Continuous line manufacturing of composite material parts

Abstract

To provide systems and methods for forming a laminate.SOLUTION: The method includes indexing a layup mandrel to a lamination station disposed at a first location, transporting the lamination station and the layup mandrel in a process direction from the first location towards a second location, laying up a laminate comprising layers of fiber-reinforced material onto the layup mandrel via the lamination machine while the lamination machine and the layup mandrel are transported in the process direction, removing the layup mandrel and the laminate at the second location, and returning the lamination station to the first location for laying up another laminate onto another mandrel.SELECTED DRAWING: None

Description

Technical Field

[0001]

[0001] This disclosure relates to the field of manufacturing, and more particularly, to the manufacture of composite parts.

Background Art

[0002]

[0002] Multilayer laminates of constituent materials (e.g., carbon fiber reinforced polymer (CFRP)) can be formed into any of a variety of shapes for curing into composite parts. To facilitate the manufacture of composite parts, robots such as automated fiber placement (AFP) machines can be utilized. For example, large (e.g., several tons) AFP machines may occupy a cell. In that case, the AFP machine lays up one or more layers of tow (fibers) of the constituent material. The layers form a laminate, which is then cured.

[0003]

[0003] However, the manufacture of composite parts is still a time-consuming operation. This is because individual processes such as layup, consolidation, bagging, and curing are performed in different cells within the manufacturing environment, and the technician must physically move the laminate onto a cart and move it before proceeding to the next step of the manufacturing process in another cell.

[0004]

[0004] Therefore, it would be desirable to have a method and system that takes into account at least some of the problems discussed above as well as other assumed problems.

[0005]

[0005] The summary of EP3653369A1 states the following: In other words, "The manufacturing system includes a plurality of lamination heads (300) and a head movement system that defines a lamination path (122) configured to move the lamination heads (300) sequentially along a continuous loop lamination path (122). The manufacturing system also includes at least one lamination mandrel (146, 148, 150) positioned along a portion of the lamination path (122). Each lamination head (300) is configured to supply layup material (316) onto at least one lamination mandrel (146, 148, 150) or onto a layup material (316) pre-applied on a lamination mandrel (146, 148, 150). In the meantime, the lamination heads (300) are moved by the head movement system via one or more rotations of the lamination path (122) to lay up composite laminates (400, 402, 404)." [Overview of the project]

[0006]

[0006] Embodiments described herein provide a laminator that actively lays up a laminate while the laminate (and the laminator itself) is being transported. This provides the combined benefits of layup and transport within a single station, enabling the laminate to be manufactured as part of a continuous moving line process. This configuration also allows for the division of the manufacturing operation into smaller parts and enables immediate detection and response to any conditions exceeding tolerances encountered during layup.

[0007]

[0007] One embodiment is a method for forming a laminate. The method includes positioning (indexing) a layup mandrel relative to a lamination station located at a first position; transporting the lamination station and layup mandrel in the process direction from the first position to a second position; laying up a laminate having a layer of fiber-reinforced material onto the layup mandrel via the lamination machine while the lamination machine and lamination mandrel are being transported in the process direction; removing the layup mandrel and laminate at the second position; and returning the lamination station to the first position in order to lay up another laminate onto another mandrel.

[0008]

[0008] A further embodiment is a non-transient computer-readable medium that embodies programmed instructions. The instructions, when executed by a processor, are operable to perform a method for manufacturing a laminate. The method includes positioning a layup mandrel relative to a lamination station positioned at a first location; transporting the lamination station and layup mandrel in the process direction from the first location to a second location; laying up a laminate having layers of fiber-reinforced material on the layup mandrel via the lamination machine while the lamination machine and lamination mandrel are being transported in the process direction; removing the layup mandrel and laminate at the second location; and returning the lamination station to the first location to lay up another laminate on another mandrel.

[0009]

[0009] A further embodiment is a system for forming a laminate having multiple layers of fiber-reinforced material. The system includes a lamination station including a layup mandrel having a mandrel positioning element. The lamination station further includes a shuttle having a shuttle positioning element for engaging with the mandrel positioning element of the layup mandrel. The lamination station further includes a laminating machine attached to the shuttle. The lamination system further includes a drive system for transporting the shuttle in the process direction while the laminating machine lays up the laminate on the layup mandrel.

[0010]

[0010] Other exemplary embodiments (for example, methods and computer-readable media related to the embodiments described above) may also be described later. The features, functions, and advantages described above can be realized individually in various embodiments or in combination in yet another embodiment, and these embodiments can be understood in more detail by referring to the following description and accompanying drawings.

[0011]

[0011] 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]

[0012] [Figure 1]

[0012] This is a schematic diagram of a stacking system in an exemplary embodiment. [Figure 2]

[0013] This is a schematic block diagram of a stacking station that may be used with the stacking system shown in Figure 1. [Figure 3]

[0014] Figures 1 and 2 show perspective views of a stacking machine and a shuttle for carrying mandrels, which may be used in conjunction with the stacking station. [Figure 4]

[0015] This is a cross-sectional side view of the shuttle in Figure 3, in an exemplary embodiment. [Figure 5]

[0016] This is a top view of a stacking station including the shuttle in Figure 3, in an exemplary embodiment. [Figure 6]

[0017] This is a top view of a plurality of stacked stations interacting with each other in an exemplary embodiment. [Figure 7]

[0018] This is a top view of the transfer of mandrels between stacking stations in Figure 6 in an exemplary embodiment. [Figure 8]

[0019] This is a top view of multiple lamination stations manufacturing laminates in two directions in an exemplary embodiment. [Figure 9]

[0020] Figures 1 to 8 are flowcharts showing the methods for operating the stacking system and stacking station. [Figure 10]

[0021] Figures 1 to 8 are flowcharts of aircraft manufacturing and maintenance methods in which stacking stations and / or the method shown in Figure 9 may be used. [Figure 11]

[0022] These are block diagrams of aircraft that may be manufactured using the stacking stations shown in Figures 1 to 8 and / or the methods shown in Figures 9 and 10. [Modes for carrying out the invention]

[0013]

[0023] The drawings and the description below provide specific exemplary embodiments of the Disclosure. 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.

