Pick and place end effector

Abstract

To provide an end effector configured to lift a composite material via two different mechanisms and a method of picking and placing the composite material.SOLUTION: The end effector comprises a vacuum end effector having a plurality of vacuum pogos for picking and placing the composite preform in contact with the plurality of vacuum pogos, and an electrostatic membrane removably retained by the plurality of vacuum pogos for picking and placing the single ply of composite material while the electrostatic membrane is retained by the plurality of vacuum pogos.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates generally to end effectors, and more particularly to a pick-and-place end effector configured to use two different lift mechanisms. [Background technology]

[0002] During composite manufacturing, composite plies are laid up and then delivered as a single ply or as a stack of multiple composite plies. When hand layup is used, a technician places each individual ply on a substrate in a precise location relative to the other plies. Hand layup utilizes ply-by-ply placement. The placement of plies is limited in size by the size the technician can handle.

[0003] When automated layup is performed, pick-and-place end effectors can be used to transfer the composite materials. However, different end effectors may be used for different types of composite materials, different thicknesses of composite materials, different shapes of composite materials, or other differences. Removing, connecting, and aligning the different end effectors can be undesirably time-consuming.

[0004] It would therefore be desirable to have a method and apparatus that takes into account at least some of the problems noted above, as well as other potential problems. For example, it may be desirable to reduce the time to pick and place composite materials. Summary of the Invention [Means for solving the problem]

[0005] One embodiment of the present disclosure provides an end effector that lifts composite material via two different mechanisms: a vacuum end effector having multiple vacuum pogos that picks and places composite preforms by contacting the multiple vacuum pogos, and an electrostatic membrane removably held by the multiple vacuum pogos that picks and places single-ply composite material while the electrostatic membrane is held by the multiple vacuum pogos.

[0006] Another embodiment of the present disclosure provides a method for picking and placing composite materials using a single end effector with two different mechanisms: picking and placing a single ply of composite material using an electrostatic membrane held by multiple vacuum pogos on the vacuum end effector; releasing the electrostatic membrane from the vacuum end effector; and picking and placing a composite preform using multiple vacuum pogos.

[0007] Yet another embodiment of the present disclosure provides a method for picking and placing composite materials using a single end effector with two different mechanisms: a curvature is formed in a composite preform held using vacuum holding from a vacuum end effector; and a curvature is formed in a single ply of composite material held using electrostatic force from an electrostatic membrane held by the vacuum end effector.

[0008] A further embodiment of the present disclosure provides a method for picking and placing composite material using a single end effector with two distinct mechanisms: repeatedly placing a single ply of composite material using an electrostatic membrane held by multiple vacuum pogos of a vacuum end effector to form a stack of composite plies; releasing the electrostatic membrane from the vacuum end effector; and lifting the stack of composite plies using multiple vacuum pogos.

[0009] The features and functions can be achieved alone in various embodiments of the present disclosure and 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 when read 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. 1 is a side view of an electrostatic end effector in accordance with an exemplary embodiment; [Figure 4] FIG. 10 is a side view of a vacuum end effector drawing a vacuum to connect an electrostatic membrane in accordance with an exemplary embodiment; [Figure 5] FIG. 10 is an illustration of a side view of a vacuum end effector for picking and placing a composite preform in accordance with an illustrative embodiment; [Figure 6] FIG. 10 is an illustration of a side view of an electrostatic end effector for picking and placing composite plies in accordance with an illustrative embodiment; [Figure 7] 10 is a flowchart of a method for picking and placing composite materials using a single end effector having two different mechanisms in accordance with an illustrative embodiment. [Figure 8] 10 is a flowchart of a method for picking and placing composite materials using a single end effector having two different mechanisms in accordance with an illustrative embodiment. [Figure 9] 10 is a flowchart of a method for picking and placing composite materials using a single end effector having two different mechanisms in accordance with an illustrative embodiment. [Figure 10] 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 11] 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] The illustrative examples recognize and take into account several considerations. The illustrative embodiments recognize and take into account that three-dimensional pick and place, also known as 3D pick and place (3D PnP), is a process in which flat plies cut from a roll of fabric are placed onto a curved tool. The fabric can be either a pre-impregnated composite (prepreg) or a dry woven fabric.

[0013] The exemplary embodiments recognize and take into account that in an automated layup environment for dry carbon woven fabrics in resin infusion applications, the pick-and-place end effector used is for picking the material and is based on the morphology of the material. The exemplary embodiments recognize and take into account that a single dry woven fabric ply or prepreg ply can be picked and placed using electrostatic bonding. The exemplary embodiments recognize and take into account that vacuum bonding can cause undesirable deformation of the ply. The exemplary embodiments recognize and take into account that vacuum bonding can maintain the shape of a single ply during pick-and-place. The exemplary embodiments recognize and take into account that a vacuum end effector can be used to pick and place multiple plies that are consolidated prior to pick-and-place.

[0014] The illustrative embodiments recognize and take into account that changing between two different types of end effectors involves removing, replacing, and aligning the entire end effectors and their frames. The illustrative embodiments recognize and take into account that removing and replacing different types of end effectors between pick-and-place operations can be undesirably time-consuming. The illustrative embodiments recognize and take into account that storing two different types of end effectors can use an undesirable amount of manufacturing space, especially in space-constrained environments. Using two different end effectors could instead require using two separate mechanisms in the manufacturing environment to move the end effectors, such as two industrial robots or two overhead gantries, which can be cost-prohibitive.

[0015] The illustrative example presents a single end effector capable of two types of adhesion for picking. The two different types of adhesion include vacuum suction and electrostatic. The illustrative example allows for space reduction and reduced downtime by eliminating the need to change between two different types of end effectors. The illustrative example provides a single end effector with a switchable option that allows for conversion of a vacuum end effector to an electrostatic end effector. The illustrative example presents an end effector that provides the ability to switch from vacuum-based adhesion to electrostatic adhesion.

