrase "at least one of..." means that different combinations of one or more of the listed items can be used, and it may be necessary to use only one of each item in the list. For example, "at least one of item A, item B, or item C" can be, but is not limited to, item A, item A and item B, or item B. This instance could also include item A, item B, and item C, or item B and item C. Of course, any combination of these items can exist. In other examples, "at least one of..." can be, for example, but not limited to, two items A; one item B; ten items C; four items B and seven items C; or other suitable combinations. Items can be specific objects, things, or categories. In other words, at least one of any combination of items and item quantities can be used from the list, but not all items in the list are required.

[0198] As used in this article, when references are used, “the number of…” refers to one or more items.

[0199] The flowcharts and block diagrams in the various described embodiments illustrate the structure, function, and operation of some possible implementations of the device and method in the exemplary embodiments. In this regard, each block in the flowchart or block diagram may represent at least one of a module, segment, function, or part of an operation or step.

[0200] In some alternative embodiments of the exemplary embodiments, one or more functions marked in the boxes may not appear in the order indicated in the figures. For example, in some cases, depending on the functions involved, two boxes displayed consecutively may be executed substantially simultaneously, or the boxes may sometimes be executed in reverse order. Furthermore, in addition to the example boxes shown in the flowchart or block diagram, other boxes may be added. Some boxes may be optional.

[0201] Exemplary embodiments of this disclosure may be implemented in Figure 16 The aircraft manufacturing and maintenance methods shown in 1600 and Figure 17 The aircraft 1700 is depicted in the background. First, it turns... Figure 16An example of an aircraft manufacturing and servicing method is illustrated in block diagram form according to an exemplary embodiment. During pre-production, the aircraft manufacturing and servicing method 1600 may include... Figure 17 Specifications and design of the 1700 aircraft 1602 and material procurement 1604.

[0202] During the production process, the manufacturing of components and subassemblies of the aircraft 1700 (1606) and system integration (1608) occur. Afterward, the aircraft 1700 can be certified and delivered (1610) for service (1612). When in service by a customer (1612), the aircraft 1700 is scheduled for routine maintenance and servicing (1614), which may include retrofitting, reconfiguration, refurbishment, or other maintenance and servicing.

[0203] Each process in the Aircraft Manufacturing and Service Method 1600 can be performed or conducted by a systems integrator, a third party, and / or an operator. In these examples, the operator may be a customer. For the purposes of this description, a systems integrator may include, but is not limited to, any number of aircraft manufacturers and major systems subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and providers; and an operator may be an airline, leasing company, military entity, service organization, etc.

[0204] Now for reference Figure 17 An example of an aircraft is described in the form of a block diagram, in which exemplary embodiments can be implemented. In this example, aircraft 1700 is composed of... Figure 16 The aircraft manufacturing and servicing method 1600 produces an aircraft and may include a fuselage 1702 having multiple systems 1704 and an interior 1706. Examples of systems 1704 include one or more of a propulsion system 1708, an electrical system 1710, a hydraulic system 1712, and an environmental system 1714. Any number of other systems may be included.

[0205] The apparatus and methods presented herein may be used during at least one stage of the aircraft manufacturing and servicing method 1600. One or more exemplary embodiments may be available. Figure 16 The components and sub-components are manufactured or used during at least one of the following periods: manufacturing 1606, system integration 1608, service 1612, or maintenance and servicing 1614.

[0206] The present invention also includes embodiments according to the following examples: Example 1. A roller press (206, 306, 405, 505, 609) comprising: The first portion (234, 419, 509, 619) of the pressed surface (210, 305, 414, 507, 607) formed from the first material (226, 326, 418, 514, 618); and The second portion (236, 421, 513, 621) of the pressing surface (210, 305, 414, 507, 607) formed of the second material (228, 328, 420, 512, 616) has a lower hardness (229, 329) than the first material (226, 326, 418, 514, 618), wherein the second portion (236, 421, 513, 621) is configured to selectively reduce pressing pressure through the second portion (236, 421, 513, 621) of the pressing surface (210, 305, 414, 507, 607).

