Method, device, and system for forming composite structures using expandable pallets
By using scalable pallet and roller systems to form composite materials on a continuous moving manufacturing line, the problem of low production efficiency in existing technologies is solved, enabling efficient and low-cost manufacturing of composite material structures.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- THE BOEING CO
- Filing Date
- 2022-05-31
- Publication Date
- 2026-06-30
AI Technical Summary
Existing technologies struggle to efficiently form composite material structures during manufacturing, especially in the use of lightweight composite materials in aerospace equipment, where issues such as low production efficiency, the need for specialized tools, and multiple molding processes exist.
Using an expandable tray and multiple roller system, composite materials are molded on a continuously moving manufacturing line, gradually forming composite material structures by utilizing the grooves on the expandable tray and the cooperation of the rollers.
It enables efficient molding of composite material structures, improves production efficiency, reduces equipment replacement time and space requirements, and lowers production costs.
Smart Images
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Abstract
Description
Technical Field
[0001] The present disclosure relates generally to systems and methods for forming composite structures using expandable pallets, and more particularly to fabricating composite components along a manufacturing line that moves continuously using a plurality of rollers and through the use of expandable pallets to form composite structures.
Background Art
[0002] Modern aircraft designs use various components such as stringers to resist bending, torsional, shear, and direct loads along the fuselage of the aircraft. Stringers are typically formed from lightweight composite materials, including, for example, tapes or fabrics in which fibers are embedded within a resin matrix. The composite layup is processed using a forming tool to define the shape of the stringer. However, it has been difficult to support the composite layup within the forming tool. For example, one approach requires that the stringer layup be pre-formed in a vertical punch-style forming operation and then moved to an assembly line for further processing. The cycle time associated with the pre-forming method limits the rate at which parts can be produced. Other approaches require forming tools specific to each part to be fabricated and the need to change machine tools as required. Still other approaches may be able to form only one ply at a time and require multiple passes of the forming apparatus to build a complete laminate.
[0003] To increase efficiency, there is a need for a method for fabricating stringers along a continuously moving manufacturing line.
Summary of the Invention
[0004] In one embodiment, a method for forming a composite structure is described. The method includes adding a laminated charge onto an expandable pallet, moving the expandable pallet in a linear motion against a plurality of rollers, and progressively pressing the laminated charge into a continuously expanding recess defined by the expandable pallet using the plurality of rollers. The plurality of rollers are oriented in a series of configurations to shape the laminated charge into at least a portion of the shape of the composite structure.
[0005] In another embodiment, a device for forming a composite structure is described. The device comprises an expandable pallet having a forming surface configured to receive a laminated charge on top, and a set of rollers oriented in a configuration for progressively pressing the laminated charge into a continuously expanding recess defined by the expandable pallet as the expandable pallet is moved linearly against a set of rollers. The rollers shape the laminated charge into at least a portion of the shape of the composite structure.
[0006] In another embodiment, a system for forming a composite structure is described. The system comprises an expandable pallet having a forming surface configured to receive a laminate charge on top; a plurality of rollers oriented in a configuration for progressively pressing the laminate charge into a continuously expanding recess defined by the expandable pallet, thereby shaping the laminate charge into at least a portion of the shape of a composite structure; and a supply assembly line on which the expandable pallet with the laminate charge is positioned. The supply assembly line moves the expandable pallet continuously in linear motion relative to the plurality of rollers.
[0007] The features, functions, and advantages described above can be realized individually in various examples or combined in yet another example. Further details of the embodiments can be understood by referring to the description and drawings below.