[0016] Turning now to Figure 1 , an illustration of an aircraft is depicted in accordance with an illustrative embodiment. Aircraft 100 has wing 102 attached to fuselage 106 and wing 104. Aircraft 100 includes engine 108 attached to wing 102 and engine 110 attached to wing 104.

[0017] The fuselage 106 has a tail section 112. A horizontal stabilizer 114, a horizontal stabilizer 116, and a vertical stabilizer 118 are attached to the tail section 112 of the fuselage 106.

[0018] Aircraft 100 is one example of an aircraft that may have composite materials formed using a pick-and-place end effector configured to lift via two different mechanisms. In some illustrative examples, a vacuum end effector having a plurality of vacuum pogos and an electrostatic end effector comprising an electrostatic membrane configured to be removably held by the plurality of vacuum pogos may be used to pick and place composite materials in manufacturing components of aircraft 100.

[0019] Turning now to FIG. 2 , a block diagram of a manufacturing environment is depicted in accordance with an illustrative embodiment. End effector 201 can be used to pick and place composite material 228 on aircraft 100 during production of aircraft 100. End effector 201 is an end effector configured to lift composite material 228 via two different mechanisms. End effector 201 includes vacuum end effector 202 having multiple vacuum pogos 208 and electrostatic membrane 204 configured to be removably held by multiple vacuum pogos 208. Multiple vacuum pogos 208 are configured to pick and place composite preforms 234 in contact with multiple vacuum pogos 208. Electrostatic membrane 204 is configured to pick and place single ply 230 of composite material 228 while electrostatic membrane 204 is held by multiple vacuum pogos 208. When the vacuum end effector 202 holds the electrostatic membrane 204 , the end effector 201 takes the form of an electrostatic end effector 206 .

[0020] Composite preform 234 comprises a plurality of composite plies 236. In some illustrative examples, composite preform 234 comprises a plurality of composite plies 236 that are consolidated prior to pick and place using vacuum end effector 202.

[0021] Each of the plurality of vacuum pogos 208 is independently extendable relative to the frame 209 of the vacuum end effector 202. Each of the plurality of vacuum pogos 208 is independently controllable to create a desired bend. Each of the plurality of vacuum pogos 208 is independently controllable to provide a vacuum to hold at least one of the electrostatic membrane 204 or the composite material 228 against the plurality of vacuum pogos 208.

[0022] In some illustrative examples, the plurality of vacuum pogos 208 maintain consistent positioning relative to the frame 209 during pick-and-place of the composite material 228. In some illustrative examples, the plurality of vacuum pogos 208 are moved relative to the frame 209 to pick-and-place a composite material 228 having a pre-existing bend 232. In some illustrative examples, the plurality of vacuum pogos 208 are maintained in a planar position to pick-and-place a planar composite material 228. In other illustrative examples, picking-and-placing the composite material 228 includes placing a bend 232 in the composite material 228. In these illustrative examples, at least one vacuum pogo of the plurality of vacuum pogos 208 is moved relative to the frame 209 to introduce the bend 232 in the composite material 228.

[0023] The electrostatic membrane 204 comprises a first surface 212 configured to be held by the vacuum end effector 202 and a second surface 220 configured to contact the composite material 228. The first surface 212 and the second surface 220 are opposing surfaces of the electrostatic membrane 204. In some illustrative examples, the first surface 212 connects the electrostatic membrane 204 to the vacuum end effector 202 to form the electrostatic end effector 206, and therefore the first surface 212 is referred to as a connecting surface 214. In some illustrative examples, the second surface 220 contacts the composite material 228 during an electrostatic pick-and-place operation, and therefore the second surface 220 is referred to as a material contact surface 222.

[0024] When a vacuum is applied via the plurality of vacuum pogos 208, the electrostatic membrane 204 is held by the plurality of vacuum pogos 208. The plurality of vacuum pogos 208 mate with a connection surface 214. In some illustrative examples, the connection surface 214 is substantially smooth where it interfaces with the plurality of vacuum pogos 208. In other illustrative examples, the connection surface 214 may include connection points for interfacing with the plurality of vacuum pogos 208. In some illustrative examples, the connection points comprise mechanical connectors configured to connect to the plurality of vacuum pogos 208.

[0025] The electrostatic membrane 204 includes a membrane 216 formed of an elastic material 218 and a plurality of electrostatic pads 224. The elastic material 218 is flexible enough to form a curve 232 in the composite material 228. The plurality of electrostatic pads 224 are configured to generate a static charge to hold the composite material 228 against the electrostatic membrane 204.

[0026] A plurality of electrostatic pads 224 form part of the material contact surface 222 of the elastic material 218. The opposite surface of the electrostatic membrane 204 is a connection surface 214 configured to be held by a plurality of vacuum pogos 208.

[0027] The electrostatic membrane 204 is electrically connected to the vacuum end effector 202 by an electrical connection 210 for supplying power to the electrostatic membrane 204. The electricity provided by the electrical connection 210 is used by a plurality of electrostatic pads 224 to generate static electricity.

[0028] The plurality of electrostatic pads 224 are arranged to allow for the formation of a curvature 232 in the composite material 228 and the electrostatic film 204. In some illustrative examples, the plurality of electrostatic pads 224 are arranged in a repeating geometric pattern 226. Different electrostatic pads can be used to form different curvatures in the composite material. The electrostatic film 204 can be replaced with a different electrostatic film having a different pattern of electrostatic pads to form different curvatures. The vacuum end effector 202 is configured to utilize any desired electrostatic film.

[0029] In some illustrative examples, the vacuum end effector 202 can removably hold a second electrostatic membrane 238. In some illustrative examples, the electrostatic membrane 204 can be removed and replaced with a second electrostatic membrane 238 configured to be removably held by a plurality of vacuum pogos 208. In some illustrative examples, the second electrostatic membrane 238 comprises a plurality of electrostatic pads 240 arranged in a second repeating geometric pattern 242 that is different from the repeating geometric pattern 226. Different electrostatic membranes can be used to pick and place composite materials 228 of different sizes or shapes. In some illustrative examples, different electrostatic membranes can be used to form different curvatures.

