Vacuum compactor and method of use

Abstract

A vacuum compactor and method of use are presented. A vacuum compactor configured to pick and place composite components of different cross sections includes a vacuum control module, a plurality of releasable connectors associated with the vacuum control module actuatable by an end effector including the vacuum control module, and a stringer interface module having a contact surface shape complementary to the composite component configured to pick, place, and compress the composite component and removably connectable to the vacuum control module by the end effector using the plurality of releasable connectors.

Description

Technical Field

[0001] This disclosure relates generally to the manufacture of composite materials, and more specifically to vacuum compactors and their use in the manufacture of composite materials. Background Technology

[0002] Preforms of composite parts may not be self-supporting when placed on the inclined surface of a tool. In particular, placing large preforms on rigid tooling with complex curvatures can be challenging. This is because the chances of large preforms detaching or shifting from the tooling increase during or after placement. Detachment can occur if the preform is not quickly and securely pressed onto the tool. Therefore, it remains desirable to move and secure preforms (and / or other objects) to complex surfaces quickly and efficiently.

[0003] Therefore, it is desirable to have a method and apparatus that can take into account at least some of the problems discussed above, as well as other possible problems. Summary of the Invention

[0004] One embodiment of this disclosure provides a method for picking up a composite material component. The cross-sectional shape of the composite material component to be placed on a forming tool is determined. A stringer interface module compatible with the cross-sectional shape of the composite material component is selected based on this cross-sectional shape. The stringer interface module is automatically coupled to the vacuum control module of the end effector. The stringer interface module engages with the composite material component.

[0005] Another embodiment of this disclosure provides a method for placing a composite material component. A stringer interface module is automatically coupled to a vacuum control module of an end effector. The end effector is used to place the composite material component into contact with the forming surface of a forming tool, while a vacuum is applied to a first region of the stringer interface module via the vacuum control module. The composite material component is then pressed against the forming tool by applying a vacuum to a second region of the stringer interface module via the vacuum control module. After the composite material component has been pressed against the forming tool, the stringer interface module is automatically removed from the vacuum control module.

[0006] Another embodiment of this disclosure provides a vacuum compactor configured to pick up and place composite material components of varying cross-sections. The vacuum compactor includes a vacuum control module; a plurality of releasable connectors associated with the vacuum control module, actuated by an end effector including the vacuum control module; and a stringer interface module having a contact surface shape complementary to the composite material component, configured to pick up, place, and compress the composite material component, and removably connectable to the vacuum control module via the end effector and using the plurality of releasable connectors.

[0007] Another embodiment of this disclosure provides a method for configuring an end effector. A stringer interface module is determined to mate with a composite material member having a cross-sectional shape. The stringer interface module is automatically coupled to the vacuum control module of the end effector.

[0008] Clause 1. A method (600) for picking up a composite material component (250), comprising: Determine (602) the cross-sectional shape of the composite component (250) to be placed on the forming tool (246); Based on the cross-sectional shape of the composite component (250), select (604) stringer interface modules (214, 304, 403, 404, 504) that are compatible with the cross-sectional shape of the composite component (250). Automatically couple (606) the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) of the end effector (202); and The stringer interface modules (214, 304, 403, 404, 504) are joined (608) to the composite material component (250).

[0009] Clause 2. The method (600) described in Clause 1 further includes: Vacuum (222) is sent (612) by the vacuum control module (208, 302, 402, 502) and sent to the first region (234, 312, 412, 512) of the stringer interface module (214, 304, 403, 404, 504) to pick up the composite material component (250).

[0010] Clause 3. The method (600) described in Clause 2 further includes: The composite material component (250) is placed (614) in contact with the forming surface (248) of the forming tool (246) while maintaining a vacuum (222) in the first region (234, 312, 412, 512) of the stringer interface module (214, 304, 403, 404, 504).

[0011] Clause 4. The method (600) described in Clause 3 further includes: Vacuum (222) is sent (616) by the vacuum control modules (208, 302, 402, 502) and sent to the second region (236, 314, 414, 514) of the stringer interface modules (214, 304, 403, 404, 504) to compact the composite material component (250) against the forming surface (248) of the forming tool (246).

[0012] Clause 5. The method (600) described in Clause 4 further includes: Vacuum (222) is released (618) from both the first region (234, 312, 412, 512) and the second region (236, 314, 414, 514). Drive the end effector (202) (620) to the storage area (238); and The stringer interface modules (214, 304, 403, 404, 504) are decoupled (622) from the end effector (202) to place the stringer interface modules (214, 304, 403, 404, 504) in the storage area (238).

