Manufacturing of curved composite preforms for aircraft via assembly lines

Abstract

To provide a system and a method for fabricating a curved preform of a fiber reinforced material.SOLUTION: A method includes laying up at least one ply onto a carrier of flexible material at a lamination station 130, loading the carrier onto a rail system 110, routing and moving the carrier to a particular Ply-By-Ply (PBP) forming station 140 at the rail system 110, separating the at least one ply from the carrier, and making the at least one ply into a preform 146 via the particular PBP forming station 140.SELECTED DRAWING: Figure 1

Description

Technical Field

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

Background Art

[0002] The mechanical structure of an aircraft is referred to as the airframe. The airframe is made from discrete components such as stringers, spars, outer panels, and frames. When assembled together, they define the shape of the aircraft. An individual aircraft can be manufactured from many such components. All or some of them can be manufactured as composite parts. For example, an aircraft can use a number of curved or undulating frames to reinforce its fuselage. Ideally, the frames are manufactured at a rate sufficient to match the desired assembly timing for the desired production speed of the aircraft. Otherwise, the manufacture of the aircraft can be undesirably delayed.

[0003] The abstract of US9,731,899B1 states that a system and method for controlling a flexible track are provided. One embodiment is a system for transporting plies of a laminate to a forming device. The system includes a flexible track assembly having a first portion of the track and a second portion of the track. Each of those portions defines a groove sized to receive a slider for transporting a ply. The second portion is arranged to transport the ply into the forming device. The track assembly also includes a guide with the ends of its portions disposed internally. The system further includes a pull-back line that applies a contracting force to bias the end of the second portion toward contact with the end of the first portion. The pull-back line is extensible to allow separation of the second portion from the first portion. Thereby, it accepts elongation of the track assembly in response to forces applied by the forming device during formation.

[0004] Thus, it would be desirable to have methods and apparatus that take into account at least some of the problems discussed above and other envisioned problems. [Overview of the project]

[0005] Embodiments described herein provide an assembly line for rapidly manufacturing curved composite components (e.g., frames) for aircraft via the use of an assembly line. The assembly line includes a track system for dynamically supplying individual plies to various ply-by-ply (PBP) forming stations clustered together. Higher work density can be achieved by dynamically supplying plies for forming to multiple PBP forming stations in a just-in-time (JIT) manner. That is, curved composite components can be rapidly manufactured via stations in a specific arrangement that occupies less factory floor space than used by conventional assembly techniques. In one embodiment, a method for manufacturing a curved preform of fiber-reinforced material is disclosed. The method includes laying up at least one ply on a carrier of flexible material at a lamination station, loading the carrier onto a rail system, routing and moving the carrier on the rail system to a specific ply-by-ply (PBP) forming station based on the properties of at least one ply carried by the carrier, separating at least one ply from the carrier, and processing at least one ply into a preform via the specific PBP forming station.

[0006] In a further embodiment, a system for manufacturing a curved preform of a fiber-reinforced material is disclosed. The system includes a lamination station for laying up plies for a curved preform on a carrier of flexible material, a rail system for routing and moving the carrier from the lamination station to a ply-by-ply (PBP) forming station, forming a loop between the lamination station and the PBP forming station, and a PBP forming station for receiving plies and processing them into a curved preform. In a further embodiment, a system exists for manufacturing a curved preform of a fiber-reinforced material. The system includes a lamination station for laying up plies for a curved preform on a carrier of flexible material, a rail system for routing and moving the carrier from the lamination station to a ply-by-ply (PBP) forming station, forming a loop between the lamination station and the PBP forming station, and a PBP forming station for receiving plies and processing them into a curved preform.

[0007] In a further embodiment, a system is disclosed that includes a rail system including tracks forming concentric circles. The concentric circles include inner concentric circles adjacent to a plurality of pry-by-ply (PBP) forming stations and outer concentric circles adjacent to stacking stations. The rail system further includes tracks forming branch lines connecting the concentric circles together, and supports that hold the tracks in an elevated position, and the system further includes carriers for transporting plies from stacking stations to PBP forming stations through the rail system.

[0008] Other exemplary embodiments (e.g., methods and computer-readable media related to the embodiments described above) may also be described later. The features, functions, and advantages discussed can be realized individually in various embodiments or combined in yet another embodiment, which can be understood in further detail by referring to the following description and drawings.

[0009] Herein, several embodiments of the present disclosure will be 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]

[0010] [Figure 1] Figure 1 shows a manufacturing system for curved preforms of fiber-reinforced material in an exemplary embodiment. [Figure 2] The movement of the carrier and ply through the manufacturing system in Figure 1 in an exemplary embodiment is depicted. [Figure 3A] The movement of the carrier and ply through the manufacturing system in Figure 1 in an exemplary embodiment is depicted. [Figure 3B] The movement of the carrier and ply through the manufacturing system in Figure 1 in an exemplary embodiment is depicted. [Figure 4] The movement of the carrier and ply through the manufacturing system in Figure 1 in an exemplary embodiment is depicted. [Figure 5] The movement of the carrier and ply through the manufacturing system in Figure 1 in an exemplary embodiment is depicted. [Figure 6] The movement of the carrier and ply through the manufacturing system in Figure 1 in an exemplary embodiment is depicted. [Figure 7] Figure 1 illustrates multiple carriers moving through the manufacturing system in an exemplary embodiment. [Figure 8] This is a flowchart illustrating a method for operating a manufacturing system for curved preforms of fiber-reinforced materials in an exemplary embodiment. [Figure 9A] A further arrangement of the stacking station and PBP formation station in one exemplary embodiment is shown. [Figure 9B] This diagram illustrates the flow of material through a manufacturing system for curved preforms of fiber-reinforced material in an exemplary embodiment. [Figure 10A] A carrier moving along a curved trajectory in one exemplary embodiment is depicted. [Figure 10B]This diagram illustrates the coupling of carriers to orbitals in an exemplary embodiment. [Figure 11] A carrier for transporting plies to be attached to a PBP forming station in an exemplary embodiment is depicted. [Figure 12] A carrier and ply rotating from horizontal to vertical orientation in an exemplary embodiment are depicted. [Figure 12A] Further illustrations show a carrier and ply rotating from horizontal to vertical orientation in an exemplary embodiment. [Figure 13] A further manufacturing system for curved preforms in an exemplary embodiment is depicted. [Figure 14] A drawing shows a raised rail that allows an engineer to pass underneath it in an exemplary embodiment. [Figure 15] The illustration depicts a technician in a manufacturing system including a PBP forming station for a semicircular preform in an exemplary embodiment. [Figure 16] This is a block diagram of a manufacturing system for curved preforms in an exemplary embodiment. [Figure 17] This is a flowchart illustrating a method for manufacturing and maintaining an aircraft in an exemplary embodiment. [Figure 18] This is a block diagram of an aircraft in an exemplary embodiment. [Modes for carrying out the invention]

[0011] Specific exemplary embodiments of the Disclosure are provided by the drawings and the description below. Therefore, those skilled in the art can devise various configurations not expressly described or illustrated herein to concretely implement the principles of the Disclosure, but should be understood to be within the scope of the Disclosure. Furthermore, any embodiments described herein are intended to aid in understanding the principles of the Disclosure and should be interpreted as not being limited to the specifically described embodiments or conditions. Consequently, it is the claims, not the specific embodiments or examples described below, that limit the Disclosure.

[0012] Composite material parts, such as carbon fiber reinforced polymer (CFRP) parts, are first laid up in multiple layers collectively referred to as preforms. The individual fibers within each layer of the preform are aligned parallel to each other, but may exhibit various fiber orientations along different dimensions to enhance the strength of the resulting composite material part. The preform contains a curable adhesive resin to solidify the preform into a composite material part (e.g., for use in an aircraft). Carbon fibers impregnated with an uncured thermosetting resin or thermoplastic resin are referred to as "prepregs". Other types of carbon fibers include "dry fibers" that are not impregnated with a thermosetting resin, but may contain a tackifier or binder. The dry fibers may be injected with resin prior to solidification. With respect to thermosetting resins, solidification is a one-way process called curing, while with respect to thermoplastic resins, the resin becomes viscous when reheated and then solidifies and solidifies into the desired shape. As used herein, the comprehensive term for the process of transitioning a preform to its final solidified shape (i.e., transitioning the preform to a composite material part) is called "hardening", and this term includes both the curing of thermosetting preforms and the forming / solidification of thermoplastic preforms into their final desired shape.

