System and method for manufacturing a composite member

Abstract

Systems and methods for fabricating a composite member are provided.SOLUTION: The system and method are configured to move different types of composite plies (75) from different supply stations (200, 300). After the composite ply is moved along the carrier member (100), it is moved to a mold (600) by a transfer station (500). One or more forming machines (700) form the composite ply on the forming tool (600).SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present disclosure relates generally to the field of composite parts, and more particularly to a manufacturing system configured to move various types of composite plies to a mold to form a composite part. [Background technology]

[0002] Fabrication of a composite component requires the laying up of plies of fiber-reinforced composite material on a mold. Each individual composite ply has its own fiber orientation angle, which aligns the fibers within the ply. Various composite plies may be oriented in various orientations relative to other plies. The stacking order of the individual composite plies within a composite component is a consideration in the design and manufacture of the component. Different types of composite plies have different design variables, such as material, fiber orientation, and ply width. Optimal orientation and sequencing of the composite plies results in optimal structural performance. The number and type of composite plies may vary depending on the application of the composite component. The composite component is fabricated by curing the stacked composite plies.

[0003] Multiple plies of composite material arranged in various orientations create composite members that can achieve structural performance superior to the individual material properties of each ply. Composite members can therefore be used in a variety of applications, including, but not limited to, various components in vehicles such as aircraft, trucks, and boats, and structural components in buildings. These members are advantageous because of their light weight, high strength-to-weight ratio, and design flexibility.

[0004] Current methods for laying up individual composite plies onto a mold are performed by hand or machine. Manual layup is a time-consuming process that requires a large number of people to perform a large amount of direct labor to lay up multiple composite plies. For large structures and high production rates, the amount of direct labor can be significant. Machines such as automated tape laying machines can reduce the amount of direct labor required to lay up composites. However, these machines are typically large, complex, and can be prohibitively expensive. Furthermore, these machines require a large amount of machine path programming, which impacts production costs and scheduling.

[0005] Current machinery and manufacturing layouts create inefficiencies during the manufacturing process. Machines are often complex, and safety hazards (such as the large mass, acceleration, and pinch points associated with the machinery) limit the proximity of personnel to the machinery. Inefficiencies also arise because personnel are located outside the machinery's operating envelope, which is much larger than the more restricted envelope. Furthermore, these machines result in low work density, meaning fewer value-added contacts per unit area at any given moment. To address these inefficiencies, current machines are designed for high acceleration, deceleration, and speed. This drives up overall costs and makes improving safety and work density more challenging. Summary of the Invention

[0006] One aspect relates to a method for manufacturing a composite member comprised of a plurality of composite plies, comprising: introducing a first composite ply having a first type from a first supply station onto a carrier member; introducing a second composite ply onto the carrier member from one or more second supply stations spaced along the carrier member from the first supply station, the second composite ply from the second supply station having a type different from the first type; orienting the first and second composite plies on the carrier member; are each individually transferred to a mold, and the first and second composite plies are molded on the mold.

[0007] In another aspect, orienting the first and second composite plies includes transferring the first and second composite plies from the carrier member onto a support surface of a first support member and individually orienting each of the first and second composite plies relative to one or more reference points on the support member.

[0008] In another aspect, the method further includes cutting one or more of the first and second composite plies on a first plane and then vertically transferring the first and second composite plies onto a second plane before forming the composite plies on the mold.

[0009] In another aspect, the method further includes cutting the first composite ply at the first supply station and cutting the second composite ply at the one or more second supply stations before introducing each of the first composite ply and the second composite ply into the carrier member.

[0010] In another aspect, the composite plies introduced from the first supply station have varying widths.

[0011] In another aspect, the method further comprises moving the mold to place each of the first and second composite plies in position on the mold.

[0012] In another aspect, the method further includes introducing a custom composite ply between adjacent ones of the first composite ply and the second composite ply, the custom composite ply being of a different type than either the first composite ply or the second composite ply.

[0013] In another aspect, the method further includes individually orienting each of the first and second composite plies on a transport medium and transferring each of the first and second composite plies to the mold while each of the first and second composite plies is supported by the transport medium.

[0014] One aspect relates to a method for manufacturing a composite member comprised of a plurality of composite plies, comprising: introducing composite plies onto a carrier member in a predetermined linear sequence from a plurality of supply stations, each supplying a different type of composite ply; moving each of the composite plies along the carrier member in the predetermined linear sequence; individually orienting each of the composite plies relative to one or more reference points; transferring each of the composite plies to a mold spaced from the carrier member when it reaches a predetermined position; and molding the composite ply on the mold.

[0015] In another aspect, the method further includes introducing a first composite ply of a first type of the composite plies from a first one of the supply stations and introducing a second composite ply of a different second type of the composite plies from a second one of the supply stations located downstream from the first supply station along the conveying member.

[0016] In another aspect, the method further includes cutting each of the composite plies at a respective one of the supply stations before introducing the composite plies into the conveying member, the composite ply from a first one of the supply stations including a leading edge aligned at a different angle than the composite ply from the second one of the supply stations.

[0017] In another aspect, the method further comprises orienting each of the composite plies on the carrier member prior to transferring the composite plies to the mold.

[0018] In another aspect, the method further comprises moving each of the composite plies along the conveying member to a support member located downstream from the supply station, and individually orienting each of the composite plies on the support member before transferring the composite plies to the mold.