[0014]

[0024] Composite parts such as CFRP parts are first laid up in a plurality of layers collectively referred to as a laminate or "preform". The individual fibers within each layer of the preform are aligned parallel to each other, but may exhibit various fiber orientations in order to enhance the strength of the resulting composite part along various dimensions. In order to solidify the laminate into a composite part (for use, for example, in an aircraft), the laminate may contain a viscous resin that solidifies. 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 contain a tackifier or binder. The dry fibers may be injected with resin prior to curing. With respect to thermosetting resins, solidification is a one-way process called curing, while with respect to thermoplastic resins, the resin can become viscous when reheated.

[0015]

[0025] FIG. 1 is a schematic diagram of a lamination system 50 used within a manufacturing line 10. The lamination system 50 can be one of a series of systems that make up the manufacturing line 10. For example, the manufacturing line 10 may further include a fastener installation system disposed behind the lamination system 50. The lamination system 50, and more specifically the lamination station 100, are used to form a laminate 140. The laminate 140 includes at least a first layer 141 and a second layer 142 of a fiber reinforcement material 147.

[0016]

[0026] The lamination system 50 has a lamination station 100 and a layup mandrel 130. The lamination system 50 may include two or more lamination stations 100. Thereby, a first lamination station 100 and a second lamination station 100' are in series along the process direction 190 of the manufacturing line 10. In such an embodiment, the lamination system 50 further includes a transfer machine 60 that can move between the lamination stations 100, 100' of the lamination system 50. The transfer machine 60 is configured to remain stationary during the transfer of the layup mandrel 130, as will be described in more detail in relation to FIG. 7.

[0017]

[0027] Still referring to FIG. 1, the lamination system 50 further includes a drive system 150. The drive system 150 moves the lamination station 100 and / or the layup mandrel 130 to execute the methods described herein. More specifically, the drive system 150 moves the lamination station 100 along the process direction 190 from the first position 102 to the second position 104 or towards the second position 104. In the embodiments described herein, the drive system 150 moves the shuttle 120 of the lamination station 100 from the first position 102 towards the second position 104. The lamination system 50 may further include a track system 160. When the lamination system 50 includes the track system 160, the drive system 150 moves the lamination station 100 and / or the layup mandrel 130 along the track system 160 at least from the first position 102 towards the second position 104. Further, the drive system 150 may include a powered rail 162. The powered rail 162 may be integrated into the tracks on the track system 160 or separated from the tracks of the track system. When the powered rail 162 is included within the lamination system 50, the drive system 150 moves the shuttle 120 along the powered rail 162 to transfer the lamination station 100.

[0018]

[0028] Further, the lamination system 50 may include two or more layup mandrels 130, such as including the layup mandrel 130 and a new layup mandrel 130'. The layup mandrels 130, 130' may be used within the same lamination station 100 or may be used with their respective lamination stations 100, 100'. The layup mandrel 130 includes a mandrel positioning element 132, as will be described in more detail below. When the lamination system 50 includes two or more layup mandrels 130, 130', each layup mandrel 130, 130' includes a mandrel positioning element 132.

[0019]

[0029] Figure 2 is a schematic block diagram of a stacking station 100 that may be used in a stacking system 50. The stacking station 100 comprises any system, device, or component capable of operating to lay up a stack 140 on a layup mandrel 130 while the layup mandrel 130 moves continuously in the process direction 190. As will be described in more detail in relation to Figures 5, 6, and 8, the stacking station 100 may also move in the reverse process direction 192 through the stacking system 50. Referring to Figure 2, the stacking station 100 includes a shuttle 120 and a stacker 110. In this embodiment, the stacking station 100 is associated with an orbital system 160. Along the orbital system 160, the shuttle 120 is transported by a drive system 150. The drive system 150 may include a chain drive 152 coupled to the orbital system 160 or an engine 154 moving along the orbital system 160. In such embodiments, power may be supplied to the shuttle 120 (e.g., a platen, vacuum platen, plane, etc.) (or an engine 154 driving the shuttle 120) via the energized or powered rails 162 of the track system 160. In further embodiments, the shuttle 120 is transported by an automated guided vehicle (AGV) or other automated device acting as a drive system 150, and the track system 160 is not used. The shuttle 120 includes a shuttle positioning element 122, such as a cup in a cup-and-cone positioning system.

[0020]

[0030] The shuttle positioning element 122 allows the layup mandrel 130 to be removably positioned on the shuttle 120 at a known offset from the laminating machine 110. The layup mandrel 130 includes a mandrel positioning element 132, which is complementary to the shuttle positioning element 122. The shuttle positioning element 122 is configured to engage with the mandrel positioning element 132, such as by receiving it. The engagement of the shuttle positioning element 122 and the mandrel positioning element 132 aligns the layup mandrel 130 to the shuttle 120. For example, in one embodiment shown in Figure 4, where the shuttle positioning element 122 is a cup, the mandrel positioning element 132 is a cone having a shape complementary to the shape of the cup. This allows the layup mandrel 130 to be positioned relative to the shuttle 120 via complementary positioning elements positioned on the layup mandrel 130 and the shuttle 120.

[0021]

[0031] The laminator 110 is positioned on / attached to the shuttle 120. The shuttle 120 is driven in a process direction 190. The laminator 110 lays up a laminate 140 having layers 141, 142 of fiber-reinforced material 147 containing resin 148 reinforced with fibers 146. In one embodiment, each layer 141, 142 laid up by the laminator 110 contains a tow of unidirectional fiber-reinforced polymer. The laminator 110 includes an end effector 115. The end effector 115 may be driven by a kinematic mechanism 114. In some embodiments, the kinematic mechanism 114 and the end effector 115 are robotic arms. The end effector 115 includes a head 116 that can supply the fiber-reinforced material 147 stored in a spool 117 in a desired fiber orientation (e.g., 0 degrees, plus 45 degrees, minus 45 degrees, and 90 degrees).