[0013] FIG. 1 shows a manufacturing system 100 for a curved preform of a fiber reinforced material in an exemplary embodiment. The laminating station 130 lays up one or more plies 220 on a carrier 210 of a flexible material (described below in connection with FIGS. 2-6). The manufacturing system 100 includes a plurality of ply-by-ply (PBP) forming stations 140. Each PBP forming station 140 manufactures a curved preform 146 by repeatedly shaping an individual ply 220 supplied on a carrier 210 of a flexible material 211 to conform to a mandrel 142 (e.g., a contoured mandrel). In one embodiment, the PBP forming station 140 includes a forming station that applies a clamping force along an arc, such as that described in U.S. Patent No. 9,314,974. In a further embodiment, the PBP forming station 140 forms a complex shape by covering the corners of the mandrel 142 with plies before shaping the plies 220.

[0014] FIG. 1 shows that the PBP forming stations 140 are arranged in a curved pattern 144 (e.g., an arc or a circle) and are accessible via a rail system 110. The rail system 110 includes tracks 118. The tracks 118 are contoured and form one or more loops (e.g., an inner concentric circle 116, an outer concentric circle 112) between the laminating station 130 and the PBP forming stations 140. In a further embodiment, other access means such as automated vehicles or tracks are utilized. The inner concentric circle 116 is adjacent to a plurality of ply-by-ply (PBP) forming stations 140, and the outer concentric circle 112 is adjacent to at least one laminating station 130. Thus, the tracks 118 couple the laminating station 130 to the PBP forming stations 140. In a further embodiment, routing and moving the carrier 210 includes advancing the carrier 210 through its path.

[0015] The concentric circles are connected via a branch line 114, which includes a confluence point in the outer concentric circle 112 and the inner concentric circle 116. That is, the track 118 forms a branch line 114 that connects both the outer concentric circle 112 and the inner concentric circle 116. The branch line 114 includes a portion of the track 118 positioned between the outer concentric circle 112 and the inner concentric circle 116. The track 118 is lifted and held in place by a support 120 (e.g., a post). In this embodiment, the support 120 is positioned between the outer concentric circle 112 and the inner concentric circle 116. This positioning allows access to the track 118 of the rail system 110 by an engineer 101 operating within a workspace 150 inside the manufacturing system 100 (e.g., within the range of the inner concentric circle 116, and therefore defined by the rail system 110). Furthermore, access to the track 118 (e.g., entry and exit) is also possible by technicians 101 positioned outside the manufacturing system 100. That is, technicians 101 inside the workspace 150 can walk to the equipment in the inner concentric circle 116, and technicians 101 outside the manufacturing system 100 can walk to the equipment in the outer concentric circle 112. In other embodiments, the support 120 is positioned at other locations relative to the outer concentric circle 112 and the inner concentric circle 116.

[0016] The branch lines 114 allow transitions between different sections of the track 118, connecting the outer concentric circle 112 and the inner concentric circle 116 together. Thus, when a carrier 210 (for example, shown in Figures 2-6) can be routed and moved to the inner concentric circle 116, there is no backup in the outer concentric circle 112. In a similar manner, if a carrier 210 in the inner concentric circle 116 is currently loaded into the PBP forming station 140, an upstream carrier 210 in the outer concentric circle 112 can be routed and moved to the next branch line 114 downstream of the loaded carrier 210 to arrive at the PBP forming station 140 without waiting. Each of the branch lines 114 can therefore be used to move material between the outer concentric circle 112 and the inner concentric circle 116. By moving to the inner concentric circle 116, the ply 220 (for example, as shown in Figures 2 to 6) is placed within ergonomically accessible reach of a technician 101 located within the workspace 150 for inspection, other work, and / or assistance with movement. In further embodiments, the paths between the outer concentric circle 112 and the inner concentric circle 116, and between the stacking station 130 and the PBP forming station 140, may proceed clockwise or counterclockwise. The paths on the outer concentric circle 112 and the inner concentric circle 116 may proceed clockwise or counterclockwise. The branch line 114 effectively off-ramps from the outer concentric circle 112 and on-ramps to the inner concentric circle 116. In further embodiments, the switching operation in the branch line 114 is controlled based on received RFID information.

[0017] Lamination stations 130 lay up plies 220 onto carriers 210 of flexible material 211 (described below in relation to Figures 2-6). The carriers 210 are positioned on layup mandrels 132. The carriers 210 are then transported to place the plies 220 onto PBP forming stations 140. Two lamination stations 130 are illustrated, but more or fewer lamination stations 130 are possible depending on design considerations. A supply line 134 supplies the fiber-reinforced material 221 shown in Figure 2 to the lamination stations 130 in a just-in-time (JIT) manner. The carriers 210 advance along rail systems 110 toward PBP forming stations 140 for attachment to mandrels 142 and for accumulating / consolidating into preforms 146 for composite parts. In the PBP formation process used by the PBP formation station 140, a single ply (or a small group of plies) 220 is formed onto the base of a preform 146 according to the desired contours, and then additional plies 220 are added to and formed onto the preform 146 until the preform 146 is complete. In further embodiments, each lamination station 130 is different. For example, different lamination stations 130 may produce plies 220 with different fiber orientations as needed. The plies 220 laid up by the lamination station 130 are arranged in a flat pattern, and each flat pattern may be associated with a different identifier provided by a radio frequency identification (RFID) chip 213 on a carrier 210. In further embodiments, there are multiple further inner concentric circles, each having a lamination station therein.

[0018] The track 118 can be positioned at various heights / altitudes above the factory floor. Thus, up to four stacking stations 130 may have four rail systems 110, including outer concentric circles 112, branch lines 114, and inner concentric circles 116 at four different heights / altitudes above the factory floor. Each rail system 110 can supply plies to the PBP forming station 140 and can be tracked according to the method using the RFID system. The order in which the plies 220 are attached from the rail systems 110 is predetermined before the plies 220 on the carrier 210 leave the stacking station 130.

[0019] Depending on the embodiment, each of the lamination stations 130 can lay up plies to supply to one or more PBP forming stations 140. In one embodiment, the lamination station 130 remains stationary while performing layup onto the carrier 210. However, in further embodiments, the lamination station 130 moves along or next to the carrier 210 and / or track 118 during layup as necessary to form plies (e.g., via actuators or other motorized elements not shown). The lamination station 130 can lay up plies via automated lamination techniques (e.g., automated taping, laying, or fiber placement), via a combination of composite cutting machines and lifting and placement techniques, or via any suitable means onto a carrier (e.g., carrier 210 in Figure 2) positioned on the layup mandrel 132. Furthermore, the lamination station 130 can perform lamination in horizontal or vertical orientation as necessary by placing the fiber-reinforced material 221 on a horizontal layup surface or a vertical layup surface, respectively. After the layup for preform 146 is completed, a new layup mandrel (for example, for a different design of preform 146) can be replaced with the current layup mandrel 132 at the lamination station 130. Since the carrier 210 is conformable, it adapts to the geometric shape of the current layup mandrel 132.

[0020] In one embodiment, a lamination station 130 dynamically lays up plies (e.g., plies 220 in Figure 2) for multiple preforms according to the design of the current preform (e.g., preform 146 in Figure 1) being formed by each PBP forming station 140. For example, a first PBP forming station 140 can manufacture a preform 146 by mounting the plies on a carrier 210 until the preform 146 is completed for an aircraft frame. A second PBP forming station 140 can manufacture preforms for frames of different designs for aircraft. A third PBP forming station 140 can manufacture a preform 146 for door frames or window frames. Each ply 220 for each preform 146 being manufactured may therefore be shaped differently or exhibit different fiber orientations to facilitate design. Thus, various plies 220 may include various configurations of fiber-reinforced material arranged in various fiber orientations. In other words, the PBP forming station 140 repeatedly shapes individual plies 220 to fit the mandrel 142.