[0013] Clause 6. The method (600) described in Clause 1 further includes: After performing pick-and-place operations (612, 632, 710, 716) using the stringer interface modules (214, 304, 403, 404, 504), the stringer interface modules (214, 304, 403, 404, 504) are decoupled from the end effector (202) (624); and A second stringer interface module (242) having a different contact surface shape (244) from the stringer interface modules (214, 304, 403, 404, 504) is automatically coupled (626) to the vacuum control module (208, 302, 402, 502) of the end effector (202).

[0014] Clause 7. The method (600) according to Clause 1, wherein (628) automatically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) includes using a quick-change connector (224) for coupling.

[0015] Clause 8. The method (600) according to Clause 1, wherein (630) automatically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) includes magnetically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502).

[0016] Clause 9. The method (600) according to Clause 1, wherein (632) automatically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) includes controlling a rotary locking mechanism (228) via the end effector (202) to couple the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502).

[0017] Clause 10. A method (700) for placing a composite material component (250), comprising: Automatically couple (702) the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) of the end effector (202); The end effector (202) is used to place (704) the composite component (250) into contact with the forming surface (248) of the forming tool (246), while the vacuum control module (208, 302, 402, 502) sends a vacuum (222) to the first region (234, 312, 412, 512) of the stringer interface module (214, 304, 403, 404, 504). The composite material component (250) is compacted (706) against the forming tool (246) by: sending a vacuum (222) to the second region (236, 314, 414, 514) of the stringer interface module (214, 304, 403, 404, 504) via the vacuum control module (208, 302, 402, 502); and After the composite material component (250) is pressed against the forming tool (246), the stringer interface module (214, 304, 403, 404, 504) is automatically removed (708) from the vacuum control module (208, 302, 402, 502).

[0018] Clause 11. The method (700) pursuant to Clause 10 further includes: A second stringer interface module (242) having a different contact surface shape (244) from the stringer interface modules (214, 304, 403, 404, 504) is automatically coupled (710) to the vacuum control module (208, 302, 402, 502) of the end effector (202).

[0019] Clause 12. The method (700) according to Clause 10, wherein (712) automatically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) includes coupling using a quick-change connector (224).

[0020] Clause 13. The method (700) according to Clause 10, wherein (714) automatically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) includes magnetically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502).

[0021] Clause 14. The method (700) according to Clause 10, wherein (716) automatically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) includes controlling a rotary locking mechanism (228) via the end effector (202) to couple the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502).

[0022] Clause 15. A vacuum compactor (204, 300, 400, 500) configured to pick up and place composite material components of different cross-sections, said vacuum compactor comprising: Vacuum control modules (208, 302, 402, 502); Multiple releasable connectors (210), associated with the vacuum control modules (208, 302, 402, 502), are actuated by an end effector (202) including the vacuum control modules (208, 302, 402, 502); and The stringer interface modules (214, 304, 403, 404, 504) have contact surface shapes (230, 316, 416, 516) that are complementary to the composite component (250) and are configured to pick up, place and compress the composite component (250) and can be removably connected to the vacuum control module (208, 302, 402, 502) via the multiple releasable connectors (210) through the end effector (202).

[0023] Clause 16. The vacuum compactor (204, 300, 400, 500) according to Clause 15, wherein the vacuum control module (208, 302, 402, 502) includes a first region (216, 308, 408, 508) and a second region (218, 310, 410, 510), the first region and the second region being controllable to provide vacuum (222) to different regions of the stringer interface module (214, 304, 403, 404, 504).

[0024] Clause 17. The vacuum compactor (204, 300, 400, 500) as described in Clause 15, wherein the stringer interface module (214, 304, 403, 404, 504) includes a first region (234, 312, 412, 512) configured to lift the composite component (250) and a second region (236, 314, 414, 514) configured to compact the composite component (250).

[0025] Clause 18. The vacuum compactor (204, 300, 400, 500) as described in Clause 17, wherein the stringer interface module (214, 304, 403, 404, 504) includes a convex surface for an inlet to the second region (236, 314, 414, 514).

[0026] Clause 19. The vacuum compactor (204, 300, 400, 500) as described in Clause 15, wherein the plurality of releasable connectors (210) includes at least one of a quick-change connector (224), a magnet (226), or a rotary locking mechanism (228).

[0027] Clause 20. The vacuum compactor (204, 300, 400, 500) according to Clause 15, wherein the contact surface shape (230, 316, 416, 516) is complementary to the composite component (250) having a cap-shaped cross section (232).

[0028] Clause 21. A method (800) for configuring an end effector, comprising: Determine (802) stringer interface modules (214, 304, 403, 404, 504) that match the composite component (250) having a cross-sectional shape (256); and The stringer interface modules (214, 304, 403, 404, 504) are automatically (804) coupled (606) to the vacuum control module (208, 302, 402, 502) of the end effector (202).