[0022]

[0032] The laminating machine 110 further includes a controller 112 and a memory 113. The controller 112 operates a kinematic mechanism 114 to control the movement of the end effector 115 according to instructions stored in a numerical control (NC) program in the memory 113. As soon as the fiber-reinforced material 147 is exhausted from the spool 117, the controller 112 operates the kinematic mechanism 114 and the end effector 115 to remove the head 116 and secure a spare 119 for the spare head 116', and / or remove the spool 117 and replace the spool 117 with a spare spool 117'. The spare spool 117' is fully loaded with the fiber-reinforced material 147. (One or more) spares 119 (e.g., spare head 116', spare spool 117') may be stored on the shuttle 120, on a second shuttle 120', or at a known location along the orbital system 160. The controller 112 can be implemented, for example, as a custom circuit, as a hardware processor that executes programmed instructions, or as some combination of these.

[0023]

[0033] In a further embodiment, a power source 170 and / or a gas source 180 are located on the shuttle 120 to power the stacker 110 and supply pressurized gas. In another further embodiment, the shuttle 120 includes an interface (I / F) 124 that connects to a powered rail 162 of the drive system 150. The interface 124 is configured to obtain power from the energized / powered rail 162 of the track system 160. That is, the interface 124 connects to the powered rail 162. The drive system 150 transports the shuttle 120 along the powered rail 162 and supplies power to the shuttle 120, which is a component on the powered rail 162. For example, it supplies power to the stacker 110 on the shuttle 120.

[0024]

[0034] During operation, the layup mandrel 130 is stacked on the shuttle 120, which moves in the process direction 190 while the laminator 110 lays up the laminate 140 on the layup mandrel 130. The layup mandrel 130 (and the laminate 140) then proceed to a second lamination station 100' in the lamination system 50 for further lamination (if necessary), or to another system in the production line 10 (shown in Figure 1) for compaction, bagging, curing, or otherwise preparation for manufacturing into composite parts.

[0025]

[0035] Figure 3 is a perspective view of a laminator 110 and a shuttle 120 carrying a layup mandrel 130 in an exemplary embodiment. In this embodiment, the laminator 110 moves along a path 318 attached to or defined within the body 320 of the shuttle 120. The path 318 allows the laminator 110 to move in a first direction 322, which is the same as the process direction 190, or in a second direction 324, which is opposite to the process direction 190. The laminator 110 can move in either the first direction 322 or the second direction 324 within the path 318. It does not matter whether the shuttle 120 moves in direction 190 or 192. Thus, the laminator 110 can move in the first direction 322 to lay up a first layer 141 on the layup mandrel 130, and move in the second direction 324 to lay up a second layer 142 on the first layer 141. The laminating machine 110 may move back and forth within the path 318 to lay up layers 141 and 142 of the laminate 140 while the shuttle 120 is moving in the process direction 190, the reverse process direction 192, or stationary.

[0026]

[0036] For example, the laminator 110 moves along a path 318 while operating on the shuttle 120. This allows the end effectors 115 of the laminator 110, such as the head 116 of the end effector 115, to lay up layers 141, 142, such as tows of fiber-reinforced material 147, along the length L of the lamination 140. The body 320 of the shuttle 120 can be carried by a track system 160 (shown in Figures 1 and 2), driven by a tag platform along the track system 160, carried by an AGV, or otherwise transported between lamination stations 100, lamination system 50, and / or locations within the production line 10. However, potential variations of the transport of the shuttle 120 are not shown in Figure 3 for brevity. This transport process helps to facilitate the handoff of the lamination 140 between lamination stations 100, 100' performing repetitive or different operations on the lamination 140.

[0027]

[0037] Figure 4 is a cross-sectional view of the shuttle 120 of Figure 3 in an exemplary embodiment. Figure 4 shows that the shuttle 120 includes a mechanical coupling 440 (e.g., a hook) for engaging with a drive system 150 (shown in Figure 2), such as a chain drive, for transport along the track system 160 (shown in Figures 1 and 2). Figure 4 further shows that the layup mandrel 130 includes a cone 432 as a mandrel positioning element 132, and the shuttle 120 includes a cup 422 as a shuttle positioning element 122. The cone 432 engages with (i.e., accepts) the cup 422 to facilitate the positioning of the layup mandrel 130 relative to the shuttle 120. The geometric dimensions of the shuttle positioning element 122 and the mandrel positioning element 132 automatically align the layup mandrel 130 with the shuttle 120 when the layup mandrel 130 is placed on the shuttle 120 (as long as the tip of each cone 432 is positioned somewhere within its corresponding cup 422). That is, the weight of the layup mandrel 130 pushes it into place. As a result, the cone 432 is positioned in the center of the cup 422 when the layup mandrel 130 is released.

[0028]

[0038] With regard to Figures 3 and 4, along with the above-described design of the shuttle 120 and its components, the further description of Figures 5 and 6 focuses on arranging the orbital system 160 and the shuttle 120 within the stacking station 100 in a manner that facilitates the manufacturing process.

[0029]

[0039] Figure 5 is a top view of a stacking station 100 including the shuttle 120 of Figure 3 in an exemplary embodiment. As shown in Figure 5, the orbital system 160 may include a first orbit 510, a second orbit 530, and a third orbit 560. The orbital system 160 further includes a first switching orbit 520 and a second switching orbit 540 extending between at least two orbits 510, 530 of the orbital system 160. In Figure 5, the shuttle 120 traverses between the first orbit 510 and the second orbit 530 via the switching orbits 520 and 540. The stacker 110 performs layup while the shuttle 120 is moving along the first orbit 510. The laminator 110 may be refilled, replenished, or otherwise replenished before proceeding through the first switching track 520 and the second track 530 to receive another mandrel for layup (e.g., a new layup mandrel 130' shown in Figure 1). As soon as it reaches the first switching track 520, the laminator 110 may be disconnected from the supply lines or other components that provide power and pressurized gas to the laminator 110. However, in a further embodiment, the laminator 110 is powered by a self-sufficient power and pressure source in or on the shuttle 120, such as a power supply 170 and / or a gas supply source 180.