[0008] Novel characteristics of the illustrated embodiments are specified in the appended claims. However, the exemplary embodiments, as well as preferred modes of use, further purposes, and their descriptions will be best understood by referring to the accompanying drawings and reading the following detailed description of the exemplary embodiments of this disclosure. [Brief explanation of the drawing]
[0009] [Figure 1] An exemplary embodiment shows an example of a composite structure (e.g., a stringer) having an internal cavity, in which a mandrel including an expandable pallet may be used for fabrication. [Figure 2] An end view of an embodiment of a device for forming a composite structure, according to an exemplary embodiment, is shown. [Figure 3] A side view of a portion of a device for forming a composite structure, according to an exemplary embodiment, is shown. [Figure 4] A perspective view of a portion of a device for forming a composite structure, according to one exemplary embodiment, is shown. [Figure 5] A perspective view of another exemplary configuration of multiple rollers according to one exemplary embodiment is shown. [Figure 6] A perspective view of a portion of an alternative configuration of a device for forming a composite structure, according to an exemplary embodiment, is shown. [Figure 7] An end-face perspective view of a portion of a device is shown, illustrating an exemplary embodiment in which forming blocks are used to form a composite structure. [Figure 8] Another end view of a portion of the device is shown, according to an exemplary embodiment, in which the forming block is used to form a composite structure. [Figure 9] Another end view of a portion of the device is shown, according to an exemplary embodiment, in which the forming block is used to form a composite structure. [Figure 10] An end-face perspective view of a portion of a device is shown, illustrating an exemplary embodiment in which an alternative configuration of a forming block is used to form a composite structure. [Figure 11] A side view conceptual diagram of a system for forming a composite structure according to an exemplary embodiment is shown. [Figure 12A] An exemplary embodiment shows one example of a first sequence of bladder installation within a bladder station. [Figure 12B] An exemplary embodiment shows one example of a second sequence of bladder installation within a bladder station. [Figure 12C] An exemplary embodiment shows one example of a third sequence of bladder installation within a bladder station. [Figure 13] This is a flowchart showing an example of a method for forming a composite material structure according to one exemplary embodiment. [Modes for carrying out the invention]
[0010] This specification will now provide a more comprehensive description of the examples disclosed with reference to the accompanying drawings. The accompanying drawings show some (but not all) of the examples disclosed. In practice, several different embodiments may be provided, and these embodiments should not be construed as limiting to the embodiments specified herein. Rather, these embodiments are described in such a way as to ensure that this disclosure is comprehensive and complete, and that the scope of this disclosure is fully conveyed to those skilled in the art.
[0011] Within the scope of the embodiments, systems and methods for forming composite structures include adding a laminated charge onto an expandable pallet, moving the expandable pallet in linear motion against a plurality of rollers, and progressively pressing the laminated charge into a continuously expanding recess defined by the expandable pallet using the plurality of rollers. The plurality of rollers are oriented into a series of configurations to shape the laminated charge into at least a portion of the shape of the composite structure.
[0012] Next, referring to the drawings, Figure 1 shows one embodiment of a composite structure 100 (e.g., a stringer) having an internal cavity, in which a mandrel including an expandable pallet may be used for fabrication, according to an exemplary embodiment. In one arrangement, the composite structure 100 may include a multiply layup of prepreg. In the illustrated arrangement, the composite structure 100 comprises a rounded hat section 102 that forms an internal stringer cavity 104, a pair of laterally extending flange sections 106, and a substantially flat outer plate section 108 that integrates with the flange sections 106 during curing. Those skilled in the art will recognize that alternative stringer shapes are possible.
[0013] After curing, all the components shown in Figure 1 form the composite structure 100. Within the scope of the embodiments described herein, the composite structure 100 is fabricated using devices and systems as described with reference to Figures 2 to 11 and Figures 12A to 12C. A bladder is used to fill the stringer cavity 104 in order to create a hollow trapezoidal space within the composite structure 100.
[0014] The exemplary composite materials used for the composite structure 100 are generally lightweight materials, such as uncured, pre-impregnated reinforcing tapes or fabrics (i.e., “prepregs”). These tapes or fabrics may contain multiple fibers, such as graphite fibers, embedded within a matrix material (e.g., polymers such as epoxy or phenol). The tapes or fabrics may be unidirectional or woven, depending on the desired degree of reinforcement. Thus, during fabrication, the prepreg tape or fabric is laid on a tool or mold, and components are used to form the tape or fabric into the desired shape of the composite structure 100. The composite structure 100 may be of any suitable dimensions, providing various degrees of reinforcement, and may contain any number of plies of the prepreg tape or fabric.
