Molded end effector and method of use

Abstract

To provide a method for molding a composite material onto a mandrel.SOLUTION: A molded end effector and a method of use are presented. A method for molding a composite material onto a mandrel is presented. The molded end effector carrying the composite material is positioned above the mandrel. The molded end effector is connected to the mandrel. The composite material is swept onto the mandrel using a sweeper of the molded end effector.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present disclosure relates generally to forming composite materials, and more particularly to a forming end effector configured to form composite materials against a mandrel. [Background technology]

[0002] Currently, gantry molding machines can be used to mold composite materials onto mandrels. However, gantry molding machines have a limited operating envelope. They cannot accommodate tool tilts of more than a few degrees.

[0003] The robot can be oriented at specific angles for a task, however, the robot is not as rigid as a gantry.

[0004] It would therefore be desirable to have a method and apparatus that takes into account at least some of the problems set forth above, as well as other potential problems.It would be desirable to provide an alternative method of forming a composite material onto a mandrel. Summary of the Invention [Means for solving the problem]

[0005] One embodiment of the present disclosure provides a method of forming a composite material over a mandrel, wherein a forming end effector carrying the composite material is positioned above the mandrel, the forming end effector is connected to the mandrel, and the composite material is swept over the mandrel using a sweeper of the forming end effector.

[0006] Another embodiment of the present disclosure provides a forming end effector for forming composite materials, the forming end effector including a frame, a number of legs operably connected to the frame, and a forming head having a sweeper operably connected to the frame by a number of actuators operably connected to the frame, the number of legs having engagement pins connecting the forming end effector to a mandrel.

[0007] Yet another embodiment of the present disclosure provides a forming end effector for forming composite materials, the forming end effector including a frame, a number of actuators operably connected to the frame, and a forming head having a sweeper operably connected to the frame by the number of actuators, the number of actuators connected to the forming head by pairs of hinges such that the forming head is configured to rotate to form the composite material.

[0008] A further embodiment of the present disclosure provides a method, wherein a composite material is formed against a mandrel using a sweeper of a forming end effector, and a load from the forming end effector is reacted against the mandrel during forming of the composite material.

[0009] The features and functions can be achieved alone in various embodiments of the present disclosure or may be combined in still other embodiments, further details of which can be seen with reference to the following description and drawings.

[0010] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments, together with their preferred modes of use, further objects and features, will best be understood by reference to the following detailed description of illustrative embodiments of the present disclosure taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is an illustration of an aircraft in accordance with an illustrative embodiment; [Figure 2] FIG. 1 is a block diagram of a manufacturing environment in accordance with an illustrative embodiment. [Figure 3] FIG. 10 is an isometric view of a molded end effector in an engagement orientation according to an exemplary embodiment. [Figure 4] FIG. 10 is an isometric view of a molded end effector in a non-engaging orientation in accordance with an exemplary embodiment; [Figure 5] FIG. 10 is a front view of a molded end effector in a non-engaged orientation according to an exemplary embodiment. [Figure 6] FIG. 10 is an isometric view of a molded end effector in an engagement orientation according to an exemplary embodiment. [Figure 7] FIG. 10 is an isometric view of an engagement pin on a leg of a molded end effector in accordance with an exemplary embodiment; [Figure 8] FIG. 10 is an isometric view of a composite retention system for a molded end effector in accordance with an illustrative embodiment; [Figure 9] FIG. 10 is a front view of a forming end effector connected to a mandrel and in an engagement orientation in accordance with an exemplary embodiment; [Figure 10] FIG. 10 is a front view of a forming end effector connected to a mandrel and in an engagement orientation in accordance with an exemplary embodiment; [Figure 11] FIG. 10 is a front view of a forming end effector connected to a mandrel and in an engagement orientation in accordance with an exemplary embodiment; [Figure 12] FIG. 10 is a front view of a forming end effector connected to a mandrel and in an engagement orientation in accordance with an exemplary embodiment; [Figure 13] FIG. 10 is a front view of a forming end effector connected to a mandrel and in an engagement orientation in accordance with an exemplary embodiment; [Figure 14] FIG. 10 is a front view of a forming end effector connected to a mandrel and in an engagement orientation in accordance with an exemplary embodiment; [Figure 15] FIG. 10 is an isometric view of a forming end effector positioned relative to a mandrel in accordance with an exemplary embodiment; [Figure 16]FIG. 10 is an isometric view of a central actuator with a central presser of a molded end effector in accordance with an exemplary embodiment; [Figure 17] FIG. 10 is an isometric view of a central actuator with a central presser of a molded end effector in accordance with an exemplary embodiment; [Figure 18] FIG. 10 is an isometric view of a composite retention system for a molded end effector in accordance with an illustrative embodiment; [Figure 19] FIG. 10 is a top view of a composite retention system for a molded end effector in accordance with an illustrative embodiment; [Figure 20] 1 is a flowchart of a method of forming a composite material over a mandrel in accordance with an illustrative embodiment. [Figure 21] 1 is a flowchart of a method of forming a composite material over a mandrel in accordance with an illustrative embodiment. [Figure 22] FIG. 1 is an illustration of an aircraft manufacturing and service method in the form of a block diagram in accordance with an illustrative embodiment; [Figure 23] FIG. 1 is an illustration of an aircraft in the form of a block diagram in which an illustrative embodiment may be implemented; DETAILED DESCRIPTION OF THE INVENTION

[0012] Referring now to Figure 1, an illustration of an aircraft is shown in accordance with an illustrative embodiment. Aircraft 100 has wing 102 and wing 104 attached to body 106. Aircraft 100 includes engine 108 attached to wing 102 and engine 110 attached to wing 104.

[0013] Body 106 has tail section 112. Horizontal stabilizer 114, horizontal stabilizer 116, and vertical stabilizer 118 are attached to tail section 112 of body 106.

[0014] Aircraft 100 is an example of an aircraft that may have a composite structure formed using the illustrative example forming end effector. Composite structures of wing 102, wing 104, body 106, or tail 112 may be produced using the illustrative example forming end effector.

[0015] With reference now to Figure 2, an illustration of a block diagram of a manufacturing environment is depicted in accordance with an illustrative embodiment. A forming end effector 200 is used within a manufacturing environment 202 to form a composite material 204.

[0016] The forming end effector 200 includes a frame 206, multiple legs 208, and a forming head 210 having a sweeper 212. The multiple legs 208 are operatively connected to the frame 206. The multiple legs 208 include an engagement pin 214 and an engagement pin 216. The multiple legs 208 include a leg 215 and a leg 217. The legs 215 and the legs 217 are on opposite sides of the frame 206. The legs 215 and the legs 217 are on opposite sides of a central actuator 256.

[0017] Engagement pin 214 and engagement pin 216 are configured to connect forming end effector 200 to mandrel 218. Leg 215 connects to mandrel 218 on the opposite side of mandrel 218 from leg 217. Leg 215 is configured to connect to a first side 228 of a base 230 of mandrel 218, while leg 217 connects to a second side 229 of base 230 of mandrel 218.

[0018] The mandrel 218 takes the form of a tool 266 onto which the composite material 204 is applied and shaped. The composite material 204 is shaped against the shaping surface 264 by sweeping the composite material 204 using the sweeper 212 of the shaping end effector 200. The mandrel 218 further comprises a base 230 to which the shaping end effector 200 connects.

[0019] The forming end effector 200 can be moved in an engagement direction 286 and a disengagement direction 288 to connect or disconnect the forming end effector 200 to the mandrel 218. The engagement direction 286 is the direction in which the forming end effector 200 connects to the mandrel 218. When in the engagement direction 286, the forming end effector 200 can be used to form the composite material 204 against the mandrel 218. The disengagement direction 288 is the direction for moving the forming end effector 200 to or from the mandrel 218. When in the disengagement direction 288, the legs 215 and 217 of the forming end effector 200 can be used to form the composite material 204 against the mandrel 218.

[0020] Forming head 210 having sweeper 212 is operably connected to frame 206 by multiple actuators operably connected to frame 206. Forming head 210 having sweeper 212 is operably connected to frame 206 by multiple actuators 220, multiple actuators 222, multiple actuators 224, and multiple actuators 226.