[0030]

[0040] While the layup mandrel 130 moves along the shuttle 120 in the process direction 190, the second shuttle 550 is moved along the third orbit 560 at the same speed as the shuttle 120 is moved along the first orbit 510. The second stacker 570 on the second shuttle 550 moves along to perform layup in conjunction with the stacker 110. For example, both of these stackers 110 and 570 may operate according to the same NC program.

[0031]

[0041] In other words, as shown in Figure 5, the manufacturing process may include moving a further second laminator 570 from the first position 102 to the second position 104 in the process direction 190. Laying up the laminate 140 can be performed through the coordinated operation of laminator 110 and the further second laminator 570. In such a scenario, the manufacturing speed is increased by using two end effectors 115 (e.g., heads 116 of end effectors 115) working simultaneously to construct the laminate 140. In this way, multiple laminators 110, 570 can operate simultaneously to add layers 141, 142 (shown in Figures 1 and 2) of fiber-reinforced material 147 onto the same layup mandrel 130. For example, the laminating machine 110 lays up the first layer 141 on the layup mandrel 130, and the second laminating machine 570, following the laminating machine 110, lays up the second layer 142 on the first layer 141 to form the laminate 140.

[0032]

[0042] The embodiment in Figure 5 also allows the lamination system 50 to simultaneously form at least two different portions 580, 582, 584, and 586 of the laminate 140 using different laminating machines 110, 570 at the same lamination station 100. Alternatively, the different portions 580, 582, 584, and 586 of the laminate 140 may be formed simultaneously by different laminating machines 110, 110' at different lamination stations 100, 100'. In the embodiment shown in Figure 5, the first laminating machine 110 forms the first axial portions 582 / 586 of the laminate 140, and the second laminating machine 570 forms the second axial portions 580 / 584 of the laminate 140. Alternatively, the first laminating machine 110 forms the first longitudinal portions 584 / 586 of the laminate 140, and the second laminating machine 570 forms the second longitudinal portions 580 / 582 of the laminate 140. Parts 580, 582, 584, and / or 586 may also be individual layers or subsets of layers that constitute the laminate 140.

[0033]

[0043] Figure 6 is a top view of a lamination system 50 having a plurality of interoperating lamination stations 100, 100', 100'' in an exemplary embodiment. The lamination stations 100, 100', 100'' may interact with each other to hand off laminates 140 (or cured composite parts) to perform different operations such as lamination, consolidation, bagging, and curing as the layup mandrel 130 is transported in the process direction 190 (e.g., along the track system 160). Each lamination station 100, 100', 100'' may be similarly configured (e.g., having the same components) as described with respect to Figures 1 to 4. However, in the embodiment of Figure 6, each lamination station 100 is configured slightly differently. For example, the first lamination station 100 is a lamination station 610 as described above, the second lamination station 100' is a consolidation station 620, and the third lamination station 100' is a bagging station 630.

[0034]

[0044] In the embodiment shown in Figure 6, a first lamination station 610 lays up the laminate 140 onto a layup mandrel 130, and a second consolidation station 620 receives the laminate 140 by lifting the layup mandrel 130 from the first lamination station 100 and consolidates the laminate 140. A third bagging station 630 receives the consolidated laminate 140 by lifting the layup mandrel 130 and places a vacuum bag 640 on top of the consolidated laminate 140. The layup mandrel 130 is then moved to a heater (e.g., an autoclave) and can be cured.

[0035]

[0045] Figure 7 is a top view of the transfer of a layup mandrel 130 between stacking stations 100, 100' using a transfer machine 60. In an exemplary embodiment of Figure 7, the transfer machine 60 transfers the layup mandrel 130 between the shuttle 120 of the first stacking station 100 and the second shuttle 120' of the second stacking station 100'. According to Figure 7, the transfer machine 60 is stationary while the shuttles 120, 120' move relative to the transfer machine 60 in order to transfer the layup mandrel 130 between the shuttles 120 and 120'. The transfer machine 60 has an arm 722 that can be inserted into the layup mandrel 130 and moves the arm 722 in the transfer direction 740. The transfer direction 740 may be the same as the process direction 190, but the transfer direction 740 may be opposite to the process direction 190. This involves transferring the layup mandrel 130 from the shuttle 120 on the first stacking station 100 on the left to the second shuttle 120' on the second stacking station 100' on the right, in order to continue laying up the laminate 140.

[0036]

[0046] Figure 8 is a top view of a stacking system 50 having a plurality of stacking stations 100, 100', 100”, 100''' that manufacture a stack 140 in two directions 190 and 192' in an exemplary embodiment. Embodiments utilizing a plurality of stacking stations 100 working in two directions 190, 192' offer technical benefits by increasing throughput and / or ensuring that work is performed during all operation of the stacking stations 100. Furthermore, each of the stacking stations 100 may operate on the same orbital system 160, or at least one of the stacking stations 100 may operate on a separate orbital system or AGV. The first stacking station 100, the second stacking station 100', the third stacking station 100'', and the fourth stacking station 100''' include at least some similar components to perform similar stacking processes simultaneously to form their respective stacks 140. Alternatively, lamination stations 100 on the same orbit of the orbital system 160, the first orbital 510, or the second orbital 530, work together to perform different parts of a composite manufacturing process to form a laminate 140 or 140''. The laminates 140 and 140'' may be of the same type or different types. In such an embodiment, the lamination station 100 may be similarly configured with an end effector 115 capable of performing multiple different composite manufacturing processes and / or forming two or more types of laminates.