[0015] FIG. 2 shows an end view of an example of a device 110 for forming a composite material structure 100 according to an exemplary embodiment. The device 110 includes an expandable pallet 112 having a forming surface 114 configured to receive a laminate charge 116 thereon, and a plurality of rollers 118 arranged in a series of configurations for progressively pressing the laminate charge 116 into a continuously expanding recess 120 defined by the expandable pallet 112 as the expandable pallet 112 is moved in a linear motion relative to the plurality of rollers 118. The plurality of rollers 118 shape the laminate charge 116 into at least a portion of the shape of the composite material structure 100.
[0016] In FIG. 2, an end view of the device is shown, and the plurality of rollers 118 are arranged in a series of configurations. Accordingly, the drawing of FIG. 2 shows only the first of the plurality of rollers 118.
[0017] The device 110 also includes a frame 122 having support structures 124a - b for holding the plurality of rollers 118. The frame 122 is shown overhead the expandable pallet 112, but other configurations are equally possible, such as the frame 122 being attached to the side of the expandable pallet 112. For example, each roller of the plurality of rollers 118 is mounted on a shaft 126 about which the roller rotates. The movement of the plurality of rollers 118 is driven by contact with the laminate charge 116. The plurality of rollers 118 may be motorized or independently driven or not, rather, they rotate passively by contact with the laminate charge 116 as the laminate charge 116 moves in a linear motion under the plurality of rollers 118. Accordingly, the plurality of rollers 118 react to the linear motion of the expandable pallet 112 that moves the laminate charge 116 under the plurality of rollers 118.
[0018] <关于这个需求你还有什么其他想法或建议吗?你可以详细说明,以便我更好地满足你的需求。 Thus, within the scope of the embodiments, device 110 includes rails 128a - b having a bearing truck driven by a motor connected to device 110, and the expandable pallet 112 is disposed on the upper ends of rails 128a - b. When rails 128a - b are driven by a motor that moves the bearings, similar to a conveyor belt, the expandable pallet 112 is moved in a linear motion under the plurality of rollers 118.
[0019] Each successive roller of the plurality of rollers 118 is oriented progressively deeper than the previous roller (based on the height above the stacked charge 116), and the plurality of rollers 118 gradually press the stacked charge 116 into the recess 120. Thereby, each successive roller of the plurality of rollers 118 presses the stacked charge 116 deeper into the recess 120. The movement of the expandable pallet 112 under the plurality of rollers 118 causes, for example, the plurality of rollers 118 to contact the stacked charge 116. Thus, as the expandable pallet 112 supporting the stacked charge 116 moves under the plurality of rollers 118, each successive roller of the plurality of rollers 118 presses the stacked charge 116 deeper into the recess 120, causing the plurality of rollers 118 to gradually press the stacked charge into the recess 120. The fact that it is gradually pressed as the expandable pallet 112 moves under the plurality of rollers 118 includes that each successive roller of the plurality of rollers 118 contributes to pressing the stacked charge 116 at least some amount deeper into the recess 120. The meaning of gradually is, for example, that one roller does not completely punch the stacked charge 116 into the recess 120.
[0020] Each roller of the plurality of rollers 118 defines a contour that complements the desired shape of the composite structure 100. In one embodiment shown in FIG. 2, the composite structure 100 is a stringer.
[0021] Figure 3 shows a side view of a portion of a device 110 for forming a composite structure 100 according to an exemplary embodiment. Figure 4 is a perspective view of a portion of the device 110 for forming a composite structure 100 according to an exemplary embodiment. Figures 3 and 4 show an expandable pallet 112 and a plurality of rollers 118. In this embodiment, there are four rollers 118a to d, but more or fewer rollers may be included in the plurality of rollers 118.