[0021] As shown, forming head 210 includes forming head 211 and forming head 213. Forming head 211 is attached to a number of actuators 220 and a number of actuators 222.

[0022] Forming head 210 is connected to multiple actuators by multiple pairs of hinges configured to rotate the sweeper relative to mandrel 218 beneath frame 206. In this illustrative example, for forming head 211, the multiple pairs of hinges comprise hinge 232 and hinge 233. Forming head 211 is connected to multiple actuators 220 by hinge 232. Forming head 211 is connected to multiple actuators 222 by hinge 233. Hinge 232 has a distance 235 of first axis 234 from forming head 211. Hinge 233 has a distance 237 of second axis 236 from forming head 211. Distance 235 differs from distance 237 such that actuation of either multiple actuators 220 or multiple actuators 222 causes rotation of sweeper 238.

[0023] The horizontal position, angle, and extension of the actuators control the movement of each forming head and each sweeper. For example, the horizontal position 248, angle 249, and extension of multiple actuators 220 and the horizontal position 250, angle 251, and extension of multiple actuators 222 can control the rotational sweep 291 and translational sweep 293 of sweeper 238. The use of rotational sweep 291 and translational sweep 293 for a sweeper, such as an inflatable bladder, allows for the ability to independently control compression and tension forces. Multiple translation systems 295 can be used to modify at least one of the horizontal position 248 or angle 249 of multiple actuators 220 or the horizontal position 250 or angle 251 of multiple actuators 222. Multiple translation systems 295 can comprise at least one of bearings, rails, or carts.

[0024] In this illustrative example, for forming head 213, the pairs of hinges comprise hinge 240 and hinge 241. Forming head 213 is connected to multiple actuators 224 by hinge 240. Forming head 213 is connected to multiple actuators 226 by hinge 241. Hinge 240 has a distance 243 of first axis 242 from forming head 213. Hinge 241 has a distance 245 of second axis 244 from forming head 213. Distance 243 differs from distance 245 such that actuation of either multiple actuators 224 or multiple actuators 226 causes sweeper 246 to rotate.

[0025] The horizontal position, angle, and extension of the actuators control the movement of each forming head and each sweeper. For example, the horizontal position 252, angle 253, and extension of multiple actuators 224 and the horizontal position 254, angle 255, and extension of multiple actuators 226 can control the rotational sweep and translational sweep of sweeper 246. Multiple translation systems 297 can be used to modify at least one of the horizontal position 252 or angle 253 of multiple actuators 224 or the horizontal position 254 or angle 255 of multiple actuators 226. Multiple translation systems 297 can comprise at least one of bearings, rails, or carts.

[0026] In some illustrative examples, sweeper 212 takes the form of an inflatable bladder. In this illustrative example, sweeper 238 takes the form of an inflatable bladder 239. In this illustrative example, sweeper 246 takes the form of an inflatable bladder 247.

[0027] Using multiple actuators 220 and multiple actuators 222, sweeper 238 is used to sweep composite material 204 against mold surface 264. Multiple actuators 220 and multiple actuators 222 are used to perform both a rotational sweep 291 and a translational sweep 293 of composite material 204 against mold surface 264. Multiple actuators 220 and multiple actuators 222 are used to rotate sweeper 238 around corners of mold surface 264 to reduce undesired tension on composite material 204. Using rotational sweep 291, sweeper 238 continues to compress composite material 204 while sweeper 238 moves around corners of mold surface 264. During translational sweep 293, sweeper 238 moves along mold surface 264 to tension composite material 204 along mold surface 264.

[0028] Using multiple actuators 224 and multiple actuators 226, sweeper 246 is used to sweep composite material 204 against mold surface 264. Multiple actuators 224 and multiple actuators 226 are used to perform both a rotational sweep 291 and a translational sweep 293 of composite material 204 against mold surface 264. Multiple actuators 224 and multiple actuators 226 are used to rotate sweeper 246 around corners of mold surface 264 to reduce undesired tension on composite material 204. Using rotational sweep 291, sweeper 246 continues to compress composite material 204 while sweeper 246 moves around corners of mold surface 264. During translational sweep 293, sweeper 246 moves along mold surface 264 to tension composite material 204 along mold surface 264.

[0029] In some illustrative examples, forming head 210 further comprises a vacuum pad configured to hold composite material 204 prior to forming. As shown, forming head 211 further comprises a composite holding system 275 configured to hold composite material 204 prior to forming. Composite holding system 275 comprises vacuum pad 277 and guard 278. Guard 278 is a mechanical component for protecting composite material 204 during transfer of composite material 204.

[0030] As shown, molding head 213 further includes a composite retention system 276 configured to hold composite material 204 prior to molding. Composite retention system 276 includes vacuum pads 279 and guards 280. Guards 280 are mechanical components for protecting composite material 204 during transfer.

[0031] The forming end effector 200 further includes a central actuator 256 connected to the frame 206 between the forming heads 210. A central presser 258 is operatively connected to the central actuator 256. In some illustrative examples, the central presser 258 includes an inflatable bladder 260 operatively connected to the central actuator 256. In this illustrative example, the central presser 258 is connected to the central actuator 256 by a rotary pedal 262. In some illustrative examples, the central actuator 256 takes the form of an air cylinder 257.

[0032] The central actuator 256 is used to press the composite material 204 against a molding surface 264 of the mandrel 218 during molding of the composite material 204. In some illustrative examples, when the central presser 258 takes the form of an inflatable bladder 260, the inflatable bladder 260 may be deactivated when the forming end effector 200 is not forming the composite material 204. In some illustrative examples, when the forming end effector 200 is not actively forming the composite material 204, the inflatable bladder 260 is not inflated to conserve space. To utilize the inflatable bladder 260 to press the composite material 204 against the molding surface 264, the inflatable bladder 260 is inflated and the rotary pedals 262 are rotated outward to press the composite material 204 onto the molding surface 264.

[0033] The forming end effector 200 can be transferred to the mandrel 218 by a robotic arm 290. The forming end effector 200 can form and shape the composite material 204 against the forming surface 264 without being connected to the robotic arm 290. The robotic arm 290 can be used to transport and position multiple forming end effectors to apply the composite material to the mandrel 218. Forming end effectors 200 that perform the forming process without being attached to a robotic arm 290 can allow fewer robotic arms to be used in the manufacturing environment 202. Furthermore, having several independently operating forming end effectors, including the forming end effector 200, allows the composite material 204 to be applied to the mandrel 218 more efficiently.

[0034] The formed end effector 200 can be connected to the formed end effector 200 via a utility port 292. The utility port 292 is connected to the frame 206. The utility port 292 is configured to interface with the robotic arm 290 for transfer of the formed end effector 200 and is configured to interface with utilities 294 for the forming process independent of the robotic arm 290. The utilities 294 can be provided to the formed end effector 200 via the manufacturing floor of the manufacturing environment 202 via the utility port 292.

[0035] In some exemplary examples, the engagement pin is further configured to receive at least one utility therethrough and transfer the utility to other components of the forming end effector. In some exemplary examples, the engagement pin 214 is configured to receive at least one utility of the utilities 294 therethrough. In some exemplary examples, the engagement pin 214 is configured to receive a utility from the mandrel 218.

[0036] In some illustrative examples, the engagement pin 214 includes a vacuum channel 282. The vacuum channel 282 can be used to provide a resource, such as vacuum or air pressure, to the forming end effector 200. In some illustrative examples, the vacuum channel 282 is present in the engagement pin 214 to receive at least one utility from the mandrel 218. In some illustrative examples, air pressure is provided to the forming end effector 200 from the mandrel 218 via the engagement pin 214.

[0037] In some illustrative examples, the engagement pin 216 includes a vacuum channel 284. The vacuum channel 284 can be used to provide a resource, such as vacuum or air pressure, to the forming end effector 200. In some illustrative examples, the vacuum channel 284 is present in the engagement pin 216 to receive at least one utility from the mandrel 218. In some illustrative examples, air pressure is provided to the forming end effector 200 from the mandrel 218 via the engagement pin 216.