[0030] In some illustrative examples, the third electrostatic membrane 244 can be removably held by a plurality of vacuum pogos 208 of the vacuum end effector 202. The third electrostatic membrane 244 comprises a plurality of electrostatic pads 246 arranged in a geometric pattern 248 that is different from the second repeating geometric pattern 242 and the repeating geometric pattern 226.

[0031] The electrostatic membrane 204 can be removed to use the vacuum end effector 202 to pick and place the composite material 228 using vacuum provided by the plurality of vacuum pogos 208. The frame 209 of the vacuum end effector 202 can remain connected to a respective robotic arm, gantry, or other movement system within the manufacturing environment 200 while the end effector 201 picks and places using either vacuum or electrostatics. In some illustrative examples, the frame 209 of the vacuum end effector 202 remains connected to the movement system 258 while picking and placing using either vacuum or electrostatics. In some illustrative examples, the frame 209 of the vacuum end effector 202 remains connected to the robotic arm 260 or gantry 262.

[0032] The electrostatic film 204 can be repeatedly held and released by the vacuum end effector 202 as desired to form a composite layup 254 on the tool 252. In some illustrative examples, at least one layer of the composite layup 254 can be picked and placed by the vacuum end effector 202 using multiple vacuum pogos 208. In some illustrative examples, at least one layer of the composite layup 254 can be picked and placed by the electrostatic end effector 206 using multiple electrostatic films 204.

[0033] In some illustrative examples, the electrostatic end effector 206 can be used to repeatedly pick and place single layers of the composite material 228 to form a stack of composite plies. In some illustrative examples, after forming the stack of composite plies, the electrostatic membrane 204 is released and the vacuum end effector 202 is used to pick and place the stack of composite plies.

[0034] In some illustrative examples, composite layup 254 has a curvature 256. In some illustrative examples, curvature 256 is formed in the layers of composite layup 254 as each layer is applied to tool 252. In other illustrative examples, curvature 256 may be applied to the layers of composite layup 254 before each layer is applied to tool 252. In some illustrative examples, curvature 256 is imparted to each layer of composite layup 254 by applying pressure to the forming tool from at least one of vacuum end effector 202 or electrostatic membrane 204.

[0035] The control system 250 is configured to selectively activate at least one of vacuum to the plurality of vacuum pogos 208 or electricity to the electrostatic membrane 204 of the electrostatic end effector 206. In some illustrative examples, the control system 250 is used to control the retention or release of the electrostatic membrane 204 from the vacuum end effector 202. In some illustrative examples, the control system 250 is further configured to move the plurality of vacuum pogos 208 to form a bend 232 in the composite material 228.

[0036] The illustration of manufacturing environment 200 in FIG. 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 combined and then divided into different blocks when implemented in an illustrative embodiment.

[0037] For example, in some illustrative examples, electrostatic membrane 204 and second electrostatic membrane 238 can differ from one another in addition to having different geometric patterns. In some illustrative examples, at least one of the material or thickness of membrane 216 may be different from that of second electrostatic membrane 238. In other illustrative examples, electrostatic membrane 204 and second electrostatic membrane 238 have different surface areas. As another example, although not shown, end effector 201 can include a slip element between vacuum end effector 202 and electrostatic membrane 204 to enable movement of the plies to conform to complex shapes.

[0038] Referring now to FIG. 3 , a side view of an electrostatic end effector is shown in accordance with an exemplary embodiment. Electrostatic end effector 300 is a physical implementation of electrostatic end effector 206. Electrostatic end effector 300 can be used to pick and place composite materials on aircraft 100 during its manufacture. Electrostatic end effector 300 is an end effector configured to lift composite materials via two different mechanisms. Electrostatic end effector 300 includes vacuum end effector 302 having multiple vacuum pogos 308 and electrostatic membrane 306 configured to be removably held by multiple vacuum pogos 308. Multiple vacuum pogos 308 are configured to pick and place composite preforms in contact with multiple vacuum pogos 308. Electrostatic membrane 306 is configured to pick and place a single ply of composite material while electrostatic membrane 306 is held by multiple vacuum pogos 308.

[0039] Each of the plurality of vacuum pogos 308 is independently extendable relative to the frame 304 of the vacuum end effector 302. Each of the plurality of vacuum pogos 308 is independently controllable to create a desired curvature. Each of the plurality of vacuum pogos 308 is independently controllable to provide a vacuum to hold at least one of the electrostatic membrane 306 or the composite material. Although depicted as curved, the plurality of vacuum pogos 308 can be positioned to pick and place planar composite materials or composite materials of any other shape.

[0040] Although not visible in Figure 3, the electrostatic membrane 306 is electrically connected to the vacuum end effector 302 for providing power to the electrostatic membrane 306. Although not visible in Figure 3, a control system configured to selectively activate at least one of vacuum to the plurality of vacuum pogos 308 or electricity to the electrostatic membrane 306 is connected to the electrostatic end effector 300. The electrostatic membrane 306 comprises a membrane formed of an elastic material and a plurality of electrostatic pads (not shown).

[0041] The plurality of electrostatic pads form part of a material contact surface 310 of the elastic material. The opposite surface of the membrane is a connection surface 312 configured to be held by a plurality of vacuum pogos 308. In some illustrative examples, the plurality of electrostatic pads are arranged in a repeating geometric pattern.

[0042] The electrostatic membrane 306 can be removed to use the vacuum end effector 302 to pick and place composite materials using vacuum provided by the plurality of vacuum pogos 308. In some illustrative examples, the electrostatic membrane 306 can be removed and replaced with a second electrostatic membrane (not shown) configured to be removably held by the plurality of vacuum pogos 308. In some illustrative examples, the second electrostatic membrane comprises a plurality of electrostatic pads arranged in a second repeating geometric pattern that is different from the repeating geometric pattern. Different electrostatic membranes can be used to pick and place composite materials of different sizes or shapes. In some illustrative examples, different electrostatic membranes can be used to form different curvatures.