[0029] Clause 22. The method (800) described pursuant to Clause 21 further includes: Select (806) the stringer interface module (214, 304, 403, 404, 504) from a plurality of stringer interface modules (241) with different contact surface shapes.

[0030] The features and functions 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

[0031] The appended claims set forth novel features that are considered to be characteristics of exemplary embodiments. However, the illustrative embodiments, their preferred modes of use, further objects, and features will be best understood by referring to the following detailed description of illustrative embodiments of the present disclosure when read in conjunction with the accompanying drawings, wherein: Figure 1 This is an illustration of an aircraft according to an illustrative embodiment; Figure 2 This is an illustration of a block diagram of a manufacturing environment according to an illustrative embodiment; Figure 3 This is an illustration of a cross-sectional view of a vacuum compactor according to an illustrative embodiment; Figure 4 This is an illustration of an isometric view showing the movement of the vacuum control module toward the stringer interface module according to an illustrative embodiment; Figure 5 This is an illustration of a cross-sectional view of a vacuum compactor according to an illustrative embodiment; Figure 6A and Figure 6B This is a flowchart of a method for picking up a composite material component according to an illustrative embodiment; Figure 7 This is a flowchart of a method for placing a composite material component according to an illustrative embodiment; Figure 8 This is a flowchart of a method for configuring an end effector according to an illustrative embodiment; Figure 9 It is an illustration of an aircraft manufacturing and maintenance method in the form of a block diagram according to an illustrative embodiment; and Figure 10 It is an illustration of an aircraft in the form of a block diagram, in which illustrative embodiments can be implemented. Detailed Implementation

[0032] The illustrative example recognizes and considers one or more different considerations. It provides a high-capacity vacuum system that quickly and efficiently picks up and places objects, such as preforms, on complex surfaces and compacts them into place via vacuum. The illustrative example utilizes a two-phase vacuum system that operates a first section to generate a suction hold for transporting the object to a tool, and a second section to generate a suction hold that compacts the object onto the tool. Compaction ensures the object remains fixed to the tool, regardless of the tool's orientation.

[0033] The illustrative example recognizes and takes into account that after the pick-and-place and compaction end effector placement, the vacuum is shut off, but the retraction of the end effector from the mandrel can facilitate vacuum clamping. Vacuum clamping during retraction can pull the placed ply out of the desired position (displacement / peeling). The illustrative example provides a vacuum system end effector that enables the compacted stringer to remain in place better than the current stringer placement.

[0034] Now go to Figure 1 An illustration of an aircraft is depicted according to an illustrative embodiment. The aircraft 100 has wings 102 and 104 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.

[0035] The main body 106 has a tail section 112. Horizontal stabilizers 114, 116 and vertical stabilizers 118 are attached to the tail section 112 of the main body 106.

[0036] Aircraft 100 is an example of an aircraft that may have a composite material structure compacted using a vacuum compactor as exemplified in some illustrative examples. In some illustrative examples, the methods of the illustrative examples may be used to compact the composite material stringers of the wings 102, wing 104, or body 106 of aircraft 100.

[0037] Now go to Figure 2 The illustration depicts a block diagram of a manufacturing environment according to an illustrative embodiment. Figure 2 The composite material component 250 can be Figure 1 The aircraft 100 has a composite material structure.

[0038] An end effector 202 can be used to pick up a composite component 250 and place it onto the forming surface 248 of a forming tool 246. The end effector 202 can then compact the composite component 250 against the forming tool 246. By forming and compacting the composite component 250 against the forming surface 248 of the forming tool 246, the profile of the composite component 250 changes from an initial profile 252 to a final profile 254. In some illustrative examples, the composite component 250 takes the form of a composite stringer 258. The composite component 250 has a cross-sectional shape 256. The cross-sectional shape 256 of the composite component 250 is maintained throughout the forming and compaction process using the end effector 202.

[0039] The end effector 202 includes a vacuum compactor 204. A base 206 remains connected to the end effector 202. The base 206 may also be referred to as a vacuum control module 208.

[0040] Manifold 212 is removably connected to base 206. Manifold 212 may also be referred to as stringer interface module 214.