[0021] Even in embodiments where ply 220 is laid up for PBP forming stations 140 manufacturing preforms of the same design, the ply 220 used for each layer of those preforms 146 may vary throughout the thickness of the preform 146. Thus, ply 220 laid up for one PBP forming station 140 in the first stage of manufacturing may differ from ply 220 laid up for a PBP forming station 140 in the second stage of manufacturing for a preform of the same design. Furthermore, although only one preform 146 is shown in Figure 1, it will be understood that preforms 146 may be manufactured simultaneously in each of the forming stations 140 (for example, resulting in four preforms 146 being formed simultaneously in the forming station in Figure 1).

[0022] In one embodiment, the stacking station 130 dynamically determines which plies 220 to lay up based on the progress of each PBP forming station 140. In a further embodiment, the order of the plies 220 to be laid up is predetermined. In any case, a carrier 210 carrying plies intended for a distant PBP forming station 140 may be routed and moved through the outer concentric circles 112 to advance, passing carriers 210 that are stopped at other PBP forming stations 140. In some embodiments, the carrier 210 advances by continuously passing through the rail system 110. On the other hand, in a further embodiment, the carrier 210 "pulsed" in the direction indicated by the arrow 192 in Figure 1, and may pulsate in different directions in the clockwise, counterclockwise, or concentric circles, respectively. The carrier 210 pulsates by moving forward synchronously and then stopping synchronously at regular intervals according to a desired takt time. The pulsating motion along arrow 192 may be performed as “micropulses,” whether manual or automated, in which case the carrier 210 moves less than their length per movement, or it may be performed as “full pulses,” in which case the carrier 210 advances at least their entire length per pulsation.

[0023] Figure 1 further illustrates the controller 199. In this embodiment, the controller 199 is coupled to communicate with the stacking station 130 and the PBP forming station 140, and / or the track 118 and the RFID scanner 215 in Figure 2. In this embodiment, the controller 199 coordinates the operation of the depicted devices and the movement of the carrier 210 along the rail system 110 in a coordinated and synchronized manner. In this case, the carrier 210 is prevented from traffic congestion with other carriers 210 in the rail system 110. This can be achieved, for example, by coordinating the operation of the stacking station 130, the PBP forming station 140, and / or the carrier 210 according to one or more numerical control (NC) programs. In one embodiment, the controller 199 is implemented as a custom circuit, as a hardware processor that executes programming instructions stored in memory, or in any combination thereof.

[0024] In a further embodiment, the manufacturing system 100 is used for just-in-time (JIT) supply of preforms 146 for frames or components to a moving line. In this case, the ply 220 is supplied to the PBP forming station 140 when needed, without the need for the PBP forming station 140 to maintain an inventory of the ply 220. Frames are supplied by the manufacturing system 100 when needed by subsequent manufacturing systems (such as for aircraft fuselage assemblies), without the need for those systems to maintain an inventory of those frames.

[0025] Components moving along the line may pulsate for a length less than or equal to their length, and then be stopped. Alternatively, components may move continuously. Various elements moving along the rail system 110 may be moved via an automated or manual process in the process direction. In one embodiment, up to four preforms 146 are manufactured simultaneously. The progress of each preform 146 is tracked by a controller 199 via inputs from the PBP forming station 140 and / or the stacking station 130. Based on the inputs received, the controller 199 determines the order and / or orientation of the plies 220 attached to each of the PBP forming stations 140, as well as the order and / or orientation of the plies 220 that have not yet been attached.

[0026] In a further embodiment, the carrier 210 includes identifiers such as markings, barcodes, or radio frequency identification (RFID) chips 213. These are used to track the plies laid up on the carrier 210, as well as the movement of the carrier 210 from the stacking station 130 to the PBP forming station 140 and in the reverse direction. In such embodiments, a tracking system 194 (e.g., a laser scanner, optical device, RFID scanner 215, etc.) detects the progress of the carrier 210 through the rail system 110. In one embodiment, the stacking station 130 and / or the PBP forming station 140 are positioned directly above or below the rail system 110 to facilitate mounting / removal operations. This can also eliminate concerns regarding congestion or bagging up. In one embodiment, the rail system 110 moves the carrier 210 continuously at a height above the factory floor.

[0027] Figures 2–6 illustrate the movement of the carrier 210 and ply 220 through the manufacturing system 100 of Figure 1 in an exemplary embodiment. In this embodiment, it is assumed that the stacking station 130 lays up the ply 220 on the carrier 210. The carrier 210 is made from a flexible material such as a deformable flexible fabric that elastically returns to its original shape after deformation, the material described in U.S. Patent No. 8,551,380, the material described in U.S. Patent No. 9,701,067, etc. The ply 220 is temporarily fastened or otherwise attached to the carrier 210. This means that as the carrier 210 moves along the track 118, the ply 220 is held in contact with the carrier 210 and bends with the carrier 210. That is, the bending / bending of the carrier 210 during its movement is not the same as the PBP formation process described above, but rather occurs during transport before the ply 220 experiences PBP formation. The newly accepted carrier 210 can be disengaged from the track 118 before being delivered to the stacking station 130 or the PBP station 140.

[0028] After the layup (for example, for one or two plies to be formed together on the preform 146 at the PBP forming station 140) is complete, the carrier 210 is placed on the track 118 of the rail system 110, as shown in Figure 2. The carrier 210 then moves forward through the rail system 110. Since the rail system 110 includes the curved track 118, the carrier 210 bends to flex along the track 118. The plies 220 on the carrier 210 are originally laid in a flat pattern that conforms to the undulations of the preform 146. The plies 220 adapt to the curvature of the track 118 during transport to the PBP forming station 140, but the transport operation does not impart permanent undulations to the plies 220.

[0029] The dynamic changes in the shape of the carrier 210 brought about by the track 118 result in the carrier 210 exhibiting an inward curve 214 and an outward curve 212. In this embodiment, the ply 220 occupies the inward curve 214 of the carrier 210 while the carrier 210 is positioned in the outer concentric circle 112. In Figure 3A, the carrier 210 switches tracks at the confluence point 115 and moves forward into the inner concentric circle 116. Since the carrier 210 is flexible and the ply 220 is either temporarily fastened or otherwise held by the carrier 210, the ply 220 and the carrier 210 adapt to the curvature of the portion of the track 118 through which they pass. For this reason, the track 118 is dimensioned to provide a geometric shape in which the radius of curvature is always at least equal to or greater than a predetermined amount (e.g., 10 inches, 2 feet, etc.). In one embodiment, the radius of curvature is always directly related to the radius of the last manufactured preform 146. The track 118 has undulations or arcs such that the ply 220 and carrier 210 remain fixed together (i.e., not tighter than a threshold of radius of curvature), but can also support a range of geometric shapes for the stacking station 130. This range of geometric shapes allows for the manufacture of preforms 146 with various radii of curvature. This curvature ensures that the carrier 210 and ply 220 are not distorted in such a way that the ply 220 cannot be separated from the carrier 210 during transport, whether through a manual or automated process.

[0030] Figure 3A shows that the carrier 210 follows a "U" shape 217 when being transported via a manual or automated process while moving along the branch line 114. In one embodiment where the carrier 210 hangs vertically from the track 118, the carrier 210 may have its orientation changing from horizontal to vertical (for example, by rotating the carrier 210). Thus, in such an embodiment, laying up the ply 220 is performed while the carrier 210 is oriented horizontally. Loading the carrier 210 involves oriented the carrier 210 vertically. The "U" shape 217 is followed when the carrier 210 bends to transition from a rotating outer concentric circle 112 to a counter-rotating inner concentric circle 116 via a manual or automated process. This results in the ply 220 occupying the outer curve of the carrier 210. This allows the ply 220 to be positioned in direct contact with the mandrel 142, thereby attaching the first ply for the preform 146, or adding material to the preform 146 already placed on the mandrel 142. However, in a further embodiment shown in Figure 3B, if both the outer concentric circles 112 and the inner concentric circles 116 rotate in the same direction via a manual or automated process, the "S" shape 219 is followed as the carrier 210 bends to transition from the outer concentric circles 112 to the inner concentric circles 116. In one embodiment in which the carrier 210 hangs vertically from the track 118, the carrier 210 may have its orientation changing from horizontal to vertical (for example, by rotating the carrier 210). Thus, in such an embodiment, laying up the ply 220 is performed while the carrier 210 is oriented horizontally, and loading the carrier 210 includes oriented the carrier 210 vertically. In this embodiment, a step of rotation or inversion is required before providing the ply 220 to the mandrel 142, but in a further embodiment, the preform 146 is attached to the carrier 210 in such a manner that the preform 146 faces the mandrel 142 after the "S" shape 219 has been followed.