[0043] Referring now to FIG. 4, a side view of a vacuum end effector drawing a vacuum to connect an electrostatic membrane is shown, according to an illustrative embodiment. Vacuum end effector 402 is a physical implementation of vacuum end effector 202 of FIG. 2. In some illustrative examples, vacuum end effector 402 is the same as vacuum end effector 302 of FIG. 3. In view 400, vacuum end effector 402 is not connected to or carrying an electrostatic membrane 404. Electrostatic membrane 404 is a physical implementation of electrostatic membrane 204 of FIG. 2.

[0044] In representation 400, a vacuum 408 is provided to a plurality of vacuum pogos 406 of a vacuum end effector 402. The vacuum 408 can be used to hold an electrostatic membrane 404 by the vacuum end effector 402. When the vacuum end effector 402 holds the electrostatic membrane 404, the vacuum end effector 402 and the electrostatic membrane 404 form an electrostatic end effector that can pick and place composite materials using electrostatic charges. When the vacuum end effector 402 is spaced from the electrostatic membrane 404, the vacuum end effector 402 can pick and place composite materials using the vacuum 408. Although depicted as curved, the plurality of vacuum pogos 406 can be positioned to pick and place planar composite materials or composite materials of any other shape. The plurality of vacuum pogos 406 can be moved before lifting the composite material, while lifting the composite material, or when the composite material is being placed on the tool.

[0045] Referring now to FIG. 5, a side view of a vacuum end effector for picking and placing a composite preform is shown in accordance with an exemplary embodiment. Vacuum end effector 502 is a physical implementation of vacuum end effector 202 of FIG. 2. In view 500, vacuum end effector 502 is picking and placing a composite preform 506. In view 500, vacuum end effector 502 holds composite preform 506 against a plurality of vacuum pogos 504. A vacuum (not shown) is provided to the plurality of vacuum pogos 504 to pick and place composite preform 506.

[0046] In this illustrative example, the vacuum end effector 502 is used to form a curved section in the composite preform 506. In other examples not shown, the vacuum end effector 502 can be used to pick and place the composite preform 506 or other composite material into a planar position. In other examples not shown, the vacuum end effector 502 can be used to pick and place the composite preform 506 or other composite material into different curved sections.

[0047] As shown, a vacuum end effector 502 positions a composite preform 506 against a curved surface 510 of a tool 508. The composite preform 506 comprises multiple composite plies. The composite preform 506 is thicker and stiffer than a single composite ply. The vacuum end effector 502 provides sufficient support to maintain the curve of the composite preform 506.

[0048] In some illustrative examples, a composite layup is formed on a tool 508. In some illustrative examples, the tool 508 is a layup tool that receives multiple composite plies. In other illustrative examples, the tool 508 is a molding tool. In some illustrative examples, the vacuum end effector 502 forms a curvature in the composite preform 506 before placing the composite preform 506 relative to the tool 508. In some illustrative examples, the vacuum end effector 502 forms a curvature in the composite preform 506 by moving multiple vacuum pogos 504. In some illustrative examples, the vacuum end effector 502 forms a curvature in the composite preform 506 by pressing the composite preform 506 against a curved surface 510 of the tool 508. In some illustrative examples, the vacuum end effector 502 forms a curvature in the composite preform 506 by pressing the composite preform 506 against a molding tool before placing the composite preform 506 relative to the tool 508.

[0049] Referring now to FIG. 6, a side view of an electrostatic end effector for picking and placing a composite ply is shown in accordance with an exemplary embodiment. The electrostatic end effector 602 is a physical implementation of the electrostatic end effector 206 of FIG. 2. In view 600, the electrostatic end effector 602 is picking and placing a composite ply 614. The electrostatic end effector 602 is an end effector configured to lift composite material via two different mechanisms. The electrostatic end effector 602 comprises a vacuum end effector 604 having a plurality of vacuum pogos 608 and an electrostatic membrane 606 configured to be removably held by the plurality of vacuum pogos 608. In view 600, the electrostatic end effector 602 holds the composite ply 614 against the electrostatic membrane 606 using electrostatic charges. Electricity is supplied to the electrostatic membrane 606 by the vacuum end effector 604 to pick and place the composite ply 614.

[0050] In this illustrative example, electrostatic end effector 602 is used to form a curvature in composite ply 614. In other examples not shown, electrostatic end effector 602 can be used to pick and place composite ply 614 in a planar position. In other examples not shown, electrostatic end effector 602 can be used to pick and place composite ply 614 in a different curvature.

[0051] As shown, the electrostatic end effector 602 positions the composite ply 614 against the curved surface 612 of the tool 610. The electrostatic end effector 602 provides sufficient support to maintain the curve of the composite ply 614.

[0052] In some illustrative examples, a composite layup is formed on a tool 610. In some illustrative examples, the tool 610 is a layup tool that receives multiple composite layers. In other illustrative examples, the tool 610 is a forming tool. In some illustrative examples, the electrostatic end effector 602 forms a curvature in the composite ply 614 before placing the composite ply 614 against the tool 610. In some illustrative examples, the electrostatic end effector 602 forms a curvature in the composite ply 614 by moving multiple vacuum pogos 608. In some illustrative examples, the electrostatic end effector 602 forms a curvature in the composite ply 614 using a vacuum end effector 604. The electrostatic end effector 602 can form a curvature in the composite ply 614 using the vacuum end effector 604 by the vacuum end effector 604 pressing the composite ply 614 against a curved surface. In some illustrative examples, the electrostatic end effector 602 forms a curvature in the composite ply 614 by forcing the composite ply 614 against the curved surface 612 of the tool 610. In some illustrative examples, the electrostatic end effector 602 forms a curvature in the composite ply 614 by forcing the composite ply 614 against a forming tool prior to placing the composite ply 614 against the tool 610.