[0019] In another aspect, the method further comprises moving the support member into the mold while supporting the composite ply.

[0020] In another aspect, the method further comprises shaping two or more of the composite plies to different widths at each of the feeding stations prior to introducing the composite plies into the carrier member.

[0021] One aspect relates to a system for manufacturing a composite part from a plurality of composite plies, including different types, including a conveying member, a mold spaced from the conveying member, and a plurality of feeding stations arranged along the conveying member, each of the feeding stations configured to shape a blank into one of the composite plies of a predetermined type different from the composite plies formed at the other feeding stations and introduce the composite ply into the conveying member, a transfer station located downstream of the conveying member and the plurality of feeding stations, the transfer station including a support member having a support surface that supports and transfers the composite ply from the conveying member to the mold, and one or more formers disposed at the mold to shape the composite ply on the mold.

[0022] In another aspect, the plurality of feeding stations shapes blanks at various positive and negative front angles.

[0023] In another aspect, the plurality of feeding stations are arranged on a first plane, the first plane being positioned vertically above the one or more molding machines, which are positioned on a second plane.

[0024] In another aspect, the method further includes a transport medium including a support surface that receives one of the composite plies, the transport medium being movable along the conveying member before reaching the transfer station.

[0025] In another aspect, the transfer station includes a robotic device with a vacuum that grasps each of the carrier media and transfers the carrier media to the mold.

[0026] The above-described features, functions, and advantages may be realized individually in various embodiments or may be combined with one another in other embodiments, and further details will become apparent by reference to the following description and drawings. [Brief explanation of the drawings]

[0027] [Figure 1] 1 is a schematic diagram of a system for manufacturing a composite member. [Figure 2] FIG. 1 is a schematic diagram of one type of composite ply. [Figure 3] FIG. 1 is a schematic diagram of one type of composite ply. [Figure 4] FIG. 1 is a schematic diagram of one type of composite ply. [Figure 5] FIG. 1 is a schematic diagram of one type of composite ply. [Figure 6] 1 is a schematic diagram of a system for manufacturing a composite member. [Figure 7] FIG. 2 is a schematic diagram of a portion of a transfer station. [Figure 8] FIG. [Figure 9] FIG. 1 is a schematic diagram of composite plies laid up in a mold. [Figure 10] FIG. 1 is a schematic view of a molding machine. [Figure 11] FIG. 2 is a schematic diagram of a system controller. [Figure 12] 1 is a flow chart of a method for manufacturing a composite member. [Figure 13]1 is a schematic diagram of a system for manufacturing a composite member. [Figure 14] 1 is a schematic diagram of a system for manufacturing a composite member. [Figure 15] 1 is a schematic diagram of a system for manufacturing a composite member. [Figure 16] 1 is a schematic diagram of a system for manufacturing a composite member. [Figure 17] 1 is a schematic diagram of a system for manufacturing a composite member. [Figure 18] 1 is a schematic diagram of a system for manufacturing a composite member. [Figure 19] 1 is a schematic diagram of a system for manufacturing a composite member. [Figure 20] 1 is a schematic diagram of an aircraft including one or more composite members. [Figure 21] FIG. 1 is a cutaway perspective view of the interior of an aircraft wing. DETAILED DESCRIPTION OF THE INVENTION

[0028] 1 illustrates a system 50 for manufacturing a composite member 1000. The system 50 is configured to move different types of composite plies 75 from a number of different supply stations 200, 300. The composite plies 75 move along a carrier member 100 and are then moved to a mold 600 by a transfer station 500. One or more formers 700 mold the composite plies 75 onto the mold 600. The composite member 1000 is then removed from the mold 600 and subjected to additional processing as needed to complete the structure.

[0029] To form the composite member 1000, composite plies 75 are laid up on the mold 600. The total number, types, and orientations of the composite plies 75 that make up the composite member 1000 are not limited. FIG. 2 shows an example of a composite ply 75. The composite ply 75 is a sheet material (e.g., prepreg) including one or more layers of fibers 76 pre-impregnated with one or more of a thermosetting matrix resin and a thermoplastic matrix resin. In one example, the fibers 76 are oriented mostly parallel to one another (e.g., parallel to the longitudinal direction). In other examples, the fibers 76 may be aligned in various orientations or may be randomly arranged (i.e., unaligned). The composite ply 75 may include one or more layers of fibers 76. In examples including multiple layers, the fibers 76 in different layers may be aligned in the same orientation relative to one another or in different orientations. In another example, the fibers 76 in one or more of the composite plies 75 are woven or knitted to form a fabric.

[0030] The fibers 76 can be formed from a variety of materials, such as aramid, polyolefin, metal, glass, carbon, boron, ceramic, mineral, and combinations thereof. The fibers 76 are pre-impregnated with a thermoset or thermoplastic matrix resin (e.g., prepreg). In another example, the matrix resin includes a hybrid system of both thermoset and thermoplastic. The matrix resin can be formed from a variety of substances, such as acrylic, fluorocarbon, polyamide (PA), polyethylene (PE) such as polyethylene terephthalate (PET), polyester, polypropylene (PP), polycarbonate (PC), polyurethane (PU), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyetherimide (PEI), and other material compositions.