[0031] In Figure 4, the carrier 210 has completed its movement through the branch line 114 via a manual or automated process. The carrier 210 has arrived at the PBP forming station 140. The portion of track 118 over which the carrier 210 has moved may be referred to as the first track 118 that leads from the stacking station 130 to location 410 before being placed at the PBP forming station 140. The ply 220 has not moved relative to the carrier 210, but due to the curvature of track 118, it now occupies the outer curve 212 of the carrier 210 and may be placed directly on the mandrel 142 of the PBP forming station 140.

[0032] Figure 5 shows the carrier 210 and ply 220 separated from the rails via a manual or automated process and pressed to contact the mandrel 142 and / or preform 146 of the PBP forming station 140. In a further embodiment, the PBP forming station 140 further performs covering and / or rotation of the carrier 210 and ply 220 to form the ply 220 into a desired complex contour. The carrier 210 is then removed from the ply 220 (for example, by peeling off the carrier 210 via manual or automated means) and returned to the rail system 110 in Figure 6. Peeling may be performed via a manual or automated process. The ply 220 now shows the outer frame portion 222 and the inner frame portion 224. The carrier 210 then moves along the rail system 110 from the inner concentric circle 116 to the outer concentric circle 112 for cleaning, repositioning, or reuse at the stacking station 130 (for example, moving only in the reverse direction via the branch line 114, as described above in relation to Figures 3A-3B). The portion of the track 118 over which the carrier 210 has moved to return for reuse may be referred to as the second track 118 leading from the PBP forming station 140 to the stacking station 130. The ply 220 is then formed on the mandrel 142 or on the preform 146 already placed on the mandrel 142.

[0033] Figure 7 depicts multiple carriers 210 moving through the manufacturing system of Figure 1 in an exemplary embodiment. As shown in Figure 7, the rail system 110 supports the use of multiple carriers 210 at one time. To ensure a continuous flow of material without blocking or interference between different carriers, the multiple carriers 210 can advance in the same direction 700 through each of the concentric circles of the track 118. The carriers 210 return to the stacking station 130 along the outer concentric circle 112 for the carriers 210. Thus, once the layup is placed on the carriers 210, the carriers 210 move to the inner concentric circle 116, where they are removed and moved to align with the PBP forming station 140, and then the carriers 210 move back to the inner concentric circle 116 and proceed to the outer concentric circle 112 to return to the stacking station 130 to bond with the ply 220. Throughout the entire process, the carriers 210 are tracked through the engineer 101 and / or components of the rail system 110.

[0034] Similarly, a multi-level track system having up to four stacking stations 130 per level of track 118 may also be employed. Track 118 moves the carrier 210 (carrying the ply 220) through the outer concentric circle 112 to the branch line 114, to the inner concentric circle 116, and to a location 410 for placement at the PBP station 140. One technician 101 may move the carrier 210 to the PBP forming station 140 from one of the multi-levels at a time, via a manual or automated system. Two or more technicians 101 may work simultaneously in the workspace 150.

[0035] Once the preform 146 is completed, it can leave the rail system 110 to be cured in an autoclave dimensionally determined for the preform 146, or in any suitable processing device. The preform 146 can leave the manufacturing system 100 via any suitable direction, such as by moving below or above the rail system 110.

[0036] In a further embodiment, the rail system 110 includes any suitable number of levels of any suitable combination of track rails, branch lines, and / or concentric or nested sections. It allows multiple carriers 210 to move back and forth from the stacking station 130 to the PBP forming station 140 in a synchronized manner and without interference. In such an embodiment, branch lines 114 act as multiple modular connecting points. They facilitate transitions between concentric sections of track 118, nested sections of track 118, and so on.

[0037] Exemplary details of the operation of the manufacturing system 100 are described in relation to Figure 8. In this embodiment, it is assumed that the manufacturing system 100 is preparing to manufacture multiple preforms 146 at once via the PBP forming station 140.

[0038] Figure 8 is a flowchart illustrating a method 800 for operating a manufacturing system for a fiber-reinforced material 221 preform 146 (e.g., a curved preform) in an exemplary embodiment. The steps of method 800 are described with reference to the manufacturing system 100 in Figure 1, but it will be understood by those skilled in the art that method 800 may be performed in other systems. The steps of the flowchart described herein are not exhaustive and may include other steps not shown. The steps described herein may be performed in an alternative order.

[0039] In step 802, one or more stacking stations 130 identify a set of curved preforms being manufactured by a PBP forming station 140. The PBP forming station 140 is located in a rail system 110. In one embodiment, step 802 includes operating the stacking stations 130 according to an NC program designed to implement a numerical control (NC) program that controls the PBP forming station 140. In a further embodiment, the stacking station 130 detects progress information from the PBP forming station 140 or another source and continuously determines which ply 220 is next required. In yet another embodiment, a controller 199 that manages the PBP forming station 140 and the stacking station 130 selects ply to be laid up based on a predetermined schedule.

[0040] In step 804, the lamination station 130 lays up at least one ply on the carrier 210. The carrier 210 is made of a flexible material. In one embodiment, the lamination station 130 lays up plies 220 for a preform 146 (e.g., a curved preform) on the carrier 210 at the lamination station 130. Each of the plies 220 is arranged on the carrier 210 in a flat pattern with a shape that facilitates conforming to a desired contour during formation at the PBP station 140. In one embodiment, each lamination station 130 lays up a ply 220 (e.g., a single ply) on the carrier 210. In a further embodiment, the lamination station 130 lays up multiple plies 220 on the carrier 210 at once (e.g., one ply on top of another). Each ply may have a slightly different flat pattern shape to facilitate formation to a certain contour (and formation to a certain contour on multiple plies). In further embodiments, each of the lamination stations 130 performs layups on multiple carriers 210 at once. In further embodiments, more or fewer lamination stations 130 and / or PBP forming stations 140 operate simultaneously to produce a number of preforms 146 equal to the number of PBP forming stations 140 during the same period. In one embodiment, the carriers 210 may be horizontally oriented and flat during the layup of the plies. In a further embodiment, the lamination station 130 performs lamination of the plies 220 into horizontal or vertical orientation as needed by arranging the fiber-reinforced material 221 on a horizontal layup surface or a vertical layup surface, respectively.

[0041] The lamination station 130 can lay up the ply 220 via an automated lamination technique (e.g., automated taping, laying, or fiber placement) via a combination of composite cutting machine and lifting and placement techniques or via any suitable means. In one embodiment, the ply 220 includes a piece of fiber-reinforced material 221 having a desired fiber orientation (e.g., 0°+ / -45°, 90°), such as a piece of CFRP. In a further embodiment, the ply 220 includes a fabric of pre-impregnated woven fiber-reinforced material, pre-impregnated random fibers, or pre-impregnated discontinuous fibers. The ply 220 may include a cut piece of a wide article formed via a manual lay-up technique and may be manufactured from a tow via an automated tape lay-up machine (ATLM), an advanced fiber placement (AFP) machine, etc. In one embodiment, the lamination station 130 compacts and / or heats the resin of the ply 220 to temporarily fix it to the carrier 210. This temporarily fastens the ply 220 to the carrier 210 so as the carrier 210 moves forward through the outer concentric circle 112, the branch line 114, and the inner concentric circle 116, it is sufficient to facilitate the flexibility of the combination of the ply 220 and the carrier 210.

[0042] In step 806, the carrier 210 is loaded onto the rail system 110. In one embodiment, this includes attaching the carrier 210 to the track 118 of the rail system 110 in the outer concentric circle 112. Thereafter, the carrier 210 can hang from the track 118 and slide or roll along the track 118 in the longitudinal direction relative to the track 118 (as depicted in Figures 10-11). For example, in one embodiment, the carrier 210 includes a number of attachment points that are inserted into or hang from the track 118, allowing the carrier 210 to hang from the track 118, as shown in Figure 10A. Furthermore, in step 806, the orientation of the carrier 210 may be changed to accommodate placement on the track 118. In one embodiment where the carrier 210 is suspended vertically from the track 118 (as depicted in Figure 12), the carrier 210 may have an orientation that changes from horizontal to vertical (for example, by rotating the carrier 210). Thus, in such an embodiment, laying up the ply 220 is performed while the carrier 210 is oriented horizontally, and loading the carrier 210 includes oriented the carrier 210 vertically (as depicted in Figure 12).

