Zone lamination of composite material components along traffic flow

Abstract

To provide systems and methods for fabricating composite parts.SOLUTION: The method includes subdividing a laminate into zones, laying up tows of fiber reinforced material for the laminate over a layup mandrel via multiple laminations such that each lamination head applies tows to a different zone, and splicing the zones together to form the laminate during the laying up of the tows.SELECTED DRAWING: None

Description

Technical Field

[0001] The present disclosure relates to the field of aircraft, and more particularly to the manufacture of aircraft components.

Background Art

[0002] Relatively large composite parts, such as those spanning dozens of feet, occupy a large amount of space within a factory. Laminates for such parts are laid up on a layup mandrel within a stationary work cell, and an automated fiber placement (AFP) machine equipped with a large end effector for a large robotic arm advances the addition of fiber reinforcement materials one tow at a time. One AFP machine alone traverses the entire part according to an optimized layup pattern.

[0003] U.S. Patent Application Publication No. 2010 / 193103 states in its abstract that a composite laminate is laid up by using a plurality of independently controlled tape-laying vehicles to apply composite tape courses having different configurations on different sectors of a tool surface.

[0004] Patent Document EP 3 173 218A1 states in its abstract that an apparatus for manufacturing a fiber composite component is described, which includes a profiling tool and a plurality of mechanically independent deposition units each designed to deposit a fiber material on the profiling tool, and these deposition units each have a control device designed to control each deposition unit to automatically interact with at least one further deposition unit for the common deposition of a predetermined fiber configuration.

[0005] According to its abstract, Patent Document DE 10 2010 015027 describes an apparatus having a tool for laying a fiber mat and a closed rail system surrounding the tool. Two robots are movably guided by the rail system and have laying heads designed to lay the fiber mat. A rotating device moves the robots between rail sections. Non-contact contour detectors are positioned to detect the contours of the fiber mat and / or fiber composite molding blanks. The rail sections surround angles of less than 150 degrees.

[0006] According to its abstract, Patent Document EP 3 406 431 describes a system and method for laying up laminates. More specifically, the method includes laying up a multilayer laminate of fiber-reinforced material on a surface by supplying a tape of fiber-reinforced material to a tape cutter that cuts the tape into multiple small pieces; picking up pieces of fiber-reinforced material using a pick-and-place device in each of a plurality of laminate units that are continuous in the direction of travel; and arranging the pieces of fiber-reinforced material using the pick-and-place device to form a laminate as a surface, wherein the laminate units are positioned relative to each other and the multiple pieces are laid up simultaneously. [Overview of the project]

[0007] Therefore, current technologies for manufacturing large composite components require a significant amount of time for the layup mandrel to be marked and then the laminate to be laid up. Thus, it would be desirable to obtain methods and apparatus that address at least some of the aforementioned problems, as well as other potential problems.

[0008] Embodiments described herein provide zone-based lamination achieved using multiple lamination heads. By dividing the laminate into zones and assigning these zones to different lamination heads operating in tandem, the overall manufacturing speed is increased. Furthermore, the layup mandrel moves forward in the processing direction during manufacturing (for example, by periodically "pulsing" in the processing direction, or by moving continuously in the processing direction), improving the factory flow. That is, the time it takes for the composite parts to pass through can be used to perform work on the composite parts, thereby increasing efficiency.

[0009] One embodiment is a method for manufacturing a composite component. This method includes dividing a laminate into zones, laying up tows of fiber-reinforced material for the laminate on a layup mandrel via a plurality of lamination heads such that each lamination head applies tows to different zones, and joining the zones together during the tow layup to form a laminate.

[0010] Further embodiments include a non-transient, computer-readable medium that embodies programmed instructions, which, when executed by a processor, is operable to carry out a method for manufacturing composite components. The method includes subdividing a laminate into zones, laying up tows of fiber-reinforced material for the laminate onto a layup mandrel via a plurality of lamination heads such that each lamination head applies tows to different zones, and joining the zones together during the tow layup to form a laminate.

[0011] A further embodiment is an apparatus for manufacturing composite parts. This apparatus includes a lamination station that allows a lamination head to follow the contour of a layup mandrel moving in a processing direction during the manufacturing of the composite part, the lamination head located in the lamination station being configured to lay up fiber-reinforced material on the layup mandrel, the lamination head being configured to operate in tandem to lay up fiber-reinforced material for a laminate in different zones of the layup mandrel and to join the zones together. In one embodiment, the lamination head operates in tandem to lay up the fiber-reinforced material simultaneously and to join the zones together.

[0012] A further embodiment is a system for manufacturing composite parts. This system includes a track that follows the contour of a layup mandrel that moves in a processing direction during the manufacturing of the composite part, and a lamination station including a lamination head that is movably mounted on the track and configured to lay up fiber-reinforced material on the layup mandrel. The lamination head is configured to operate in tandem to simultaneously lay up fiber-reinforced material for a laminate in different zones of the layup mandrel and to join the zones together.

[0013] Other exemplary embodiments (e.g., methods and computer-readable media relating to the embodiments described above) will be described later. The features, functions, and advantages described above can be realized individually or in combination in various embodiments, and further details of these embodiments can be found in the following description and drawings.

[0014] Hereinafter, several embodiments of the present disclosure are described for illustrative purposes only with reference to the accompanying drawings. In all drawings, the same reference numerals represent the same element or element of the same type. [Brief explanation of the drawing]

[0015] [Figure 1A]This specification shows an aircraft that can be manufactured using composite components produced according to the methods, systems, and apparatus described herein. [Figure 1B] This is a block diagram of a manufacturing environment for laying up laminates to be solidified into composite parts, in an exemplary embodiment. [Figure 2A] This is a flowchart illustrating a method for laying up a laminate in an exemplary embodiment. [Figure 2B] This is a flowchart illustrating a method for selecting the bonding position in a laminate in an exemplary embodiment. [Figure 2C] This is a flowchart illustrating a method for selecting the bonding position in a laminate in an exemplary embodiment. [Figure 2D] This is a flowchart illustrating a method for offsetting the cutouts created for the joint in an exemplary embodiment. [Figure 2E] This is an end view of the joint in a laminate in an exemplary embodiment. [Figure 2F] This shows the overlapping inclined edges between zones in an exemplary embodiment. [Figure 2G] This is an end view of the joint in a laminate in an exemplary embodiment. [Figure 2H] The exemplary embodiment shows overlapping, non-sloping, i.e., straight edges between zones. [Figure 3A] This is a perspective view of a manufacturing environment for laying up a fuselage section in an exemplary embodiment. [Figure 3B] This is a side view of the manufacturing environment shown in Figure 3A, in an exemplary embodiment. [Figure 4A] This is a top view of the ply map of a section of the fuselage in an exemplary embodiment. [Figure 4B] This is a top view of the ply map of the laminated wing panel in an exemplary embodiment. [Figure 5] This is a perspective view of a manufacturing environment for laying up the wing skin in an exemplary embodiment. [Figure 6]A perspective view of a manufacturing environment for laying up an outer wing panel in an exemplary embodiment. [Figure 7] A flowchart of a method for manufacturing and maintaining an aircraft in an exemplary embodiment. [Figure 8] A block diagram of an aircraft in an exemplary embodiment. **DETAILED DESCRIPTION**

[0016] The accompanying drawings and the following description provide specific exemplary embodiments of the present disclosure. Accordingly, those skilled in the art will be able to devise various configurations that, although not explicitly described or illustrated herein, embody the principles of the present disclosure and are included within the scope of the present disclosure. Further, any examples described herein are intended to assist in understanding the principles of the present disclosure and should not be construed as being limited to the specifically described examples and conditions. As a result, the present disclosure is not limited to the specific embodiments or examples described below, but is limited by the claims and their equivalents.

[0017] First, composite parts such as carbon fiber reinforced polymer (CFRP) parts are laid up into a plurality of layers collectively called a preform. The individual fibers within each layer of the preform are aligned parallel to each other, but different layers with different fiber orientations can be used to increase the strength of the resulting composite part along different dimensions. The preform contains a viscous resin that solidifies (e.g., for use in an aircraft) to convert the preform into a composite part. Carbon fibers impregnated with an uncured thermosetting resin or thermoplastic resin are called "prepregs". Other types of carbon fibers include "dry fibers" that are not impregnated with a thermosetting resin, but may include an adhesion promoter or binder. Resin is injected into the dry fibers before curing. In the case of thermosetting resins, curing is a one-way process called curing, and in the case of thermoplastic resins, the resin reaches a viscous form when reheated.

[0018] Referring now to Figure 1A, a diagram of an aircraft in which an exemplary embodiment may be implemented is shown. Aircraft 10 is one embodiment of aircraft 10 formed by a semi-cylindrical section 24 of the fuselage 12.

[0019] In this embodiment, the aircraft 10 has wings 15 and wings 16 attached to a body 38. The aircraft 10 includes an engine 14 attached to wing 15 and an engine 14 attached to wing 16. Each wing 15, 16 has a tip 11 and a root 17. Each wing extends from forward 19 to aft 23.

[0020] The main body 38 has a tail section 18. Horizontal stabilizers 20, 21, and 22 are attached to the tail section 18 of the main body 38.

[0021] The fuselage 12 is manufactured from semi-cylindrical sections 24, where the upper semi-cylindrical section 26 is joined to the lower semi-cylindrical section 28 to form complete cylindrical sections 29-1, 29-2, 29-3, 29-4, and 29-5. The complete cylindrical sections are joined in series to form the fuselage 12.

[0022] Each of the wings 15 and 16 is formed by a wing panel 30 which includes an upper wing panel 32 and a lower wing panel 34 joined together.

[0023] Figure 3A is a perspective view of a manufacturing environment 300 for laying up a semi-cylindrical preform 24-1. In this embodiment, the layup mandrel 110 includes a surface 112 precisely formed to conform to a desired contour 112-1. The layup mandrel 110 also includes machined features 114 to facilitate indexing of the semi-cylindrical preform 24-1 to the over-manufacturing portion 122. The laminate 120 is laid up on the surface 112 as the layup mandrel 110 moves in the processing direction 180. For example, the layup of the semi-cylindrical preform 24-1 is performed by the lamination station 130 between micropulses, during pauses between pulses, or during the continuous movement of the layup mandrel 110. The laminate 120 includes the over-manufacturing portion 122. The excess portion 122 can acquire index characteristics by machining after the laminate 120 has solidified, or it can acquire index characteristics imparted to the excess portion 122 by the surface 112. The excess portion 122 includes the strip shown in Figure 1B along the door cutout area 375 and window cutout area 378 shown in Figure 3B.