[0041] Vacuum compactor 204 is configured to pick up and place composite material components 250 and other composite material components with different cross-sections. Vacuum compactor 204 includes a vacuum control module 208, a plurality of releasable connectors 210, and a stringer interface module 214. The plurality of releasable connectors 210 are associated with the vacuum control module 208 and can be actuated by an end effector 202 including the vacuum control module 208. The stringer interface module 214 has a contact surface shape 230 complementary to that of the composite material component 250, is configured to pick up, place, and compress the composite material component 250, and is configured to be coupled to and removed from the vacuum control module 208 via the end effector 202 and using the plurality of releasable connectors 210. The vacuum compactor 204 includes a vacuum control module 208, a plurality of releasable connectors 210, and a stringer interface module 214. The plurality of releasable connectors 210 are associated with the vacuum control module 208 and can be actuated by an end effector 202 including the vacuum control module 208. The stringer interface module 214 has a contact surface shape 230 complementary to the composite material member 250, is configured to pick up, place, and compress the composite material member 250, and can be removably connected to the vacuum control module 208 via the end effector 202 and using the plurality of releasable connectors 210.

[0042] In this illustrative example, the vacuum control module 208 includes a first region 216 and a second region 218, which are controllable to provide vacuum to different regions of the stringer interface module 214.

[0043] In some illustrative examples, the stringer interface module 214 includes a first region 234 configured to lift the composite member 250 and a second region 236 configured to compact the composite member 150. In this illustrative example, the contact surface shape 230 is configured to be complementary to the cross-sectional shape 256. In some illustrative examples, the contact surface shape 230 is complementary to the composite member 250 having a cap-shaped cross-section 232.

[0044] When the stringer interface module 214 is decoupled from the vacuum control module 208, the second stringer interface module 242 can be coupled to the vacuum control module 208. The second stringer interface module 242 has a contact surface shape 244 that is different from the contact surface shape 230. The contact surface shape 244 is configured to complement a composite material component having a cross-sectional shape that is different from the cross-sectional shape 256.

[0045] The plurality of releasable connectors 210 include connectors of any desired type. In some illustrative examples, the plurality of releasable connectors 210 include at least one of a quick-change connector 224, a magnet 226, or a rotary locking mechanism 228. In some illustrative examples, the stringer interface module 214 is vacuum-coupled to the vacuum control module 208.

[0046] Vacuum 222 is provided by vacuum control module 208 to at least one of the first region 234 or the second region 236 of stringer interface module 214. Vacuum control module 208 provides vacuum 222 from vacuum source 220. End effector 202 can be moved within manufacturing environment 200 by manipulator 240. In some illustrative examples, manipulator 240 takes the form of a collaborative robot.

[0047] Figure 2 The illustration of the manufacturing environment 200 does not imply any physical or architectural limitations on the implementation of the exemplary embodiments. Other components besides those shown may be used, or components that replace the shown components may be used. Some components may be unnecessary. Furthermore, these boxes are presented to illustrate some functional components. When implemented in the illustrative embodiments, one or more of these boxes may be combined, divided, or combined and divided into different boxes.

[0048] For example, in some illustrative examples, more than two stringer interface modules may exist in storage area 238. In another illustrative example, stringer interface module 214 may have a different surface shape than the cap-shaped cross-section 232.

[0049] Now go to Figure 3 The illustration depicts a cross-sectional view of a vacuum compactor according to an illustrative embodiment. The vacuum compactor 300 can be... Figure 2The physical implementation method of the vacuum compactor 204.

[0050] A vacuum compactor 300 is configured to pick up and place composite material components with different cross-sections. The vacuum compactor 300 includes a vacuum control module 302 and a stringer interface module 304. The stringer interface module 304 has a contact surface shape 316 complementary to the composite material component, is configured to place and compress the composite material component, and is removably connectable to the vacuum control module 302 via an end effector using multiple releasable connectors. In this illustrative example, the contact surface shape 316 is complementary to a composite material component having a cap-shaped cross-section. In this illustrative example, multiple releasable connectors (not shown) are associated with the vacuum control module 302 and are actuable by an end effector including the vacuum control module 302. In some illustrative examples, the multiple releasable connectors include at least one of quick-change connectors, magnets, or rotary locking mechanisms. In some illustrative examples, the stringer interface module 304 can be vacuum-connected to the vacuum control module 302.

[0051] Vacuum control module 302 includes a first region 308 and a second region 310, which are controllable to provide vacuum to different regions of stringer interface module 304. In this illustrative example, a vacuum source can provide vacuum to vacuum control module 302 via vacuum section 306. By actuating a portion of vacuum control module 302, vacuum can be selectively controlled to the first region 308 and the second region 310. Stringer interface module 304 includes a first region 312 configured to lift the composite material member and a second region 314 configured to compact the composite material member.

[0052] In this illustrative example, the stringer interface module 304 includes a convex surface for an entrance to the second region 314. In this illustrative example, the convex surface can be used for indexing. In this illustrative example, the convex surface can be used to connect the second region 310 to the second region 314.