[0043] In step 808, the carrier 210 is routed and moved to a specific forming station 140 based on the characteristics of at least one ply 220 carried by the carrier 210 (for example, depending on the preform 146 to which at least one ply 220 of the carrier 210 is intended). In one embodiment, the carrier 210 is routed and moved to various PBP forming stations 140 based on the ply 220 carried by the carrier 210. The characteristics of the ply 220 may include the size of the flat pattern of the ply 220 and the orientation of the fibers. Thus, based on these characteristics, the ply 220 may be suitable for a particular layer of a particular preform 146 currently being manufactured at a particular PBP forming station 140. Thus, based on these characteristics of the ply 220, the carrier 210 may be routed and moved to various PBP forming stations 140.

[0044] In other words, the carrier 210 is routed and moved to a PBP forming station 140 that will utilize those plies 220. In one embodiment, routing and moving the carrier 210 to a PBP forming station 140 includes identifying a confluence point 115 before the PBP forming station 140 (for example, located adjacent to or upstream of it), moving the carrier 210 to the confluence point 115, and switching the carrier 210 to a track 118 at the confluence point 115, which leads directly to the PBP forming station 140. As shown in Figures 3A and 3B, during routing and movement, the transition from the outer concentric circle 112 to the inner concentric circle 116 is made using the confluence point 115 immediately preceding the desired PBP forming station 140. In one embodiment, routing and moving the carrier 210 to a specific PBP forming station 140 in the rail system 110 is based on the characteristics of the plies 220 being carried by the carrier 210. The characteristics of ply 220 include the size of the flat pattern and the orientation of the fibers.

[0045] Each carrier 210 is routed and moved to a PBP forming station 140. The PBP forming station 140 will utilize the plies 220 carried by the carriers 210 during the next PBP forming process for the preform 146 currently being manufactured by the PBP forming station 140. In one embodiment, routing and moving the carriers 210 includes bending / deforming / flexing the shape of the carriers 210 as they move along the rail system 110. Bending / flexing the shape of the carriers 210 facilitates the movement of the carriers 210 and plies 220 along the rail system 110 and does not cause a permanent change in shape. The rail system 110 bends the carriers 210 to temporarily conform to the track 118 as the carriers 210 move. This is due to the shape of the rail system 110 and the length of the carriers 210. In a further embodiment, routing and moving the carrier 210 includes advancing the carrier 210 through one or more loops (e.g., inner concentric circles 116, outer concentric circles 112) between the rail system 110 formed between the stacking station 130 and the PBP forming station 140.

[0046] In step 810, at least one ply 220 is separated from the carrier 210. In one embodiment, the ply 220 is attached from the carrier 210 to a corresponding PBP forming station 140. This includes transferring the ply 220 to the mandrel 142 and / or preform 146 of the PBP forming station 140. In one embodiment, this includes pressing the carrier 210 toward the mandrel 142 until the ply 220 in the carrier 210 comes into contact with and adheres to the mandrel 142 or the preform 146 formed on the mandrel 142. In further embodiments, as each ply 220 is attached, the controller 199 instructs the technician to attach a particular ply 220 and / or separate the carrier 210 from the ply 220 (e.g., according to timing information or feedback from the PBP forming station 140).

[0047] The carrier 210 is removed from the ply (or preform) by removing the temporary fastening between the carrier 210 and the ply 220, for example, by mechanical or manual peeling (e.g., peeling). The carrier 210 is then returned to the track 118 of the rail system 110, returned to the stacking station 130 for reuse via the rail system 110, moved to the washing station for cleaning, or completely removed from the rail system 110.

[0048] In step 812, at least one ply 220 is fabricated onto a preform 146 via a specific PBP forming station 140. Upon receipt at the PBP forming station 140, the ply 220 is formed. That is, after each ply 220 has been transferred to the PBP forming station 140, the PBP forming station 140 forms the ply 220 on an existing preform (or mandrel 142, if the ply 220 is the first ply of the preform). Depending on the embodiment, this may be performed while the carrier 210 remains in contact with the ply 220, or after the carrier 210 has been separated. This operation (e.g., a compaction operation) integrates the ply 220 with the underlying preform 146, if the preform 146 is present at the PBP forming station 140. This operation also temporarily fastens the ply 220 to the preform 146. In some embodiments, once step 812 is completed, a further step 814 includes returning the carrier 210 to the stacking station 130 via the rail system 110. The returning step 814 may be performed via a branch line 114 in the rail system 110.

[0049] Method 800 offers substantial benefits that surpass prior systems and techniques, because it enables a higher work density than prior systems. Multiple lamination stations 130 are clustered closer to the forming stations 140 than before, thereby significantly increasing the work density. Specifically, more PBP forming stations 140 can be placed within a proximity range to form preforms 146 for composite parts (e.g., curved preforms). Multiple PBP forming stations 140 (e.g., four stations) can be monitored by a single technician, which increases work efficiency. Specifically, a single technician 101 can provide automated or semi-automated operation of the PBP forming stations 140, for example, by removing carriers 210 or performing visual inspections.

[0050] Figure 9A illustrates a further arrangement of lamination stations and PBP forming stations in an exemplary embodiment. In this embodiment, the manufacturing system 950 includes lamination stations 912 and 914. They lay up plies of fiber-reinforced material on carriers 904 for supply to PBP forming stations 922, 924, 926, and 928. Lamination station 912 is supplied by fiber-reinforced material supply line 916. Lamination station 914 is supplied by fiber-reinforced material supply line 918.

[0051] The carrier 904 moves along the trajectory 902 in the direction indicated by the arrow, providing plies to the PBP forming station 140 as needed. Two lamination stations 130 and four PBP forming stations 140 are illustrated, but in further embodiments, any appropriate number of each may be used (e.g., four lamination stations and four PBP stations). In a further embodiment, each of the lamination stations 130 is dedicated to layups with different fiber orientations (e.g., +45 degrees, -45 degrees, 90 degrees, 0 degrees). This can reduce the complexity of the lamination stations 130, while also increasing throughput.

[0052] Figure 9B is a diagram of the material flow through the manufacturing system 950 of Figure 9A for a curved preform of fiber-reinforced material in an exemplary embodiment. In Figure 9B, material such as ply 220 flows from lamination stations 912 and 914 to PBP forming stations 922, 924, 926, and 928. According to Figure 900, lamination stations 912 and 914 determine the next ply for the preform being manufactured at PBP forming station 140. In this embodiment, all of the PBP forming stations 140 are at the same stage of manufacturing for a preform 146 of the same design. This means that the newly generated ply 220 may be supplied to any of the PBP forming stations 140.

[0053] Laying stations 912 and 914 lay up plies of a flat pattern onto the carrier 210, which then moves forward through the PBP forming station 140. The periphery of the flat pattern is sized to the specific positions where the plies can be placed within the preform 146 and the reliefs designed for those plies 220. Since the laying stations 912 and 914 are located at different positions along the rail system 110, as the carrier 210 moves along the rail system 110, they arrive at different PBP forming stations first. Specifically, the carrier 210 from laying station 912 arrives at PBP forming station 926 first, while the carrier 210 from laying station 914 arrives at PBP forming station 922 first. These are indicated by the top “move carrier forward” arrows from laying station 912 and from laying station 914. Next, the plies are attached to the PBP formation stations 922 and 926.

[0054] Lamination stations 912 and 914 prepare further plies. They are laid up on carrier 210 and moved along rail system 110. In a further embodiment, different carriers 904 are positioned at different points in Figure 9A (for example, at the lamination station, on track 902, at PBP formation station 922 or 926 before peeling, and at PBP formation station 922 or 926 after peeling).

[0055] Upon reaching PBP formation stations 926 and 922, it is determined that these stations are blocked. Therefore, the carrier 210 proceeds to PBP formation stations 924 and 928, and the plies are attached to those PBP formation stations 924 and 928. Once the PBP formation operation for individual plies is complete, the corresponding carrier 210 for those plies 220 is detached from the plies 220 and returned to the stacking station 130 via the rail system 110.