[0024] The semi-cylindrical preform 24-1 described above is carried out using a lamination head 134 positioned along a track 132. In one embodiment, the lamination head 134 begins placing tows 124, 124-1 at one radial position and works counterclockwise 65 until it stops. In one embodiment, the lamination head 134 moves in the hoop direction 66 to perform layups in the corresponding zones as the lamination head 134 performs a coordinated sweep in the clockwise 64 or counterclockwise 65 direction (or both directions). In one embodiment, the lamination head 134 starts at one radial position and works clockwise 64 until it stops at the far end. The lamination head 134 can perform multiple passes in this manner and apply multiple tows 124, 124-1 to various fiber orientations. The lamination head 134 then pauses until the next micropulse, pulse, continuous movement of the structure, and clockwise 64 work toward the starting point. The stacking head 134 sweeping in one direction and then returning in the opposite direction is an efficient movement that reduces movement to only what is necessary for positioning the tows 124 and 124-1. A single stacking head 134 can be removed and replaced, and then serviced while such replacements are carried out.

[0025] The considerations provided herein do not limit the requirement that all lamination heads operate simultaneously in the same direction. The zones provided herein allow the lamination head 134 to simultaneously apply layups of different layup orientations and / or patterns. This is particularly important because the different zones will implement different layup requirements in the form of different outer plate thicknesses, different pad-ups, doubling and sacrificial ply inclusions, etc. Therefore, the layup is not necessarily uniform from edge to edge or along the hoop 66 direction.

[0026] Figure 1B is a block diagram of a manufacturing environment 100 for laying up laminates to be solidified into composite parts 55, 55-1 in an exemplary embodiment. The manufacturing environment 100 includes any system, apparatus, or components that can operate to perform laying up the laminates 120 onto the surface 112 of a layup mandrel 110 that moves in a processing direction 180 during manufacturing, utilizing a synchronously movable lamination head. The layup mandrel 110 already has a number of stringers (not shown) positioned in the longitudinal direction 181 within the surface 112 and forming part of the surface. The stringers are located upstream 181-1 of the lamination stations 130, 130-1. The lamination stations 130, 130-1 lay up onto the layup mandrel 110 and the stringers. Surface 112 may form a semi-cylindrical preform 129 (i.e., a semi-cylinder) when viewed from the end, and may define the inner mold line (IML) 121 of the semi-cylindrical preform 129. The diagram shown in Figure 1B shows only the front side of the layup mandrel 110 and the laminate 120. Thus, zone 2 117 is shown in its entirety, zone 1 115 is shown only in part, and the back zone 3 117-1 is not shown. Refer to Figure 3A, which shows zones 1 115, zone 2 117, and zone 3 117-1 drawn by line 319. In this embodiment, the layup mandrel 110 moves along a track 132, such as the transport of the layup mandrel 110 during manufacturing. The layup mandrel 110 may advance in pulses in the processing direction 180, for example, in micropulses less than the length 181-7 of the layup mandrel 110 or pulses corresponding to its entire length 181-7. In such embodiments, the work performed on the layup mandrel 110 may be performed during pauses between pulses. In further embodiments, the layup mandrel 110 advances continuously in the processing direction 180. The layup mandrel 110 defines the contours 113, 113-1 of the semi-cylindrical section 24 and the wing panel 30 (Figure 1A), respectively. In further embodiments, the layup mandrel 110 defines the outer mold line (OML) 521 (Figure 5) of the wing panel 30.

[0027] Lamination stations 130, 130-1 lay up tows 124 of fiber-reinforced material (e.g., carbon fiber reinforced polymer or carbon fiber reinforced plastic CFRP) on a layup mandrel 110 via a plurality of lamination heads 134. In this embodiment, the plurality of lamination heads 134 are arranged along a track 132 (e.g., a shared track), but in further embodiments, the lamination heads 134 do not share a track 132, but each lamination head 134 independently utilizes one track 132 and thus lays up tows from independent tracks. Furthermore, although only one lamination station 130 is shown in the longitudinal region 123, 123-1, a plurality of lamination stations 130, 130-1 or lamination heads 134 may be arranged in the longitudinal direction 181 and perform work simultaneously or in series and synchronously. Furthermore, the lamination heads 134 can be arranged in series and / or parallel in the longitudinal direction 181 and / or circumferentially. Tracks 132 may be provided at different offsets 135 from the layup mandrel 110, and to improve versatility and avoid collisions, particularly in the bonding zones 190, 123-5, tracks 132 and laminating heads 134 may be arranged so that they pass over other tracks 132 and other laminating heads 134. Each laminating head 134 may include an internal actuator or other components (not shown) to facilitate movement across tracks 132, which may move longitudinally 181 relative to the layup mandrel 110 during layup. In one embodiment, tracks 132 are complementary to the contours 113, 113-1 of the layup mandrel 110. During layup, the lamination head 134 operates in tandem, applying tows 124 in a parallel process to lay up zones 1 115, 2 117, and 3 117-1 and / or longitudinal regions 123, 123-1 on the layup mandrel 110 to produce the laminate 120, which is then solidified into a semi-cylindrical compartment preform 24 or wing panel 30. In this embodiment, the visible layer of the laminate 120 includes tows 124-1 at a 45-degree angle, while other layers may include tows 124 arranged in a different fiber orientation than the tows 124, as illustrated in a zero-degree orientation.

[0028] Each lamination head 134 can operate within zones 191, 123-2 that overlap with adjacent lamination heads 134. Bonding zone 190 in overlapping zones 191, 123-2 is carried out in a manner that allows for the formation of bonding zones 190 and 123-5 without the risk of collision between lamination heads 134. The lamination heads 134 cooperate to lay up not only zone 1 115, zone 2 117 and longitudinal regions 123, 123-1, but also bonding portions 392, 394, 395, 392-1, 394-1, 395-1 in bonding zones 190, 123-5 to form a single laminate 120. Furthermore, the lamination heads 134 can move in a specific orientation (e.g., 0°, + / - 45°, 90°, etc.) or can be specialized to lay tows in only one orientation. In one embodiment, different stacking stations 130, 130-1 include different combinations of stacking heads 134. For example, an upstream stacking station 130-1 may include five stacking heads 134, i.e., one stacking head 134 for zone 1 115 and two stacking heads 134 each for zone 2 117 and zone 3, 117-1. A downstream stacking station 130 may include three stacking heads 134, for example, one stacking head 134 for zone 1 115 and one stacking head each for zone 2 117 and zone 3, 117-1. In a further embodiment, the stacking head 134 is used as an end effector (not shown) for a robotic arm that sweeps across the laminate 120 without requiring a track 132. The stacking head 134 is paired with the robotic arm in a one-to-one relationship.

[0029] In this embodiment, the laminate 120 includes an over-manufacturing portion 122, which can receive indicator features such as holes, slots, or pins after being solidified or formed into the laminate 120 by the surface 112 during layup and processing, in order to facilitate the indicator of the composite parts 55, 55-1 to a post-solidification assembly workstation after the composite parts 55, 55-1 have been removed from the layup mandrel 110. Unlike prior art systems that relied on a single integrated AFP machine, the manufacturing environment 100 shown in Figure 1B offers a technological advantage by reducing the size of a single layup area to a smaller area for efficiency, dividing the layup operation into multiple areas between multiple lamination heads 134 and joining the areas together using joints. This allows multiple lamination heads to operate simultaneously and integrate the boundaries between areas using scarves or step overlaps. Furthermore, the multiple stacking head 134 systems described herein facilitate the use of smaller and lighter dedicated stacking heads 134, which are less complex than traditional AFP heads and therefore have less bulk and complexity to operate. This allows the stacking head 134 to move more quickly and accurately, and also improves the reliability and ease of maintenance.

[0030] The lamination head 134 can be designed to perform various movements relative to the layup mandrel 110. For example, the lamination head 134 can move while the layup mandrel 110 is stationary, the layup mandrel 110 can move relative to a fixed lamination head 134, or the movement of the layup mandrel 110 and the lamination head 134 relative to each other can be utilized to facilitate layup.

[0031] Track 132 may include a rigid track having a contour complementary to the layup mandrel 110 and positioned at a known offset O from the indexing unit 136. The indexing unit 136 mates with machined features 114, such as slots, blind holes, holes, and pins, on the layup mandrel 110 to accurately index the layup mandrel 110 to the stacking stations 130, 130-1, but in further embodiments, more stacking stations 130, 130-1 are arranged in the processing direction 180 (i.e., longitudinally 181). In addition, in one embodiment, the pre-autoclave side stacking stations 130, 130-1 include a vacuum bag placement station (not shown), followed by a backing plate placement station (not shown). Another embodiment has a backing plate that performs a dual function of backing plate and vacuum bag. In one embodiment, a stacking station 130 downstream 181-2 of the current stacking station 130-1 includes a single stacking head 134 for performing any desired rework or additional layup. This single stacking head 134 can perform additional layups that were not performed if the stacking head 134 upstream 181-1 is lagging behind. In a further embodiment, each stacking station 130, 130-1 can be moved back and forth in the processing direction 180 to facilitate the layup process. In another further embodiment, zone 1 115 has fewer stacking heads 134 than zone 2 117 or zone 3 117-1. Because there are less complex layups and / or fewer pies in zone 1 115, layups in zone 1 115 can be performed using fewer stacking heads 134 than zones 2 117 and 3 117-1.

[0032] Figure 1B further shows a stacking server 170 that controls the operation of stacking stations 130, 130-1. In this embodiment, the stacking server 170 optionally includes an interface 172, which includes a wired connection 171, e.g., an Ethernet interface, a Universal Serial Bus (USB) interface, or a wireless interface, to communicate with the stacking stations 130, 130-1 and / or the indexing unit 136. The stacking server 170 includes a memory 176 that stores one or more numerical control (NC) programs for operating the stacking stations 130, 130-1. In one embodiment, the NC program ensures that multiple stacking heads 134 do not operate so close to each other that they collide, and reduces the risk of collision by coordinating the operation of two or more stacking heads 134 to ensure that multiple stacking heads 134 do not collide during operation. Pairing one track 132 for each stacking head 134 with various offsets 135 reduces the complexity of guiding the stacking heads 134 through overlapping zones 191, 123-2 by avoiding the application of multiple stacking heads 134 to a single track 132 within overlapping zones 191, 123-2. The various offsets 135 allow track 132 to pass under another track 132. In further embodiments, the stacking head 134 includes sensors to detect proximity to other stacking heads 134, and the stacking head 134 moves to stop and / or move away if it comes closer to each other than a threshold proximity. The controller 174 manages the operation of the stacking server 170 by processing feedback from stacking stations 130, 130-1 and / or indexing units 136 and providing instructions based on such feedback. The controller 174 may be implemented, for example, as custom circuitry, as a hardware processor that executes programmed instructions, or as any combination thereof.