[0031] 2-5 show examples of various types of composite plies 75. As shown in FIG. 2, these various composite plies 75 have opposing end faces 77, 78 and opposing side faces 79. In one example, these end faces 77, 78 are referred to in relation to their movement along the conveying member 100, with the end face 77 referred to as the leading end, the end face 78 referred to as the trailing end, and the side faces 79 referred to as lateral sides. The composite ply 75 has a length L between the end faces 77 and 78 and a width W between the side faces 79. The composite plies 75 may have various shapes and sizes depending on the type.

[0032] The orientation of the fibers 76 within the composite ply 75 may vary. In the example shown in Figures 2, 3, and 4, the majority of the fibers 76 are oriented parallel to the longitudinal direction connecting the end faces 77 and 78 (referred to as a 0° composite ply). Another example is a 90° composite ply 75, as shown in Figure 5, in which the fibers 76 are substantially perpendicular to the longitudinal direction. Other examples include those in which the fibers 76 are aligned at various angular orientations between these types. In a composite ply 75 having multiple layers of fibers 76, the fibers 76 in each layer may be aligned in the same orientation or in different orientations. Additionally, the thickness of each composite ply 75 may vary. For example, the thickness of each composite ply 75 may be approximately 0.0025 to 0.0175 inches, but is not limited to this.

[0033] Different composite plies 75 are dispensed from different supply stations 200, 300. In one example, supply stations 200, 300 dispense different types of composite plies 75. Examples of different types include, but are not limited to, different shapes (e.g., rectangular, parallelogram), different widths, different fiber orientations (e.g., 0°, 90°), different thicknesses, and different constructions (e.g., different fibers and / or resins). Dispensing different types of composite plies 75 from different supply stations 200, 300 improves efficiency. This configuration prevents a single supply station 200, 300 from changing between different composite plies 75, which could slow down the supply process.

[0034] FIG. 6 illustrates a manufacturing system 50 for producing a composite member 1000. The system 50 includes four supply stations 200, 300a, 300b, and 300c that supply composite plies 75 to the carrier member 100. One of the supply stations 200 is aligned with an end of the carrier member 100. In one example, the primary supply station 200 supplies the most frequently used types of composite plies 75. For example, the primary supply station 200 supplies one or more widths of 0° rectangular composite plies 75 (e.g., 60-inch composite plies 75, 30-inch composite plies 75, and 75-inch composite plies 75). In one specific example, the primary supply station 200 supplies three different widths of 0° rectangular composite plies 75.

[0035] Additional supply stations 300a, 300b, 300c are located downstream along the conveying member 100 from the main supply station 200. These additional supply stations 300a, 300b, 300c supply different types of composite plies 75 than the main supply station 200. In one example, each supply station 300a, 300b, 300c supplies a different type of composite ply 75. One or more of the additional supply stations 300a, 300b, 300c may supply composite plies 75 of different widths.

[0036] In one example, one or more of the feed stations 200, 300 includes a cutter 101 for cutting the composite ply 75 to a desired shape and size. The cutter 101 includes one or more blades that cut the composite ply 75. In one embodiment, the cutter 101 is a guillotine-style cutter. The stations 200, 300 may further include a table 103 having a support surface for placing the composite plies 75 to be cut. In one example, a roll of composite material is placed at the feed stations 200, 300. The roll is spread across the table 103 and cut by the cutter 101 to form the composite plies 75. Once cut, the composite plies 75 are introduced into the conveying member 100. The feed stations 200, 300 may further include a relatively small conveying member 102 for moving the cut composite plies 75 to the conveying member 100. In another example, the composite plies 75 are stored in the feed stations 200, 300 already cut. These cut composite plies 75 are then moved to the conveying member 100 by the feed stations 200, 300.

[0037] The composite plies 75 may be cut to the desired shape and / or size at the supply stations 200, 300. This prevents and / or reduces the generation of waste composite material that would otherwise occur if the composite plies 75 were not prepared until they reached the mold 600.

[0038] In one example, the composite material includes a backing used to control the dispense length, and the table 103, conveying member 102, or other structure is configured to remove the backing before the composite ply 75 reaches the conveying member 100.

[0039] As shown in Figure 6, the various supply stations 200, 300 can be aligned at various orientations relative to the conveying member 100. Figure 6 shows supply station 200 aligned with the conveying member 100 (i.e., at a 0° angle), supply station 300a at a 90° angle, supply station 300b at a 45° angle, and supply station 300c at a -45° angle.

[0040] The conveying member 100 functions to move the composite plies 75 from each of the supply stations 200, 300 to the transfer station 500. The conveying member 100 may include a support surface, such as a conveyor, on which the composite plies 75 are placed. In another example, the composite plies 75 are first transferred to a transport medium, such as a tray or sheet, which is then moved by the conveying member 100. In one example, the composite plies 75 are oriented and placed on the conveying member 100 after exiting the supply stations 200, 300. In another example, the composite plies 75 are simply moved by the conveying member 100 to be oriented at a downstream location.

[0041] In one example, shown in FIG. 6 , the conveying member 100 includes a belt 105. The belt 105 directly supports the composite ply 75 as it moves along its length, or indirectly supports the composite ply 75 via support members. To adequately support the composite ply 75, the belt 105 may be rigid, for example. In one example, the belt 105 includes apertures, and a vacuum source 106 applies a vacuum to maintain the composite ply 75 in contact with the belt 105. The conveying member 100 may come in a variety of lengths and shapes. In one specific example, the conveying member 100 is a plank-type conveyor.