[0056] With the above-described overall process flow, the following drawings illustrate exemplary embodiments of the track and carrier. Figure 10A depicts a rail system 1000, in which the carrier 1030 moves along a curved track 1010 in one exemplary embodiment. In this embodiment, a support 1020 holds the track 1010 in an elevated position. The track 1010 may include an inner concentric circle 116, an outer concentric circle 112, a branch line 114, or a portion of another part of the rail system 110. The support 1020 includes a post 1022, which supports a head 1024 from which an arm 1026 protrudes. The carrier 1030 includes a plurality of components, which include a body 1032 made of flexible material and a band 1034 that is thicker than the body 1032. In this embodiment, the band 1034 is heavier than the body 1032 and helps the carrier 1030 move along the track 1010 by ensuring that the carrier 1030 is constantly suspended from the track 1010. The mounting element 1036 is attached to the carrier 1030 and enables a sliding or rolling mounting of the carrier 1030 to the track 1010, and may include, for example, wheels or rollers that fit into grooves or protrusions of the track 1010. In a further embodiment, the mounting element 1036 or the track 1010 includes motorized wheels that enable automatic movement of the carrier 1030 as needed. In any case, the mounting element 1036 moves slidably on the track 118.

[0057] The carrier 1030 is attached to the mounting element 1036 and moves along the track 1010 using the mounting element 1036, bending / flexing to conform to the uneven track as it moves. As the carrier 1030 moves forward along the track 1010, it hangs vertically from the track 1010 and flexes to conform to the unevenness of the track 1010. This feature is made possible by the flexible nature of the body 1032 of the carrier 1030.

[0058] Figure 10B illustrates the coupling of the carrier to the track in an exemplary embodiment, corresponding to arrow 10B in Figure 10A. As shown in Figure 10B, the retaining element 1044 positioned on the rod 1042 of the carrier 1030 slides into a channel 1052 defined by the body 1050 in the track 1010. Thus, the channel 1052 is for receiving the retaining element 1044 of each mounting element 1036. The retaining element 1044 (e.g., a wheel or a stationary button) is inserted from the end of the track 1010 or positioned within the range of the track 1010 in a notch. As the carrier 1030 moves in or out of the page along the track 1010, the retaining element 1044 slides within the channel 1052. In a further embodiment, a roller 1054 positioned on the track 1010 or carrier 1030 drives the retaining element 1044 through the track 1010 (for example, by rotating the roller or retaining element 1044).

[0059] Figure 11 illustrates a carrier 1030 for transporting plies to be attached to a PBP forming station in an exemplary embodiment. The plies 1100 are temporarily attached to the carrier 1030 (for example, by applying pressure during layup, thereby fixing the resin within the plies 1100 to the surface of the body 1032 in accordance with the applied heat and compaction force). The plies 1100 themselves are also flexible to a limited extent. Therefore, as long as the radius of curvature (R) of the track 1010 remains greater than a predetermined limit, the preforms 1100 remain attached to the carrier 1030.

[0060] Figure 12 illustrates a carrier 1220 and ply 1222 rotating from horizontal orientation to vertical orientation in an exemplary embodiment. This depicts the carrier 1220 at a series of points in time during the transition between orientations, which are shown in Figure 12 as horizontal orientation 1250, orientation 1252, orientation 1254, and vertical orientation 1260. The rotation facilitates the transition of the carrier 1220 from horizontal orientation 1250 to receive layups from the stacking head 1210 at the stacking station 1200, to vertical orientation 1260 to perform transport on the track 1230. In one embodiment, the stacking station 1200 lays up ply 1222 onto the carrier 1220. Meanwhile, the carrier 1220 is in horizontal orientation 1250, and after the layup of the ply is complete, the carrier 1220 becomes vertical orientation 1260 via a rotating machine 1240 (e.g., an end effector or rotating element). In one embodiment, the rotating machine 1240 may cause the carrier 1220 to connect to the track 1230 while it is in a horizontal orientation 1250, and then allow the carrier 1220 to become vertically oriented 1260.

[0061] Figure 12A depicts an alternative exemplary embodiment of the one shown in Figure 12. In this embodiment, the carrier 1220 and ply 1222 are rotated from horizontal orientation to vertical orientation in the opposite direction to that shown in Figure 12. Figure 12A depicts the carrier 1220 at a series of points in time during the transition between orientations, shown as horizontal orientation 1250, orientation 1252, orientation 1254, and vertical orientation 1260. In an alternative embodiment of the transport and formation station of the ply 1222 and carrier 1220, the carrier 1220 and ply 1222 are positioned in an alternative configuration relative to the track 1230, if necessary, in vertical orientation 1260.

[0062] Figure 13 depicts a further manufacturing system 1300 for curved preforms in an exemplary embodiment. In this embodiment, the manufacturing system 1300 includes a track 1320 that forms a curved, "serpentine" shaped pattern. In this case, two PBP forming stations 1330 are monitored by a technician 101 located in a workspace 1310. The PBP forming stations 1330 are positioned in various orientations, such as after each point of the bend 1322 of the track 1320. The inner mold line (IML) surfaces 1340-1 to 1340-6 change from an orientation facing downwards to the page to an orientation facing upwards to accommodate the workspace 1310 (or vice versa). The outer mold line (OML) surfaces, 1350-1 to 1350-6 change from an orientation facing upwards to the page to an orientation facing downwards (or vice versa). This configuration allows a single stacking station 1360 to service multiple PBP formation stations 1330 simultaneously.

[0063] Figure 14 depicts a raised rail 1410 in an exemplary embodiment, allowing a technician 101 to pass beneath it, corresponding to arrow 14 in Figure 1. Specifically, the raised rail 1410 is held in place so that a carrier 1430 is raised to a height H from the factory floor 1420. The raised rail 1410 is held in place by supports 1440. Depending on the embodiment, H may be set to the top of a range of the worker's expected maximum height (e.g., 7 feet, 8 feet, etc.), or to the ceiling height (e.g., 8 or 10 feet), etc. The spacing of the supports 1440, together with the height H, forms an exit 1450 for the technician 101 to safely leave the workspace. In a further embodiment, a height H plus the width of the carrier (Δ) is added to the height range. This allows the technician 101 to exit the exit 1450 without being partially obstructed by the carrier 1430. In a further embodiment, the technician 101 utilizes a raised work stand or other component to perform work within the workspace, and then moves away from the work stand to exit the workspace, thereby passing under the raised rail 1410.

[0064] Figure 15 depicts a technician 101 in a manufacturing system 1500, including a PBP forming station 1510 for a semicircular preform 1550, in an exemplary embodiment. In this embodiment, the PBP forming station 1510 forms a semicircle. However, in further embodiments, the PBP forming station 1510 may form any suitable arc-shaped portion. In this embodiment, the PBP forming station 1510 surrounds a workspace 1520. The technician 101 is positioned within the workspace 1520. The technician 101 can enter and / or exit the workspace 1520 via an access passage 1530. Note that for clarity and simplicity, the rail system is omitted in Figure 15. However, the rail system may be raised to allow the technician 101 to pass underneath it, or the technician 101 may be provided with means to ascend above the rail system to enter above it. In further embodiments, a portion of the rail system may be hinged to allow passage through the entrance and exit.

[0065] In the following embodiments, further processes, systems, and methods are described in the context of manufacturing systems for curved composite parts.

[0066] Figure 16 is a block diagram of a manufacturing system 1600 for curved preforms in an exemplary embodiment. In this embodiment, the manufacturing system 1600 includes a rail system 1610. The rail system 1610 includes an outer concentric circle 1612 and an inner concentric circle 1616 of track 1618. Track 1618 is held in place by supports 1620. A branch line 1614 includes a confluence point 1615 that connects track 1618 in the inner concentric circle 1616 to track 1618 in the outer concentric circle 1612. Multiple lamination stations 1630 lay up plies 1682 of fiber-reinforced material onto a carrier 1680, although in a further embodiment, only one lamination station 1630 is used to service the entire manufacturing system 1600. The carrier 1680 holding the plies 1682 moves through the rail system 1610 to reach a PBP station 1640. If PBP station 1640 already has a preform 1644, the ply 1682 is attached to the preform 1644. Alternatively, the ply is attached directly to the mandrel 1642 of PBP station 1640. The carrier 1680 may be returned to the washing station 1632 for cleaning and residue removal, for repair, and / or replacement before proceeding to the stacking station 1630.