[0053] Now go to Figure 4 According to an illustrative embodiment, an isometric view of a vacuum control module moving toward the stringer interface module is depicted. The vacuum compactor 400 may be... Figure 2 The physical implementation of the vacuum compactor 204. In some illustrative examples, the vacuum control module 402 and... Figure 3 The vacuum control module 302 is the same. In some illustrative examples, the stringer interface module 404 is... Figure 3 The same as the stringer interface module 304.

[0054] A vacuum compactor 400 is configured to pick up and place composite material components with different cross-sections. The vacuum compactor 400 includes a vacuum control module 402 and a stringer interface module 404. In this illustrative example, the vacuum control module 402 is connected to a manipulator 401. In this illustrative example, the manipulator 401 takes the form of a collaborative robot. The vacuum compactor 400 is an end effector configured to pick up, place, and compact composite material components.

[0055] The stringer interface module 404 has a contact surface shape 416 complementary to the composite material member. The vacuum compactor 400 is configured to place and compress the composite material member. The stringer interface module 404 can be removably connected to the vacuum control module 402 via an end effector and using multiple releasable connectors. In this illustrative example, the contact surface shape 416 is complementary to the composite material member having a cap-shaped cross-section. In this illustrative example, multiple releasable connectors 420 are associated with the vacuum control module 402 and can be actuated by an end effector including the vacuum control module 402. In this illustrative example, the multiple releasable connectors 420 include magnets associated with the vacuum control module 402. In this illustrative example, the multiple releasable connectors 420 are configured to connect to multiple releasable connectors 422 in the stringer interface module 404. In this illustrative example, the multiple releasable connectors 422 include magnets.

[0056] In some illustrative examples, the multiple releasable connectors include at least one of a quick-change connector, a magnet, or a rotary locking mechanism. In some illustrative examples, the stringer interface module 404 can be vacuum connected to the vacuum control module 402.

[0057] Vacuum control module 402 includes a first region 408 and a second region 410, which are controllable to provide vacuum to different regions of stringer interface module 404. In this illustrative example, a vacuum source can provide vacuum to vacuum control module 402 via a vacuum port. By actuating portions of vacuum control module 402, vacuum can be selectively controlled to the first region 408 and the second region 410. Stringer interface module 404 includes a first region 412 configured to lift the composite material member and a second region 414 configured to compact the composite material member.

[0058] In this illustrative example, the stringer interface module 404 includes a convex surface for an entrance to the second region 414. In this illustrative example, the convex surface can be used for indexing. In this illustrative example, the convex surface can be used to connect the second region 410 to the second region 414.

[0059] Now go to Figure 5The illustration depicts a cross-sectional view of a vacuum compactor according to an illustrative embodiment. The vacuum compactor 500 can be... Figure 2 The physical implementation of the vacuum compactor 204. In some illustrative examples, the vacuum control module 502 and... Figure 3 The vacuum control module 502 is the same as that of the vacuum control module 302. In some illustrative examples, the vacuum control module 502 may be the same as... Figure 4 It is the same as the vacuum control module 402.

[0060] A vacuum compactor 500 is configured to pick up and place composite material components with different cross-sections. The vacuum compactor 500 includes a vacuum control module 502 and a stringer interface module 504. The stringer interface module 504 has a contact surface shape 516 complementary to the composite material component, is configured to place and compress the composite material component, and is removably connected to the vacuum control module 502 via an end effector using multiple releasable connectors. In this illustrative example, the contact surface shape 516 is complementary to a composite material component having a flat surface. In this illustrative example, multiple releasable connectors (not shown) are associated with the vacuum control module 502 and can be actuated by an end effector including the vacuum control module 504. In some illustrative examples, the multiple releasable connectors include at least one of quick-change connectors, magnets, or rotary locking mechanisms. In some illustrative examples, the stringer interface module 504 can be vacuum-connected to the vacuum control module 502.

[0061] Vacuum control module 502 includes a first region 508 and a second region 510, which are controllable to provide vacuum to different regions of stringer interface module 504. In this illustrative example, a vacuum source can provide vacuum to vacuum control module 502 via vacuum section 506. By actuating a portion of vacuum control module 502, vacuum can be selectively controlled to the first region 508 and the second region 510. Stringer interface module 504 includes a first region 512 configured to lift the composite material member and a second region 514 configured to compact the composite material member.

[0062] In this illustrative example, the stringer interface module 504 includes a convex surface for an entrance to the second region 514. In this illustrative example, the convex surface can be used for indexing. In this illustrative example, the convex surface can be used to connect the second region 510 to the second region 514.