[0037]

[0047] As shown in Figure 8, the shuttle 120 of the first stacking station 100 and the second shuttle 120' operate to lay up the first stack 140 as they move to the right along the first trajectory 510. The third shuttle 120" of the third stacking station 100" and the fourth shuttle 120"' of the fourth stacking station 100"' operate to lay up the second stack 140" as they move to the left along the second trajectory 530. Shuttles 120 and 120" move in a loop from the first trajectory 510 to the first switching trajectory 520, to the second trajectory 530, to the second switching trajectory 540, and back to the first trajectory 510.

[0038]

[0048] The first stacking station 100 operates the stacker 110 to place the first stack 140 on the layup mandrel 130, and the third stacking station 100" operates the stacker 110" to place the second stack 140" on the mandrel 130". The first stack 140 is transferred from shuttle 120 to the second shuttle 120' (for example, using the transfer device 60) and moves to the right (for example, in the process direction 190). Meanwhile, the second stack 140'' is transferred from the third shuttle 120'' to the fourth shuttle 120''' (for example, using the second transfer machine 60') and proceeds to the left (for example, in the reverse process direction 192). In this manner, by repeated operation, stacking stations 100, 100', 100'', 100''' can produce two different types of stacks 140, 140' along the process direction 190 and the opposite reverse process direction 192.

[0039]

[0049] Exemplary details of the operation of the stacking system 50 and the stacking station 100 will be described in reference to Figure 9. In this embodiment, it is assumed that the layup mandrel 130 is positioned near the shuttle 120 within the reach of the end effector 115, such as within the reach of the arm of the end effector 115.

[0040]

[0050] Figure 9 is a flowchart illustrating a method 900 for operating the lamination system 50 and lamination station 100 shown in Figures 1 to 8 to form a laminate 140. While the steps of method 900 are described with reference to the lamination station 100, those skilled in the art will understand that method 900 can also be performed in other systems. The steps in 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.

[0041]

[0051] Referring to Figures 1, 2, and 9, Method 900 includes positioning the layup mandrel 130 (902), transporting the lamination station 100 and the layup mandrel 130 (904), and laying up the laminate 140 onto the layup mandrel 130 via the laminating machine 110 (906). Method 900 further includes removing the layup mandrel 130 and the laminate 140 (908), and returning the lamination station 100 to the first position 102 (910).

[0042]

[0052] When the lamination system 50 is configured as shown in Figure 5, the method 900 may begin by partitioning the laminate 140 into portions 580, 582, 584, and / or 586 (912). Positioning (902), transporting (904), laying up (906), removing (908), and returning (910) are performed independently in each of the multiple laminating machines 110, 570 arranged along the process direction 190. Each of the multiple laminating machines 110, 570 forms one of the portions 580, 582, 584, and / or 586 of the laminate 140. In one embodiment, the laminate 140 is partitioned into portions 580, 582, 584, and / or 586 (e.g., similar portions, specific subsets of layers, etc.) (912). Positioning (902), transporting (904), laying up (906), removing (908), and returning (910) are performed independently in each of the multiple laminating machines 110, 110' and / or multiple laminating stations 100, 100' arranged along the process direction 190. Each of the multiple laminating machines 110, 110' lays up (906) one of the partitioned (912) portions 580, 582, 584, and / or 586 of the laminate 140. The laminate 140 in process is handed off between the laminating machines 110, 110'.

[0043]

[0053] In positioning (902), the layup mandrel 130 is positioned relative to the stacking station 100. More specifically, while the stacking station 100 is in a first position 102 (for example, to the left of the orbital system 160), the layup mandrel 130 is positioned (902) relative to the shuttle 120 of the stacking station 100. Positioning the layup mandrel 130 relative to the stacking station 100 (902) also positions the layup mandrel 130 relative to the stacker 110. Positioning the layup mandrel 130 relative to the stacker 110 (902) occurs when the layup mandrel 130 is positioned relative to the shuttle 120. The stacker 110 is located on the shuttle 120. Positioning the layup mandrel 130 relative to the laminating machine 110 (902) includes positioning the layup mandrel 130 relative to the shuttle 120 via the mandrel positioning element 132 and the shuttle positioning element 122, which are located on the layup mandrel 130 and the shuttle 120.

[0044]

[0054] Positioning (902) the layup mandrel 130 may include lifting or sliding the layup mandrel 130 into place. In this case, the mandrel positioning element 132 aligns with and / or engages with the shuttle positioning element 122. Positioning (902) may be performed by an actuated arm (e.g., the kinematic mechanism 114 and end effector 115 of the stacker 110, or another robotic arm outside the stacking station 100). The arm lifts and positions the layup mandrel 130 on the shuttle 120 based on instructions in the NC program. In a further embodiment, lifting by a robot is not necessary, because engagement via positioning (902) may occur where the platform trajectory and the mandrel trajectory intersect and the shuttle positioning element 122 and the mandrel positioning element 132 align and / or engage.

[0045]

[0055] In transfer (904), the stacker 110 and the layup mandrel 130 are transferred in the process direction 190 from a first position 102 to a second position 104 (for example, the final position on the right side of the track system 160 when viewed in the drawing). For example, the shuttle 120 is driven in the process direction 190 to transfer (904) the stacker 110 and the layup mandrel 130. To perform the transfer (904) operation, the controller 112 may instruct the drive system 150 to move the shuttle 120 along the track system 160 at a desired speed. In embodiments where the drive system 150 comprises an AGV, the drive system 150 may be operated independently by another controller. In embodiments where the drive system 150 comprises a chain drive, a mechanical coupling 440 (shown in Figure 4) on the shuttle 120 may engage with the chain drive to transfer (904) the shuttle 120 at a desired speed. In embodiments of the stacking system 50 shown in Figures 6 to 8, the shuttle 120 at each of the multiple stacking stations 100 may be transported via a drive system 150 to ensure that the stacking stations 100 operate at a uniform speed.