[0038] In some illustrative examples, the load from the forming end effector 200 reacts the load on the mandrel 218 during the sweep. In some illustrative examples, reacting the load from the forming end effector 200 includes reacting the load from the forming end effector 200 through legs 215 and 217 of the forming end effector 200 connected to the mandrel 218. In some illustrative examples, reacting the load from the forming end effector 200 includes reacting the load from the forming end effector 200 through engagement pins 214 and 216 of legs 215 and 217. In some illustrative examples, the connection to the mandrel 218 through engagement pins 214 and 216 reacts the load from the forming end effector 200 on the mandrel 218 during the forming of the composite material 204. Reacting the load from the forming end effector 200 to the mandrel 218 allows for the use of the forming end effector 200 rather than a larger gantry system.

[0039] In some illustrative examples, the forming end effector 200 comprises a frame 206, a number of actuators 220, 222, 224, and 226 operably connected to the frame 206, and a forming head 210 having a sweeper 212 operably connected to the frame 206 by the number of actuators 220, 222, 224, and 226. The number of actuators 220, 222, 224, and 226 are connected to the forming head 210 by multiple pairs of hinges such that the forming head 210 is configured to rotate to form the composite material 204. The forming end effector 200 further comprises a number of legs 208 operably connected to the frame 206. The multiple legs 208 have engagement pins, namely engagement pin 214 and engagement pin 216, configured to connect the forming end effector 200 to the mandrel 218 and to react loads from the forming end effector 200 against the mandrel 218 during forming of the composite material 204.

[0040] In some illustrative examples, each of the forming heads 210 includes a set of compliant joints to provide for forming the composite material 204 over a mandrel 218 having a bend 270. The bend 270 is perpendicular to the length 268 of the mandrel 218. The bend 270 may be a vertical bend or a horizontal bend in the mandrel 218. In some illustrative examples, the set of compliant joints may be used to accommodate either a horizontal or vertical bend 270 in the mandrel 218.

[0041] The illustration of manufacturing environment 202 in Figure 2 is not meant to imply physical or architectural limitations to the manner in which an illustrative embodiment may be implemented. Other components in addition to or in place of the illustrated components may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks may be combined, divided, or both combined and divided into different blocks when implemented in an illustrative embodiment.

[0042] For example, in some illustrative examples, sweeper 212 may take the form of a different type of sweeper than inflatable bladder 260. In some illustrative examples, sweeper 212 may take the form of a foam sweeper, a squeegee, or other acceptable form of sweeper.

[0043] 3, an isometric view of a shaped end effector in an engagement orientation is shown, according to an exemplary embodiment. The shaped end effector 300 is a physical implementation of the shaped end effector 200 of FIG.

[0044] The forming end effector 300 includes a frame 302, a number of legs 304 operably connected to the frame 302, and a forming head 306 having a sweeper 308 operably connected to the frame 302 by a number of actuators 310 operably connected to the frame 302. As seen in FIG. 301 , the number of legs 304 can be moved by an actuator 312. As shown, the actuator 312 is a hydraulic actuator. The number of legs 304 have an engagement pin 305 configured to connect the forming end effector 300 to a mandrel. In some illustrative examples, the engagement pin 305 reacts loads from the forming end effector 300 to the mandrel during molding of a composite material. In some illustrative examples, the engagement pin 305 provides a number of utilities from the mandrel to the forming end effector 300. In some illustrative examples, the engagement pin 305 is hollow and serves as a conduit for supplying hydraulic pressure from the mandrel to the forming end effector 300. In some illustrative examples, the engagement pin 305 is further configured to receive at least one utility through the engagement pin 305 and transfer the utility to other components of the forming end effector 300 .

[0045] The multiple legs 304 are operably connected to the frame 302 to allow application and removal of the forming end effector 300 from the mandrel. The forming end effector 300 can be applied to the mandrel, form the composite material, and then removed from the mandrel. The forming end effector 300 can be used sequentially across mandrels. The forming end effector 300 can be used on multiple different mandrels.

[0046] In view 301 of forming end effector 300, forming end effector 300 is in engagement orientation 318. Engagement orientation 318 is the orientation in which forming end effector 300 is connected to a mandrel. When in engagement orientation 318, forming end effector 300 can be used to form a composite material against a mandrel.

[0047] To form the composite material onto the mandrel, multiple actuators 310 move along multiple translation systems 314. In some illustrative examples, multiple translation systems 314 comprise multiple cart and rail systems. In these illustrative examples, multiple actuators 310 are connected to multiple cart and rail systems that move multiple actuators 310 horizontally relative to frame 302. As an actuator of multiple actuators 310 moves horizontally, the actuator moves toward one pair of legs of multiple legs 304 and away from another pair of legs of the multiple legs.

[0048] In some illustrative examples, forming end effector 300 can transport a composite material (not shown) to be formed. As shown, forming end effector 300 includes a composite retention system 316. Composite retention system 316 enables forming end effector 300 to transport the composite material as it is moved to and connected to the mandrel.

[0049] As shown, sweeper 308 takes the form of an inflatable bladder 309. In other illustrative examples, sweeper 308 can take the form of a squeegee or other form of sweeper capable of reaching all depressions and surface features.

[0050] The forming head 306 is connected to multiple actuators 310 by multiple pairs of hinges configured to rotate a sweeper 308 relative to the mandrel beneath the frame 302. The hinges and multiple actuators 310 are configured to enable a translational sweep of the sweeper 308. The hinges and multiple actuators 310 are configured to enable independent rotational sweep of the sweeper 308. The rotational sweep allows the sweeper 308 to rotate around corners of the forming surface of the mandrel.

[0051] 4, an isometric view of a forming end effector in a non-engaging orientation is shown, according to an exemplary embodiment. View 400 is a view of the forming end effector 300 in a non-engaging orientation 401. In the non-engaging orientation 401, the forming end effector 300 can be transferred to or from a mandrel.

[0052] View 400 shows the composite retention system of molded end effector 300. Molded end effector 300 includes composite retention system 403 and composite retention system 405.

[0053] Forming head 306 further comprises vacuum pad 402 configured to hold the composite material prior to forming. In this illustrative example, composite holding system 403 comprises vacuum pad 402 configured to hold the composite material prior to forming. Composite holding system 403 further comprises guard 404. Guard 404 is a mechanical component for protecting the composite material during transfer of the composite material.

[0054] Forming head 306 further comprises vacuum pad 406 configured to hold the composite material prior to forming. In this illustrative example, composite holding system 405 comprises vacuum pad 406 configured to hold the composite material prior to forming. Composite holding system 405 further comprises guard 408. Guard 408 is a mechanical component for protecting the composite material during transfer of the composite material.

[0055] 5, a front view of a shaped end effector in a non-engaging orientation is shown, according to an exemplary embodiment. View 500 is a front view of shaped end effector 300. In view 500, shaped end effector 300 is in non-engaging orientation 401.

[0056] The forming end effector 300 includes a central actuator 504 connected to the frame 302 between the forming heads 306. A central presser 506 is operatively connected to the central actuator 504.

[0057] The central presser 506 comprises an inflatable bladder operatively connected to the central actuator 504 .

[0058] A utility port 502 is connected to the frame 302. The utility port 502 is configured to interface with a robot arm for transfer of the forming end effector 300. The utility port 502 is also configured to interface with utilities for the forming process independent of the robot arm. The utility port 502 allows the forming end effector 300 to be powered and operated even when a robot is not connected.

[0059] 6, an isometric view of a shaped end effector in an engagement orientation is shown in accordance with an exemplary embodiment. View 600 of shaped end effector 300 shows utility port 502. As shown, utility port 502 takes the form of a robotic tool changer.

[0060] Referring now to FIG. 7, an isometric view of an engagement pin in a leg of a shaped end effector is shown in accordance with an exemplary embodiment. In FIG. 700, an engagement pin 704 is connected to a leg 702 of a shaped end effector 701. The engagement pin 704 is a physical implementation of the engagement pin 214 of FIG. 2. The engagement pin 704 may be one of the engagement pins 305 of FIGS. 3-6. The engagement pin 704 includes a vacuum channel 706. The vacuum channel 706 may be used to provide a resource, such as vacuum or air pressure, to the shaped end effector 701.