[0033] Figure 1B further shows a joining zone 190 between zone 1 115 and zone 2 117, and similarly, there is an unshown joining zone between zone 1 115 and zone 3 117-1. The illustrated joining zone 190 is arranged longitudinally, but a circumferential joining area (Figure 1B), for example a hoop-shaped joining zone 123-5 arranged along the length 181-7 of the laminate 120, may be used in the overlapping area 123-2 between longitudinal regions 123, 123-1. In a further embodiment, a single lamination head 134 on a dedicated track 132 with a suitable offset 135 is applied to all tows 124, 124-1, and since joining is not required, the joining zone 123-5 is omitted within zone 1 115 of the laminate 120. Furthermore, although the length 181-7 of the illustrated laminate 120 is short compared to its height 181-9, in one embodiment the length 181-7 of the laminate 120 is, for example, 7.62 m (25 feet), and in another embodiment the length 181-7 is 12.2 m (40 feet) or more. Thus, a first set of laminating heads 134 in the laminating station 130 can lay up plies 126 in a first region R1 along the length 181-7 of the laminate 120. The first region R1 overlaps with the longitudinal region 123. Next, the laminate 120 advances in micropulses in the processing direction 180 until its longitudinal region 123 reaches and overlaps with a second region R2 within the range of another set of lamination heads 134 of lamination station 130-1, while simultaneously, the longitudinal region 123-1 advances in micropulses until it overlaps with a third region R3 (not shown) and enters the range of lamination station 130-N (not shown). Similarly, the mandrel advances in the processing direction 180 from lamination stations 130, 130-1 to lamination station 130-N until the laminate 120 is completed. A micropulse is the advance of the layup mandrel 110 and the laminate 120 in the processing direction 180, with a length less than 181-7. In the illustrated embodiment, the micropulse is about half the length 181-7. Other embodiments, including lamination stations (130, 130-1) located in closer proximity, have micropulses of about one-third or less the length 181-7.A complete pulse is the advance of the layup mandrel 110 and the lamination 120 in the processing direction 180 for a length of 181-7 minutes. After a micropulse, the first region R1 becomes the second region R2, and the lamination station 130-1 stands on the tow 124 positioned by the lamination station 130 in the first region R1 by adding an additional tow 124, 124-1 to the first region R1, and the lamination station 130 lays the ply 128 of the next region R2 of the lamination 120. Furthermore, the lamination station 130, 130-1 and / or the lamination head 134 can be positioned and / or the pulsation of the lamination 120 can be adjusted to allow operation within the bonding zones 190, 123-2 as needed. Each joint may include a scarf joint (not shown), a lap joint 392-1, or a step-lap joint (not shown), and its thickness may vary compared to the unjointed pies 396, 397, and 398.

[0034] Unlike layup using a single AFP machine that distributes tows 124, 124-1 for plies of a laminate spanning length 181-7 and height 181-9, each laminating head 134 is dedicated to a specific zone 1 115, zone 2 117, zone 3 117-1, or longitudinal region 123 or 123-1, or a combination thereof. This reduces the potential risk of collisions and increases the efficiency of the layup. To adapt to this overall speed increase of layup using multiple laminating heads 134 and to enable the production of a single, integrated laminate 120, specific zones 1 115, zone 2 117, zone 3 117-1, or longitudinal region 123 or 123-1 are joined together.

[0035] In some embodiments, as shown in Figures 2E-2H, the bonding zones 190, 123-5 have layup bonding sections 392, 394, 395 that are successively shifted by overlapping sections 399, 399-1 through the laminate 120, from ply adjacent to ply 396 to ply 398, ply 397, and so on. In such arrangements, the tows 124, 124-1 of individual plies within bonding zones 190, 123-5, such as ply segment 393, are separated from the ply segment 393-1 of the layup bonding section 392 either without separation or only slightly (for example, by a small amount of 2.54 cm (1 inch)) and terminate at the layup bonding section 392-1, which has a configuration of beveled ends 385, 386 (see Figure 2F) and unbeveled ends 387, 387-1 (see Figure 2H). The layup joint 392 has ply segments 393 and 393-1 cut and positioned as part of a lap joint 392-1 having overlapping portions 399, 399-1 offset from the layup joint 394, and complementary inclined ends 385, 386 and non-inclined ends 387, 387-1. This type of overlapping portion 399, 399-1 of the offset layup joints 392, 394, 395 provides a lap joint 392-1 that facilitates load transfer through the joint zones 190, 123-5. Another embodiment has a joint in a scarf or step-lap configuration (not shown). All joint types require that ply segments 393 and 393-1 be trimmed to complementarily match. Ply 396 has a layup joint 392 that is offset for each subsequent ply of the laminate 120 from the layup joint 394 of ply 398. Furthermore, the joint zones 190, 123-5 are located in less complex or thinner parts of the laminate 120, such as window / door enclosures, pad-ups, or areas without other complex shapes. In this way, the joints are positioned between rather than inside the complex layup areas. The joints can be thinner than the thickness of the unjointed laminate 120, and therefore the joints may include offset joints of one or more cut portions of the ply through the thickness of the laminate 120.In a further embodiment, the positions of the notches of individual plies 396, 398, 397 within the layup joints 392, 394, 395 are offset relative to the inclined ends 385, 386 and non-inclined ends 387, 387-1 of the other plies in the joint zones 190, 123-5. This causes the joints 392, 394, 395 to be offset over the distance of several overlapping sections 399, 399-1, improving the load-bearing capacity of the lap joint 392-1. By offsetting the positions of the ply notches within the joint zones 190, 123-5, the load-bearing capacity of the joint zones 190, 123-5 is improved when solidified into composite parts 55, 55-1. After receiving the layup, the layup mandrel 110 proceeds to the autoclave 193.

[0036] Exemplary details of the operation of the manufacturing environment 100 are described in relation to Figure 2A. In such an embodiment, the layup mandrel 110 is marked but has not yet received any composite material and has just begun to move along the lower track 132.

[0037] Figure 2A is a flowchart illustrating method 200 for laying up a laminate in an exemplary embodiment. The steps of method 200 are described with reference to the manufacturing environment 100 in Figure 1B, but those skilled in the art will recognize that method 200 may be carried out in other systems. The steps in the flowcharts described herein are not exhaustive and may include other steps not shown. The steps described herein may also be carried out in an alternative order.

[0038] In step 202, the layup mandrel 110 moves to the lamination stations 130, 130-1 in the processing direction 180, either continuously or in pulses, during the manufacturing of the composite parts 55, 55-1. Receiving the layup mandrel 110 may include the first region R1 of the layup mandrel 110 moving below the lamination station 130, or the layup mandrel 110 reaching a position that can be indexed by the indexing unit 136.

[0039] In step 204, the indexing unit 136 indexes the layup mandrel 110 to multiple stacking heads 134. This can be done by placing a compensation feature 136-1 of the indexing unit 136 within one or more of the machined features 114 of the layup mandrel 110 to accurately determine the position of the layup mandrel 110 and the surface 112 relative to the stacking station 130. Since the overlap offset O 399 of the indexing unit 136 is precisely known, the position of the layup mandrel 110 relative to the stacking station 130, 130-1 and any stacking head 134 can be determined programmatically based on the position of the layup mandrel 110 relative to the indexing unit 136. Based on this information, the NC program of the controller 174 can be updated to account for any misalignment of the layup mandrel 110 or the surface 112 from the predicted nominal orientation / position. The layup mandrel 110 can be repositioned to the stacking station 130 and / or NC program to eliminate such discrepancies.

[0040] In step 206, the layup is subdivided by the controller 174 and / or the N / C program into zone 1 115, zone 2 117, zone 3 117-1 and longitudinal regions 123, 123-1. Within each zone 1 115, zone 2 117, zone 3 117-1 and longitudinal regions 123, 123-1, a single stacking head 134 operates. By creating such zones 1 115, zone 2 117, zone 3 117-1 and longitudinal regions 123, 123-1 and limiting the movement of the stacking head 134 to zones or regions, the layup can be performed independently by the stacking heads 134 of stacking stations 130, 130-1 and / or further stacking stations 130-n without the need for complex detection and collision avoidance. In other words, since the lamination heads 134 do not operate in each other's zones and regions, and the movement of the lamination heads 134 is coordinated with each other, there is no possibility of collision even if the lamination heads 134 are running in parallel. Collision avoidance is achieved even in environments that include overlapping zones 191, 123-2 to form layup joints 392, 394, 395. For example, the controller 174 can orient its lamination heads 134 to operate in parallel in zone 1 115, zone 2 117, zone 3 117-1 and the front portion 127-1 of the longitudinal regions 123, 123-1. The lamination heads 134 move in parallel to the rear portion 127 of each of those zones or longitudinal regions, etc., to ensure that the lamination head 134 in longitudinal region 123 does not operate too close to the lamination head 134 in longitudinal region 123-1 during layup.

[0041] In one embodiment, the controller 174 positions the joint zones 190, 123-5 described above in relation to step 206 into overlapping zones 191, 123-2. In one embodiment, the controller 174 positions the joint zones 190, 123-5 at locations identified by the designer of the composite parts 55, 55-1 according to an NC program designed for the specific part. The joint zones 190, 123-5 allow structural strength to transfer from one zone to an adjacent zone in the same manner as in parts without joint zones 190, 123-5. The joint zones 190, 123-5 facilitate the definition of zone 1 115, zone 2 117, zone 3 117-1 and longitudinal region 123, 123-1 instead of one large laminated zone without a joint. The number of lamination zones 1 115, zone 2 117, zone 3 117-1, and longitudinal regions 123, 123-1 increases the rate at which the material is laid. Thus, in one embodiment, when each semi-cylindrical body is laminated zone by zone by three material layup zones, the rate of material placement can be increased to six times that of a complete cylindrical section using only one material placement device.

[0042] In step 208, the tows 124, 124-1 of the unidirectional fiber-reinforced material of the laminate 120 are simultaneously applied / laid up onto the layup mandrel 110 via the lamination head 134, such that each lamination head 134 applies the tows 124, 124-1 to zone 1 115, zone 2 117, zone 3 117-1 and longitudinal regions 123, 123-1. In this way, the layup is applied either directly onto the layup mandrel 110 of the first layer ply 396 or to subsequent plies 398 on top of the first layer ply 396. That is, the controller 174 operates the lamination head 134 simultaneously and synchronously according to one or more stored NC programs to lay up the tows 124, 124-1 of the laminate 120. During such operations, the lamination head 134 precisely positions the tows 124, 124-1 to ensure that the gaps 125 between edges and the overlaps 125-1, and the start and stop, do not exceed the desired tolerance. A tow 124 moving in the processing direction 180 is shown in Figure 1B, but the tows 124 are positioned such that their fiber orientations (e.g., 0°, +45°, -45°, 90°) change relative to the laminate 120 depending on the layer being laid up. The lamination head 134 may also make lateral movements 134-1 relative to the track 132 to facilitate movements to position the tow at 0° and / or precise movements 134-2 relative to the track 132 to position the tow at 45°. The layup process may be completed in a single lamination station 130 or partially carried out by multiple lamination stations 130, 130-1, 130-n arranged in series with respect to the processing direction 180. In many cases, different parts of the aircraft fuselage 12 or wings 15, 16 exhibit varying thicknesses due to padding, so multiple lamination station processes 130, 130-1, 130-n are desirable. For example, padding for window or door enclosures, or for wing roots or inspection hatches, or for antennas, is substantially thicker than the area of ​​the laminate 120.