[0053] Referring now to FIG. 7 , a flowchart of a method for picking and placing composite materials using a single end effector having two different mechanisms is depicted in accordance with an illustrative embodiment. Method 700 may be used to manufacture composite components for aircraft 100. Method 700 may be performed using vacuum end effector 202 and electrostatic membrane 204 of FIG. 2 . Method 700 may be performed using vacuum end effector 302 and electrostatic membrane 306 of FIG. 3 . Method 700 may be performed using vacuum end effector 402 and electrostatic membrane 404 of FIG. 4 . Method 700 may be performed using vacuum end effector 502 of FIG. 5 . Method 700 may be performed using vacuum end effector 604 and electrostatic membrane 606 of FIG. 6 .

[0054] The method 700 picks and places a single-ply composite material using an electrostatic membrane held by a plurality of vacuum pogos of a vacuum end effector (operation 702). The electrostatic membrane is held by a vacuum provided by the plurality of vacuum pogos of the vacuum end effector. The end effector is an electrostatic end effector configured to pick and place the composite material using electrostatic charges while the vacuum holds the electrostatic membrane.

[0055] The method 700 then releases the electrostatic membrane from the vacuum end effector (operation 704). After releasing the electrostatic membrane, the end effector is configured to pick and place the composite material using a vacuum. After releasing the electrostatic membrane, the end effector is a vacuum end effector.

[0056] The method 700 then picks and places the composite preform using a plurality of vacuum pogos (operation 706). To pick and place the composite preform, a vacuum is applied to the composite preform using vacuum delivered through the plurality of vacuum pogos. The method 700 then ends.

[0057] In some illustrative examples, method 700 connects the electrostatic membrane to the vacuum end effector by drawing a vacuum through multiple vacuum pogos of the vacuum end effector that are in contact with the electrostatic membrane (operation 708). In some illustrative examples, the connecting surface of the electrostatic membrane is smooth to enable the multiple vacuum pogos to hold the electrostatic membrane. In some illustrative examples, the connecting surface of the electrostatic membrane has a mechanical connector for connecting to the multiple vacuum pogos.

[0058] In some illustrative examples, picking and placing the single-ply composite material includes lifting, forming a curvature in the single-ply composite material, and placing the composite material with the curvature (Operation 710). In some illustrative examples, forming the curvature is performed by moving multiple vacuum pogos of a vacuum end effector. In some illustrative examples, forming the curvature is performed by pressing the single-ply composite material against a forming tool before placing the single-ply composite material. In some illustrative examples, the single-ply composite material is formed and placed on a tool having a curved surface to form a curvature in the single-ply composite material as it is placed on the tool.

[0059] In some illustrative examples, releasing the electrostatic membrane from the vacuum end effector includes releasing vacuum from multiple vacuum pogos of the vacuum end effector (OPERATION 712). In some illustrative examples, air is pumped through the multiple vacuum pogos to push the electrostatic membrane away from the multiple vacuum pogos.

[0060] In some illustrative examples, picking and placing the composite preform includes lifting, forming a curvature in the composite preform, and placing the composite preform with the curvature (Operation 714). In some illustrative examples, forming the curvature is performed by moving a plurality of vacuum pogos of a vacuum end effector. In some illustrative examples, forming the curvature is performed by pressing the composite preform against a molding tool before placing the composite preform. In some illustrative examples, the composite preform is formed and placed on a tool having a curved surface to form a curvature in the composite preform when the composite preform is placed on the tool.

[0061] Referring now to FIG. 8 , an illustration of a flowchart of a method for picking and placing composite materials using a single end effector having two different mechanisms is shown in accordance with an illustrative embodiment. Method 800 may be used to manufacture composite components for aircraft 100. Method 800 may be performed using vacuum end effector 202 and electrostatic membrane 204 of FIG. 2 . Method 800 may be performed using vacuum end effector 302 and electrostatic membrane 306 of FIG. 3 . Method 800 may be performed using vacuum end effector 402 and electrostatic membrane 404 of FIG. 4 . Method 800 may be performed using vacuum end effector 502 of FIG. 5 . Method 800 may be performed using vacuum end effector 604 and electrostatic membrane 606 of FIG. 6 .

[0062] The method 800 forms a curvature in the held composite preform using vacuum holding from a vacuum end effector (operation 802). In some illustrative examples, forming the curvature is performed by moving multiple vacuum pogos of the vacuum end effector. In some illustrative examples, forming the curvature is performed by pressing the composite preform against a forming tool prior to placing the composite preform. In some illustrative examples, the composite preform is formed and placed on a tool having a curved surface to form a curvature in the composite preform when the composite preform is placed on the tool.

[0063] The method 800 then forms a curvature in the single-ply composite material held by the vacuum end effector using electrostatic force from an electrostatic membrane held by the vacuum end effector (operation 804). In some illustrative examples, forming the curvature is performed by moving multiple vacuum pogos of the vacuum end effector. In some illustrative examples, forming the curvature is performed by pressing the single-ply composite material against a forming tool before placing the single-ply composite material. In some illustrative examples, the single-ply composite material is formed and placed on a tool having a curved surface to form a curvature in the single-ply composite material as it is placed on the tool. The method 800 then ends.

[0064] In some illustrative examples, forming the composite preform includes pressing the composite preform against a molding tool using a vacuum end effector (OPERATION 806). In some illustrative examples, method 800 also includes connecting the electrostatic membrane to the vacuum end effector by drawing a vacuum through a vacuum pogo of the vacuum end effector, which is in contact with the electrostatic membrane (OPERATION 808).

[0065] In some illustrative examples, forming the single-ply composite material includes forcing the single-ply composite material against a forming tool while an electrostatic membrane holds the single-ply composite material to a vacuum end effector (operation 810). In some illustrative examples, method 800 also includes connecting a second electrostatic membrane to the vacuum end effector by drawing a vacuum through a vacuum pogo of the vacuum end effector in contact with the electrostatic membrane, the second electrostatic membrane configured to form a different curvature (operation 812).