[0042] Sensors 405 are positioned along the supply stations 200, 300 and the conveying member 100. The sensors 405 configure the system controller 400 (see FIG. 11 ) for monitoring and controlling the movement of the composite plies 75. In one example, the sensors 405 include one or more cameras or recording devices that detect the leading edge 77 and / or trailing edge 78 of the composite plies 75. In another example, the sensors 405 include a servo motor controller attached to the motor that drives the conveying member 100. The system controller 400 can maintain a positive registry of the composite plies 75 as they move through the system 50. For each composite ply 75, the registry includes: , for example, orientation, type, initial position, current position, and travel path. In the case of a transport medium, the medium has a positive registry position, allowing the medium to be rapidly transported between stations and ultimately to the mold 600 .

[0043] The transfer station 500 is located downstream from the conveying member 100 and receives the composite ply 75 from the conveying member. As shown in FIG. 6 , the transfer station 500 includes a first reference point 503 disposed near the conveying member 100 and a second reference point 513 disposed near the mold 600. The reference points 503 and 513 are reference points for aligning the support member 501 that supports the composite ply 75. In one example, the first reference point 503 and the second reference point 513 include one or more pins that extend upward and are positioned to be inserted into corresponding openings 507 in the support member 501. In another example, the reference points 503 and 513 include one or more edges that abut against and position the support member 501. In one example, the reference points 503 and 513 are the same (e.g., each is composed of a pair of pins). In another example, the reference points 503 and 513 are different.

[0044] The transfer station 500 further includes the support member 501 and a movable support surface 502. In one example, the support member 501 is positioned immediately downstream of the conveying member 100, allowing the composite ply 75 to move directly from the conveying member 100 to the support surface 502. In another example, as shown in FIG. 6 , a movable support member 504 extends between the conveying member 100 and the support surface 502 to transfer the composite 75 to the support surface 502. The movable support member 504 may be, for example, a motorized belt or roller, or a surface that slides the composite ply 75 onto the support surface 502.

[0045] 6 and 7, the support member 501 extends around the periphery of the support surface 502. In one example, the support member 501 extends around the entire support surface 502. In other examples, the support member 501 may extend around a portion of the support surface 502 or may be located below the support surface 502. One or more openings 507 extend through the support member 501 to provide for engagement with the reference points 503, 513.

[0046] The support surface 502 is sized to receive and support one of the composite plies 75. In one example, the support surface 502 is relatively flat to contact and support the composite ply 75. One or more openings may be provided in the support surface 502 and connected to a vacuum source 505 to apply a vacuum and maintain the position of the composite ply 75. The support surface 502 is further configured to be adjustable relative to the support member 501. The adjustment of the support surface 502 is achieved by a motor 506. This adjustment may position the composite ply 75 in a predetermined position. A scanner 508, including one or more cameras, scans the composite ply 75 while it is on the support surface 502. One or more additional sensors 405 may be positioned in the transfer station 500 to detect the position of the support surface 502 and / or the composite ply 75.

[0047] Transfer station 500 is further configured to transfer support member 501 and support surface 502 supporting composite ply 75 from carrier member 100 to mold 600. In one example, as shown in FIGS. 6 and 7 , rails 515 extend between carrier member 100 and mold 600. Support member 501 includes a receptacle 516 configured to engage rail 515 and move support member 501 from carrier member 100 to mold 600. In another example, a robotic arm engages and moves support member 501.

[0048] In use, one composite ply 75 is transferred from the carrier member 100 to the support surface 502. Composite ply 75 may be transferred directly to support surface 502, or, if transferred by a transport medium, may be transferred while still resting on the transport medium. Composite ply 75 is aligned with reference point 503. Once aligned, composite ply 75 is transferred to mold 600.

[0049] The mold 600 is shaped and sized to correspond to the forming surface of a desired composite member 1000, such as an airplane wing stringer or other primary or secondary structure, i.e., a Z-beam, I-beam, hat stiffener, C-channel, J-stiffener, blade stiffener, floor beam, rib, frame, or spar. While molds 600 come in a variety of shapes and sizes, the present disclosure is particularly applicable to elongated molds 600. For example, in an aircraft wing, a mold 600 for a stringer can be up to 130 feet or longer in length.

[0050] As shown generally in Figure 8, mold 600 is mounted on a mold table 602 configured to move along a forming lane 601. Mold table 602 is movable along a pair of rails 603, which allow mold 600 to be moved to sequentially place a series of composite plies 75 at various spanwise locations along mold 600. Rails 603 may be attached to a work site or other surface. In one example, rollers 604 extend from the bottom or sides of mold table 602 and contact and ride on rails 603.

[0051] In one example, rail 603 has a discontinuous length. Mold table 602 moves back and forth along rail 603. In another example, rail 603 is formed as a continuous loop. Mold table 602 moves repeatedly in one direction around the loop.

[0052] Mold 600 moves along forming lane 601 to receive composite plies 75 from transfer station 500. In one example, mold 600 initially receives composite plies 75 with a first end positioned at transfer station 500. Mold 600 then receives additional composite plies 75 end-to-end by moving sequentially through transfer stations 500. Continuing this process, multiple courses of composite plies 75 can be laid spanwise as mold 600 with the first course of material moves end-to-end along forming lane 601. Additional composite plies 75 can be laid on top of previously laid plies in the manner described above until the desired ply stacking arrangement is achieved.