[0043] In step 210, the controller 174 operates the lamination head 134 to join the zones together while applying the tow 124. That is, simultaneously with step 208, the lamination head 134 joins the zones together during the zone layup. This is done to form a single, integrated laminate. Any suitable joint or connection may be provided, such as a scarf joint (not shown), a lap joint 392-1, a step overlap (not shown), etc., and sufficient overlap 399-1 may be selected to ensure high joint strength, such as having a slope ratio of 30:1 or more between the overlap 399-1 and the ply thickness. Furthermore, the “joint” may include a configuration of beveled ends 385, 386 or non-beveled ends 387, 387-1, overlaps 399, 399-1, or otherwise overlapping layers of zone 1 115, zone 2 117 and zone 3 117-1 and longitudinal regions 123, 123-1. This can be carried out as a separate process or integrated into step 208, such that tows 124, 124-1 from each of zone 1 115, zone 2 117 and zone 3 117-1 and longitudinal regions 123, 123-1 extend into joining zones 190, 123-5 by the desired amount or gradient of overlap 399, 399-1 to form a joint between zone 1 115, zone 2 117 and zone 3 117-1 and longitudinal regions 123, 123-1.

[0044] In one embodiment, the application of fiber-reinforced material tows 124, 124-1 to the layup mandrel 110 is performed simultaneously via the lamination heads 134 of the lamination stations 130, 130-1, in which case each of the lamination heads 134 applies tows 124, 124-1 to an assigned zone of the layup mandrel 110, and the lamination heads 134 of different lamination stations 130, 130-1, 130-n apply tows 124, 124-1 to different assigned zones and / or areas. The steps of moving the layup mandrel 110, marking the layup mandrel 110, and applying tows 124, 124-1 are then repeated iteratively. In this embodiment, each stacking head 134 is assigned to zone 1 115, zone 2 117, and zone 3 117-1, as well as longitudinal regions 123, 123-1, while the tow 124 is being applied, and the zones assigned to each stacking head 134 change as the layup mandrel 110 moves in the processing direction 180.

[0045] This process can be further continued by moving the layup mandrel 110 further in the processing direction 180 so that each lamination head 134 applies tow to a different zone, and by simultaneously applying additional fiber-reinforced material tows 124, 124-1 to the layup mandrel 110 via the lamination head 134. In further embodiments, this may include moving the layup mandrel 110 further in the processing direction 180, marking the layup mandrel 110 for the lamination head 134, and simultaneously applying additional fiber-reinforced material tows 124, 124-1 to the layup mandrel 110 via the lamination head 134, in which case each of the lamination heads 134 applies tow to a new zone 1 of zones Z1-Z3 in Figure 3A. Next, adjacent zones, namely zone 1 115, zone 2 117, and zone 3 117-1, as well as longitudinal regions 123 and 123-1, are structurally joined by the use of joining zones 190 and 123-5.

[0046] The completed laminate 120 is compressed and moved into the autoclave 193. In the autoclave 193, the laminate 120 is solidified on the layup mandrel 110 in step 212 to form composite parts 55, 55-1. The composite parts 55, 55-1 are then removed from the mold, machined, and assembled with other parts to form the aircraft 10.

[0047] Method 200 offers technological advantages over conventional technologies and systems to synergistically enhance lamination throughput. Considering laminates 120 for semi-cylindrical compartment preforms 24-1 with lengths of 7.6 to 12.2 meters (25 to 40 feet), or laminates 509 for wing panels 510 in Figure 5, more lamination heads 134 operate on the laminates 120 for composite parts 55, 55-1, thus reducing the layup time for these parts. Wing panels 510 correspond to wing panels 30 after solidification and post-solidification assembly. Furthermore, since the parts travel along the manufacturing environment 100, transportation time does not add much to non-value-added time.

[0048] Figure 2B is a flowchart illustrating Method 250 for selecting bond locations in a laminate in an exemplary embodiment. Step 252 includes subdividing the laminate design into zones of the lamination head 134 (e.g., zones Z2A, Z2B, Z2C, Z3A, Z3B, Z3C in Figure 3B) so that different zones receive layups from different lamination heads 134. Step 254 includes identifying contiguous regions within the laminate (e.g., contiguous region 377 in Figure 3B) that have a ply count below the average ply count in the laminate. Step 256 involves the controller placing bond zones 190, 123-5 into the design between zones within the contiguous region (e.g., zones Z2A, Z2B, Z2C, Z3A, Z3B, Z3C in Figure 3B). Step 258 involves laying up the laminate 120 according to the design. Method 250 offers technical advantages by reducing the complexity of the layup. In other words, the addition of joining zones 190 and 123-5 does not substantially increase the complexity of the existing layup, nor does the addition of joining zones 190 and 123-5 increase the complexity of already complex areas (e.g., areas near windows, doors, etc.).

[0049] Figure 2C shows another method 260 for selecting a joint location in a laminate in an exemplary embodiment. Step 262 includes cutting the applied tows 124, 124-1 to lengths convenient for joint zones 115, zone 2 117 and zone 3 117-1, and between longitudinal regions 123, 123-1 and joint zones 190, 123-5, which are assigned to different lamination heads 134 in the design of the laminates 120, 509. In one embodiment, the layup joint 392 is formed from a combination of slanted ends 385, 386 that are offset in overlapping portions 399, 399-1 that cross the pies 396, 398, 397 (see Figures 2E, 2F, 2G, 2H). Step 264 includes identifying adjacent pies 398, which include neighboring pies in the laminates 120, 509. Step 266 includes overlapping the trim position of the adjacent ply 398 from the layup joint 392 of the length of the previous ply 396 399, 399-1. In one embodiment, overlapping the toes 124, 124-1 399 may include changing the trim angle of the toes 124, 124-1 or offsetting the layup joint 392 of ply 396 from the layup joint 394 of the adjacent ply 398.

[0050] Figure 2D is a flowchart illustrating a method 270 for offsetting the placement of layup joints 392, 394, and 395 in an exemplary embodiment, and is described in relation to Figure 2E. Figures 2E and 2G correspond to arrows 2E and 2G in Figure 1B. Step 272 includes inserting the layup joint 392 into the ply 396 in the joint zone 190 between zones 115, 217, and 317-1, which are assigned to different lamination heads 134 in the design of the laminate 120, and step 274 includes identifying the adjacent ply 398 next to the ply 396 of the laminate 120. Step 276 includes offsetting the cutting position of the layup joint 394 of the adjacent ply 398 from the trimmed length of the ply 396. This can be done by overlapping the layup joint 394 by a predetermined amount 399. The layup joint 392 within the bonding zone 190 refers to the layup joint 392 within the longitudinal regions 123, 123-1, and within the plies 396 in zones 1 115 and 2 117, which are laid up using different lamination heads 134. The layup joint 394 of ply 398 is offset within the bonding zone 190 from the next layup joint 395 of ply 397 and the layup joint 392 of the previous ply 396. In Figure 2G, the lap joint 392-1 within the bonding zone 123-5 refers to the joint 392-1 within the longitudinal regions 123, 123-1, and within the plies 396-1 in zones 1 115 and 2 117, which are laid up using different lamination heads 134. The layup joint 394-1 of ply 398-1 is offset within the bonding zone 123-5 from the next layup joint 395-1 of ply 397-1 and the lap joint 392-1 of the previous ply 396-1. Steps 272-276 can be repeated for the pies until the layup joints 392, 394, and 395 pass through the laminate 120 in the overlap 399. In one embodiment, the bonding zone 123-5 is formed from a combination of layup joints 392, 394, and 395, offset across the pies 396, 398, and 397.Method 270 offers technical advantages by distributing plices 396, 398, and 397 across the joining zones 123-5 in the overlapping portion 399.

[0051] In a further embodiment, the method includes operating a single lamination head 134 to place material into zone 1 115 of the laminate 120, while operating multiple lamination heads 134 to place material into zones 2 117 and 3 117-1 of the laminate 120. In another further embodiment, the method includes selecting the amount of overlap 399, 399-1 between different plies 396, 398, 397 of the layup joints 392, 394, 395.

[0052] In another embodiment, the method further includes selecting the amount of offset between cuts in different layers of the joint. In some embodiments, the joint zones 190, 123-5 have layup joints 392, 394, 395 that are offset from adjacent plies by overlapping portions 399, 399-1, such as from ply 396 to ply 398, ply 397, through the laminate 120. In such an arrangement, the tows 124, 124-1 of individual plies within the joint zones 190, 123-5, such as ply segment 393, are separated from the ply segment 393-1 of the layup joint 392 either without separation or slightly (for example, by a small amount of 2.54 cm (1 inch)) and terminate in the layup joint 392 having beveled ends 385, 386 and unbeveled ends 387, 387-1 as part of the lap joint 392-1. The layup joint 392 has ply segments 393 and 393-1 cut and positioned as part of a lap joint 392-1 having overlapping segments 399 and 399-1 offset from joint 394, and complementary inclined ends 385, 386 and non-inclined ends 387, 387-1. This type of overlapping segment 399 and 399-1, offset from the subsequent layup joints 392, 394, and 395, provides a lap joint 392-1 that facilitates load transfer through the joint zones 190, 123-5. Another embodiment has a joint in a scarf or step-lap configuration (not shown). All joint types require that ply segments 393 and 393-1 be trimmed to complementarily match. Ply 396 has a layup joint 392 that is offset for each subsequent ply of the laminate 120 from the layup joint 394 of ply 398. Furthermore, the joint zones 190, 123-5 are located in less complex or thinner parts of the laminate 120, such as window / door enclosures, pad-ups, or areas without other complex shapes. In this way, the joints are positioned between rather than inside the complex layup areas. The joints can be thinner than the thickness of the unjointed laminate 120, and therefore the joints may include offset joints of one or more cut portions of the ply through the thickness of the laminate 120.In a further embodiment, the positions of the notches of the individual plies 396, 398, 397 within joints 392, 394, 395 are offset relative to the inclined ends 385, 386 and non-inclined ends 387, 387-1 of the other plies in joint zones 190, 123-5. This causes joints 392, 394, 395 to be offset over the distance of several overlapping sections 399, 399-1, thereby improving the load-bearing capacity of the lap joint 392-1. By offsetting the positions of the ply notches within joint zones 190, 123-5, the load-bearing capacity of joint zones 190, 123-5 is improved when solidified into composite parts 55, 55-1. After receiving the layup, the layup mandrel 110 proceeds to the autoclave 193.