[0066] Referring now to FIG. 9 , a flowchart of a method for picking and placing composite materials using a single end effector having two different mechanisms is depicted in accordance with an illustrative embodiment. Method 900 may be used to manufacture composite components for aircraft 100. Method 900 may be performed using vacuum end effector 202 and electrostatic membrane 204 of FIG. 2 . Method 900 may be performed using vacuum end effector 302 and electrostatic membrane 306 of FIG. 3 . Method 900 may be performed using vacuum end effector 402 and electrostatic membrane 404 of FIG. 4 . Method 900 may be performed using vacuum end effector 502 of FIG. 5 . Method 900 may be performed using vacuum end effector 604 and electrostatic membrane 606 of FIG. 6 .

[0067] The method 900 repeatedly places single plies of composite material to form a stack of composite plies using an electrostatic membrane held by multiple vacuum pogos of a vacuum end effector (operation 902). The method 900 releases the electrostatic membrane from the vacuum end effector (operation 904). The method 900 lifts the stack of composite plies using the multiple vacuum pogos (operation 906). The method 900 then ends.

[0068] In some illustrative examples, the method 900 forms a curvature in each respective single-ply composite material as it is held using electrostatic force from an electrostatic membrane held by a vacuum end effector (operation 908). The curvature can be formed in each respective single-ply composite material at least one of during lifting, against a forming tool, or when the vacuum end effector and electrostatic membrane position each respective single ply.

[0069] In some illustrative examples, method 900 moves at least one vacuum pogo of the plurality of vacuum pogos to form a curvature in the vacuum end effector while the electrostatic membrane is held by the plurality of vacuum pogos (operation 910). In some illustrative examples, the curvature is formed in the vacuum end effector before lifting each single-ply composite material. In some illustrative examples, the curvature is formed in the vacuum end effector during lifting each single-ply composite material. In some illustrative examples, the curvature is formed in the vacuum end effector during placement of each single-ply composite material.

[0070] In some illustrative examples, the method 900 forms a curvature in the stack of composite plies by moving at least one vacuum pogo of the plurality of vacuum pogos (operation 912). In some illustrative examples, the curvature is formed in the stack of composite plies during lifting of the stack of composite plies. In some illustrative examples, the curvature is formed in the stack of composite plies during placement of the stack of composite plies.

[0071] In some illustrative examples, the method 900 moves at least one vacuum pogo of the plurality of vacuum pogos to conform the plurality of vacuum pogos to a curved surface of a tool (OPERATION 914). In some illustrative examples, the tool is a forming tool for forming a curvature in the composite material prior to placing the composite material. In some illustrative examples, the tool is a layup tool having a curved surface configured to accept the composite material.

[0072] In some illustrative examples, moving at least one vacuum pogo of the plurality of vacuum pogos forms a curvature in the stack of composite plies (OPERATION 916). In some illustrative examples, moving at least one vacuum pogo of the plurality of vacuum pogos forms a curvature in the single ply of composite material held by the electrostatic membrane (OPERATION 918).

[0073] 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.

[0074] As used herein, "a number of," when used in reference to an item, means one or more of the item.

[0075] The flowcharts and block diagrams in the various depicted embodiments illustrate the architecture, functionality, and operation 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.

[0076] In some alternative implementations of the exemplary embodiments, one or more functions noted in the blocks may occur out of the order noted in the figures. For example, in some cases, two blocks shown in succession may be executed substantially concurrently or may even be executed 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, operations 708 through 714 may be optional. As another example, operations 806 through 812 may be optional. As yet another example, operations 908 through 918 may be optional.

[0077] An exemplary embodiment of the present disclosure may be described with reference to aircraft manufacturing and service method 1000, as shown in Figure 10, and aircraft 1100, as shown in Figure 11. Referring initially to Figure 10, an illustration of an aircraft manufacturing and service method is shown in block diagram form in accordance with an exemplary embodiment. During pre-production, aircraft manufacturing and service method 1000 may include specification and design 1002 and material procurement 1004 of aircraft 1100 in Figure 11.

[0078] During production, component and subassembly manufacturing 1006 and systems integration 1008 of the aircraft 1100 occurs. The aircraft 1100 may then go through certification and delivery 1010 to place it in service 1012. While in service 1012 by a customer, the aircraft 1100 is scheduled for routine maintenance and service 1014, which may include modification, reconfiguration, refurbishment, or other maintenance and service.

[0079] Each of the processes of aircraft manufacturing and service method 1000 may be performed 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.

[0080] Referring now to Figure 11 , an illustration of an aircraft in block diagram form is shown in which an illustrative embodiment may be implemented. In this example, aircraft 1100 is produced by aircraft manufacturing and service method 1000 in Figure 10 and may include an airframe 1102 having a number of systems 1104 and an interior 1106. Example systems 1104 include one or more of a propulsion system 1108, an electrical system 1110, a hydraulic system 1112, and an environmental system 1114. Any number of other systems may also be included.

[0081] Apparatus and methods embodied herein may be used during at least one of the stages of aircraft manufacturing and service method 1000. One or more illustrative embodiments may be manufactured or used during at least one of component and subassembly manufacturing 1006, system integration 1008, in-service 1012, or maintenance and service 1014 of Figure 10.

[0082] Illustrative examples provide one end effector frame that can be used to provide two mechanisms for picking and placing composite materials. Illustrative examples provide a vacuum end effector with vacuum suction cups sporadically positioned across different pogos / actuators. A separate but removably connectable electrostatic membrane is provided. The electrostatic adhesion is provided as a separate component, i.e., the electrostatic membrane, that is picked up by the vacuum end effector. In some illustrative examples, electrical terminals are clipped into place to convert the pick surface of the end effector from vacuum to electrostatic.