[0061] The engagement pin 704 can be used to connect the forming end effector 701 to the mandrel. The connection to the mandrel by the engagement pin 704 allows the load from the forming end effector 701 to be reacted against the mandrel during forming of the composite material.

[0062] Referring now to Figure 8, an isometric view of a composite retention system for a molded end effector is shown in accordance with an illustrative embodiment. Figure 800 is an isometric view of a composite retention system 806 for a molded end effector 802. Composite retention system 806 is a physical implementation of composite retention system 275 of Figure 2. Composite retention system 806 may be the same as composite retention system 316 of Figures 3-6.

[0063] A composite holding system 806 is connected to the forming head 804 of the forming end effector 802. The composite holding system 806 is configured to hold a composite material 812 to be formed by the forming end effector 802. The composite holding system 806 enables the forming end effector 802 to hold the composite material 812 and transport the composite material 812 to a mandrel where the composite material 812 is formed.

[0064] Composite retention system 806 includes vacuum pads 810 configured to hold composite material 812 prior to molding. Composite retention system 806 further includes guards 808. Guards 808 are mechanical components for protecting composite material 812 during transport.

[0065] Referring now to FIG. 9, a front view of a forming end effector connected to a mandrel and in an engagement orientation is shown, according to an exemplary embodiment. In FIG. 900, forming end effector 902 is connected to mandrel 904. Forming end effector 902 is a physical implementation of forming end effector 200 of FIG. 2. Forming end effector 902 can be the same as forming end effector 300 of FIGS. 3-6. In some exemplary examples, forming end effector 902 is connected to mandrel 904 by engagement pin 704 of FIG. 7. In some exemplary examples, forming end effector 902 is the same as forming end effector 802 of FIG. 8.

[0066] In diagram 900, a forming end effector 902 is at the start of the forming process. The forming end effector 902 comprises a frame 901, multiple legs 908 operatively connected to the frame 901, and a forming head 914 having a sweeper 916. The multiple legs 908 have engagement pins (not shown) configured to connect the forming end effector 902 to a mandrel 904 and to react loads from the forming end effector 902 against the mandrel 904 during forming of the composite material.

[0067] In diagram 900, the forming end effector 902 is in an engagement orientation 906. In the engagement orientation 906, multiple legs 908 of the forming end effector 902 connect the forming end effector 902 to a mandrel 904. The mandrel 904 is a tool on which the forming end effector 902 forms a composite material 917. The mandrel 904 comprises a base 910 and a forming surface 912. The base 910 is the portion of the mandrel 904 configured to interface with the forming end effector 902. In some illustrative examples, the base 910 also interacts with the manufacturing floor. The forming surface 912 is a surface on which the composite material 917 is formed. The forming surface 912 is a surface on which a sweeper 916 of the forming end effector 902 forms the composite material 917.

[0068] In diagram 900, sweeper 916 is in contact with composite material 917 to apply pressure to composite material 917 on forming surface 912. In diagram 900, central presser 920 is not activated. In diagram 900, central presser 920 has not yet expanded. Forming head 914 with sweeper 916 is operably connected to frame 901 by multiple actuators 903. The multiple actuators 903 are connected to forming head 914 by multiple pairs of hinges such that forming head 914 is configured to rotate to form composite material 917.

[0069] A central actuator 918 is connected to the frame 901 between the forming heads 914. A central presser 920 is operatively connected to the central actuator 918. The central presser 920 comprises an inflatable bladder operatively connected to the central actuator 918.

[0070] Referring now to FIG. 10 , a front view of a forming end effector connected to a mandrel and in an engagement orientation is shown, according to an exemplary embodiment. Between FIG. 900 and FIG. 1000 , the forming head 914 has moved relative to the mandrel 904. In FIG. 1000 , the side inflatable bladders, or sweepers 916, have begun to sweep the formed part outward. In FIG. 1000 , the inflatable bladders 1020 of the central presser 920 press against the inflatable bladders of the sweepers 916 as the central actuator 918 extends downward and the rotary pedals 1018 rotate open.

[0071] In diagram 1000, actuator 903 comprises multiple actuators 1002 and multiple actuators 1008. In diagram 1000, forming head 914 comprises forming head 1004 connected to multiple actuators 1002 and forming head 1010 connected to multiple actuators 1008. Actuator 1002 is connected to translation system 1006, and actuator 1008 is connected to translation system 1012. Between diagrams 900 and 1000, actuator 1002 and forming head 1004 are moved in direction 1014 away from central actuator 918. Between diagrams 900 and 1000, actuator 1008 and forming head 1010 are moved in direction 1016 away from central actuator 918. Between diagrams 900 and 1000, actuator 1002 and actuator 1008 are moved in opposite directions such that actuator 1002 and actuator 1008 are moved away from each other.

[0072] The horizontal position, angle, and extension of the actuator 1002 controls the movement of the forming head 1004 and its respective sweeper. The horizontal position, angle, and extension of the actuator 1002 are controlled to perform both rotational and translational sweeps. Between views 900 and 1000, the actuator 1002 is moved in direction 1014 to perform a translational sweep of the composite material 917 by the sweeper of the forming head 1004 in direction 1014.

[0073] The horizontal position, angle, and extension of the actuators 1008 control the movement of the forming head 1010 and their respective sweepers. The horizontal position, angle, and extension of the actuators 1008 are controlled to perform both rotational and translational sweeps. Between views 900 and 1000, the actuators 1008 are moved in direction 1016 to perform a translational sweep of the composite material 917 by the sweepers of the forming head 1010 in direction 1016.

[0074] In diagram 1000, central presser 920 is operatively connected to a central actuator 918 that is actuated to compress composite material 917. In diagram 1000, central presser 920 takes the form of an inflatable bladder 1020. Inflatable bladder 1020 is connected to a rotary pedal 1018. Between diagrams 900 and 1000, the rotary pedal is rotated outward to allow inflation of inflatable bladder 1020.

[0075] 11 , a front view of a forming end effector connected to a mandrel and in an engagement orientation is shown, according to an exemplary embodiment. In this illustrative example, sweeper 916 includes inflatable bladders, namely inflatable bladders 1118 and 1120. In FIG. 1100, inflatable bladders 1118 and 1120 begin to rotate around corners 1202 and 1204 of mandrel 904. In some illustrative examples, corners 1202 and 1204 may be referred to as radii. Between FIG. 1000 and FIG. 1100, the horizontal position, angle, and extension of actuator 1002 change to begin rotating inflatable bladder 1118 around corner 1202. Between FIG. 1000 and FIG. 1100 , the horizontal position, angle, and extension of actuator 1008 changes to begin rotating inflatable bladder 1120 about corner 1204 .

[0076] In FIG. 1100, inflatable bladders 1118 and 1120 are sweeping but beginning to rotate around each corner of mandrel 904. Rotating forming head 1004 and forming head 1010 prevents an undesirable amount of tensioning of composite material 917.

[0077] The actuator 1002 includes an actuator 1102 and an actuator 1104. The actuator 1102 is connected to the forming head 1004 by a hinge 1110. The actuator 1104 is connected to the forming head 1004 by a hinge 1112. The hinge 1110 is spaced a first distance from the forming head 1004, and the hinge 1112 is spaced a second distance from the forming head 1004. As seen in FIG. 1100, the difference between the first and second distances allows for rotation of the inflatable bladder 1118 to shape the composite material 917 around an edge, such as a corner 1202. As seen in FIG. 1100, the hinge 1110 is at a greater distance from the forming head 1004 than the hinge 1112. The actuator 1102 expanding and / or the actuator 1104 contracting causes the inflatable bladder 1118 to rotate in a direction 1122.