[0053] Figure 2F shows overlapping 399-1 inclined ends 385, 385-1, 386 between zones in an exemplary embodiment. As shown in Figure 2F, the first zone 381 and the second zone 382 include upper pies 383, 383-1 and lower pies 384, 384-1. The inclined end 385 of the upper pies 383, 383-1 is located in the overlap 399-1 with the inclined end 386 of the lower pies 384, 384-1. The inclined ends 385, 385-1, 386 are at an angle of 45 degrees 386-2, as shown. In other embodiments, the angle 386-2 of the inclined ends 385, 385-1, 386 can be set to any angle between approximately 20 and 90 degrees, as long as the inclined ends 385, 385-1, 386 are set to maintain the minimum overlap 399-1. Figure 2G shows 385 and 385-1, illustrating the overlapping non-sloping ends 387, 387-1, and 387-2 between zones in an exemplary embodiment. As shown in Figure 2H, the first zone 381 and the second zone 382 include upper pies 383, 383-1 and lower pies 384, 384-1. The non-sloping end 387 of the upper pies 383, 383-1 is located at the overlap 399-1 with the sloping end 387-1 of the lower pies 384, 384-1.

[0054] Figure 3B is a side view of the semi-cylindrical compartment 24-2 after separation from the layup mandrel 110, viewed from the same field of view as Figure 3A, but with the same field of view as Figure 1B. The semi-cylindrical compartment 24 corresponds to the semi-cylindrical compartment 24-2, but the post-solidification assembly has progressed to completion.

[0055] In Figure 3B, the zones are separated both radially and longitudinally, with zones Z2A, Z2B, and Z2C situated above zones Z3A, Z3B, and Z3C. The continuous region 377 has a ply count below the average ply count of the laminate. Zones Z3A, Z3B, and Z3C include pad-ups 372 for window strips, which house window cutout regions 378. However, the pad-ups 372 are interrupted by window cutout regions 378, which cut out material from the laminate 320 to allow for window installation, corresponding to the laminate 120. Zone Z3C includes a pad-up 374 for a door and a door cutout region 375 for a door to be installed therein. Meanwhile, zone Z2A includes a pad-up 376 for a crown module. Further and more complex ply arrangements may be implemented within each zone during the design as needed. The longitudinal joint 379 corresponds to the joint zone 190, is located between the zones of the continuous region 377, and proceeds longitudinally L. The longitudinal joint 379, shown as a line in Figure 3B, has a predetermined width. Furthermore, the circumferential joint 373 corresponds to the joint zones 123-5, is positioned between the zones, and proceeds in the circumferential direction C around the laminate 320.

[0056] That is, after each micropulse or pulse, the lamination head 134 changes its direction of operation from counterclockwise to clockwise, or vice versa. Thus, all of the lamination heads 134 work counterclockwise, then wait for a micropulse or pulse, then operate clockwise, then wait for a micropulse or pulse, and so on. This can be done without using any type of "carriage return" between a single micropulse and pause sequence, or by returning from a counterclockwise movement to position the tows 124, 124-1 to a clockwise return movement. Combinations of movement of the track 132, layup mandrel 110, and / or lamination head 134 can be implemented to position tows 124, 124-1 with different fiber orientations.

[0057] In another embodiment, the lamination head 134 performs layup in a clockwise direction 64 until it reaches the end of a radial zone (e.g., Z1, Z2, Z3), and then resets counterclockwise 65 to return to the beginning of the radial zone (e.g., Z1, Z2, Z3) in a manner similar to the carriage return of a typewriter. Thus, the lamination head 134 always works clockwise 64 after a micropulse or pulse, then returns to the starting position, and works clockwise again (CW) after the next pulse. Needless to say, similar operation may be performed for counterclockwise operation 65 instead of clockwise 64. In yet another embodiment, the plies (e.g., plies 126 and 128 in Figure 1B) are laid up longitudinally (along dimension L) by the movement of the track 132, the lamination head 134, or the pulsed movement (P) of the lower layup mandrel 110.

[0058] In a further embodiment, after the structure (i.e., the layup mandrel 110) is pulsed (P), the lamination head 134 moves stepwise in one direction (e.g., clockwise 64, counterclockwise 65), performing layups during such movements as each of them moves across its zones (Z1, Z2, Z3). The lamination head 134 then moves in the opposite direction to return to the starting point 338 during a micropulse or pulse / pause cycle to prepare for additional layups. The layup mandrel 110 can then move pulsed to the next lamination station 130, and the lamination head moves in the counterclockwise direction 65 to position the lamination material.

[0059] The layup mandrel 110 moves continuously in the processing direction 180 (for example, at a speed of 2.54 cm (1 inch) per minute). In further embodiments, a combination of movement of the track 132, the layup mandrel 110, and / or the lamination head 134 can be performed to carry out the layup on the moving mandrel.

[0060] Zones 1 115, 2 117, and 3 117-1, each approximately 60 degrees, are shown in Figure 3A, as are joints 190 and 123-5 that structurally join zones 1 115, 2 117, and 3 117-1. Any suitable number of zones 1 115, 2 117, and 3 117-1 can be selected, and the number and size of zones 1 115, 2 117, and 3 117-1 may vary along the length 181-7 of the layup mandrel 110, or relative to each other in the same longitudinal portion 318 of the layup mandrel 110. Furthermore, in some embodiments, certain zones 1 115, 2 117, and 3 117-1 may be skipped by certain stacking stations 130. For example, one lamination station 130 can perform layup in zones 2 117 and 3 117-1 but not in zone 1 115, while a downstream lamination station 130 181-2 can perform layup in zones 1 115, 2 117, and 3 117-1. This allows for environments where zones 2 117 and 3 117-1 have more plies than Z2 in the laminate. In further embodiments, the layup mandrel 110 may be designed for full cylindrical sections 29-1, 29-2, 29-3, 29-4, 29-5, a quarter-cylindrical section of the body, or any suitable arched section of the body. In further embodiments, the zone size 317 may be selected so that each zone takes a similar (or the same) amount of layup time at each lamination station 130. This facilitates a common cycle time for each stacking station 130, which in turn facilitates a more uniform distribution of work between the stacking stations 130. In such embodiments, zones with more pies or requiring more complex layup patterns can be reduced compared to thinner or less complex zones.

[0061] In one embodiment, during downtime of the lamination station 130 or lamination head 134, the lamination head 134 is subject to maintenance, such as reloading a new tow into the lamination head 134, replacing or cleaning the cutter of the lamination head 134, or replacing the entire lamination head. Maintenance can be one factor in the division of the workload, and the downtime of the lamination station 130 or lamination head 134 generating a common takt for the scheduled line constitutes part of the process of producing the laminate 120 or laminate 509. In such an embodiment, the amount of material laid up in each zone is selected to be lower than the maximum speed of the lamination head 134 serving the zone, and the remaining downtime is left for maintenance. In this way, when layup is not taking place, the lamination head 134 can receive maintenance during any relevant downtime.

[0062] Figure 4A is a top view of the plymap 400 of the laminate 120 after all tows 124, 124-1 have been placed in the embodiment shown. Figure 4A coincides with arrow 4 in Figure 3A. According to Figure 4A, the plymap 400 includes zone A, which is utilized by the first lamination station 130, and zone B, which is utilized by the second lamination station 130-1. The joints 410 between zones 1 115, 2 117, and 3 117-1 vary along the length 181-7 of the plymap 400 to form a staggered pattern 430, preventing a single seam from forming along the length 181-7 of the plymap 400. Overlapping zones 191 occur between zone 1 115 and zone 2 117, and between zone 1 115 and zone 3 117-1. Either the first lamination station 130 or the second lamination station 130-1 can form a joint between zone A and zone B, and the ply map 400 has a layup joint 392, with ply segments 393 positioned by lamination station 130 and ply segments 393-1 positioned by lamination station 130-1. That is, zone lamination is carried out such that the boundary 412 between zones is offset between layers to avoid the layup joint 392 in the laminate 120 or laminate 509. In a further embodiment, zones A and B overlap in an inclined shape depending on the fiber orientation of the material being laid up and the local configuration of the structure being laid up.

[0063] Each joint 410 may be worked by multiple lamination heads 134 dedicated to specific zones 1 115, 2 117, and 3 117-1. For example, a portion of joint 410 located between two zones 431-1 may receive layup from two lamination heads 134 at different times (one each for zones 1 115 and 2 117, or zones 1 115 and 3 117-1). A portion of joint 410 located at a corner 431 between four zones 431-2 may receive layup from four lamination heads 134 at different times (one each for zones 1 115, 2 117, and 3 117-1). Although joints 410 are illustrated as lines, each joint 410 either occupies a joint zone 190, 123-5 between adjacent zones where the zone plies are joined, or, if not, is physically fabricated as one unit with one another. That is, the position of the joints 410 changes stepwise between layers, forming a staggered pattern 430 (e.g., a stepped pattern, a staggered shape, etc.) across the laminate 120. The staggered pattern 430 of the joints 410 helps prevent overlapping joints 392-2 from directly stacking on the previous lap joint 392-1 or the next overlapping joint 392-3, and also helps prevent the laminate 120 from unnecessarily increasing in thickness within the joint zone 190. Thus, in one embodiment, the positions of the layup joints 392, 394, and 395 of the joints 410 change between plies. The joints 410 extend across the thickness of the laminate 120. The joints 410 are selected / positioned so as not to intersect with the pad-ups 420 in order to prevent a substantial increase in thickness or complexity near the pad-ups 420. In this way, the boundary 412 is offset from ply 396 to ply 398, forming a pattern 430 that is offset for each ply 396, 398, and 397.

[0064] Figure 4B shows similar configurations of zones A and B and the joint 410 of the plymap 450 of the wing panel. A pad up 420 is also included in the plymap 450, which may be used to provide reinforcement for inspection windows, rib land sections, spar land sections, etc. Figures 4A-4B show that the zone lamination technique described herein is applicable to various laminate designs. Figure 4B is a top view of the plymap 450 of the laminate 509 after all tows 124, 124-1 have been placed in an embodiment corresponding to the wing panel 30 before solidification. According to Figure 4B, the plymap 450 includes zone A, which is utilized by a first lamination station 130, and zone B, which is utilized by a second lamination station 130-1. The joints 410-1 between zone 1 115-1, zone 2 117-2, and zone 3 117-3 vary along the length 181-8 of the ply map 450 to form a staggered pattern 430, preventing a single seam from forming along the length 181-8 of the ply map 450. Overlapping zones 191 occur between zone 1 115-1 and zone 2 117-2, and between zone 1 115-1 and zone 3 117-3. Either the first stacking station 130 or the second stacking station 130-1 can form the joint between zone A and zone B, and the ply map 450 has a layup joint 392, with ply segments 393 placed by the stacking station 130 and ply segments 393-1 placed by the stacking station 130-1. That is, zone lamination is carried out such that the boundaries 412-1 between zones are offset between layers in order to avoid the layup joints 392 within the laminate 509. In a further embodiment, zones A and B overlap in an inclined shape depending on the fiber orientation of the material being laid up and the local configuration of the structure being laid up.