[0083] In these illustrative examples, the end effector frame remains the same regardless of the adhesive technique selected for the pick-and-place process. The electrostatic membrane can be attached to the end effector using the vacuum cups of a vacuum end effector. The illustrative examples provide a dockable method for attaching the electrostatic membrane to the end effector using the vacuum cups. The same end effector frame can be used with different electrostatic membranes in pick-and-place applications. The shape and size of the electrostatic pads can vary between electrostatic membranes. In some illustrative examples, the electrostatic pads take the form of a triangle. The electrostatic pads can be tailored to the layup tool to accept the composite material.

[0084] Illustrative examples provide the same end effector that can be used for vacuum pick-and-place or electrostatic pick-and-place. The illustrative examples can reduce production downtime by eliminating the need to switch between two different end effectors for pick-and-place. In some illustrative examples, electrostatics can be used primarily for pick-and-place of single-ply dry fabrics, while vacuum can be used for pick-and-place of ply stackups. This is a "pick-and-place" system that combines both vacuum and electrostatic end effectors. The end effector includes pogos that extend to conform to the contour to be picked up. In some illustrative examples, an electrostatic film (ES) is vacuum-bonded to the end effector. The end effector can be used to pick and place a contoured single ply for pick-and-place. In some illustrative examples, the end effector includes a slip element between the vacuum and electrostatic end effectors to allow movement of the ply to conform to complex shapes. The vacuum bond to the electrostatic film can be terminated, and then vacuum bonding at the end of the pogo allows bonding to a reinforced / adhesive (multi-ply) structure.

[0085] 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 disclosed form. 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]

[0086] 100 aircraft, 102, 104 wing, 106 fuselage, 108, 110 engine, 112 tail, 114, 116 horizontal stabilizer, 118 vertical stabilizer, 200 manufacturing environment, 201 end effector, 202 vacuum end effector, 204 electrostatic membrane, 206 electrostatic end effector, 208 vacuum pogo, 209 frame, 210 electrical connection, 212 first surface, 214 connecting surface, 216 membrane, 218 elastic material, 220 second surface, 222 material contact surface, 224 electrostatic pad, 226 repeating geometric pattern, 228 composite material, 230 single ply, 232 flexure, 234 composite preform, 236 composite ply, 238 second electrostatic membrane, 240 electrostatic pad, 242 Second repeating geometric pattern, 244 Third electrostatic membrane, 246 Electrostatic pad, 248 Geometric pattern, 250 Control system, 252 Tool, 254 Composite layup, 256 Flexure, 258 Movement system, 260 Robot arm, 262 Gantry, 300 Electrostatic end effector, 302 Vacuum end effector, 304 Frame, 306 Electrostatic membrane, 308 Vacuum pogo, 310 Material contact surface, 312 Connection surface, 400 Display, 402 Vacuum end effector, 404 Electrostatic membrane, 406 Vacuum pogo, 408 Vacuum, 500 Display, 502 Vacuum end effector, 504 Vacuum pogo, 506 Composite preform, 508 Tool, 510 Flexure surface, 600 Display, 602 Electrostatic end effector, 604 Vacuum end effectors, 606 Electrostatic membranes, 608 Vacuum pogos, 610 Tools, 612 Curved surfaces, 614 Composite plies, 1000 Maintenance methods, 1002 Specification and design, 1004 Material procurement, 1006 Component and subassembly manufacturing, 1008 System integration, 1010 Certification and delivery, 1012 In-service, 1014 Maintenance and overhaul, 1100 Aircraft, 1102 Airframe, 1104 Systems, 1106 Interior, 1108 Propulsion systems, 1110 Electrical systems, 1112 Hydraulic systems, 1114 Environmental systems

Claims

1. An end effector (201) that lifts a composite material (228) via two different mechanisms, a vacuum end effector (202, 302, 402, 502, 604) having a plurality of vacuum pogos (208, 308, 406, 504, 608) for contacting and picking and placing a composite preform (234, 506) with the plurality of vacuum pogos (208, 308, 406, 504, 608); an electrostatic membrane (204, 306, 404, 606) that is removable by the plurality of vacuum pogos (208, 308, 406, 504, 608), wherein the electrostatic membrane (204, 306, 404, 606) picks and places a single ply (230) of composite material (228, 614) while the electrostatic membrane (204, 306, 404, 606) is held by the plurality of vacuum pogos (208, 308, 406, 504, 608); The end effector (201) comprises:

2. The end effector (201) of claim 1, wherein the electrostatic membrane (204, 306, 404, 606) is electrically connected to the vacuum end effector (202, 302, 402, 502, 604) to provide power to the electrostatic membrane (204, 306, 404, 606).

3. a control system (250) for selectively activating at least one of vacuum to the plurality of vacuum pogos (208, 308, 406, 504, 608) or electricity to the electrostatic membranes (204, 306, 404, 606); The end effector (201) of claim 1, further comprising:

4. The end effector (201) of claim 1, wherein the electrostatic membrane (204, 306, 404, 606) comprises a membrane (216) formed of a resilient material (218) and a plurality of electrostatic pads (224).

5. 5. The end effector (201) of claim 4, wherein the plurality of electrostatic pads (224) form part of a material contact surface (222) of the elastic material (218), and an opposite surface of the membrane is a connection surface (214) held by the plurality of vacuum pogos (208, 308, 406, 504, 608).

6. The end effector (201) of claim 4, wherein the plurality of electrostatic pads (224) are arranged in a repeating geometric pattern (226).