[0022] In one embodiment, a plurality of rollers 118 are held stationary at their respective heights (with respect to the height above the stacked charge 116). In the embodiments shown in Figures 3 and 4, the height above the stacked charge 116 for a continuous sequence of rollers decreases from roller 118a to roller 118b, from roller 118b to roller 118c, and from roller 118c to roller 118d. The expandable pallet 112 moves in linear motion under the plurality of rollers 118 to progressively expand from a first end 130 of the expandable pallet 112 to a second end 132 of the expandable pallet 112 opposite the first end 130. The expandable pallet 112 includes a pair of pallet members 134a-b. They are two separate blocks that slide towards and away from each other due to their interconnected internal features. In one configuration where the pair of pallet members 134a-b are interconnected, the recess 120 is a small area as shown in Figure 2. Therefore, a pair of pallet members 134a and 134b, which are interlocked with each other, define a recess 120 between them. When the pair of pallet members 134a and 134b slide away from each other, the recess 120 becomes larger. Thus, the pair of pallet members 134a and 134b are movable relative to each other and move in parallel to change the size and configuration of the recess 120.
[0023] The expandable pallet 112 moves linearly to the right in the direction indicated by the arrow "A" in Figures 3 and 4, along rails 128a and 128b. As the expandable pallet 112 moves, the stacked charge 116 (not shown in Figures 3 and 4) is progressively pressed into a recess 120 that is continuously expanded by a plurality of rollers 118. The plurality of rollers 118 press the stacked charge 116 into the recess 120, causing the expandable pallet 112 to expand in a direction substantially perpendicular to the linear motion. In Figures 3 and 4, the expandable pallet 112 expands in the direction indicated by the arrow "B". The plurality of rollers 118 press the stacked charge 116 into the continuously expanding recess 120, causing a pair of pallet members 134a and 134b to move outward relative to each other, and continuously expanding the recess 120.
[0024] The multiple rollers 118 are oriented in a wedge configuration to progressively form the shape of the composite structure 100, specifically the desired shape of the hat portion of the stringer. In other words, each roller of the multiple rollers 118 is progressively deeper than the previous roller. Thereafter, the multiple rollers 118 gradually press into the recess 120 as the expandable pallet 112 passes beneath them, pushing a pair of pallet members 134a-b away from each other until the desired shape is generated by the last roller 118d. As described above, the multiple rollers 118 define a contour that complements the desired shape of the hat portion of the stringer, for example.
[0025] As the expandable pallet 112 moves in linear motion under the multiple rollers 118, the pair of pallet members 134a and 134b slide apart, causing the expandable pallet 112 to open slowly. For example, as the expandable pallet 112 moves under the multiple rollers 118, the expandable pallet 112 opens progressively from the first end 130 to the second end 132. The force required to open the pair of pallet members 134a and 134b can be adjusted, for example, using compressed air and the air cylinder of the device 110.
[0026] In another embodiment, a plurality of rollers 118 are arranged to move vertically (e.g., perpendicular to the linear motion of the expandable pallet 112). In one embodiment, the vertical movement is passively controlled using springs or air cylinders coupled to the plurality of rollers 118. In yet another embodiment, the vertical movement is actively controlled by an electric motor. The vertical movement assists and accommodates changes in the thickness of the laminate (e.g., ply drop).
[0027] Figure 5 shows a perspective view of another exemplary configuration of a plurality of rollers 118 according to an exemplary embodiment. In Figure 5, the plurality of rollers 118A to D are arranged such that subsequent rollers have alternative shapes, such as progressively deepening roller shapes, to further assist each subsequent roller in continuing to contact the stacked charge 116. Figure 5 conceptually shows the arrangement of the plurality of rollers 118A to D in a series of configurations to represent a progressively deepening shape.
[0028] Figure 6 shows a perspective view of a portion of an alternative configuration of a device 110 for forming a composite structure 100, according to an exemplary embodiment. In Figure 6, the device 110 is shown having a single roller 118a. In the exemplary configuration shown in Figure 6, the laminated charge 116 includes a multiply fabric stringer. It is formed by an expandable pallet 112 passing under the roller 118a for only a few cycles, such as about 10 to 15 cycles. In each subsequent cycle, the roller 118a is lowered to simulate a multi-roller device with a desired pitch depth between the rollers.