[0065] Each joint 410-1 may be worked by multiple lamination heads 134 dedicated to specific zones 1 115-1, 2 117-2, and 3 117-3. For example, a portion of joint 410-1 located between two zones 431-7 may receive layups at different times from two lamination heads 134 (one each for zones 1 115-1 and 2 117-2, or zones 1 115-1 and 3 117-3). A portion of joint 410-1 located at a corner 431-9 between four zones 431-8 may receive layups at different times from four lamination heads 134 (one each for zones 1 115-1, 2 117-2, and 3 117-3). Although the joints 410-1 are illustrated as lines, each joint 410-1 occupies a joint zone 190, 123-5 between adjacent zones where the plies of the zone are joined, or, if not, is physically constructed integrally with one another. That is, the position of the joints 410-1 changes stepwise between layers, forming a staggered pattern 430-1 (e.g., a stepped pattern, a staggered shape, etc.) through the laminate 509. The staggered pattern 430-1 of the joints 410-1 helps prevent overlapping joints 392-2 from directly stacking on the previous lap joint 392-1 or the next overlapping joint 392-3, and also helps prevent the laminate 509 from unnecessarily increasing in thickness within the joint zone 190. Thus, in one embodiment, the position of the layup joints 392, 394, 395 of the joints 410-1 changes between plies. The joint 410-1 extends across the thickness of the laminate 509. The joint 410-1 is selected / positioned so as not to intersect with the pad-up 420 in order to prevent a substantial increase in thickness or complexity near the pad-up 420. Thus, the boundary 412 is positioned offset from ply 396 to ply 398, forming a pattern 430-1 offset for each ply 396, 398, and 397.

[0066] Figures 5-6 are perspective views of a manufacturing environment for laying up wing skins (e.g., wing panels 510 and 610) in an exemplary embodiment. Wing panels 510 and 610 correspond to wing panel 30 after solidification and after solidification assembly. According to Figure 5, wing panel 510 is divided into zones 117-3, 115-1, and 117-2 from front to rear in the manufacturing environment 500. A lamination head 522 of lamination station 520 moves along track 524 and performs layup in these zones 117-3, 115-1, and 117-2. A joint 540 is located between zones 117-3, 115-1, and 117-2. In a further embodiment, lamination heads 522 of different lamination stations 520 operate simultaneously on different parts of wing panel 510. For example, stacking heads 134 at different stations perform layup in different zones such as zones 117-1, 115-1, and 117-2. In this embodiment, stacking heads 522 are positioned staggered between different stacking stations 520 such that each stacking head 522 at each stacking station 520 does not work in adjacent zones 117-3, 115-1, and 117-2, but works in zones 117-3, 115-1, and 117-2 every other zone.

[0067] As shown in Figure 6, the wing panel 610 is divided into zones Z1, Z2, and Z3 from the wingtip to the fuselage in the manufacturing environment 600. The lamination head 622 of the lamination station 620 moves along track 624 and performs layup in these zones. Zones Z1, Z2, and Z3 are physically manufactured as a single unit via joints 640. Within each joint 640, the pies of different zones overlap in a offset manner. In further embodiments, four or more zones are implemented on each wing. Furthermore, zones Z1, Z2, and Z3 may be separated into a checkerboard pattern by combining forward / rear (see Figure 5) and fuselage-side / wingtip-side (see Figure 6) divisions, and multiple lamination heads 522, 622 arranged across multiple lamination stations 520, 620 can operate on the wing panels 510, 610 as they move in processing directions 180-1, 180-2 to increase the manufacturing speed. For example, each stacking station 520, 620 shown in Figure 5-6 includes a stacking head 522, 622, and the tracks 524, 624 of the stacking heads 522, 622 can be substantially flat or, if not, dimensional to correspond to the passage of the wing panels 510, 610. In a further embodiment, the stacking heads 522, 622 of different stacking stations 520, 620 operate simultaneously on different parts of the wing panels 510, 610. For example, the stacking heads 622 of different stacking stations 620 perform layups in different zones Z1, Z2, Z3. In this embodiment, the stacking heads 622 of each stacking station 620 are offset from each other so that the stacking heads 622 of each stacking station 620 do not work in adjacent zones Z1, Z2, Z3, but work in every other zone Z1, Z2, Z3.

[0068] Examples With more detailed reference to the drawings, embodiments of the present disclosure can be described in relation to a method 700 for manufacturing and maintaining an aircraft shown in Figure 7, and an aircraft 702 shown in Figure 8. In the pre-manufacturing stage, the method 700 may include the specification and design 704 of the aircraft 702 and the procurement of materials 706. In the manufacturing stage, the manufacturing 708 of the components and subassemblies of the aircraft 702 and system integration 710 are carried out. The aircraft 702 can then be put into operation 714 after approval and delivery 712. While in operation by the customer, the aircraft 702 is scheduled for periodic maintenance and upkeep 716 (which may include modifications, reconfigurations, and refurbishments). Apparatus and methods embodied herein may be employed during any suitable stage of one or more manufacturing and maintenance described in Method 700 (e.g., specification and design 704, material procurement 706, component and subassembly manufacturing 708, system integration 710, authorization and delivery 712, operation 714, maintenance and servicing 716) and / or in any suitable component of the aircraft 702 (e.g., airframe 718, systems 720, interior 722, propulsion systems 724, electrical systems 726, hydraulic systems 728, environmental systems 730).

[0069] Each of the processes of Method 700 may be carried out or performed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes described herein, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military organization, service organization, etc.

[0070] As shown in Figure 8, an aircraft 702 manufactured by Method 700 may include a fuselage 718 with a plurality of systems 720 and interior 722. Examples of systems 720 include one or more of the propulsion system 724, electrical system 726, hydraulic system 728, and environmental system 730. Any number of other systems may be included. Although an aerospace embodiment is shown, the principles of this disclosure may also be applicable to other industries, such as the automotive industry.

[0071] As described above, the apparatus and methods embodied herein may be employed at any stage of one or more of the manufacturing and maintenance described in Method 700. For example, components or subassemblies corresponding to the manufacturing of components and subassemblies 708 may be manufactured or produced in a similar manner to components or subassemblies manufactured during the operational life of the aircraft 702. Also, one or more embodiments of apparatus, embodiments of methods, or combinations thereof may be used during the manufacturing of subassemblies 708 and system integration 710, for example, by substantially streamlining the assembly of the aircraft 702 or reducing the cost of the aircraft 702. Similarly, one or more embodiments of apparatus, embodiments of methods, or combinations thereof may be used during the operational life of the aircraft 702, for example, during maintenance and upkeep 716, but not limited to these. Accordingly, this disclosure can be used in any stage or any combination thereof described herein, for example, in specification and design 704, material procurement 706, manufacturing of components and subassemblies 708, system integration 710, authorization and delivery 712, operation 714, maintenance and repair 716) and / or in any suitable component of the aircraft 702 (for example, the airframe 718, systems 720, interior 722, propulsion system 724, electrical system 726, hydraulic system 728, and / or environmental system 730).

[0072] In one embodiment, the part includes a portion of the airframe 718 and is manufactured during the manufacture of components and subassemblies 708. The part can then be assembled into the aircraft in system integration 710 and subsequently used in operation 714 until it becomes unusable due to wear. The part can then be discarded in maintenance and servicing 716 and replaced with a newly manufactured part. Ingenious components and methods can be used throughout the manufacture of components and subassemblies 708 to manufacture a new part.

[0073] Any of the various control elements (e.g., electrical or electronic components) illustrated or described herein may be implemented as hardware, processor-implemented software, processor-implemented firmware, or any combination thereof. For example, an element may be implemented as dedicated hardware. Dedicated hardware elements may be referred to as “processors,” “controllers,” or any similar technical terms. When provided by processors, functions may be provided by a single dedicated processor, a single shared processor, or multiple individual processors, some of which may be shared. Furthermore, the explicit use of the terms “processors” or “controllers” should not be interpreted as referring only to, and not limiting to, hardware capable of running software, but may implicitly include digital signal processor (DSP) hardware, network processors, application-specific integrated circuits (ASICs) or other circuits, field-programmable gate arrays (FPGAs), read-only memory (ROM) for software storage, random-access memory (RAM), non-volatile memory, logic or any other physical hardware components or modules.

[0074] Furthermore, control elements can be implemented as instructions that can be executed by a processor or computer, thereby enabling them to perform their functions. Some examples of instructions are software, program code, and firmware. Instructions are operable once executed by a processor, instructing the processor to perform the function of the element. Instructions can be stored in a memory device that can be read by the processor. Some examples of memory devices are digital or solid-state memory, magnetic storage media such as magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media.

[0075] While specific embodiments are described herein, the scope of this disclosure is not limited to these specific embodiments. The scope of this disclosure is defined by the claims and their equivalents.

[0076] This disclosure further includes the following embodiments, which should not be confused with any claims determining the scope of protection.

[0077] Example 1. A method (200) for manufacturing composite material parts (55, 55-1), wherein: - Dividing the layup of the laminate (120) into smaller zones (115, 117, 117-1) (206); - Applying the tow (124) of the fiber-reinforced material for the laminate (120) onto the layup mandrel (110) via multiple lamination heads (134) such that each lamination head (134) applies the tow (124) to different zones (115, 117, 117-1) (208); and - During the layup of the tow (124), the zones (115, 117, 117-1) are joined together (210) to form a laminate (120). A method including (200).

[0078] Example 2. The method of Example 1 (200), wherein the layup mandrel (110) includes a mandrel for semi-cylindrical compartments; the layup (208) of the laminate (120) is subdivided into zones, which includes assigning a lamination head (134) to the zones (115, 117, 117-1).

[0079] Example 3. The method of Example 1 (200), wherein the layup mandrel (110) includes a wing panel layup mandrel; and subdividing the layup of the laminate (120) into zones (115, 117, 117-1) (206) includes assigning the lamination head (134) to zones (115, 117, 117-1) extending from the tip (11) of the wing panel to the root (17) of the wing panel.

[0080] Example 4. The method of Example 1 (200), wherein the layup mandrel (110) includes a layup mandrel for the wing panel; and subdividing the layup of the laminate into zones (115, 117, 117-1) (206) includes assigning the lamination head (134) to zones (115, 117, 117-1) that extend from the front (19) of the wing panel to the rear (23) of the wing panel.