[0053] FIG. 9 schematically illustrates an example mold 600 shaped to correspond to a desired composite part. The mold 600 has a top surface 605 and side surfaces 606. In one example, the mold 600 is configured to translate back and forth, as indicated by arrow X. In another example, the mold 600 moves in a loop. In these various examples, a first composite ply 75a is placed at the end of the mold 600. The first composite ply 75a extends over a portion of the top surface 605 and over the side surfaces 606, including the end surfaces and opposing sides. The mold 600 is sequentially moved so that additional composite plies 75b-75e are sequentially placed end-to-end along the mold 600. In one example, adjacent composite plies 75 overlap only a limited amount. In another example, adjacent composite plies 75 abut without overlap. FIG. 9 illustrates composite plies 75 partially laid along the mold 600. Continuing the process, additional composite plies 75 are placed along the remaining length of mold 600. Once this is complete, one or more additional layers of composite plies 75 can be laid up in whole or in one or more sections. Sensors 405 can be positioned to detect the number and placement of composite plies 75 on mold 600.

[0054] One or more molding machines 700 mold the composite plies 75 on the mold 600. The molding machine 700 includes one or more arms, each having a contact surface that contacts the composite plies 75 and applies a mechanical force to them. Figure 10 shows an example of a molding machine 700. The molding machine 700 straddles a molding lane 601 along which the molding machine 600 travels. In one example, the one or more molding machines 700 are fixed in place, and the molding machine 600 travels along the molding lane 601 relative to the molding machine 700.

[0055] The molding machine 700 may include one or more support members 701 including legs 702 and one or more cross braces 703. The legs 702 are spaced apart and positioned on either side of the forming lane 601. A shroud 704 extends below the support members 701 and includes an interior space 705 that accommodates the forming mold 600. The shroud 704 is configured to surround and / or extend at least partially around the forming mold 600. In one example, as shown in FIG. 10 , the shroud 704 has a substantially U-shaped cross-sectional shape. The shroud 704 may be formed to be rigid or at least substantially rigid, for example, from any suitable material. An engagement member 708 may maintain and position the shroud 704. The engagement member 708 may include one or more of a screw jack, a linear actuator, a motor, an electric motor, or a pneumatic motor.

[0056] A force applicator 706 is disposed within shroud 704 and is configured to apply a force to cause composite ply 75 to conform to mold table 602. In one example, force applicator 706 is an inflatable bladder. In another example, force applicator 706 is an inflatable bladder. In this case, force applicator 706 includes a mechanical arm with a contact member at its distal end that contacts and applies a force to composite ply 75. Sensor 405 is positioned to detect and adjust the amount of force applied by force applicator 706.

[0057] In one example, the force applicator 706 directly contacts the top composite ply 75. In another example, an intermediate film is placed on top of the top composite ply 75. In such a case, the force applicator 706 directly contacts the intermediate film and indirectly contacts the composite ply 75. Examples of intermediate films include, but are not limited to, contact films, release films, fluoropolymer films, etc.

[0058] In one example, the former 700 forms a single layer of composite ply 75 on the mold 600. In another example, multiple layers of composite plies 75 are laid up on the mold 600 to form multiple layers. The former 700 is configured to apply pressure to each of the multiple layers of composite plies 75 to conform to the mold 600. This may include, for example, forcing at least two or more of the stacked composite plies 75 against the mold 600 simultaneously.

[0059] The former 700 may maintain pressure on the composite ply 75. Examples of threshold pressure differentials include less than 5 kilopascals (kPa), less than 10 kPa, less than 15 kPa, less than 20 kPa, less than 25 kPa, less than 30 kPa, less than 50 kPa, or less than 75 kPa.

[0060] The molding machine 700 may further include one or more heaters 709 for heating the composite ply 75 while pressure is being applied. Heating the composite ply 75 may occur prior to molding the composite ply 75 on the mold 600. Heating may allow the composite ply 75 to conform more readily to the mold 600 than a composite ply 75 at ambient or room temperature. Heating may be accomplished using infrared lamps, conventional light bulbs, or other known heating techniques. Depending on the composition of the composite ply 75, temperatures may be increased to approximately 200°F or less. The temperature of the composite ply 75 can be measured in any conventional manner, such as by attaching a thermocouple.

[0061] Some or all of the functions of the system 50 may be controlled by a system controller 400. The system controller 400 communicates with the various components and manages the operation of the composite member 1000. The system controller 400 may be housed in a cabinet or the like some distance away from the components. In another example, the system controller 400 is housed in one of the components.

[0062] 11, the system controller 400 includes processing circuitry 401, which may include one or more microprocessors, microcontrollers, and ASICs with appropriate software and / or firmware. Memory circuitry 402 stores data and computer-readable program code that configures the control circuitry to implement the techniques described above. Memory circuitry 402 is a non-transitory computer-readable medium and may include a variety of storage devices, such as random access memory, read-only memory, flash memory, etc.

[0063] The system controller 400 may further include a communications interface 403 for transmitting data to and receiving data from the components. The communications interface may provide communication via a cable system with various cables extending between elements. The cables are configured to carry various data signals. In some designs, the systems communicate via a LAN, while in other designs, they communicate via a communications bus. The communications interface 403 may also provide wireless communication, such as a Bluetooth interface or a Wireless Local Area Network (WLAN) interface. In some cases, cabled and wireless communication are combined.