[0067] Figure 16 further illustrates a controller 1690 that controls the operation of the rail system 1610, the stacking station 1630, and / or the PBP station 1640 according to sensor inputs, NC programs, a time-specified schedule, and / or other factors. In one embodiment, the controller 1690 is implemented as a custom circuit, as a hardware processor that executes programming instructions stored in memory, or in any combination thereof.

[0068] With more detailed reference to the drawings, embodiments of the present disclosure can be described in terms of the manufacture and maintenance of an aircraft in Method 1700 shown in Figure 17, and in terms of an aircraft 1702 shown in Figure 18. In the pre-manufacturing stage, Method 1700 may include the specification and design 1704 of the aircraft 1702 and the procurement of materials 1706. In the manufacturing stage, the manufacture 1708 of the components and subassemblies of the aircraft 1702 and system integration 1710 are carried out. The aircraft 1702 may then undergo authorization and delivery 1712 to be put into operation 1714. During the period of operation by the customer, the aircraft 1702 is scheduled for periodic maintenance and servicing 1716 (which may also include modifications, reconfigurations, and refurbishments). Apparatus and methods embodied herein may be used in one or more preferred stages of manufacturing and maintenance described in Method 1700 (e.g., specification and design 1704, material procurement 1706, manufacturing of components and subassemblies 1708, system integration 1710, authorization and delivery 1712, operation 1714, maintenance and servicing 1716), and / or in any preferred component of the aircraft 1702 (e.g., airframe 1718, multiple systems 1720, interior 1722, propulsion system 1724, electrical system 1726, hydraulic system 1728, environmental system 1730).

[0069] Each step of Method 1700 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, 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 18, an aircraft 1702 manufactured by method 1700 may include a fuselage 1718 having multiple systems 1720 and interior 1722. Examples of multiple systems 1720 include one or more of the propulsion system 1724, electrical system 1726, hydraulic system 1728, and environmental system 1730. Any number of other systems may also be included. Although an aerospace example is shown, the principles of the present invention can also be applied to other industries such as the automotive industry.

[0071] As already stated above, the apparatus and methods embodied herein may be used in any one or more stages of the manufacturing and maintenance described in Method 1700. For example, components or subassemblies corresponding to the manufacturing of components and subassemblies 1708 may be manufactured or produced in the same manner as components or subassemblies manufactured during the operational period of the aircraft 1702. Also, one or more embodiments of the apparatus, embodiments of the method, or combinations thereof may be used in the manufacturing of subassemblies 1708 and system integration 1710, for example, by significantly improving the efficiency of the assembly of the aircraft 1702 or by significantly reducing the cost of the aircraft 1702. Similarly, one or more embodiments of the apparatus, embodiments of the method, or combinations thereof may be used during the operation of the aircraft 1702, for example, during maintenance and servicing 1716, but not limited to these. Thus, the present invention may be used in any stage or combination thereof described herein. For example, specifications and design 1704, material procurement 1706, manufacturing of components and subassemblies 1708, system integration 1710, authorization and delivery 1712, operation 1714, maintenance and servicing 1716. And / or it may be used in any suitable component of an aircraft 1702 (e.g., airframe 1718, multiple systems 1720, interior 1722, propulsion system 1724, electrical system 1726, hydraulic system 1728, and / or environmental system 1730).

[0072] In one embodiment, a component comprises a portion of the airframe 1718 and is manufactured during the manufacture of components and subassemblies 1708. This component may, in this case, be assembled to the aircraft during system integration 1710 and then be used during operation 1714 until it becomes unusable due to wear. Thereafter, during maintenance and servicing 1716, the component may be discarded and replaced with a newly manufactured component. The components and methods of the present invention may be used throughout the period of manufacture of components and subassemblies 1708 to manufacture new components.

[0073] Any of the various control elements (e.g., electrical components 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 some similar terminology. If functions are provided by processors, they may be provided by a single dedicated processor, a single shared processor, or by a number of separate processors, some of which may be shared. Furthermore, the explicit use of the terms “processor” or “controller” should not be interpreted as referring only to, and not limited to, hardware capable of executing 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 devices, logic units, 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 to perform the function of that element. Some examples of instructions are software, program code, and firmware. When executed by a processor, an instruction is operable to instruct the processor to perform the function of that element. Instructions can be stored in a processor-readable storage device. Some examples of storage 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] Further embodiments are provided for in the following clauses. 1. A method (800) for producing a curved preform (146) of a fiber-reinforced material (221), Laying up at least one ply (220) on a carrier (210) of flexible material (804) at a stacking station (130), Loading the carrier (210) onto the rail system (110) (806), Based on the characteristics of the at least one ply (220) carried by the carrier (210), the rail system (110) is routed and moved to a specific ply-by-ply (PBP) forming station (140) (808). Separating at least one ply (220) from the carrier (210) (810), and A method (800) comprising processing the at least one ply (220) into the preform (146) via the specific PBP forming station (140) (812). 2. The method according to Clause 1 (800), further comprising identifying (802) a curved preform (146) manufactured by the particular PBP forming station (140). 3. The method according to Clause 2 (800), wherein laying up the at least one ply (220) (804) includes laying up the at least one ply for the curved preform (146). 4. The method according to any one of claims 1 to 3 (800), wherein the characteristics of the at least one ply (220) are selected from the group consisting of the size of the flat pattern of the at least one ply (220) and the orientation of the fibers. 5. The method (800) of any one of the claims 1 to 4, further comprising routing and moving the carrier (210) to a different PBP forming station (140) among a plurality of PBP forming stations (140) in the rail system (110) based on the characteristics of the at least one ply (220) carried by the carrier (210) (808). 6. Separating the ply (220) from the carrier (210) (810) is performed by an engineer (101) in the manner described in any one of the clauses 1 to 5 (800). 7. Laying up the ply (220) (804) is performed while the carrier (210) is oriented horizontally. Loading the carrier (210) (806) includes oriented the carrier (210) vertically, as described in any one of clauses 1 to 6 (800). 8. Route and move the carrier (210) to the PBP forming station (140) (808) is the method according to any one of the provisions 1 to 7 (800), which includes identifying a confluence point adjacent to the PBP forming station (140), moving the carrier (210) to the confluence point (115), and at the confluence point (115), switching the carrier (210) to a track (118) that is directly connected to the PBP forming station (140). 9. The method according to any one of the claims 1 to 8 (800), wherein routing and moving the carrier (210) (808) includes flexing the shape of the carrier (210) and the at least one ply (220) as the carrier (210) moves along the rail system (110). 10. Route and move the carrier (210) (808) is the method (800) of any one of the provisions of Clauses 1 to 9, which includes advancing the carrier (210) through a branch line (114) within the rail system (110). 11. The method according to any one of the claims 1 to 10 (800), wherein the processing of the at least one ply (220) into the preform (146) (812) includes compacting the at least one ply (220) into the corresponding preform (146) by operating the PBP forming station (140). 12. The method according to Clause 11 (800), wherein compacting the at least one ply (220) comprises forming a first ply for the preform (146) on a mandrel (142). 13. The method according to any one of the claims 1 to 12 (800), further comprising returning the carrier (210) to the stacking station (130) via the rail system (110) (814). 14. Returning the carrier (210) (814) is performed via a branch line (114) of the rail system (110) as described in the method of 15. A portion of an aircraft (1702) assembled according to the method (800) described in any one of claims 1 to 14. 16. A system (100) for manufacturing a curved preform (146) of a fiber-reinforced material (221), A lamination station (130) lays up plies (220) for curved preforms (146) onto a carrier (220) of flexible material. A rail system (110) that routes and moves the carrier (220) from the stacking station (130) to the private-by-private (PBP) formation station (140), and forms loops (112, 116) between the stacking station (130) and the PBP formation station (140), and A system (100) comprising a PBP forming station (140) that receives the ply (220) and processes the ply (220) into the curved preform (146). 17. The PBP forming station (140) is the system (100) described in Clause 16, which applies a clamping force along an arc. 18. The stacking station (130) lays up the plies (220) on the carrier (210) while the carrier (210) is oriented horizontally, and after the layup for the plies (220) is completed, the carrier (210) is oriented vertically, in the system (100) according to clause 16 or 17. 19. The rail system (110) is a system (100) according to any one of the clauses 16 to 18, which bends the carrier (210) when the carrier moves. 20. The system (100) according to any one of the clauses 16 to 19, wherein the PBP forming stations (140) are arranged in a curved pattern (144), and the system (100) further comprises a workspace (150) for a technician (101) positioned between the PBP forming stations (140). twenty one. The rail system (110) is raised to form an exit (1450) for a technician (101) from a work space (150) defined by the rail system (110), as described in any one of Clauses 16 to 20. twenty two. The rail system (110) is a system (100) according to any one of the clauses 16 to 21, including a branch line (114) that routes and moves the carrier (210) between an inner concentric circle (116) and an outer concentric circle (112). twenty three. The stacking station (130) lays up plies for a plurality of preforms (146) manufactured by the PBP forming station (140), the system (100) according to any one of clauses 16 to 22. twenty four. The aforementioned preform (146) includes a system (100) as described in any one of clauses 16 to 23, which includes a preform for the frame of an aircraft (1702). twenty five. A system (100) according to any one of the clauses 16 to 24, wherein the track (118) of the rail system (110) forms concentric circles (112, 116). 26. The system (100) according to any one of the clauses 16 to 25, further comprising a further stacking station (130) for laying up plies (220) for the preform (146). 27. To manufacture a part of an aircraft (1702) using a system (100) as described in any one of clauses 16 to 26. 28. A system (100) comprising a rail system (110), wherein the rail system (110) is The orbit (118) includes a concentric circle (112, 116) which includes an inner concentric circle (116) adjacent to a plurality of private-by-private (PBP) formation stations (140), and an outer concentric circle (112) adjacent to a stacking station (130). The rail system (110) further includes: A track (118) that forms a branch line (114) connecting the aforementioned concentric circles (112, 116), and The support (120) includes a support that holds the track (118) in an elevated position, The aforementioned system (100) further, A system (100) comprising a carrier (210) for transporting plies (220) from the stacking station (130) to the PBP forming station (140) via the rail system. 29. The system (100) according to Clause 28, further comprising a workspace (150) located within the range of the aforementioned inner concentric circles (116). 30. The system (100) according to Clause 28 or 29, wherein the aforementioned outer concentric circles (112) are also adjacent to a further stacking station (130). 31. The carrier (210) is a system (100) according to any one of the clauses 28 to 30, comprising a flexible material. 32. The carrier (210) flexes as it moves through the rail system (110), as described in any one of the clauses 28 to 31. 33. To manufacture a part of an aircraft (1702) using the system (100) described in any one of clauses 28 to 32.