[0081] Example 5. - Moving the layup mandrel (110) in the processing direction (202); and - Simultaneously applying additional tows (124) of fiber-reinforced material via the lamination head (134) (208) such that each lamination head (134) applies tows (124) to different zones (115, 117, 117-1). The method (200) of any one of Examples 1-4, further comprising the above.

[0082] Example 6. - Move the layup mandrel (110) in the processing direction (202); - Marking the layup mandrel (110) on the stacking head (134) (204); and - Applying additional tows (124) of fiber-reinforced material simultaneously via lamination heads (134) (208), wherein each lamination head (134) applies tows (124) to a new zone, and applying additional tows (124) simultaneously. The method (200) of any one of Examples 1-4, further comprising the above.

[0083] Example 7. One of the methods (200) of Examples 1-6, wherein applying the tow (124) (208) includes operating the stacking head (134) along a shared track to lay up the tow (124).

[0084] Example 8. One of the methods (200) of Examples 1-7, wherein applying the tow (124) (208) includes operating a stacking head (134) along a separate track to lay up the tow (124).

[0085] Example 9. A method (200) of any one of Examples 1-8, wherein applying the tow (124) (208) includes applying the tow (124) by a first stacking station (130) and applying the tow (124) by a second stacking station (130-1).

[0086] Example 10. - Identify the region of the laminate (120) that will receive the pad-up. Further including: - Dividing the layup of the laminate (120) into zones (115, 117, 117-1) includes assigning a lamination head (134) to perform the layup in each zone (115, 117, 117-1), and positioning the joints so as not to intersect with the pad-up of the laminate (120) between zones (115, 117, 117-1). Any one of the methods from Examples 1-9 (200).

[0087] Example 11. Any one of the methods (200) of Examples 1-10, wherein the layup of the laminate (120) is subdivided into zones (115, 117, 117-1), a lamination head (134) is assigned to perform the layup in each zone, and the joints are positioned between the zones (115, 117, 117-1) in a staggered pattern.

[0088] Example 12. Any one of the methods (200) of Examples 1-11, further comprising moving a layup mandrel (110) in the processing direction (202) during the manufacture of composite material parts (55, 55-1).

[0089] Example 13. Any one of the methods (200) of Examples 1-12, further comprising solidifying a laminate (120) on a layup mandrel (110) (212).

[0090] Example 14. A portion of an aircraft assembled according to any one of the methods (200) of Examples 1-13.

[0091] Example 15. Apparatus (100) for manufacturing composite material parts (55, 55-1): - Lamination stations (130, 130-1) that allow a lamination head (134) to follow the contour of a layup mandrel (110) moving in the processing direction during the manufacturing of composite material parts (55, 55-1); and - A lamination head (134) positioned in a lamination station (130, 130-1) configured to lay up a tow (124) of fiber-reinforced material onto a layup mandrel (110), wherein the lamination head (134) is configured to operate in tandem, laying up the fiber-reinforced material for a laminate (120) onto different zones (115, 117, 117-1) of the layup mandrel (110) while joining the zones (115, 117, 117-1) together. A device equipped with the following features.

[0092] Example 16. Apparatus (100) of Example 15, further comprising a layup mandrel (110) for defining the contours of the body compartments; and a controller for subdividing a laminate (120) into zones (115, 117, 117-1) by assigning a lamination head (134) to zones (115, 117, 117-1) that include arched portions of the body compartments, based on instructions from a numerical control (NC) program.

[0093] Example 17. Apparatus (100) of Example 15, further comprising a controller (174) which divides a laminate (120) into zones (115, 117, 117-1) by assigning a lamination head (134) to zones (115, 117, 117-1) extending from the tip (11) of the wing panel to the root (17) of the wing panel, based on instructions from a numerical control (NC) program.

[0094] Example 18. Apparatus (100) of Example 15, in which a layup mandrel (110) defines the outer mold line (OML) of the wing.

[0095] Example 19. Apparatus (100) of Example 15, in which a layup mandrel (110) defines the inner mold line (IML) of a fuselage compartment.

[0096] Example 20. Apparatus (100) of Example 15, further comprising a controller (174) which divides a laminate (120) into zones (115, 117, 117-1) by assigning a lamination head (134) to zones (115, 117, 117-1) extending from the front (19) to the rear (23) of the wing panel, based on instructions from a numerical control (NC) program.

[0097] Example 21. A device (100) from any one of Examples 15-20, comprising a controller for identifying a region of a laminate (120) to receive pad-ups and subdividing the laminate (120) into zones (115, 117, 117-1), further comprising a controller for positioning boundaries between zones (115, 117, 117-1) at locations that do not intersect with the pad-ups of the laminate (120).

[0098] Example 22. Any one of the devices (100) from Examples 15-21, further comprising a controller that divides a laminate (120) into zones (115, 117, 117-1) and arranges the boundaries between the zones (115, 117, 117-1) in a staggered pattern.

[0099] Example 23. Any one of the apparatus (100) from Examples 15-22, further comprising a lamination head (134) positioned downstream of a lamination head (134) for performing rework on a laminate (120).

[0100] Example 24. Apparatus (100) of Example 15, in which a lamination head (134) simultaneously lays up fiber-reinforced materials and joins zones (115, 117, 117-1) together.

[0101] Example 25. Manufacturing of an aircraft part using any one apparatus (100) from Examples 15-24.

[0102] Example 26. A system for manufacturing composite material parts (55, 55-1), wherein the apparatus is: Tracks (132) that follow the contour of a layup mandrel (110) moving in the processing direction during the manufacturing of composite material parts (55, 55-1); and A lamination head (134) is movably mounted on a track (132) and configured to lay up fiber-reinforced material onto a layup mandrel (110), wherein the lamination head (134) is configured to operate in tandem to simultaneously lay up fiber-reinforced material for a laminate (120) into different zones (115, 117, 117-1) of the layup mandrel (110) and to join the zones (115, 117, 117-1) together. stacking station including A system equipped with these features.

[0103] Example 27. The system of Example 26, wherein the layup mandrel (110) defines the outer mold line (OML) of the wing.

[0104] Example 28. The system of Example 26, wherein a layup mandrel (110) defines the inner mold line (IML) of the fuselage compartment.

[0105] Example 29. Manufacturing of an aircraft component using any one of the systems from Examples 26-28.

[0106] Example 30. A method (250) for designing a laminate (120), wherein: Designing the laminate (120) to subdivide the zones (115, 117, 117-1) of the lamination head (134) so ​​that different zones (115, 117, 117-1) receive layup from different lamination heads (134) (252); and - The joints are positioned in the design between zones (115, 117, 117-1) within the continuous region (256) Methods including (250).

[0107] Example 31. The method of Example 30 (250), wherein the joint is formed from offset cuts.

[0108] Example 32. The method (250) of Example 30 or 31, further comprising operating a single head (134) to place material in the crown modular of the laminate (120) while operating multiple heads (134) to place material in the side of the laminate (120).

[0109] Example 33. Any one of the methods (250) of Examples 30-32, further comprising selecting the amount of overlap between the plies of different layers at the joint.

[0110] Example 34. Any one of the methods of Examples 30-33 (250), further comprising selecting the amount of displacement between cuts in different layers of the joint.

[0111] Example 35. - Laying up the laminate (120) according to the design (258); and - Identifying a continuous region within a laminate having a ply count below the average ply count (254) Any one of the methods (250) of Examples 30-34, further comprising the above.

[0112] Example 36. A portion of an aircraft assembled according to any one of the methods of Examples 30-35.

[0113] Example 37. - In the design of the laminate (120), cutting the applied toe (262) to form a joint between zones (115, 117, 117-1) assigned to different lamination heads (134); - Identifying adjacent plies (264); and - Offset the cutting position of the adjacent ply from the cut (266) A method (260) for inserting a joint into a laminate (120), including the joint.

[0114] Example 38. The method of Example 37 (260), wherein the joint is formed from a combination of ends that are offset from each other between layers.

[0115] Example 39. A portion of an aircraft assembled according to the method (260) of Example 37 or 38.

[0116] Example 40. A method (200) for manufacturing composite material parts (55, 55-1) from laminated boards (120), wherein: - During the manufacturing of the composite parts (55, 55-1), move the layup mandrel (110) in the processing direction (202) to expose the zones for lamination (115, 117, 117-1) to the lamination head (134); - Dividing the layup of the laminate (120) into smaller zones (115, 117, 117-1) (206); - Applying the fiber-reinforced material tow (124) to the layup mandrel (110) via multiple layup heads (134) such that each layup head (134) applies the tow (124) to a different zone (208); and - While applying the tow (124), the zones (115, 117, 117-1) are joined together (210) to form a single laminate (120). A method including (200).

[0117] Example 41. The method (200) of Example 40, wherein the layup mandrel (110) is a layup mandrel (110) for the body section; and the method (206) of dividing the layup of the laminate (120) into zones (115, 117, 117-1) includes assigning the lamination head (134) to the zones (115, 117, 117-1) that include the arched portion of the body section.

[0118] Example 42. The method of Example 40 or 41 (200), comprising moving a layup mandrel (110) (202) to receive a layup mandrel for a wing panel; and dividing the layup of the composite into zones (115, 117, 117-1) (206), comprising assigning a lamination head (134) to zones (115, 117, 117-1) extending from the tip (11) of the wing panel to the root (17) of the wing panel.

[0119] Example 43. A layup mandrel (110) comprising a layup mandrel for the wing panel; dividing the layup of the composite into zones (115, 117, 117-1) (206) comprising assigning a lamination head (134) to zones (115, 117, 117-1) extending from the front (19) of the wing panel to the rear (23) of the wing panel, in any one method (200) of Examples 40-42.

[0120] Example 44. - Moving the layup mandrel (110) further in the processing direction (202); and - Applying additional tows (124) of fiber-reinforced material to the layup mandrel (110) via the layup head (134) simultaneously (208) such that each lamination head (134) applies tows (124) to different zones. The method (200) of any one of Examples 40-43, further comprising the above.

[0121] Example 45. - Move the layup mandrel (110) further in the processing direction (202); - Marking the layup mandrel (110) on the stacking head (134) (204); and - Simultaneously applying additional tows (124) of fiber-reinforced material to a layup mandrel via a lamination head (134) (208), wherein each of the lamination heads (134) applies the tows (124) to a new zone, thereby simultaneously applying the additional tows (124). Any one of the methods (200) of Examples 40-44, further comprising the above.

[0122] Example 46. Any method (200) of Examples 40-45, comprising applying (208) a tow (124), operating a lamination head (134) along a shared track to lay up the tow (124); and moving a layup mandrel (110) in the processing direction (202).

[0123] Example 47. - Identify the region of the laminate (120) that will receive the pad-up. Further including: - Dividing the layup of the laminate (120) into zones (115, 117, 117-1) includes positioning the boundaries between the zones (115, 117, 117-1) at locations that do not intersect with the pad-up of the laminate (120). Any one of the methods in Examples 40-46 (200).