[0064] The user interface 404 includes one or more user input devices, such as a keypad, touchpad, function keys, a scroll wheel, or other type of computer input device. The user interface 404 may also include a display screen, such as a conventional liquid crystal display (LCD) or a touchscreen display that also functions as a user input device. The user interface 404 allows an operator to control the functions of various components in communication with the system controller 400.

[0065] One or more sensors 405 may detect the position of the composite ply 75 as it moves through the system 50. The sensors 405 may also detect the operating state of one or more of the components. Various types of sensors may be used, such as cameras, thermal sensors, motion sensors, etc. Scanners 508 may be located at the transfer station 500 to capture the orientation of the composite ply 75. FIG. 11 schematically illustrates the sensors 405 and scanners 508 included in the system controller 400. One or more of the sensors 405 and / or scanners 508 may be part of an associated component and may communicate with the system controller 400 via the communication interface 403.

[0066] 12 illustrates a method for manufacturing a composite member 1000 from composite plies 75. The method includes introducing a first type of composite ply 75 from a supply station 200 onto a carrier member 100 (block 150). Another second type of composite ply 75 is introduced from one or more of the other supply stations 300 (block 152). The first and second composite plies 75 are then oriented on the carrier member 100 (block 154). Orientation can occur when the composite ply 75 is placed on the carrier member 100 at the supply stations 200, 300, or on a support surface 502 at a transfer station 500. In one example, the composite ply 75 is placed and oriented on a carrier member, and the carrier member is then oriented. The composite plies 75 are then moved through the system 50 while still mounted. In another example, the composite plies 75 are placed directly onto the carrier member 100. The composite plies 75 are then individually transferred to the mold 600 (block 156). The composite plies 75 are then molded on the mold 600 (block 158).

[0067] A more detailed method can be employed in combination with the system 50 shown in Figure 6 and controlled by a system controller 400. The system controller 400 controls the supply of composite plies 75 from supply stations 200, 300a, 300b, and 300c to the conveying member 100 in a predetermined order. For example, a first type of composite ply 75 is supplied from supply station 200, followed by a second type of composite ply 75 from supply station 300a, followed by a third type of composite ply 75 from supply station 300c.

[0068] In one example, composite plies 75 are placed and oriented on a transport medium, remain oriented on the transport medium while traveling through system 50, and are transferred at some downstream point.

[0069] Once dispensed from the supply stations 200, 300a, 300b, 300c, the composite plies 75 are then moved by the conveying members away from the supply stations 200, 300a, 300b, 300c to the transfer station 500. The orientation and position of the composite plies 75 can be monitored by the system controller 400 via sensors 405 positioned along the supply stations 200, 300a, 300b, 300c and the conveying members 100.

[0070] At transfer station 500, each composite ply 75 is individually moved onto support surface 502. Composite plies 75 are scanned on support surface 502 by scanner 508. If necessary, composite plies 75 are reoriented to align composite plies 75 with one or more reference points 503. Once aligned, transfer station 500 moves composite plies 75 to mold 600. Support surface 502 is aligned with one or more reference points 513 to maintain the desired orientation of composite plies 75. Composite plies 75 are then placed into mold 600. Prior to placement, mold 600 is positioned along forming lane 601 to receive composite plies 75.

[0071] A plurality of composite plies 75 are oriented, transported, and placed on the mold. Once the desired number of composite plies 75 have been placed on mold 600, mold 600 is moved along forming lane 601 to position composite plies 75 on former 700. Former 700 forms composite plies 75 onto the mold into the desired shape.

[0072] System 50 may further include a custom feed station 800, as shown in FIG. 6, to accommodate custom composite plies 75 that are not supplied by one of the other feed stations 200, 300. For example, the custom composite plies 75 may have different shapes, sizes, or configurations. Custom feed station 800 may include one or more of a cutter 801, a conveying member 802, and a table 803. In one example, the composite plies 75 from custom feed station 800 are manually transferred to transfer station 500 or placed directly into mold 600. In another example, custom feed station 800 includes a loading mechanism 804, such as a conveyor or gripper (e.g., vacuum or mechanical finger gripper), for moving the composite plies 75 to transfer station 500 or directly to mold 600.

[0073] System 50 may also be configured with additional components and / or different configurations. FIG. 13 shows a cross-sectional view of a composite ply 75 being moved to transfer station 500. 1. System 50 is shown having a custom feed station 800 arranged as follows: Custom feed station 800 includes a support table 803 that translates or rotates to orient composite plies 75 before moving them to transfer station 500.

[0074] 14 illustrates system 50 in which supply stations 200, 300a, 300b, and 300c supply a pair of molds 600a and 600b. Supply stations 200, 300a, 300b, and 300c move composite plies 75 to a carrier member 100. A first transfer station 500a receives the composite plies 75 and transfers them to a first mold 600a. Some of the composite plies 75 travel, still on carrier member 100, past first transfer station 500a and to a second transfer station 500b. These composite plies 75 are then transferred to a second mold 600b via second transfer station 500b. An advantage of this system 50 is that a worker or group of workers can be positioned at the supply stations 200, 300a, 300b, 300c to supply composite plies 75 to two different molds 600a, 600b.