[0029] In other embodiments, alternative depths are used depending on the size and shape of the composite structure 100 being fabricated. Furthermore, rollers of different shapes other than the wedge shape shown in Figure 6 may also be used to produce alternative molded structures. Furthermore, the number of rollers used may also vary. Moreover, different combinations of rollers may be used, such as rollers with the same diameter and varying height above the expandable pallet 112, or rollers that are held at the same height above the expandable pallet 112 but have different or varying diameters or shapes. Embodiments of various configurations of the device 110 include a plurality of rollers 118, each about 50 to 100 × 1 / 100th of an inch deeper, to produce a stringer about 1 to 2 inches high using 20 to 30 rollers, and a plurality of flat rollers 118, each slightly deeper than the previous roller, to simulate punching into the expandable pallet 112. Other exemplary configurations of the device 110 are also possible, using various combinations of the number of rollers 118, the depth of the rollers 118, and the shape of the rollers 118.
[0030] Figures 7 to 9 show a partial end view of a device 110 in which a forming block 136 is used to form a composite structure 100, according to an exemplary embodiment.
[0031] In Figure 7, after a laminate charge 116 (not shown) is added to the expandable pallet 112, a forming block 136 is placed on top of the laminate charge 116. The forming block includes a base 138 and projections 140 extending from the base 138 that define a contour complementing the desired shape of the composite structure 100. In operation, the forming block 136 is then progressively pressed downwards, thereby continuously expanding the recess 120, and the expandable pallet 112 passes under a plurality of rollers 118 to press the laminate charge 116 into the recess 120.
[0032] Figure 7 shows the first stage of pressing, in which the protrusion 140 of the forming block 136 enters the recess 120. Figure 8 shows the second stage, following pressing the forming block 136 by the multiple rollers 118, in which the forming block 136 moves further downward, pushing the pair of pallet members 134a-b and expanding the recess 120 outward. Figure 9 shows the third stage, following the second stage, in which the forming block 136 is pressed further downward, pushing the pair of pallet members 134a-b and expanding the recess 120 further outward.
[0033] Figure 10 shows an end face perspective view of a portion of the device 110 in an exemplary embodiment in which an alternative configuration of the forming block 136 is used to form the composite structure 100. In some embodiments, the forming block 136 is further defined as a flat plate 142 and a bladder 144 (e.g., a reinforcing bladder or a curable tool bladder), the bladder 144 being progressively pressed toward an expandable pallet 112 for forming the composite structure 100. In this embodiment, a plurality of rollers 118 may define a uniform cylindrical contour and do not directly engage with the lamination charge 116. Any shape may be used for the plurality of rollers 118, since the bladder 144 is pressed into the lamination charge 116 to produce the desired shape of the composite structure 100.
[0034] In some embodiments, after the composite structure 100 is fabricated, it is elaborately manufactured offline and then supplied to a forming station for further processing. At this stage, the composite structure 100 is pre-formed and further steps of bladder installation, noodle extrusion, compaction, and curing are performed. Thus, in some embodiments for fabrication, the composite structure 100 remains in a different production area while awaiting to move to the next stage of production.
[0035] In other embodiments, systems for high-speed stringer production along a continuously moving production line are used to continuously produce several composite structures, such as about two or three per minute. Each composite structure may include a stringer package of a desired length prepared for curing.
[0036] Figure 11 shows a side view of a system 150 for forming a composite structure 100 according to an exemplary embodiment. The system 150 includes an expandable pallet 112 having a forming surface 114 configured to receive a laminated charge 116 on top of it, a plurality of rollers 118 oriented in a configuration for progressively pressing the laminated charge 116 into a continuously expanding recess 120 defined by the expandable pallet 112, thereby shaping the laminated charge 116 into at least a portion of the shape of the composite structure 100, and a supply assembly line 152 on which the expandable pallet 112 having the laminated charge 116 is positioned, the supply assembly line 152 moving the expandable pallet 112 continuously in linear motion relative to the plurality of rollers 118.
[0037] The supply assembly line 152 includes several different stations for the production of laminated charges 116 and then for post-processing in order to produce composite structure 100. Each of the different stations is located over a portion of a conveyor belt 154 that moves expandable pallets 112 in linear motion relative to each station.