7. a second electrostatic membrane (204, 306, 404, 606) removably held by the plurality of vacuum pogos (208, 308, 406, 504, 608), wherein picking and placing a single ply (230) of composite material (228, 614) while the second electrostatic membrane (204, 306, 404, 606) is held by the plurality of vacuum pogos (208, 308, 406, 504, 608) comprises a plurality of electrostatic pads (240) arranged in a second repeating geometric pattern (242) different from the repeating geometric pattern (226); The end effector (201) of claim 6, further comprising:

8. A method (700) for picking and placing composite materials (228) using a single end effector (201) having two different mechanisms, comprising: picking and placing (702) a single ply (230) of composite material (228, 614) using an electrostatic membrane (204, 306, 404, 606) held by a plurality of vacuum pogos (208, 308, 406, 504, 608) of a vacuum end effector (202, 302, 402, 502, 604); Releasing (704) the electrostatic membrane (204, 306, 404, 606) from the vacuum end effector (202, 302, 402, 502, 604); picking and placing (706) composite preforms (234, 506) using the plurality of vacuum pogos (208, 308, 406, 504, 608); A method (700).

9. 10. The method (700) of claim 8, wherein picking and placing the single-ply (230) of composite material (228, 614) comprises lifting, forming a curved portion (232) in the single-ply (230) of composite material (228, 614), and placing (710) the composite material (228) with the curved portion (232).

10. 10. The method (700) of claim 8, wherein picking and placing the composite preform (234, 506) comprises lifting, forming a curved portion (232) in the composite preform (234, 506), and placing (714) the composite preform (234, 506) with the curved portion (232).

11. 10. The method (700) of claim 8, wherein releasing the electrostatic membrane (204, 306, 404, 606) from the vacuum end effector (202, 302, 402, 502, 604) comprises releasing (712) a vacuum from a vacuum pogo (208, 308, 406, 504, 608) of the vacuum end effector (202, 302, 402, 502, 604).

12. connecting (708) the electrostatic membrane (204, 306, 404, 606) to the vacuum end effector (202, 302, 402, 502, 604) by drawing a vacuum through a vacuum pogo (208, 308, 406, 504, 608) of the vacuum end effector (202, 302, 402, 502, 604) that is in contact with the electrostatic membrane (204, 306, 404, 606); 9. The method (700) of claim 8, further comprising:

13. 1. A method (800) for picking and placing composite materials (228) using a single end effector having two different mechanisms, comprising: forming (802) a curved portion (232) in a held composite preform (234, 506) using vacuum holding from a vacuum end effector (202, 302, 402, 502, 604); forming (804) a curved portion (232) in a single-ply composite material (228) held by the vacuum end effector (202, 302, 402, 502, 604) using electrostatic force from an electrostatic film (204, 306, 404, 606); A method (800).

14. connecting (808) the electrostatic membrane (204, 306, 404, 606) to the vacuum end effector (202, 302, 402, 502, 604) by drawing a vacuum through a vacuum pogo (208, 308, 406, 504, 608) of the vacuum end effector (202, 302, 402, 502, 604) that is in contact with the electrostatic membrane (204, 306, 404, 606); 14. The method (800) of claim 13, further comprising:

15. 14. The method (800) of claim 13, wherein forming the composite preform (234, 506) includes using the vacuum end effector (202, 302, 402, 502, 604) to press the composite preform (234, 506) against a molding tool (806).

16. 14. The method (800) of claim 13, wherein forming the single-ply (230) composite material (228, 614) includes forcing the single-ply (230) composite material (228, 614) against a forming tool (810) while the electrostatic membrane (204, 306, 404, 606) holds the single-ply (230) composite material (228, 614) against the vacuum end effector (202, 302, 402, 502, 604).

17. connecting (812) a second electrostatic membrane (204, 306, 404, 606) to the vacuum end effector (202, 302, 402, 502, 604) by drawing a vacuum through a vacuum pogo (208, 308, 406, 504, 608) of the vacuum end effector (202, 302, 402, 502, 604) that is in contact with the electrostatic membrane (204, 306, 404, 606); 14. The method (800) of claim 13, further comprising: wherein the second electrostatic membrane (204, 306, 404, 606) is configured to form a differential curvature.

18. A method (900) for picking and placing composite materials (228) using a single end effector (201) having two different mechanisms, comprising: repeatedly placing (902) single plies of composite material (228) to form a stack of composite plies using electrostatic membranes (204, 306, 404, 606) held by a plurality of vacuum pogos (208, 308, 406, 504, 608) of a vacuum end effector (202, 302, 402, 502, 604); Releasing (904) the electrostatic membrane (204, 306, 404, 606) from the vacuum end effector (202, 302, 402, 502, 604); lifting (906) said stack of composite plies using said plurality of vacuum pogos (208, 308, 406, 504, 608); A method (900).

19. forming (908) a curved portion (232) in each respective single-ply composite material (228) as the composite material (228, 614) of each respective single-ply (230) is held using electrostatic force from the electrostatic membrane (204, 306, 404, 606) held by the vacuum end effector (202, 302, 402, 502, 604); 20. The method (900) of claim 18, further comprising:

20. forming a curvature (232) in the stack of composite plies by moving at least one vacuum pogo of the plurality of vacuum pogos (208, 308, 406, 504, 608); 20. The method (900) of claim 18, further comprising:

21. and moving (910) at least one of the plurality of vacuum pogos (208, 308, 406, 504, 608) to form a curved portion (232) in the vacuum end effector (202, 302, 402, 502, 604) while the electrostatic membrane (204, 306, 404, 606) is held by the plurality of vacuum pogos (208, 308, 406, 504, 608).

20. The method (900) of claim 18, further comprising:

22. moving (914) at least one vacuum pogo of the plurality of vacuum pogos (208, 308, 406, 504, 608) to conform the plurality of vacuum pogos (208, 308, 406, 504, 608) to the curved surface of the tool; 20. The method (900) of claim 18, further comprising:

23. 23. The method (900) of claim 22, wherein moving the at least one vacuum pogo of the plurality of vacuum pogos (208, 308, 406, 504, 608) forms (916) a bend (232) in the stack of composite plies.

24. 23. The method (900) of claim 22, wherein the step of moving the at least one vacuum pogo of the plurality of vacuum pogos (208, 308, 406, 504, 608) forms (918) a curved portion (232) in a single ply (230) of composite material (228) held by the electrostatic membrane (204, 306, 404, 606).

Images