[0076] While specific embodiments are described herein, the scope of this disclosure is not limited to such specific embodiments. The scope of this disclosure is defined by the following claims.

Claims

1. A method (800) for producing a curved preform (146) of a fiber-reinforced material (221), At the stacking station (130), lay up at least one ply (220) on a carrier (210) of flexible material (804), Loading the carrier (210) onto the rail system (110) (806), Based on the characteristics of the at least one ply (220) carried by the carrier (210), the rail system (110) is routed and moved to a specific ply-by-ply (PBP) forming station (140) (808). Separating the at least one ply (220) from the carrier (210) (810), The process involves processing the at least one ply (220) into the curved preform (146) via the specific PBP forming station (140) (812), and A method (800) comprising routing (808) the carrier (210) to different PBP forming stations (140) among a plurality of PBP forming stations (140) in the rail system (110) based on the characteristics of the at least one ply (220) carried by the carrier (210).

2. The method according to claim 1 (800), further comprising identifying (802) a curved preform (146) being manufactured by the particular PBP forming station (140), and optionally including laying up the at least one ply (220) (804) for the curved preform (146).

3. The method according to claim 1 or 2 (800), wherein the characteristics of the at least one ply (220) are selected from the group consisting of the size of the flat pattern of the at least one ply (220) and the orientation of the fibers.

4. The separation of at least one ply (220) from the carrier (210) (810) is performed by an engineer (101) and / or Laying up the at least one ply (220) (804) is performed while the carrier (210) is oriented horizontally. The method according to any one of claims 1 to 3 (800), wherein loading the carrier (210) (806) includes oriented the carrier (210) vertically.

5. Route and move the carrier (210) to the specific PBP formation station (140) (808) includes identifying a junction adjacent to the specific PBP formation station (140), moving the carrier (210) to the junction (115), and at the junction (115), switching the carrier (210) to a track (118) directly connected to the specific PBP formation station (140), and / or Route and movement of the carrier (210) (808) includes flexing the shape of the carrier (210) and the at least one ply (220) as the carrier (210) moves along the rail system (110), and / or Route and movement of the carrier (210) (808) includes advancing the carrier (210) through the branch line (114) within the rail system (110), and / or Processing the at least one ply (220) into the curved preform (146) (812) includes operating the PBP forming station (140) to compact the at least one ply (220) into the corresponding preform (146), The method according to any one of claims 1 to 4 (800), wherein compacting the at least one ply (220) optionally includes forming a first ply for the preform (146) on the mandrel (142).

6. The process further includes returning the carrier (210) to the stacking station (130) via the rail system (110) (814), The method according to any one of claims 1 to 5 (800), wherein the carrier (210) is returned (814) via a branch line (114) of the rail system (110).

7. A system (100) for manufacturing a curved preform (146) of a fiber-reinforced material (221), A lamination station (130) configured to lay up plies (220) for curved preforms (146) on a carrier (210) of flexible material, A rail system (110) configured to route and move the carrier (210) from the stacking station (130) to the private-by-private (PBP) formation station (140), and to form loops (112, 116) between the stacking station (130) and the PBP formation station (140), and A system (100) comprising a PBP forming station (140) configured to receive the ply (220) and process the ply (220) into the curved preform (146).

8. The system according to claim 7, wherein each PBP forming station (140) is configured to produce the curved preform (146) by repeatedly shaping the ply (220).

9. The system (100) according to claim 7 or 8, wherein each PBP forming station (140) includes a curved mandrel (142) and is configured to process the ply (220) into the curved preform (146) on the mandrel (142).

10. The stacking station (130) is configured to lay up the plies (220) on the carrier (210) while the carrier (210) is oriented horizontally, and to oriented the carrier (210) vertically after the layup for the plies (220) is complete, according to any one of claims 7 to 9.

11. The system (100) according to any one of claims 7 to 10, wherein the rail system (110) is configured to bend the carrier (210) as the carrier moves, and / or the PBP forming stations (140) are arranged in a curved pattern (144), and the system (100) further comprises a workspace (150) for technicians (101) positioned between a plurality of the PBP forming stations (140).

12. The rail system (110) is raised to form an exit (1450) for a technician (101) from a work space (150) defined by the rail system (110), and / or the rail system (110) includes a branch line (114) that routes and moves the carrier (210) between an inner concentric circle (116) and an outer concentric circle (112), and / or The stacking station (130) is configured to lay up plies for a plurality of curved preforms (146) manufactured by the PBP forming station (140), and / or the curved preforms (146) include preforms for the frame of an aircraft (1702), and / or the tracks (118) of the rail system (110) form concentric circles (112, 116), and / or The system (100) according to any one of claims 7 to 11, further comprising a further lamination station (130) for laying up plies (220) for the curved preform (146).

13. Multiple private-by-private (PBP) formation stations (140), Stacking station (130), A system (100) comprising a rail system (110), wherein the rail system (110) is The orbit (118) includes a concentric circle (112, 116) which is adjacent to a plurality of private-by-private (PBP) formation stations (140), and an outer concentric circle (112) which is adjacent to a stacking station (130). The rail system (110) further comprises: A track (118) that forms a branch line (114) connecting the concentric circles (112, 116), and The support (120) includes a support that holds the track (118) in an elevated position, The system (100) further includes: A system (100) comprising a carrier (210) configured to transport plies (220) from the stacking station (130) to the PBP forming station (140) via the rail system (110).

14. The system (100) according to claim 13, further comprising a work space (150) located within the range of the inner concentric circle (116), and / or the outer concentric circle (112) also adjoins a further stacking station (130), and / or the carrier (210) comprises a flexible material, and / or the carrier (210) is configured to flex while moving through the rail system (110).

15. A system (100) for producing a curved preform (146) of a fiber-reinforced material (221) according to any one of claims 7 to 12, the system (100) comprising the system according to claim 13 or 14.

16. A method for manufacturing a part of an aircraft (1702) using the system (100) according to any one of claims 7 to 15.

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