[0046]

[0056] In layup (906), the laminating machine 110 lays up the laminate 140 having layers 141 and 142 of fiber-reinforced material 147 onto the layup mandrel 130. In one exemplary embodiment, layup (906) is performed while the laminating station 100 and the layup mandrel 130 are being transported (904) in the process direction 190. When the laminating system 50 is configured as shown in Figure 8, transport (904) and layup (906) may also be performed when the laminating station 100 and the layup mandrel 130 are moving in the reverse process direction 192. Layup (906) includes laying up a first layer 141 onto the layup mandrel 130, laying up a second layer 142 onto the first layer 141, and so on, until the layers of the laminate 140 are laid up (906) onto the layup mandrel 130.

[0047]

[0057] In one embodiment, laying up the laminate 140 (906) includes moving the laminator 110 in a first direction 322 in the process direction 190 (914) to lay up a first layer 141 (906), and moving the laminator 110 in a second direction 324 opposite to the process direction 190 (916) to lay up a second layer 142 (906). The moving steps (914, 916) are repeated to add further layers to construct the laminate 140. That is, during layup (906), the laminator 110 may move independently of the process direction 190 (918) and move in any suitable direction to perform the layup (906).

[0048]

[0058] Laying up the laminate 140 906 includes moving the laminator 110 independently of the process direction 190 (918). More specifically, the laminator 110 is moved independently of the direction in which the shuttle 120 of the lamination station 100 moves (918). This is because the laminator 110 moves along the path 318 relative to the shuttle 120 (918), as described in more detail with respect to Figure 3.

[0049]

[0059] When the lamination system 50 includes multiple laminating machines 110, 570 as shown in Figure 5, laying up the laminate 140 (906) includes operating the multiple laminating machines 110, 570 simultaneously (920) to add layers 141, 142 of fiber-reinforced material 147 onto the layup mandrel 130.

[0050]

[0060] The layup mandrel 130 is positioned relative to the shuttle 120 (902), and the stacker 110 is attached to the shuttle 120, so any offset between the stacker 110 and the layup mandrel 130 is known. This means that, regardless of the position of the shuttle 120 along the trajectory system 160, the stacker 110 continues to operate according to the NC program without interference.

[0051]

[0061] To reiterate the transfer (904), in a further embodiment, the end effector 115 compacts (922) the laminate 140 while the lamination station 100 and the layup mandrel 130 are being transferred (904) in the process direction 190 (and / or the reverse process direction 192 when the lamination system 50 is configured as shown in Figure 8). Compaction (922) is performed by applying pressure to the laminate 140 while the lamination station 100 and the layup mandrel 130 are being transferred (904) in the process direction 190 (and / or the reverse process direction 192 when the lamination system 50 is configured as shown in Figure 8). The transfer (904) speed of the shuttle 120 may be any desired speed, such as one-tenth of a mile per hour (0.05 meters per second).

[0052]

[0062] During layup (906), the spool 117 in head 116 may be depleted of fiber-reinforced material 147, or the laminator 110 may be programmed to perform the subsequent process using a different head. In such cases, method 900 includes exchanging (924) head 116 and / or spool 117 during transfer (904). For example, when the lamination station 100 is transferred (904) in the process direction 190 or the reverse process direction 192, head 116 is replaced (924) with a spare head 116', and / or spool 117 is replaced (924) with a spare spool 117'. In a particular embodiment, a controller 112 may operate a kinematic mechanism 114 and an end effector 115 to exchange (924) head 116 (or spool 117) of the laminator 110 during transfer (904). The exchange (924) may include obtaining spares 119, such as a spare head 116' and / or a spare spool 117', from shuttle 120 or from a second shuttle 120' that is moving in the same direction and at the same velocity and / or is in an off-shuttle position at a known offset from shuttle 120 and / or the orbital system 160.

[0053]

[0063] In removal (908), the layup mandrel 130 and the laminate 140 are removed at a second position 104. More specifically, the layup mandrel 130 having the laminate 140 on top is removed (908) from the lamination station 100 at the second position 104. In one embodiment, removal (908) includes operating a robotic arm (e.g., located in the lamination machine 110) and / or a transfer machine 60 to move the layup mandrel 130 (and thus the laminate 140) from the lamination station 100 to another station in the lamination system 50 or in the production line 10. The other station may also lay up (906) another portion of the laminate 140, compact (922) the laminate 140 by applying pressure, and cure the laminate 140 by attaching a vacuum bag 640 to the laminate 140 or by applying heat.

[0054]

[0064] In returning (910), the stacking station 100 is returned to the first position 102 to form an additional stack 140' on a new layup mandrel 130'. For example, the stacker 110 is carried on a shuttle 120. The shuttle 120 is transported along the orbital system 160 (for example, along parallel orbits 510, 530, 560) (928) to return (910) to the first position 102. In one embodiment, the orbital system 160 includes switching orbits 520, 540 to form a loop or to transport the shuttle 120 to a return orbit such as a second orbit 530. In this way, multiple shuttles 120, 120' can move steadily back and forth between the first position 102 and the second position 104 without interfering with each other.

[0055]

[0065] In one embodiment, before or during the return (910) on the loop, a new layup mandrel 130' is positioned (926) relative to the stacking station 100. Positioning (926) the new layup mandrel 130' is similar to positioning (902) the first layup mandrel 130. For example, the mandrel positioning element 132 of the new layup mandrel 130' aligns with and / or engages with the shuttle positioning element 122 in order to position (926) the new layup mandrel 130' relative to the shuttle 120. In a particular embodiment, the new layup mandrel 130' is positioned (926) relative to the stacking machine 110 while the stacking station 100 is in the second position 104.