[0207] Example 2. The roller press (206, 306, 405, 505, 609) according to Example 1, wherein the pressing surfaces (210, 305, 414, 507, 607) are complementary to the cross-sectional shapes (252, 352) of the composite components (248, 348).

[0208] Example 3. The roller press (206, 306, 405, 505, 609) according to Example 2, wherein the pressing surface (210, 305, 414, 507, 607) is complementary to the forming surface (258, 383) of the forming tool (256, 379, 902).

[0209] Example 4. The roller press (206, 306, 405, 505, 609) according to Example 1, wherein the second part (236, 421, 513, 621) is selected to reduce pressing inconsistencies in the composite material (254, 347, 904) pressed by rolling the roller press (206, 306, 405, 505, 609) over the composite material (254, 347, 904).

[0210] Example 5. Roller presses (206, 306, 405, 505, 609) as described in Example 4. The second portion (236, 421, 513, 621) is selected to locally relax the compression (259) outside the concave radius (251) of the cross-sectional shape (252, 352) of the composite material (254, 347, 904) to strengthen the compression (259) in the concave radius (251).

[0211] Example 6. The roller press (206, 306, 405, 505, 609) according to Example 1, wherein the first portion (234, 419, 509, 619) of the pressing surface (210, 305, 414, 507, 607) includes a web forming surface (214, 314, 608), and wherein the second portion (236, 421, 513, 621) of the pressing surface (210, 305, 414, 507, 607) includes a cap forming surface (220, 320, 610).

[0212] Example 7. The roller press (206, 306, 405, 505, 609) according to Example 6, wherein the size and shape of the cap forming surface (220, 320, 610) are configured to reduce bridging (912) in the elongated composite member (248, 348).

[0213] Example 8. The roller press (206, 306, 405, 505, 609) according to Example 6, wherein the roller body (208, 308, 408, 508, 603) includes a trapezoidal cross section (310, 611), the trapezoidal cross section (310, 611) including the web forming surface (214, 314, 608) and the cap forming surface (220, 320, 610).

[0214] Example 9. The roller press (206, 306, 405, 505, 609) according to Example 6 further includes: The radius (322, 324, 612, 614) between the web forming surface (214, 314, 608) and the cap forming surface (220, 320, 610), wherein the radius (322, 324, 612, 614) is formed by the first material (226, 326, 418, 514, 618).

[0215] Example 10. The roller press (206, 306, 405, 505, 609) according to Example 1 further includes an adhesive (357) between the first material (226, 326, 418, 514, 618) and the second material (228, 328, 420, 512, 616).

[0216] Example 11. A roller press (206, 306, 405, 505, 609) according to Example 1, wherein the second material (228, 328, 420, 512, 616) is constrained against the first material (226, 326, 418, 514, 618) by friction (359).

[0217] Example 12. The roller press (206, 306, 405, 505, 609) according to Example 1 further includes: Protrusions (353, 526), ​​said protrusions (353, 526) being formed of the first material (226, 326, 418, 514, 618); and The second material (228, 328, 420, 512, 616) has a groove (355, 522) positioned above the protrusion (353, 526) to secure the second material (228, 328, 420, 512, 616) to the first material (226, 326, 418, 514, 618).

[0218] Example 13. A roller press (206, 306, 405, 505, 609) according to Example 1, wherein the first material (226, 326, 418, 514, 618) and the second material (228, 328, 420, 512, 616) are configured to provide sufficient friction (359), wherein the composite material (254, 347, 904) is pressed to passively roll the roller press (206, 306, 405, 505, 609) about a rotation axis (272, 372, 406, 506, 606).