[0078] The actuator 1008 includes an actuator 1106 and an actuator 1108. The actuator 1106 is connected to the forming head 1010 by a hinge 1114. The actuator 1108 is connected to the forming head 1010 by a hinge 1116. The hinge 1114 is spaced a first distance from the forming head 1010, and the hinge 1116 is spaced a second distance from the forming head 1010. As seen in FIG. 1100, the difference between the first and second distances allows for rotation of the inflatable bladder 1120 to shape the composite material 917 around an edge, such as a corner 1204. As seen in FIG. 1100, the hinge 1116 is spaced a greater distance from the forming head 1010 than the hinge 1114. The actuator 1108 expanding and / or the actuator 1106 contracting causes the inflatable bladder 1120 to rotate in a direction 1124.

[0079] 12, a front view of a forming end effector connected to a mandrel and in an engagement orientation is shown in accordance with an exemplary embodiment. In FIG. 1200, the inflatable bladder 1118 has rotated in direction 1122 around corner 1202, compressing the composite material 917 against the forming surface 912 of the mandrel 904. In FIG. 1200, the rotation of the inflatable bladder 1118 has been completed, and the inflatable bladder 1118 begins a translational sweep in direction 1206 along the forming surface 912.

[0080] In FIG. 1200, the inflatable bladder 1120 is rotating in direction 1124 around corner 1204, compressing the composite material 917 against the forming surface 912 of the mandrel 904. In FIG. 1200, the rotation of the inflatable bladder 1120 is complete and the inflatable bladder 1120 begins a translational sweep in direction 1208 along the forming surface 912.

[0081] 13, a front view of a forming end effector connected to a mandrel and in an engagement orientation is shown, according to an exemplary embodiment. In FIG. 1300, inflatable bladder 1118 has been rotated in direction 1122. In FIG. 1300, inflatable bladder 1120 has been rotated in direction 1124. Rotation of inflatable bladder 1118 in direction 1122 may be referred to as counter-rotation in this example.

[0082] In diagram 1300, inflatable bladder 1118 and inflatable bladder 1120 rotate in opposite directions to further sweep and tension composite material 917 as the end of molding approaches. In diagram 1300, actuator 1102 moves horizontally in direction 1014 to perform rotational and translational sweeps. Actuator 1104 is extended to perform rotational and translational sweeps. The cooperative interaction of actuators 1102 and 1104 creates the intentional rotational motion.

[0083] 14, a front view of a forming end effector connected to a mandrel and in an engagement orientation is shown, according to an exemplary embodiment. In FIG. 1400, inflatable bladder 1118 has been rotated in direction 1122. In FIG. 1400, inflatable bladder 1120 has been rotated in direction 1124. Rotation of inflatable bladder 1120 in direction 1124 may be referred to as counter-rotation in this example.

[0084] Between views 1300 and 1400, actuator 1104 is extended to rotate inflatable bladder 1120 in direction 1124. Between views 1300 and 1400, actuator 1106 is extended to rotate inflatable bladder 1120 in direction 1124.

[0085] Counter-rotation and tension are shown in diagram 1400. Rotational and translational sweeps are shown in diagram 1400. In diagram 1400, the translational sweep involves moving inflatable bladder 1118 down molding surface 912 away from corner 1202. In diagram 1400, the translational sweep involves moving inflatable bladder 1120 down molding surface 912 away from corner 1204. The rotational and translational sweeps while compressing the final portion of composite material 917 prevent delamination and wrinkling.

[0086] Referring now to FIG. 15, an isometric view of a forming end effector positioned relative to a mandrel is shown, according to an exemplary embodiment. Forming end effector 1504 and forming end effector 1506 are physical implementations of forming end effector 200 of FIG. 2. Mandrel 1502 is a physical implementation of mandrel 218 of FIG. 2. Forming end effector 1504 can be the same as forming end effector 300 of FIGS. 3-6. Forming end effector 1506 can be the same as forming end effector 300 of FIGS. 3-6. Forming end effector 1504 can be the same as forming end effector 902 of FIGS. 9-14. Forming end effector 1506 can be the same as forming end effector 902 of FIGS. 9-14.

[0087] In diagram 1500, a forming end effector 1504 is connected to a base 1510 of a mandrel 1502 and forms a composite material against a forming surface 1512 of the mandrel 1502. In this illustrative example, an engagement pin 1516 of the forming end effector 1504 engages with a hole 1514 in the base 1510 of the mandrel 1502. The engagement pin 1516 secures the forming end effector 1504 to the mandrel 1502.

[0088] After forming the composite material on the mandrel 1502, the forming end effector 1504 can be decoupled and moved from the mandrel 1502. In some illustrative examples, to move the forming end effector 1504 from the mandrel 1502, a robotic arm 1508 disengages the forming end effector 1504 from the mandrel 1502 and connects to the forming end effector 1504 to move the forming end effector 1504 from the mandrel 1502. In this illustrative example, the robotic arm 1508 connects to the forming end effector 1504 using a utility port 1518.

[0089] In view 1500, a forming end effector 1506 is positioned relative to and connected to the mandrel 1502. In view 1500, a robotic arm 1508 is connected to the forming end effector 1506 and positions the forming end effector 1506 relative to the mandrel 1502. The robotic arm 1508 is connected to a utility port 1522 of the forming end effector 1506. In this illustrative example, an engagement pin 1520 of the forming end effector 1506 is used to engage with a hole 1514 in a base 1510 of the mandrel 1502. The engagement pin 1520 secures the forming end effector 1506 to the mandrel 1502.

[0090] As shown, neither forming end effector 1504 nor forming end effector 1506 is positioned over the bend in mandrel 1502. However, in some illustrative examples, at least one of forming end effector 1504 or forming end effector 1506 can be used over the bend in mandrel 1502 due to a set of compliant joints in the forming head.

[0091] Referring now to FIG. 16, an isometric view of a central actuator with a central presser of a shaped end effector is shown in accordance with an exemplary embodiment. In FIG. 1600, a shaped end effector 1602 includes a central actuator 1606 connected to a frame 1604. The shaped end effector 1602 can be a physical implementation of the shaped end effector 200. The shaped end effector 1602 can be the same as the shaped end effector 300 of FIGS. 3-6. The shaped end effector 1602 can include legs 702 of FIG. 7. The shaped end effector 1602 can be the same as the shaped end effector 802 of FIG. 8. The shaped end effector 1602 can be the same as the shaped end effector 902 of FIGS. 9-14. The shaped end effector 1602 can be the same as either the shaped end effector 1504 or the shaped end effector 1506.

[0092] A central actuator 1606 of the forming end effector 1602 is connected to a frame 1604. The central actuator 1606, connected to the frame 1604, is disposed between the forming heads. The central actuator includes an extendable shaft 1607 connected to a platform 1608. A central presser 1610 is operatively connected to the central actuator 1606.

[0093] The central presser 1610 includes an inflatable bladder 1612 operably connected to the central actuator 1606. The central presser 1610 includes an inflatable bladder 1612 connected to a rotating pedal 1614. As shown, the inflatable bladder 1612 is unfilled. The inflatable bladder 1612 is deflated to conserve space. The rotating pedals 1614 can rotate away from each other to provide additional space for the inflatable bladder 1612 to inflate.

[0094] 17, an isometric view of a central actuator with a central presser of a forming end effector is shown in accordance with an exemplary embodiment. In FIG. 1700, the central presser 1610 is in an extended position 1702. In the extended position 1702, the central presser 1610 can be used to hold a central portion of the composite material against the forming surface of the mandrel.

[0095] Between views 1600 and 1700, pedal 1614 has rotated outward from the center of platform 1608. Platform 1608 acts as a hard stop for pedal 1614.

[0096] 18, an isometric view of a forming head and respective composite retention system of a forming end effector is shown in accordance with an exemplary embodiment. Forming head 1802 comprises a portion 1804 and a portion 1806 connected by a set of compliant joints 1808. The set of compliant joints 1808 allows for forming of the composite material over a mandrel having a bend.

[0097] Section 1804 of forming head 1802 is a separate plate from section 1806. By having two separate plates, sections 1804 and 1806 allow forming head 1802 to flex. A set of compliant joints 1808 include rod ends with floating pins to allow flexing. The set of compliant joints 1808 include compliant rod ends and rail joints that allow the mandrel to conform to kinks or bends.