[0056]

[0066] When a new layup mandrel 130' is provided to the lamination station 100, the laminating machine 110 may continue laying up (906) to form a further laminate 140' on the new layup mandrel 130'. In one such embodiment, after the first layup mandrel 130 is removed (908), the lamination station 100 and the new layup mandrel 130' are moved in the reverse process direction 192, opposite to the process direction 190, from a second position 104 towards a first position 102 (928). While the laminating station 100 and the new layup mandrel 130' are being moved in the opposite direction to the process direction 190 (928), the laminating machine 110 lays up (906) a further laminate 140' having layers 141, 142 of fiber-reinforced material 147 on the new layup mandrel 130'. Transferring in the reverse process direction 192 (928) may be substantially the same as the transfer (904) described above. For example, layup (906), compaction (922), and / or exchange (924) may be performed during transfer (928) in the reverse process direction 192.

[0057]

[0067] For the laminating machine 110 to perform the steps of method 900, the laminating machine 110 is powered (930). More specifically, the laminating machine 110 is powered (930) by a power supply 170 located on the shuttle 120. Alternatively, the laminating machine 110 is powered (930) via a powered rail 162. Along the powered rail 162, the laminating station 100 moves during transport (904). Powering (930) is performed at least during layup (906), also during transport (904) (e.g., to perform consolidation (922) and / or exchange (924)), or during any other step of method 900. In this case, the laminating machine 110 is either performing an operation or is not performing but is ready.

[0058]

[0068] Method 900 is advantageous over prior systems and techniques because it allows a continuous in-line manufacturing technique to be applied to composite parts such as stringers or frames of aircraft (e.g., aircraft 1002 shown in Figure 11). Meanwhile, the laminates for those parts move through the manufacturing line 10 (shown in Figure 1). Furthermore, Method 900 does not require dedicated heavy machinery such as APFs. Therefore, if one laminating machine 110 requires maintenance during the execution of Method 900, the laminating machine 110, end effector 115, head 116, or spool 117 can be quickly replaced by a technician (or another APF machine) without disrupting the manufacturing process.

[0059] Examples

[0069] In the following embodiments, further processes, systems, and methods are described in the context of a continuous line manufacturing process for composite parts.

[0060]

[0070] More specifically with reference to the drawings, embodiments of the present disclosure can be described in reference to the manufacture and maintenance of an aircraft by Method 1000 shown in Figure 10 and the aircraft 1002 shown in Figure 11. In the pre-manufacturing stage, Method 1000 may include the specification and design 1004 of the aircraft 1002 and the procurement of materials 1006. In the manufacturing stage, the manufacture 1008 of the components and subassemblies of the aircraft 1002 and system integration 1010 are carried out. Method 900 (shown in Figure 9) may be performed during the manufacture 1008 of the components and subassemblies to produce a portion of the aircraft 1002. The aircraft 1002 may then be put into operation 1014 after approval and delivery 1012. During the period of operation by the customer, the aircraft 1002 is scheduled for periodic maintenance and servicing 1016 (which may also include modifications, reconfigurations, and refurbishments).

[0061]

[0071] The systems and methods embodied herein may be employed in one or more suitable stages of manufacturing and maintenance described in Method 1000 (e.g., specification and design 1004, material procurement 1006, manufacturing of components and subassemblies 1008, system integration 1010, authorization and delivery 1012, operation 1014, maintenance and servicing 1016) and / or in any suitable component of the aircraft 1002 (e.g., airframe 1018, systems 1020, interior 1022, propulsion system 1024, electrical system 1026, hydraulic system 1028, environmental system 1030).

[0062]

[0072] Each step of Method 1000 may be carried out or performed 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.

[0063]

[0073] As shown in Figure 11, an aircraft 1002 manufactured by method 1000 may include a fuselage 1018 having a plurality of systems 1020 and interior 1022. Examples of systems 1020 include one or more of the propulsion system 1024, electrical system 1026, hydraulic system 1028, and environmental system 1030. Any number of other systems may also be included. Although an example from the aerospace industry is shown, the principles of this disclosure can also be applied to other industries (such as the automotive industry).

[0064]

[0074] As already stated above, the systems 50 and methods 900 (shown in Figures 1 to 9) embodied herein can be employed in manufacturing and maintenance at any one or more stages described in Method 1000. For example, components or subassemblies corresponding to the manufacturing of components and subassemblies 1008 can be manufactured or produced in the same manner as components or subassemblies manufactured during the operation of the aircraft 1002. Furthermore, one or more embodiments of the system, embodiments of the method, or combinations thereof can be utilized during the manufacturing of subassemblies 1008 and system integration 1010, for example, to substantially streamline the assembly of the aircraft 1002 or to reduce the cost of the aircraft 1002.

[0065]

[0075] Similarly, one or more embodiments of the system, embodiments of the method, or combinations thereof may be used during the operation of the aircraft 1002, for example, during maintenance and servicing 1016, but not limited to these. For example, the methods 900 and the laminated system 50 described herein may be used for material procurement 1006, manufacturing of components and subassemblies 1008, system integration 1010, operation 1014, and / or maintenance and servicing 1016, and / or for the airframe 1018 and / or interior 1022. These methods 900 and the laminated system 50 may also be used to produce any suitable components for a plurality of systems 1020, for example, a propulsion system 1024, an electrical system 1026, a hydraulic system 1028, and / or an environmental system 1030.

[0066]

[0076] In one embodiment, a component, comprising part of the airframe 1018, is manufactured during the production of components and subassemblies 1008 using Method 900 and the stacking system 50. This component is then assembled into the aircraft 1002 during system integration 1010, and can subsequently be used in operation 1014 until the component is replaced. During maintenance and servicing 1016, the component may be discarded and replaced with a newly manufactured component produced using any suitable method, such as Method 900. The system and methods of the invention may be utilized during the production of components and subassemblies 1008 to manufacture a new component.

[0067]

[0077] 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 a processor, they may be provided by a single dedicated processor, a single shared processor, or by a number of individual 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.

[0068]

[0078] 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, instructions are operable to instruct the processor to perform the function of that element. Instructions can be stored in a memory device that is readable 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.