[0075] 15 illustrates a system 50 in which multiple supply stations 200, 300 supply various types of composite plies 75 to a conveying member 100. In one example, supply station 200 supplies various widths of composite plies 75 having a first structure. Supply station 300 supplies different types of composite plies 75. In one example, different supply stations 300 supply both 30 inch and 60 inch broad goods of different sizes and shapes. System 50 of FIG. 15 allows for the production of various types of composite plies 75 in a single work area. This allows a user to replenish supply station 200 with different composite materials. System 50 of Figure 15 can be doubled as shown in Figure 16 to allow supply to two separate conveying members 100 from a single work station.

[0076] FIG. 17 illustrates a system 50 in which a custom feed station 800 feeds customized composite plies 75 to a carrier member 100 .

[0077] In one example, as shown in FIG. 6, the composite ply 75 is placed directly on the conveying member 100 and moved from the supply stations 200, 300 to the transfer station 500. In another example, as shown in FIG. 18, the composite ply 75 is placed on a conveying medium 900 and moved. The composite ply 75 is removed from the supply station 200 and aligned on the conveying medium 900. The example of FIG. 18 includes a single supply station 200. Other examples may include multiple different supply stations 200, 300 capable of supplying different types of composite plies 75. The conveying medium 900 and composite ply 75 are moved along the conveying member 100 to the transfer station 500. The transfer station 500 includes a robotic device 520 having a movable arm 521 and a gripper 522 at its distal end. The gripper 522 may include one or more vacuum openings. The robotic device 520 is movable from a first position, where the grippers 522 engage the surface of the carrier medium 900, to a second position on the mold 600. In the second position, the robotic device 520 aligns the carrier medium 900 with the mold 600. The composite ply 75 is then removed from the carrier medium 900 and placed in the mold 600. In one example, a vacuum from the robotic device 520 is used to hold the composite ply 75 on the carrier medium 900. Once the carrier medium 900 is positioned on the mold 600 with slight pressure, the vacuum is released and the composite ply 75 is placed on the mold 600.

[0078] 18, after the composite plies 75 are transferred, the transport medium 900 is loaded onto a handling system 950. The handling system 950 moves the transport medium 900 back to the start of the conveying member 100 and the process is repeated.

[0079] In one example, system 50 includes various components (e.g., carrier member 100, supply stations 200, 300, mold 600) arranged in the same plane, along which composite ply 75 moves during the manufacturing process. In another example, one or more of the components are arranged in a different plane, thereby reducing the size of the work area and the travel distance of composite ply 75 as it moves between the various components.

[0080] FIG. 19 schematically illustrates system 50 with components arranged in multiple different planes 349, 350. In this example, feed stations 200, 300, each including one or more cutters 101, are arranged in a second plane 350 elevated above first plane 349 by support members 351. Composite plies 75 of a desired shape and size are cut and transferred to transfer station 500. In one example, each of composite plies 75 is cut while in first plane 349. In another example, one or more of composite plies 75 are already in the desired shape and / or size and are not cut while in first plane 349. Transfer station 500 moves composite plies 75 vertically from second plane 350 to first plane 349. Composite plies 75 are placed on mold 600 and then formed by former 700.

[0081] In another example, the supply stations 200, 300 include cutters 101 for cutting the composite plies 75 to a desired shape and size. The composite plies 75 are then transferred from the supply stations 200, 300 to a transfer station 500.

[0082] These various systems 50 overcome problems with prior art designs. The system 50 allows a user to have a workspace within the area where they are working that occupies a small portion of the overall system 50. The workspace is separate from other equipment that is part of the system 50, allowing the operator to work closer to the equipment they need to operate as part of the process. For example, a user may be located at one or more of the supply stations 200, 300 to cut or place composite plies 75 onto the carrier member 100 while remaining remote from the transfer station 500, mold 600, and former 700.

[0083] The components included in system 50 are relatively small compared to more complex machines. System 50 components have relatively low mass, limited functionality, and a small machine envelope. This allows for safer and higher process density, including the number of workers and machines in a given area. It also allows for an increased number of parallel operations occurring at any one time, thereby increasing process density (process equipment or personnel per square foot of area) and product density (the number of value-added operations on a product at any one moment). The reduction in workspace, simplification and miniaturization of equipment and processes, and the number of parallel operations, combined with increased process density and product density, create a step change in productivity.

[0084] In one example, many of the operations are automated, thereby reducing the number of personnel required to operate the system 50. In one specific example, personnel operate one or more supply stations 200, 300 to supply composite plies 75. The remaining operations are automated and can be performed without active human involvement.

[0085] The system 50 and method can be used to manufacture a wide variety of composite members 1000, including composite members for various components of a vehicle, such as the aircraft 250 shown in Figure 20. Examples include, but are not limited to, one or more components of a fuselage 251 and wings 252.

[0086] 21 , wing 252 includes a plurality of stringers 742, which extend, for example, along the length of the wing. Wing 252 may also include ribs, also referred to herein as spars 254. Stringers 742 and spars 254 may together form and / or comprise at least a portion of the inner support structure of wing 252, which may support the inner surface of skin portion 255. Composite member 1000 manufactured by the methods and systems disclosed herein may be used to manufacture one or more of skin portion 255, stringers 253, and spars 254.