[0219] Example 14. A method (1100) for pressing composite materials (254, 347, 904), comprising: Roller presses (206, 306, 405, 505, 609) are rolled (1102) along the pressing path (307) such that the pressing surfaces (210, 305, 414, 507, 607) of the roller presses (206, 306, 405, 505, 609) come into contact with the composite material (254, 347, 904), the pressing surfaces (210, 305, 414, 507, 607) comprising a first material (226, 3... A first portion (234, 419, 506, 619) formed of 26, 418, 514, 618 and a second portion (236, 421, 513, 621) formed of a second material (228, 328, 420, 512, 616) having a lower hardness (229, 329) than the first material (226, 326, 418, 514, 618); and A reduced pressing pressure (257) is applied to the composite material (254, 347, 904) by the second portion (236, 421, 513, 621) of the pressing surface (210, 305, 414, 507, 607).

[0220] Example 15. The method (1100) according to Example 14, wherein (1106) applying the reduced pressing pressure (257) to the composite material (254, 347, 904) includes applying the reduced pressing pressure (257) between the radii (322, 324, 612, 614) of the cross-sectional shape (252) of the composite material (254, 347, 904).

[0221] Example 16. The method (1100) according to Example 14 further includes: Identify the first region (251) of the cross-sectional shape (252, 352) of the elongated composite member (248, 348) to receive higher pressing pressure (255); and The first portion (234, 419, 509, 619) of forming a pressed surface (210, 305, 414, 507, 607) is configured to contact the first region (251) of the cross-sectional shape (252, 352) made of the first material (226, 326, 418, 514, 618).

[0222] Example 17. The method (1100) according to Example 14 further includes: Identify (1112) the second region (253) of the cross-sectional shape (252, 352) of the elongated composite member (248, 348) to receive the reduced pressing pressure (257); and The second portion (236, 421, 513, 621) of the pressed surface (210, 305, 414, 507, 607) is formed (1114) using the second material (228, 328, 420, 512, 616), wherein the second portion (236, 421, 513, 621) of the pressed surface (210, 305, 414, 507, 607) is configured to contact the second region (253) of the cross-sectional shape (252, 352).

[0223] Example 18. A method (1200) for controlling the pressing pressure of a roller press (206, 306, 405, 505, 609), comprising: The first portions (234, 419, 619) of the pressing surfaces (210, 305, 414, 507, 607) of the roller press (206, 306, 405, 505, 609) formed by the first material (226, 326, 418, 514, 618) of the roller press (1202) are formed from the first material (226, 326, 418, 514, 618). The second portion (236, 421, 513, 621) of the pressing surface (210, 305, 414, 507, 607) of the roller press (206, 306, 405, 505, 609) is formed of the second material (228, 328, 420, 512, 616) of the roller press (1204), the second material (228, 328, 420, 512, 616) having a lower hardness (229, 329) than the first material (226, 326, 418, 514, 618).

[0224] Example 19. The method (1200) according to Example 18 further includes: The roller press (206, 306, 405, 505, 609) is used to press (1206) elongated composite components (248, 348), wherein the pressing includes applying pressing pressure (255) through the first material (226, 326, 418, 514, 618) and applying reduced pressing pressure (257) through the second material (228, 328, 420, 512, 616).

[0225] Example 20. The method (1200) according to Example 18, wherein (1208) forming the second portion (236, 421, 513, 621) of the pressed surface (210, 305, 414, 507, 607) includes applying the second material (228, 328, 420, 512, 616) onto the first material (226, 326, 418, 514, 618).

[0226] Example 21. The method (1200) according to Example 20, wherein (1210) forming the second portion (236, 421, 513, 621) of the pressed surface (210, 305, 414, 507, 607) further comprises using an adhesive (357) to bond the second material (228, 328, 420, 512, 616) to the first material (226, 326, 418, 514, 618).

[0227] Example 22. The method (1200) according to Example 20, wherein (1212) forming the second portion (236, 421, 513, 621) of the pressed surface (210, 305, 414, 507, 607) further includes forming a mechanical connection between the first material (226, 326, 418, 514, 618) and the second material (228, 328, 420, 512, 616) and a mechanical connector (351).