[0098] View 1800 shows composite retention system 1810. Composite retention system 1810 includes vacuum pad 1812 and guard 1814. Vacuum pad 1812 includes vacuum pad 1816, vacuum pad 1818, vacuum pad 1820, and vacuum pad 1822. When portion 1804 moves relative to portion 1806, vacuum pad 1816 and vacuum pad 1818 move relative to vacuum pad 1820 and vacuum pad 1822.

[0099] As shown, a set of compliant joints 1808 allows an angle between portion 1804 and portion 1806 in direction 1824. Direction 1824 may be referred to as the vertical direction.

[0100] 19, an illustration of a top view of a forming head and respective composite retention system of a forming end effector in accordance with an illustrative embodiment. View 1900 is a view from direction 1824 of FIG.

[0101] View 1900 shows the floating pins of a pair of compliant joints 1808. The pair of compliant joints 1808 includes floating pin 1902 and floating pin 1904. The floating pins, 1902 and 1904, extend through respective rod ends of connecting rods that couple forming head 1802 to the forming end effector. Floating pins 1902 and 1904 are connected to outer rod ends that are part of forming head 1802.

[0102] In diagram 1900, movement of portion 1804 and portion 1806 can be in direction 1910. Movement in direction 1910 causes the edge of portion 1804 to be a different distance from the edge of portion 1806. Movement in direction 1910 can be referred to as horizontal movement.

[0103] In this illustrative example, the set of compliant joints 1808 form part of a first set of hinges 1906 and a second set of hinges 1908. The first set of hinges 1906 may include hinges 232 of Figure 2. The second set of hinges 1908 may include hinges 233 of Figure 2. Extending selected actuators to perform the rotational sweep includes extending an actuator connected to one of the first set of hinges 1906 or the second set of hinges 1908 more than the other of the first set of hinges 1906 or the second set of hinges 1908.

[0104] Referring now to FIG. 20 , a flowchart of a method for forming composite material on a mandrel is shown in accordance with an illustrative embodiment. Method 2000 may be used to form composite components of aircraft 100 of FIG. 1 . Method 2000 may be performed using forming end effector 200 of FIG. 2 . Method 2000 may be performed using forming end effector 300 of FIGS. 3-6 . Method 2000 may be performed using forming end effector 701 of FIG. 7 . Method 2000 may be performed using forming end effector 802 of FIG. 8 . Method 2000 may be performed using forming end effector 902 of FIGS. 9-14 . Method 2000 may be performed using mandrel 1502 and at least one of forming end effector 1504 or forming end effector 1506 of FIG. 15 . Method 2000 can be performed using a forming end effector having a central presser 1610 of Figures 16-17. Method 2000 can be performed using a forming end effector having a composite retention system 1810 of Figures 18-19.

[0105] Method 2000 positions a forming end effector carrying a composite material over a mandrel (step 2002). Method 2000 connects the forming end effector to the mandrel (step 2004). Method 2000 sweeps the composite material over the mandrel using a sweeper on the forming end effector (step 2006). Method 2000 then ends.

[0106] In some illustrative examples, positioning the forming end effector over the mandrel includes using a robotic arm to move the forming end effector (step 2008). In some illustrative examples, the robotic arm is used only to transfer and connect the forming end effector to the mandrel. In some illustrative examples, the robotic arm is used to move multiple forming end effectors that are connected to the mandrel.

[0107] In some illustrative examples, the method 2000, after positioning the forming end effector, disconnects the robot arm from the utility port of the forming end effector (step 2010). In some illustrative examples, the method 2000 connects the forming end effector to a utility using the utility port (step 2012) before sweeping the composite material over the mandrel. In some illustrative examples, the utility is provided by the mandrel. In some illustrative examples, the utility is provided by an outlet on the manufacturing floor.

[0108] In some illustrative examples, connecting the shaped end effector to the mandrel includes securing the shaped end effector to the mandrel using an engagement pin (step 2014). In some illustrative examples, the engagement pin is connected to a leg of the shaped end effector.

[0109] In some illustrative examples, the method 2000 provides at least one utility from the mandrel to the forming end effector via the engagement pin (step 2016). In some illustrative examples, a vacuum channel is present in the engagement pin to receive the at least one utility from the mandrel. In some illustrative examples, air pressure is provided from the mandrel to the forming end effector via the engagement pin.

[0110] In some illustrative examples, sweeping the composite material against the mandrel includes using an inflatable bladder of a sweeper to press the composite material against the mandrel (step 2018). In some illustrative examples, pressing the composite material includes moving the inflatable bladder against the mandrel. In some illustrative examples, pressing the composite material includes moving the inflatable bladder along the molding surface of the mandrel.

[0111] In some illustrative examples, sweeping the composite material over the mandrel includes rotating the inflatable bladder before forcing the composite material against the corner of the mandrel (step 2020). In some illustrative examples, sweeping the composite material includes a rotational sweep and a translational sweep. In some illustrative examples, the rotational sweep and the translational sweep can be performed independently. A rotational sweep is an active rotation of the inflatable bladder. In some illustrative examples, the rotational sweep is performed using multiple actuators.

[0112] In some illustrative examples, the method 2000 reacts the load from the forming end effector to the mandrel during the sweep (step 2022). In some illustrative examples, reacting the load from the forming end effector includes reacting the load from the forming end effector through a leg of the forming end effector connected to the mandrel. In some illustrative examples, reacting the load from the forming end effector includes reacting the load from the forming end effector through an engagement pin of the leg.

[0113] Referring now to FIG. 21 , a flowchart of a method for forming a composite material on a mandrel is shown in accordance with an illustrative embodiment. Method 2100 may be used to form a composite component of aircraft 100 of FIG. 1 . Method 2100 may be performed using forming end effector 200 of FIG. 2 . Method 2100 may be performed using forming end effector 300 of FIGS. 3-6 . Method 2100 may be performed using forming end effector 701 of FIG. 7 . Method 2100 may be performed using forming end effector 802 of FIG. 8 . Method 2100 may be performed using forming end effector 902 of FIGS. 9-14 . Method 2100 may be performed using mandrel 1502 and at least one of forming end effector 1504 or forming end effector 1506 of FIG. 15 . Method 2100 can be performed using a forming end effector having a central presser 1610 of Figures 16-17. Method 2100 can be performed using a forming end effector having a composite retention system 1810 of Figures 18-19.

[0114] The method 2100 forms the composite material against the mandrel using a sweeper of the forming end effector (step 2102). The method 2100 reacts a load from the forming end effector against the mandrel during forming of the composite material (step 2104). The method 2100 then ends.

[0115] In some illustrative examples, the method 2100 connects a forming end effector to the mandrel prior to forming the composite material on the mandrel (step 2106). In some illustrative examples, connecting the forming end effector to the mandrel includes securing the forming end effector to the mandrel using an engagement pin (step 2108). In some illustrative examples, the engagement pin is connected to a leg of the forming end effector.

[0116] In some illustrative examples, connecting the shaped end effector to the mandrel includes securing the shaped end effector to the mandrel using legs of the shaped end effector (step 2110). In some illustrative examples, engagement pins on the legs of the shaped end effector secure the shaped end effector to the mandrel. In some illustrative examples, engagement pins on the legs of the shaped end effector secure the legs to holes in the base of the mandrel.

[0117] In some illustrative examples, reacting the load from the forming end effector includes reacting the load from the forming end effector through legs of the forming end effector connected to the mandrel (step 2112). In some illustrative examples, reacting the load from the forming end effector includes reacting the load from the forming end effector through engagement pins of the legs.

[0118] As used herein, the phrase "at least one of," when used in conjunction with a list of items, means that various combinations of one or more of the listed items may be used, and that only one of each item in the list may be required. For example, "at least one of item A, item B, or item C" may include, but is not limited to, item A, item A and item B, or item B. This example may also include item A, item B, and item C, or item B and item C. Of course, any combination of these items is possible. In other examples, "at least one of" may be, for example, but is not limited to, two items A, one item B, and ten items C, four items B, and seven items C, or other suitable combinations. An item may be a specific object, thing, or category. In other words, at least one of means that any combination of items and multiple items may be used from the list, but not all of the items in the list are required.