[0069]

[0079] 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 (900) for forming a laminate (140), Positioning the layup mandrel (130) relative to the stacking station (100) located at the first position (102) (902), Transferring the stacking station (100) and the layup mandrel (130) in the process direction (190) from the first position (102) to the second position (104) (904), While the laminating machine (110) and the layup mandrel (130) are being transported in the process direction (190), the laminate (140) having layers (141, 142) of fiber-reinforced material (147) is laid up on the layup mandrel (130) via the laminating machine (110) (906). The layup mandrel (130) and the laminate (140) are removed at the second position (104) (908), and A method (900) comprising returning the lamination station (100) to the first position (102) (910) in order to lay up a further lamination (140') on a new layup mandrel (130').

2. The stacking machine (110) is positioned on a shuttle (120) that is driven in the process direction (190), Positioning the layup mandrel (130) relative to the stacking station (100) (902) includes positioning the layup mandrel (130) relative to the shuttle (120) via complementary positioning elements (132, 122) arranged on the layup mandrel (130) and the shuttle (120), Preferably, the method (900) according to claim 1, further comprising supplying power (930) to the stacking machine (110) via a power supply (170) located on the shuttle (120).

3. The method according to claim 1 or 2 (900), wherein laying up the laminate (140) (906) includes moving the laminating machine (110) independently of the process direction (190) (918).

4. The method according to any one of claims 1 to 3 (900), further comprising supplying power to the stacking machine (110) via a powered rail (162) (930), wherein the stacking station (100) moves along the powered rail (162) during the transfer (904).

5. Replacing the head (116) of the stacking machine (110) during the transfer (904) (924), and / or During the transfer (904), replace the spool (117) of the stacking machine (110) (924), and / or The lamination station (100) and the layup mandrel (130) further include compacting (922) the laminate (140) while they are being transported (904) in the process direction (190), and / or Laying up the laminate (140) (906) includes operating the laminator (110) in the process direction (190) (914) to lay up (906) the first layer (141), and operating the laminator (110) in a second direction (324) opposite to the process direction (190) (916) to lay up (906) the second layer (142), and / or The above method (900) further, Position the new layup mandrel (130') relative to the stacking station (100) (926), Transferring the stacking station (100) and the new layup mandrel (130') from the second position (104) toward the first position (102) in the reverse process direction (192) opposite to the process direction (190) (928), and The method according to any one of claims 1 to 4 (900), comprising laying up a further laminate (140') including layers (141, 142) of fiber-reinforced material (147) on the new layup mandrel (130') via the laminating machine (110) (906) while the laminating station (100) and the new layup mandrel (130') are being transported (928) in the reverse process direction (192).

6. The stacking station (100) includes a plurality of stacking machines (110, 570), and the method (900) further includes, The laminate (140) is divided into parts (580, 582, 584, and / or 586) (912), and The method (900) according to any one of claims 1 to 5, comprising independently performing the positioning (902), transporting (904), laying up (906), removing (908), and returning (910) in each of the plurality of laminating machines (110, 570) arranged along the process direction (190), wherein each of the plurality of laminating machines (110, 570) forms one of the portions (580, 582, 584, and / or 586) of the laminate (140).

7. The stacking station (100) includes a plurality of stacking machines (110, 570), The method according to claim 6 (900), wherein laying up the laminate (140) (906) includes operating the plurality of laminating machines (110, 570) simultaneously (920) to add layers (141, 142) of fiber-reinforced material (147) onto the layup mandrel (130).

8. A method for manufacturing a part of an aircraft (1002) using the method (900) described in any one of claims 1 to 7.

9. A lamination system (50) for forming a laminate (140) having multiple layers (141, 142) of a fiber-reinforced material (147), A layup mandrel (130) having a mandrel positioning element (132), A stacking station (100) comprising a shuttle (120) having a shuttle positioning element (122) for engaging with the mandrel positioning element (132) of the layup mandrel (130), and a stacking machine (110) attached to the shuttle (120), While the laminating machine (110) lays up the layers (141, 142) of the laminate (140) onto the layup mandrel (130), a drive system (150) moves the shuttle (120) in the process direction (190), A stacking system (50) is provided.

10. The lamination system (50) according to claim 9, further comprising a transfer machine (60) for transferring the layup mandrel (130) from the lamination station (100) to another lamination station (100') after the laminate (140) has been laid up, preferably the transfer machine (60) includes an arm (722) that is inserted into the layup mandrel (130).

11. The stacking system (50) according to claim 9 or 10, wherein the shuttle (120) includes a power supply (170) and a gas supply source (180) that enable the stacking machine (110) to operate while the drive system (150) is transporting the shuttle (120).

12. The drive system (150) includes a powered rail (162), and the drive system (150) transports the shuttle (120) along the powered rail (162). The stacking system (50) according to any one of claims 9 to 11, wherein the shuttle (120) includes an interface (124) that connects to the powered rail (162).

13. The drive system (150) includes an automated guided vehicle and / or The drive system (150) comprises a chain drive (152) coupled to the shuttle (120), and / or The shuttle (120) includes at least one of a spare head (116') and a spare spool (117') for the stacker (110), and / or The stacking station (100) lays up a portion (580, 582, 584, 586) of the stack (140), and The lamination system (50) further comprises a further lamination station (100') for laying up further portions (580, 582, 584, 586) of the laminate (140), and the lamination system (50) is configured to transfer the layup mandrel (130) from the lamination station (100) to the further lamination station (100'), and / or The laminating machine (110) is configured to lay up multiple layers (141, 142) of the laminate (140) while being transported in the process direction (190), and / or The lamination system (50) according to any one of claims 9 to 12, wherein the shuttle positioning element (122) comprises a cup (422) and the mandrel positioning element (132) comprises a cone (432).

14. The lamination system (50) according to any one of claims 9 to 13, further comprising a second shuttle (550) having a second laminating machine (570), wherein the laminating machine (110) and the second laminating machine (570) are configured to lay up the laminate (140) through coordinated operation.

15. A method for manufacturing a part of an aircraft (1002) using the lamination system (50) according to any one of claims 9 to 14.

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