[0087] Other types of vehicles that may include composite member 1000 include, but are not limited to, unmanned aerial vehicles, manned spacecraft, unmanned spacecraft, manned rotorcraft, unmanned rotorcraft, satellites, rockets, missiles, manned ground aircraft, unmanned ground aircraft, manned surface aircraft, unmanned surface aircraft, manned underwater aircraft, unmanned underwater aircraft, and combinations thereof.

[0088] When the term "substantially" is used in reference to a quantity or measurement, it means that the stated characteristic, parameter, or value need not be achieved exactly. For example, deviations and variations based on tolerances, measurement errors, measurement accuracy limits, and other factors known to those skilled in the art may occur to the extent that they do not eliminate the effect that is intended to be achieved by the characteristic.

[0089] The present invention may be practiced otherwise than as specifically set forth herein without departing from its essential characteristics. The described embodiments are to be considered in all respects as illustrative and not restrictive, and all changes which come within the meaning and range of equivalency of the appended claims are intended to be embraced.

Claims

1. 1. A method of manufacturing a composite member comprised of a plurality of composite plies, comprising: introducing a first composite ply including a first type from a first supply station onto a carrier member; introducing second composite plies onto the conveying member from one or more second supply stations spaced along the conveying member from the first supply station, the second composite plies from the second supply stations comprising a type different from the first type; orienting the first and second composite plies on the carrier member; transferring each of the first and second composite plies individually to a mold; forming the first and second composite plies on the mold.

2. 2. The method of claim 1, wherein orienting the first and second composite plies comprises transferring the first and second composite plies from the carrier member onto a support surface of a first support member, and individually orienting each of the first and second composite plies relative to one or more reference points on the support member.

3. 3. The method of claim 1 or 2, further comprising cutting one or more of the first and second composite plies on a first plane and then vertically transferring the first and second composite plies onto a second plane before forming the composite plies on the mold.

4. 4. The method of claim 1, further comprising: prior to introducing each of the first composite ply and the second composite ply into the carrier member, cutting the first composite ply at the first supply station and cutting the second composite ply at the one or more second supply stations.

5. The method of any one of claims 1 to 4, wherein the composite plies introduced from the first supply station have varying widths.

6. The method of any one of claims 1 to 5, further comprising moving the mold to place each of the first and second composite plies in a predetermined position on the mold.

7. 7. The method of claim 1, further comprising introducing a custom composite ply, the custom composite ply being of a type different from both the first composite ply and the second composite ply, between adjacent ones of the first composite ply and the second composite ply.

8. 8. The method of claim 1, further comprising orienting each of the first and second composite plies individually on a transport medium, and transferring each of the first and second composite plies to the mold while each of the first and second composite plies is supported by the transport medium.

9. 1. A method of manufacturing a composite member comprised of a plurality of composite plies, comprising: introducing the composite plies into the carrier member in a predetermined sequence from a plurality of supply stations, each supplying a different type of composite ply; moving each of the composite plies along the conveying member in the predetermined in-line sequence; individually orienting the composite plies relative to one or more reference points; transferring each of the composite plies to a mold spaced from the carrier member when the composite ply reaches a predetermined position; forming the composite ply on the mold.

10. 10. The method of claim 9, further comprising introducing a first composite ply of a first type of the composite plies from a first one of the supply stations and introducing a second composite ply of a different second type of the composite plies from a second one of the supply stations located downstream from the first supply station along the conveying member.

11. 11. The method of claim 10, further comprising cutting each of the composite plies at a respective one of the supply stations prior to introducing the composite plies into the carrier member, the composite ply from a first one of the supply stations including a leading edge aligned at a different angle than the composite ply from the second one of the supply stations.

12. 12. The method of claim 10 or 11, further comprising moving each of the composite plies along the conveying member to a support member located downstream from the supply station, and individually orienting each of the composite plies on the support member before transferring the composite plies to the mold.

13. The method of claim 12 further comprising moving the support member into the mold while supporting the composite ply.

14. The method of any one of claims 9 to 13, further comprising orienting each of the composite plies on the carrier member before transferring the composite plies to the mold.

15. 15. The method of any one of claims 9 to 14, further comprising shaping two or more of the composite plies to different widths at respective feeding stations before introducing the composite plies into the carrier member.

16. 1. A system for manufacturing a composite component from a plurality of composite plies, including different types, comprising: A conveying member; a molding die spaced from the conveying member; a plurality of feeding stations disposed along the conveying member, each of the feeding stations configured to form a blank into one of the composite plies of a predetermined type different from the composite plies formed at the other feeding stations and to introduce the composite ply onto the conveying member; a transfer station located downstream of the conveying member and the plurality of supply stations, the transfer station including a support member having a support surface for supporting and transferring the composite ply from the conveying member to the mold; and one or more forming machines positioned on the mold to form the composite plies on the mold.

17. The system of claim 16 , wherein the plurality of feeding stations shapes blanks at a variety of positive and negative front angles.

18. 18. The system of claim 16 or 17, wherein the plurality of supply stations are arranged on a first plane, the first plane being positioned vertically above the one or more molding machines positioned on a second plane.

19. and a conveying medium including a support surface for receiving one of the composite plies, the conveying medium being movable along the conveying member before reaching the transfer station.

19. The system according to any one of 16 to 18.

20. 20. The system of claim 19, wherein the transfer station includes a robotic device with a vacuum, the robotic device gripping each of the carrier media and transferring the carrier media to the mold.

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