[0063] Now go to Figure 6A and Figure 6B A flowchart of a method for picking up a composite material component is depicted according to an illustrative embodiment. Method 600 can be used... Figure 2 The vacuum control module 208 and stringer interface module 214 are used to execute this. Method 600 can be performed using... Figure 3 The vacuum control module 302 and stringer interface module 304 are used to execute this. Method 600 can be performed using... Figure 4 The vacuum control module 402 and the stringer interface module 404 are used to execute this. Method 600 can be performed using... Figure 5 The vacuum control module 502 and the stringer interface module 504 are used to perform this.

[0064] Method 600 determines the cross-sectional shape of the composite component to be placed on the forming tool (operation 602). Method 600 selects a stringer interface module compatible with the cross-sectional shape of the composite component based on the cross-sectional shape of the composite component (operation 604). Method 600 automatically couples the stringer interface module to the vacuum control module of the end effector (operation 606). Method 600 engages the stringer interface module with the composite component (operation 608). Subsequently, Method 600 terminates.

[0065] In some illustrative examples, method 600 sends a vacuum via a vacuum control module to a first region of the stringer interface module to pick up the composite component (operation 612). In some illustrative examples, method 600 positions the composite component in contact with the forming surface of the forming tool while maintaining a vacuum in the first region of the stringer interface module (operation 614).

[0066] In some illustrative examples, method 600 sends a vacuum via a vacuum control module to a second region of the stringer interface module to compact the composite component against the forming surface of the forming tool (operation 616).

[0067] In some illustrative examples, method 600 releases the vacuum from both the first and second regions (operation 618). The vacuum can be released from both the first and second regions after placing and compacting the composite material component using a vacuum compactor that includes a vacuum control module and a stringer interface module.

[0068] In some illustrative examples, method 600 drives the end effector to the storage area (operation 620). In some illustrative examples, method 600 decouples the stringer interface module from the end effector to place the stringer interface module in the storage area (operation 622). In some illustrative examples, method 600 decouples the stringer interface module from the end effector after performing pick-and-place operations using the stringer interface module (operation 624). In some illustrative examples, method 600 automatically couples a second stringer interface module having a different contact surface shape than the stringer interface module to the vacuum control module of the end effector (operation 626).

[0069] In some illustrative examples, automatically coupling the stringer interface module to the vacuum control module includes using a quick-connect connector for coupling (operation 628). In some illustrative examples, automatically coupling the stringer interface module to the vacuum control module includes magnetically coupling the stringer interface module to the vacuum control module (operation 630). In some illustrative examples, automatically coupling the stringer interface module to the vacuum control module includes controlling a rotary locking mechanism via an end effector to couple the stringer interface module to the vacuum control module (operation 632). In some illustrative examples, automatically coupling the stringer interface module to the vacuum control module includes using a vacuum to couple the stringer interface module to the vacuum control module. In some illustrative examples, an additional vacuum source is used to couple the vacuum control module to the stringer interface module.

[0070] Now go to Figure 7 A flowchart of a method for placing a composite material component is depicted according to an illustrative embodiment. Method 700 can be used... Figure 2 The vacuum control module 208 and stringer interface module 214 are used to execute this. Method 700 can be performed using... Figure 3 The vacuum control module 302 and stringer interface module 304 are used to execute this. Method 700 can be performed using... Figure 4 The vacuum control module 402 and stringer interface module 404 are used to execute this. Method 700 can be performed using... Figure 5 The vacuum control module 502 and the stringer interface module 504 are used to perform this.

[0071] Method 700 automatically couples the stringer interface module to the vacuum control module of the end effector (operation 702). Method 700 uses the end effector to position the composite component in contact with the forming surface of the forming tool, while simultaneously applying a vacuum to a first region of the stringer interface module via the vacuum control module (operation 704). Method 700 compacts the composite component against the forming tool by applying the vacuum to a second region of the stringer interface module via the vacuum control module (operation 706). After compacting the composite component against the forming tool, Method 700 automatically removes the stringer interface module from the vacuum control module (operation 708). Method 700 then terminates.

[0072] In some illustrative examples, method 700 automatically couples a second stringer interface module, having a different contact surface shape than the stringer interface module, to the vacuum control module of the end effector (operation 710). In some illustrative examples, automatically coupling the stringer interface module to the vacuum control module includes coupling the stringer interface module to the vacuum control module using a vacuum. In some illustrative examples, an additional vacuum source is used to connect the vacuum control module to the stringer interface module.