[0124] Example 48. Any method (200) of Examples 40-47, wherein the layup of the laminate (120) is subdivided into zones (115, 117, 117-1) (206), and the boundaries between the zones (115, 117, 117-1) are arranged in a staggered pattern.

[0125] Example 49. Any one of the methods (200) of Examples 40-48, further comprising solidifying the laminate on a layup mandrel (110) (214).

[0126] Example 50. A portion of an aircraft assembled according to any one of the methods of Examples 40-49.

[0127] Example 51. A method (200) for manufacturing composite material parts (55, 55-1) from laminated boards (120), wherein: - Dividing the layup of the laminate (120) into smaller zones (115, 117, 117-1) (206); - Applying the tow (124) of the fiber-reinforced material to the layup mandrel (110) simultaneously via multiple layup heads (134) such that each lamination head (134) applies the tow (124) to a different zone (208); and - Joining zones (115, 117, 117-1) together to form a single laminate (120) while laying up the tow (124). A method including (200).

[0128] Example 52. The method (200) of Example 51, wherein the layup mandrel (110) includes a layup mandrel for the body compartments; and the subdivision (206) of the layup of the laminate (120) into zones (115, 117, 117-1) includes subdivision of the layup mandrel into arched portions of the body compartments.

[0129] Example 53. The method (200) of Example 51, wherein the layup mandrel (110) includes a layup mandrel for the wing; and the subdivision (206) of the layup of the laminate (120) into zones (115, 117, 117-1) includes subdivision (206) of the layup mandrel (110) into portions extending from the wingtip (11) to the wingtip (17).

[0130] Example 54. The method (200) of Example 51, wherein the layup mandrel (110) includes a layup mandrel for the wing; and the subdivision (206) of the layup of the laminate (120) into zones (115, 117, 117-1) comprises subdivision (206) of the layup mandrel (110) into portions extending from the front (19) to the rear (23) of the wing.

[0131] Example 55. - Moving the layup mandrel (110) in the processing direction; and - To apply additional tows (124) of fiber-reinforced material to the layup mandrel (110) via the layup head (134) simultaneously, such that each lamination head (134) applies tows (124) to different zones. The method (200) of any one of Examples 51-54, further comprising the above.

[0132] Example 56. - Move the layup mandrel (110) in the processing direction; - Marking the layup mandrel (110) on the stacking head (134); and - Applying additional tows (124) of fiber-reinforced material to a layup mandrel simultaneously via a lamination head (134), wherein each of the lamination heads (134) applies the tows (124) to a new zone, thereby simultaneously applying the additional tows (124). The method (200) of any one of Examples 51-55, further comprising the above.

[0133] Example 57. One of the methods (200) of Examples 51-56, wherein applying the tow (124) includes operating a lamination head (134) along a shared track to lay up the tow (124); and moving a layup mandrel (110) in the processing direction.

[0134] Example 58. - Identify the region of the laminate (120) that will receive the pad-up. Further including: - Dividing the layup of the laminate (120) into zones (115, 117, 117-1) includes positioning the boundaries between the zones (115, 117, 117-1) at locations that do not intersect with the pad-up of the laminate (120). Any one of the methods from Examples 51-57 (200).

[0135] Example 59. Any method (200) of Examples 51-58, wherein the layup of the laminate (120) is subdivided into zones (115, 117, 117-1) (206), and the boundaries between the zones (115, 117, 117-1) are arranged in a staggered pattern.

[0136] Example 60. Any one of the methods (200) from Examples 51-59, further comprising solidifying a laminate (120) on a layup mandrel (110).

[0137] Example 61. Any method (200) of Examples 51-60, wherein the lamination head (134) applies the fiber tow (124) in parallel and simultaneously.

[0138] Example 62. Any one of the methods (200) of Examples 51-61, further comprising the lamination head (134) simultaneously applying fiber tows (124) in series.

[0139] Example 63. Any one of the methods (200) of Examples 51-62, further comprising the lamination head (134) simultaneously applying fiber tows (124) in series and parallel.

[0140] Example 64. A portion of an aircraft assembled according to any one of the methods of Examples 51-63.

[0141] Example 65. A method (200) for manufacturing composite material parts (55, 55-1) from laminated boards (120), wherein: - Move the layup mandrel (110) in the processing direction (202); - Marking the layup mandrel (110) on the stacking head (134) of the stacking station (130, 130-1) (204); and - Simultaneously applying a tow (124) of fiber-reinforced material to a layup mandrel (110) via a lamination head (134) of a lamination station (130, 130-1) (208), wherein each lamination head (134) applies the tow (124) to an assigned zone of the layup mandrel (110), and the lamination heads (134) of different lamination stations (130, 130-1) apply the tow (124) to different assigned zones (115, 117, 117-1); and - Repeat the process of moving (202), indexing (204), and applying (208). A method that includes this.

[0142] Example 66. The method of Example 65 (200), wherein applying the tow (124) (208) includes operating the stacking head (134) along the shared track (132) to lay up the tow (124).

[0143] Example 67. The method of Example 65 or 66 (200), wherein applying the tow (124) (208) includes operating the stacking head (134) independently to lay up the tow (124).

[0144] Example 68. A method (200) of any one of Examples 65-67, in which each stacking head (134) is assigned to a different zone while the tow (124) is being applied; the zone assigned to each stacking head changes as the layup mandrel (110) moves in the processing direction.

[0145] Example 69. A portion of an aircraft assembled according to any one of the methods of Examples 65-68.

[0146] Example 70. A method (270) for inserting a joint into a laminate (120): - Inserting notches into the plies at the joints between zones (115, 117, 117-1) assigned to different lamination heads (134) in the design of the laminate (120) (272); - Identifying adjacent plies (274); and - Offset the cutting position of the adjacent ply from the cut (276) A method that includes this.

[0147] Example 71. The method of Example 70, wherein the cutting position 394 of the adjacent ply 398 (276) is offset by offsetting the joint by a predetermined amount.

[0148] Example 72. A portion of an aircraft assembled according to the method described in Example 70 or 71.

Claims

1. A method (200) for manufacturing composite material parts (55, 55-1): - During the manufacturing of the composite material parts (55, 55-1), move the layup mandrel (110) in the processing direction (202); - Dividing the layup of the laminate (120) into smaller zones (115, 117, 117-1) (206); - Applying the tow (124) of the fiber-reinforced material for the laminate (120) onto the layup mandrel (110) via a plurality of lamination heads (134) such that each lamination head (134) applies the tow (124) to different zones (115, 117, 117-1) (208); and - During the layup of the tow (124), the zones (115, 117, 117-1) are joined together to form the laminate (120) (210) A method including (200).

2. Applying additional tows (124) of fiber-reinforced material simultaneously through the lamination head (134) such that each lamination head (134) applies tows (124) to different zones (115, 117, 117-1) (208); or The layup mandrel (110) is marked on the stacking head (134) (204), and Applying additional tows (124) of fiber-reinforced material simultaneously (208) via the lamination head (134), wherein each of the lamination heads (134) applies the tows (124) to a new zone. The method according to claim 1 (200), further comprising:

3. Applying the aforementioned tow (124) (208) means: To lay up the tow (124), the lamination head (134) is moved along the shared track (132); and the layup mandrel (110) is moved in the processing direction (202). The method according to claim 1 or 2 (200), including the method according to claim 1 or 2.

4. Further including identifying the region of the laminate (120) that receives the pad-up: Dividing the layup of the laminate (120) into zones (115, 117, 117-1) includes arranging the boundaries between the zones (115, 117, 117-1) at positions that do not intersect with the pad-up of the laminate (120). The method according to any one of claims 1 to 3 (200).

5. The layup of the laminate (120) is subdivided into zones (115, 117, 117-1) (206), and the boundaries are arranged between the zones (115, 117, 117-1) in a staggered pattern. The method according to any one of claims 1 to 4 (200).

6. Apparatus (100) for manufacturing composite material parts (55, 55-1): - Lamination stations (130, 130-1) that enable a lamination head (134) to follow the contour of a layup mandrel (110) moving in the processing direction during the manufacturing of the composite material parts (55, 55-1); and - A lamination head (134) positioned in the lamination station (130, 130-1) configured to lay up a tow (124) of fiber-reinforced material onto the layup mandrel (110), wherein the lamination head (134) is configured to operate in tandem to lay up the fiber-reinforced material for a laminate (120) into different zones (115, 117, 117-1) of the layup mandrel (110) and to join the zones (115, 117, 117-1) together. A device equipped with the following features.

7. A lamination head (134) positioned downstream of the lamination head (134) for performing rework on the laminated plate (120). The apparatus (100) according to claim 6, further comprising the above.

8. The apparatus (100) according to claim 6, wherein the lamination head (134) simultaneously lays up the fiber-reinforced material and joins the zones (115, 117, 117-1) together.

9. A system for manufacturing composite material parts (55, 55-1): Tracks (132) that follow the contour of a layup mandrel (110) that moves in the processing direction during the manufacturing of the composite material parts (55, 55-1); and A lamination station comprising a lamination head (134) movably mounted on the track (132) and configured to lay up fiber-reinforced material onto the layup mandrel (110), wherein the lamination head (134) is configured to operate in tandem to simultaneously lay up fiber-reinforced material for a laminate (120) into different zones (115, 117, 117-1) of the layup mandrel (110) and simultaneously join the zones (115, 117, 117-1) together. A system equipped with these features.

10. The layup mandrel (110) defines the outer mold line (OML) of the wing, or The layup mandrel (110) defines the inner mold line (IML) of a section of the fuselage. The system according to claim 9.

11. A method (200) for manufacturing composite material parts (55, 55-1) from a laminate (120): - Move the layup mandrel (110) in the processing direction (202); - Marking the layup mandrel (110) on the stacking head (134) of the stacking station (130, 130-1) (204); and - Applying a tow (124) of fiber-reinforced material to the layup mandrel (110) simultaneously via the lamination heads (134) of the lamination stations (130, 130-1) (208), wherein each of the lamination heads (134) applies the tow (124) to an assigned zone of the layup mandrel (110), and the lamination heads (134) of different lamination stations (130, 130-1) apply the tow (124) to different assigned zones (115, 117, 117-1); and - Repeating the actions of moving (202), marking (204), and applying (208). A method that includes this.

12. Applying the tow (124) (208) includes moving the stacking head (134) along the shared track (132) to lay up the tow (124), or Applying the tow (124) (208) includes operating the stacking head (134) independently to lay up the tow (124), The method according to claim 11.

13. Each stacking head (134) is assigned to a different zone while applying the tow (124); The zones assigned to each stacking head change as the layup mandrel (110) moves in the processing direction. The method according to claim 11 or 12 (200).

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