[0119] As used herein, "a number of," when used in reference to an item, means one or more of the item.

[0120] The flowcharts and block diagrams in the various depicted embodiments illustrate the architecture, functionality, and processes of some possible implementations of apparatuses and methods in the illustrative embodiments. In this regard, each block in the flowcharts or block diagrams may represent at least one of a module, a segment, a function, or a portion of an operation or step.

[0121] In some alternative implementations of the exemplary embodiments, the function or functions noted in the blocks may be performed out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be performed substantially concurrently or may be performed in the reverse order, depending on the functionality involved. Also, other blocks may be added in addition to the illustrated blocks in a flowchart or block diagram. Some blocks may be optional. For example, steps 2008 through 2022 may be optional. As another example, steps 2106 through 2112 may be optional.

[0122] An exemplary embodiment of the present disclosure may be described in the context of aircraft manufacturing and service method 2200, as shown in Figure 22, and aircraft 2300, as shown in Figure 23. Referring initially to Figure 22, an illustration of an aircraft manufacturing and service method in block diagram form is shown in accordance with an exemplary embodiment. During prototyping, aircraft manufacturing and service method 2200 may include specification and design 2202 and material procurement 2204 of aircraft 2300 in Figure 23.

[0123] During production, component and subassembly manufacturing 2206 and systems integration 2208 of the aircraft 2300 occurs. The aircraft 2300 may then undergo certification and delivery 2210 for entry into service 2212. While in service 2212 by a customer, the aircraft 2300 is scheduled for routine maintenance and service 2214, which may include modification, reconfiguration, alteration, or other maintenance and service.

[0124] Each process of aircraft manufacturing and service method 2200 may be performed or carried out by a system integrator, a third party, and / or an operator. In these examples, the operator may be a customer. For purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and primary system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; an operator may be an airline, a leasing company, the military, a service provider, etc.

[0125] Referring now to Figure 23, a diagram of an aircraft in block diagram form is shown in which an illustrative embodiment may be implemented. In this example, aircraft 2300 is produced by aircraft manufacturing and service method 2200 in Figure 22 and may include airframe 2302 with a number of systems 2304 and interior 2306. Example systems 2304 include one or more of propulsion system 2308, electrical system 2310, hydraulic system 2312, and environmental system 2314. Any number of other systems may also be included.

[0126] Apparatus and methods embodied herein may be used during at least one stage of aircraft manufacturing and service method 2200. One or more illustrative embodiments may be manufactured or used during at least one of component and subassembly manufacturing 2206, system integration 2208, in-service 2212, or maintenance and service 2214 of Figure 22.

[0127] Illustrative examples enable composite molding in multiple directions using a robotic system. Illustrative examples provide a molding end effector designed with several articulating joints to enable more complex molding sweeps that allow for compression while preventing radius thinning. The molding end effector includes a picking system for flat, pre-cured composite material for transfer onto a complex mandrel tool to begin molding. The molding end effector of the illustrative example is capable of molding composite material onto mandrels that are not cost-effective for traditional gantry system designs. The molding end effector is attached to the mandrel (tool) using several indexing pins that hold the molding end effector in place and allow the robot to retract while the end effector continues molding.

[0128] The forming end effector includes a utility coupler that continues to supply energy and air pressure. The use of forming end effectors that receive utilities independent of the robotic arm allows multiple forming end effectors to be positioned at desired locations on the mandrel (tool).

[0129] In some illustrative examples, the shaped end effector uses pins to attach the shaped end effector directly to the mandrel (tool), which removes stress from bending the robot.

[0130] The sweeper for compressing / forming the composite is configured to actively rotate. The sweeper, which can take the form of an inflatable bladder, is not fixed at a static angle. Rotating the sweeper prevents radius thinning that can occur when applying a compressive force with only a translational sweep around the corner of the mandrel. Rotating the sweeper allows the sweeper to apply sufficient compressive force without pulling the composite fibers under excessive tension around the bent corner. In some illustrative examples, the sweeper takes the form of an inflatable bladder.

[0131] In illustrative examples, a robotic arm attaches a forming end effector to a mandrel (tool) to create a rigid cage for forming. The use of a rolling sweeper is used in addition to pressing. The sweeper can take the form of an inflatable bladder. The ability to detach the forming end effector to operate without the robot allows the robotic asset to perform other tasks, such as measuring on previously formed portions of the tool. The forming end effector can use a central pressing mechanism with fins (rotating pedals) that open to expand the pressing area on top of the tool to hold a flat insert (charge) in place. In some illustrative examples, the use of an articulated plate at the forming head for pressing allows for forming kinks and reaching into the tool pit.

[0132] The use of legs and pins to connect the forming end effector to the mandrel allows for forming forces of 3 to 10 kips, depending on the length of the formed part segment. An illustrative example utilizes a rotating sweeper, such as an inflatable bladder, so that the compression force and pulling tension can be independently controlled. The forming end effector includes an inflatable central compression foot.

[0133] Illustrative examples can allow for larger or more complex composite molding as a single part. In some illustrative examples, the robotic arm can be a commercially available shelf robot. An off-the-shelf robot can be easily serviced and / or replaced during production. Service or replacement of the robotic arm can be less time consuming or cheaper than a large custom gantry that would be taken offline and impact production speed.

[0134] The descriptions of different exemplary embodiments are presented for purposes of illustration and description and are not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different exemplary embodiments may offer different features compared to other exemplary embodiments. The selected embodiment or embodiments have been chosen and described in order to best explain the principles and practical applications of the embodiments, and to enable others skilled in the art to understand the disclosure of the various embodiments with various modifications suitable for the particular use contemplated. [Explanation of symbols]

[0135] 300 Molded End Effector 302 frames 304 Legs 305 Engagement pin 306 Molding Head 308 Sweeper 309 Inflatable Bladder 310,312 Actuator 314 Parallel Moving System 316 Composite Retention System 318 Engagement direction 401 Non-engaged direction 402,406 Vacuum pad 403,405 Composite Retention System 404,408 Guard 502 Utility Port 504 Central Actuator 506 Central Pressa 701 Molded End Effector 702 Legs 704 Engagement pin 706 Vacuum Channel 802 Molded End Effector 804 Molding Head 806 Composite Retention System 808 Guard 810 Vacuum Pad 812 Composite materials 901 Frame 902 Molded End Effector 903 Actuator 904 Mandrel 906 Engagement direction 908 Legs 910 base 912 Molding surface 914 Molding Head 916 Sweeper 917 Composite materials 918 Central Actuator 920 Central Press 1002 Actuator 1004 Molding head 1006 Parallel Moving System 1008 Actuator 1010 Molding Head 1012 Parallel Moving System 1018 Rotating Pedal 1020 Inflatable Bladder 1102,1104,1106,1108 Actuators 1110,1112,1114,1116 hinges 1118,1120 Inflatable bladders 1502 Mandrel 1504,1506 Molded end effector 1508 Robot Arm 1510 base 1512 Molding surface 1514 hole 1516,1520 Engagement pin 1518,1522 Utility Port 1602 Molded End Effector 1604 frames 1606 Central Actuator 1607 Extendable Shaft 1608 Platform 1610 Central Press 1612 Inflatable Bladder 1614 Rotating Pedal 1802 Molding Head 1804,1806 part 1808 Compliant Joint 1810 Composite Retention System 1812 Vacuum Pad 1814 Guard 1816,1818,1820,1822 Vacuum Pad

Claims

1. A method (2000) of molding a composite material (204, 812, 917) against a mandrel (218, 904, 1502), comprising: positioning (2002) a forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) carrying the composite material (204, 812, 917) above the mandrel (218, 904, 1502); connecting (2004) the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to the mandrel (218, 904, 1502); sweeping (2006) the composite material against the mandrel (218, 904, 1502) using a sweeper (212, 308, 916) of the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602); A method (2000) comprising:

2. 2. The method of claim 1, wherein the step of positioning the forming end effector over the mandrel includes using a robotic arm to move the forming end effector.