[0073] In some illustrative examples, automatically coupling the stringer interface module to the vacuum control module includes using a quick-connect connector for coupling (operation 712). In some illustrative examples, automatically coupling the stringer interface module to the vacuum control module includes magnetically coupling the stringer interface module to the vacuum control module (operation 714). In some illustrative examples, automatically coupling the stringer interface module to the vacuum control module includes controlling a rotary locking mechanism via an end effector to couple the stringer interface module to the vacuum control module (operation 716).

[0074] Now go to Figure 8 A flowchart of a method for configuring an end effector is depicted according to an illustrative embodiment. Method 800 can be used... Figure 2 The vacuum control module 208 and stringer interface module 214 are used to execute this. Method 800 can be performed using... Figure 3 The vacuum control module 302 and stringer interface module 304 are used to execute this. Method 800 can be performed using... Figure 4 The vacuum control module 402 and the stringer interface module 404 are used to execute this. Method 800 can be performed using... Figure 5 The vacuum control module 502 and the stringer interface module 504 are used to perform this.

[0075] Method 800 identifies a stringer interface module that mates with the composite material component having a cross-sectional shape (operation 802). Method 800 automatically couples the stringer interface module to the vacuum control module of the end effector (operation 804). Subsequently, Method 800 terminates.

[0076] In some illustrative examples, method 800 selects a stringer interface module from a plurality of stringer interface modules having different contact surface shapes (operation 806).

[0077] As used in this article, 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 only one of each item in the list is required. 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 example 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 of item A; one of item B; and ten of item C; four of item B and seven of item C; or other suitable combinations. Items can be specific objects, things, or categories. In other words, at least one of any combination of items in the list and any number of items can be used, but not all items in the list are required.

[0078] As used in this article, when referring to projects, "multiple" means one or more projects.

[0079] The flowcharts and block diagrams in the different depicted embodiments illustrate the architecture, functionality, and operation of some possible implementations of the apparatus and methods in the illustrative embodiments. In this regard, each block in the flowchart or block diagram may represent at least one of a module, segment, function, or operation or step.

[0080] In some alternative implementations of the illustrative embodiments, one or more functions described in the boxes may appear in different orders as shown in the figures. For example, in some cases, two boxes shown consecutively may be executed substantially simultaneously, or these boxes may sometimes be executed in reverse order, depending on the functions involved. Furthermore, in addition to the boxes shown in the flowchart or block diagram, other boxes may be added. Some boxes may be optional. For example, operations 612 through 632 may be optional. For example, operations 710 through 716 may be optional.

[0081] Exemplary embodiments of this disclosure may be implemented as follows: Figure 9 The aircraft manufacturing and maintenance methods 900 and as shown Figure 10 The description is presented against the background of the aircraft 1000 shown. First, switch to... Figure 9 An illustration of an aircraft manufacturing and maintenance method is depicted in block diagram form according to an illustrative embodiment. During pre-production, the aircraft manufacturing and maintenance method 900 may include... Figure 10 Specifications and design of China Aircraft 1000 902 and material procurement 904.

[0082] During production, the manufacturing of aircraft 1000 parts and sub-assemblies (906) and system integration (908) occur. Afterward, aircraft 1000 can be certified and delivered (910) for service (912). Upon service by the customer (912), aircraft 1000 is scheduled for routine maintenance and upkeep (914), which may include modifications, reconfigurations, refurbishments, or other repairs and maintenance.

[0083] Each process in the Aircraft Manufacturing and Maintenance Method 900 can be performed or conducted by a systems integrator, a third party, and / or an operator. In these examples, the operator can be the customer. For the purposes of this description, a systems integrator can include, but is not limited to, any number of aircraft manufacturers and major systems subcontractors; a third party can include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator can be an airline, leasing company, military entity, service organization, etc.

[0084] Now for reference Figure 10 The diagram illustrates an aircraft in block form, where illustrative embodiments can be implemented. In this example, the aircraft 1000 is... Figure 9 The aircraft is manufactured using the aircraft manufacturing and maintenance method 900, and may include a fuselage 1002 having multiple systems 1004 and an interior 1006. Examples of systems 1004 include one or more of a propulsion system 1008, an electrical system 1010, a hydraulic system 1012, and an environmental system 1014. Any number of other systems may be included.

[0085] The apparatus and methods embodied herein can be used during at least one stage of the aircraft manufacturing and maintenance method 900. One or more exemplary embodiments may be used. Figure 9 The components and sub-assemblies are manufactured or used during at least one of the following periods: manufacturing 906, system integration 908, commissioning 912, or repair and maintenance 914.

[0086] The illustrative example provides an end effector design for automating the exchange of vacuum pick-up / compaction tools for different stringer types / shapes. The exemplary end effector includes a permanent vacuum control module and an interchangeable stringer interface module.