[0228] Example 23. The method (1200) according to Example 18, wherein (1214) forming the first portion (234, 419, 509, 619) of the pressed surface (210, 305, 414, 507, 607) includes 3D printing the first portion (234, 419) of the pressed surface (210, 305, 414, 507, 607) of the first material (226, 326, 418, 514, 618) from the first material. , 509, 619), and wherein (1116) forms the second portion (236, 421, 513, 621) of the pressed surface (210, 305, 414, 507, 607) including the 3D printing of the second material (228, 328, 420, 512, 616) of the pressed surface (210, 305, 414, 507, 607) of the second material (210, 305, 414, 507, 607) of the second portion (236, 421, 513, 621).

[0229] The description of several different exemplary embodiments is presented for illustrative and descriptive purposes and is not exhaustive, nor is it limited to the embodiments of the disclosed form. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different exemplary embodiments may provide different features compared to other exemplary embodiments. The selection and description of one or more embodiments are intended to best explain the principles of the embodiments, their practical application, and to enable those skilled in the art to understand the disclosure of various embodiments with various modifications suitable for the particular purpose contemplated.

Claims

1. A roller press (206, 306, 405, 505, 609), comprising: The first portion (234, 419, 509, 619) of the pressed surface (210, 305, 414, 507, 607) formed from the first material (226, 326, 418, 514, 618); and The second portion (236, 421, 513, 621) of the pressing surface (210, 305, 414, 507, 607) formed of the second material (228, 328, 420, 512, 616) has a lower hardness (229, 329) than the first material (226, 326, 418, 514, 618), wherein the second portion (236, 421, 513, 621) is configured to selectively reduce pressing pressure through the second portion (236, 421, 513, 621) of the pressing surface (210, 305, 414, 507, 607).

2. The roller press (206, 306, 405, 505, 609) according to claim 1, wherein the pressing surfaces (210, 305, 414, 507, 607) are complementary to the cross-sectional shapes (252, 352) of the composite components (248, 348).

3. The roller press (206, 306, 405, 505, 609) according to claim 2, wherein the pressing surface (210, 305, 414, 507, 607) is complementary to the forming surface (258, 383) of the forming tool (256, 379, 902).

4. The roller press (206, 306, 405, 505, 609) according to claim 1, wherein the second portion (236, 421, 513, 621) is selected to reduce pressing inconsistencies in the composite material (254, 347, 904) pressed by rolling the roller press (206, 306, 405, 505, 609) over the composite material (254, 347, 904).

5. The roller press (206, 306, 405, 505, 609) according to claim 4. The second portion (236, 421, 513, 621) is selected to locally relax the compression (259) outside the concave radius (251) of the cross-sectional shape (252, 352) of the composite material (254, 347, 904) to strengthen the compression (259) in the concave radius (251).

6. The roller press (206, 306, 405, 505, 609) according to claim 1, wherein the first portion (234, 419, 509, 619) of the pressing surface (210, 305, 414, 507, 607) includes a web forming surface (214, 314, 608), and wherein the second portion (236, 421, 513, 621) of the pressing surface (210, 305, 414, 507, 607) includes a cap forming surface (220, 320, 610).

7. The roller press (206, 306, 405, 505, 609) according to claim 6, wherein the size and shape of the cap forming surface (220, 320, 610) are configured to reduce bridging (912) in the elongated composite member (248, 348).

8. The roller press (206, 306, 405, 505, 609) according to claim 6, wherein the roller body (208, 308, 408, 508, 603) includes a trapezoidal cross section (310, 611), the trapezoidal cross section (310, 611) including the web forming surface (214, 314, 608) and the cap forming surface (220, 320, 610).

9. The roller press (206, 306, 405, 505, 609) according to claim 6, further comprising: The radius (322, 324, 612, 614) between the web forming surface (214, 314, 608) and the cap forming surface (220, 320, 610), wherein the radius (322, 324, 612, 614) is formed by the first material (226, 326, 418, 514, 618).

10. The roller press (206, 306, 405, 505, 609) according to claim 1, further comprising an adhesive (357) between the first material (226, 326, 418, 514, 618) and the second material (228, 328, 420, 512, 616).

Images