3. a step (2010) of disconnecting the robot arm (290, 1508) from a utility port (292, 502, 1522) of the shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) after the step of disposing the shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602); connecting (2012) the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to a utility (294) using the utility port (292, 502, 1522) prior to the step of sweeping the composite material (204, 812, 917) against the mandrel (218, 904, 1502); The method (2000) of claim 2, further comprising:

4. 2. The method (2000) of claim 1, wherein the step (2014) of connecting the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to the mandrel (218, 904, 1502) includes the step of securing the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to the mandrel (218, 904, 1502) using an engagement pin (214, 216, 305, 704, 1902, 1904).

5. 5. The method (2000) of claim 4, further comprising the step (2016) of supplying at least one utility (294) from the mandrel (218, 904, 1502) to the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) via the engagement pin (214, 216, 305, 704, 1902, 1904).

6. 2. The method of claim 1, wherein the step of sweeping the composite material against the mandrel includes using an inflatable bladder of the sweeper to press the composite material against the mandrel.

7. 7. The method of claim 6, wherein the step of sweeping the composite material against the mandrel includes rotating the inflatable bladder before forcing the composite material against a corner of the mandrel.

8. The method (2000) of claim 1, further comprising the step (2022) of reacting a load from the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) against the mandrel (218, 904, 1502) during the sweep.

9. A molding end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) for molding a composite material (204, 812, 917), comprising: Frames (206, 302, 901, 1604), a number of legs (208, 215, 217, 304, 908) operably connected to the frame (206, 302, 901, 1604), the number of legs (208, 215, 217, 304, 908) having engagement pins (214, 216, 305, 704, 1902, 1904) configured to connect the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to a mandrel (218, 904, 1502); a forming head (210, 211, 213, 804, 1004, 1010, 1802) having a sweeper (212, 308, 916) operably connected to said frame (206, 302, 901, 1604) by a number of actuators (220, 222, 224, 226, 310, 312, 903, 1002, 1008) operably connected to said frame (206, 302, 901, 1604); A molded end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) comprising:

10. The molding end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 9, wherein the legs (208, 215, 217, 304, 908) are configured to react loads from the molding end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) against the mandrel (218, 904, 1502) during molding of the composite material (204, 812, 917).

11. 10. The molding end effector of claim 9, wherein the molding head further comprises a vacuum pad that holds the composite material prior to molding.

12. 10. The shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 9, wherein the sweeper (212, 308, 916) takes the form of an inflatable bladder (239, 247, 1118, 1120).

13. 10. The forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 9, wherein the forming head (210, 211, 213, 804, 1004, 1010, 1802) is connected to the multiple actuators (220, 222, 224, 226, 310, 312, 903, 1002, 1008) by multiple pairs of hinges (1906, 1908) that rotate the sweeper (212, 308, 916) relative to a mandrel (218, 904, 1502) directly below the frame (206, 302, 901, 1604).

14. a central actuator (219, 256, 504, 918, 1606) connected to the frame (206, 302, 901, 1604) between the forming heads (210, 211, 213, 804, 1004, 1010, 1802); a central presser (258, 506, 920, 1610) operatively connected to said central actuator (219, 256, 504, 918, 1606); 10. The shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 9, further comprising:

15. 15. The shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 14, wherein the central presser (258, 506, 920, 1610) comprises an inflatable bladder (239, 247, 309, 1118, 1120) operatively connected to the central actuator (256, 504, 918, 1606).

16. The molding end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 9, further comprising a utility port (292, 502, 1522) connected to the frame (206, 302, 901, 1604), the utility port (292, 502, 1522) configured to cooperate with a robot arm (290, 1508) for transfer of the molding end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) and configured to cooperate with a utility (294) for the molding process independent of the robot arm (290, 1508).

17. The shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 9, wherein the engagement pin (214, 216, 305, 704, 1902, 1904) is further configured to receive at least one utility via the engagement pin (214, 216, 305, 704, 1902, 1904) and transfer the utility to other components of the shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602).

18. A molding end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) for molding a composite material (204, 812, 917), comprising: Frames (206, 302, 901, 1604), a number of actuators (220, 222, 224, 226, 310, 312, 903, 1002, 1008) operably connected to said frame (206, 302, 901, 1604); a forming head (210, 211, 213, 804, 1004, 1010, 1802) having a sweeper (212, 308, 916) operatively connected to the frame (206, 302, 901, 1604) by the plurality of actuators (220, 222, 224, 226, 310, 312, 903, 1002, 1008), a forming head, wherein the multiple actuators (220, 222, 224, 226, 310, 312, 903, 1002, 1008) are connected to the forming head (210, 211, 213, 804, 1004, 1010, 1802) by multiple pairs of hinges (1906, 1908) such that the multiple actuators (220, 222, 224, 226, 310, 312, 903, 1002, 1008) are configured to rotate to form the composite material (204, 812, 917); A molded end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) comprising:

19. The sweeper (212, 308, 916) includes an inflatable bladder (239, 247, 309, 1118, 1120), and the pairs of hinges (1906, 1908) include first hinges (232, 233, 240, 241, 1110, 1112, 1114, 1116) spaced a first distance (235, 237, 243, 245) from the forming head (211, 213, 804, 1004, 1010, 1802) and second hinges (235, 237, 243, 245) spaced a second distance (235, 237, 243, 245) from the forming head (211, 213, 804, 1004, 1010, 1802). and a second hinge (232, 233, 240, 241, 1110, 1112, 1114, 1116) spaced apart by a first distance (235, 237, 243, 245), the difference between the first distance (235, 237, 243, 245) and the second distance (235, 237, 243, 245) allowing rotation of the sweeper (212, 308, 916) to shape the composite material (204, 812, 917) around an edge.

20. 20. The molding end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 18, wherein each of the molding heads (210, 211, 213, 804, 1004, 1010, 1802) comprises a composite holding system (275, 276, 316, 403, 405, 806, 1810) for carrying the composite material (204, 812, 917) to be molded.

21. a number of legs (208, 215, 217, 304, 908) operably connected to the frame (206, 302, 901, 1604), the number of legs (208, 215, 217, 304, 908) connecting the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to a mandrel (218, 904, 1502) and supporting the forming end effector during forming of the composite material (204, 812, 917); 20. The forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 18, further comprising multiple legs (208, 215, 217, 304, 908) having engagement pins (214, 216, 305, 704, 1902, 1904) that react loads from the effector (200, 300, 701, 802, 902, 1504, 1506, 1602) against the mandrel (218, 904, 1502).

22. 20. The forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) of claim 18, wherein each of the forming heads comprises a set of compliant joints for providing forming of the composite material over a mandrel having a bend.

23. forming (2102) a composite material (204, 812, 917) against a mandrel (218, 904, 1502) using a sweeper (212, 308, 916) of a forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602); reacting (2104) a load from the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) against the mandrel (218, 904, 1502) during forming of the composite material (204, 812, 917); A method (2100) comprising:

24. 24. The method (2100) of claim 23, wherein the step (2112) of reacting a load from the shaping end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) includes the step of reacting a load from the shaping end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) through legs (208, 215, 217, 304, 908) of the shaping end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) connected to the mandrel (218, 904, 1502).

25. 24. The method (2100) of claim 23, further comprising the step of connecting (2106) the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to the mandrel (218, 904, 1502) prior to the step of forming the composite material (204, 812, 917) against the mandrel (218, 904, 1502).

26. 26. The method (2100) of claim 25, wherein the step (2108) of connecting the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to the mandrel (218, 904, 1502) includes the step of securing the forming end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to the mandrel (218, 904, 1502) using an engagement pin (214, 216, 305, 704, 1902, 1904).

27. 26. The method (2100) of claim 25, wherein the step (2110) of connecting the shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to the mandrel (218, 904, 1502) includes a step of securing the shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602) to the mandrel (218, 904, 1502) using legs (208, 215, 217, 304, 908) of the shaped end effector (200, 300, 701, 802, 902, 1504, 1506, 1602).

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