[0087] The illustrative example provides an end effector design for automated exchange of vacuum pick-up / compaction tools for different stringer types / shapes. The illustrative example includes a locking mechanism between a permanent vacuum control module and interchangeable stringer interface modules. In some illustrative examples, the locking mechanism includes a magnet system or other locking mechanism. In some illustrative examples, a toolbox or other storage area includes various interchangeable stringer interface modules.

[0088] The illustrative example is configured to handle multiple stringer types. The illustrative example provides an end effector with a design featuring multiple stringer interface modules that can interface with various stringers. The illustrative example provides a vacuum control module designed to be permanently attached to the end effector mount. The illustrative example provides stringer interface modules specific to a given stringer type, designed to be interchangeable automatically.

[0089] The descriptions of various illustrative embodiments are presented for purposes of illustration and description and are not intended to be exhaustive or limited to the embodiments of the disclosed forms. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different illustrative embodiments may provide different features compared to other illustrative 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 intended use.

Claims

1. A method (600) for picking up a composite material component (250), comprising: Determine (602) the cross-sectional shape of the composite component (250) to be placed on the forming tool (246); Based on the cross-sectional shape of the composite component (250), select (604) stringer interface modules (214, 304, 403, 404, 504) that are compatible with the cross-sectional shape of the composite component (250). Automatically couple (606) the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) of the end effector (202); and The stringer interface modules (214, 304, 403, 404, 504) are joined (608) to the composite material component (250).

2. The method (600) according to claim 1, further comprising: Vacuum (222) is sent (612) by the vacuum control module (208, 302, 402, 502) and sent to the first region (234, 312, 412, 512) of the stringer interface module (214, 304, 403, 404, 504) to pick up the composite material component (250).

3. The method (600) according to claim 2, further comprising: The composite material component (250) is placed (614) in contact with the forming surface (248) of the forming tool (246) while maintaining a vacuum (222) in the first region (234, 312, 412, 512) of the stringer interface module (214, 304, 403, 404, 504).

4. The method (600) according to claim 3, further comprising: Vacuum (222) is sent (616) by the vacuum control modules (208, 302, 402, 502) and sent to the second region (236, 314, 414, 514) of the stringer interface modules (214, 304, 403, 404, 504) to compact the composite material component (250) against the forming surface (248) of the forming tool (246).

5. The method (600) according to claim 4, further comprising: Vacuum (222) is released (618) from both the first region (234, 312, 412, 512) and the second region (236, 314, 414, 514). Drive the end effector (202) (620) to the storage area (238); and The stringer interface modules (214, 304, 403, 404, 504) are decoupled (622) from the end effector (202) to place the stringer interface modules (214, 304, 403, 404, 504) in the storage area (238).

6. The method (600) according to claim 1, further comprising: After performing pick-and-place operations (612, 632, 710, 716) using the stringer interface modules (214, 304, 403, 404, 504), the stringer interface modules (214, 304, 403, 404, 504) are decoupled from the end effector (202) (624); and A second stringer interface module (242) having a different contact surface shape (244) from the stringer interface modules (214, 304, 403, 404, 504) is automatically coupled (626) to the vacuum control module (208, 302, 402, 502) of the end effector (202).

7. The method (600) of claim 1, wherein (628) automatically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) includes using a quick-change connector (224) for coupling.

8. The method (600) according to claim 1, wherein (630) automatically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control module (208, 302, 402, 502) comprises magnetically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control module (208, 302, 402, 502).

9. The method (600) according to claim 1, wherein (632) automatically coupling the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control module (208, 302, 402, 502) comprises controlling a rotary locking mechanism (228) via the end effector (202) to couple the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control module (208, 302, 402, 502).

10. A method (700) for placing a composite material component (250), comprising: Automatically couple (702) the stringer interface modules (214, 304, 403, 404, 504) to the vacuum control modules (208, 302, 402, 502) of the end effector (202); The end effector (202) is used to place (704) the composite component (250) into contact with the forming surface (248) of the forming tool (246), while the vacuum control module (208, 302, 402, 502) sends a vacuum (222) to the first region (234, 312, 412, 512) of the stringer interface module (214, 304, 403, 404, 504). The composite material component (250) is compacted (706) against the forming tool (246) by: sending a vacuum (222) to the second region (236, 314, 414, 514) of the stringer interface module (214, 304, 403, 404, 504) via the vacuum control module (208, 302, 402, 502); and After the composite material component (250) is pressed against the forming tool (246), the stringer interface module (214, 304, 403, 404, 504) is automatically removed (708) from the vacuum control module (208, 302, 402, 502).

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