[0038] The first station includes a laminator 156 that adds a full set of plies onto an expandable pallet 112 at once. The full set of plies is the laminate charge 116.
[0039] The conveyor belt 154 is driven by a motor to move the expandable pallet 112 in linear motion (as indicated by the rightward arrow in Figure 11), and then advances the expandable pallet 112, with the stacked charge 116 placed on top, to the next station which includes a plurality of rollers 118. As described, the plurality of rollers 118 progressively press the stacked charge 116 into the recess 120 of the expandable pallet 112.
[0040] The conveyor belt 154 continues to move the expandable pallet 112 in linear motion (as indicated by the rightward arrow in Figure 11), and then advances the expandable pallet 112, which has a stacked charge 116 pressed into a recess 120, to the next station, which includes a bladder station 158. The bladder station 158 is located in the supply assembly line 152 after a plurality of rollers 118, and as the expandable pallet 112 moves through the bladder station 158, a bladder 144 is placed over the stacked charge 116 in a cavity 160 formed by the plurality of rollers 118.
[0041] Figures 12A–12C show an exemplary sequence of installation of a bladder 144 in a bladder station 158 according to an exemplary embodiment. As shown in Figure 12A, the bladder 144 is laid in the cavity 160 in a longitudinal manner, starting from the right side as it exits the multiple rollers 118. As the expandable pallet 112 moves to the right in linear motion, the bladder 144 is further inserted into the cavity 160, as indicated by the arrows in Figures 12A–12C. In one embodiment, the bladder 144 is inserted into the cavity 160 manually. In other embodiments, a machine (not shown) is used to insert the bladder 144 into the cavity 160.
[0042] Figure 12B shows the bladder 144 being further inserted into the cavity 160 as the expandable pallet 112 continues to move through the bladder station 158. Figure 12C shows the bladder 144 fully installed within the cavity 160 at the end of the bladder station 158. As seen in Figures 12A to 12C, the expandable pallet 112 moves continuously through the supply assembly line 152, and one portion of the expandable pallet 112 may be under multiple rollers 118 as another portion of the expandable pallet 112 enters the bladder station 158.
[0043] Referring back to Figure 11, the conveyor belt 154 continues to move the expandable pallet 112 in linear motion (as indicated by the rightward arrow in Figure 11), and then advances the expandable pallet 112 with the bladder 144 installed to the next station, which includes the R-section filling station 161 located after the bladder station 158 in the supply assembly line 152. As the expandable pallet 112 moves through the R-section filling station 161, the R-section filler 162 is placed in the stacked charge 116.
[0044] Gaps or void regions may be formed by the radial range of any curved fragments of the laminated charge. Such gaps or void regions are typically referred to as “radius filler regions” or “noodle regions.” Radius filler stations fill the radius filler regions or noodle regions with “noodles” made of radius filler components or composite or adhesive / epoxy materials. The “noodles” generally have a triangular cross-section to provide further structural reinforcement to such regions. The radius filler 162 includes carbon fiber reinforced plastic (CFRP) which is placed in the gaps or voids by machine as the expandable pallet 112 moves through the radius filler station 161.
[0045] The conveyor belt 154 continues to move the expandable pallet 112 in linear motion (as indicated by the rightward arrow in Figure 11), and then advances the expandable pallet 112, which is now filled with R-section filler 162, to the next station, which includes a consolidation station 164 located after the R-section filling station 161 in the supply assembly line 152. As the expandable pallet 112 moves through the consolidation station 164, the stacked charge 116 is consolidated into the finished package.
[0046] Therefore, the system 150 operates the supply assembly line 152 by continuously moving the expandable pallet 112 in linear motion, enabling the fabrication of composite structures at a speed of approximately several feet per minute. The continuously moving assembly line allows for a substantial improvement in the speed and manufacturing efficiency of composite reinforcement production, because it does not stop for replacement tools to be placed.
[0047] In an alternative embodiment, a forming block 136 including a flat plate 142 and a bladder 144 is used, and the bladder station 158 is positioned within the supply assembly line 152 in front of a plurality of rollers 118.
[0048] Figure 13 is a flowchart illustrating one embodiment of a method 200 for forming a composite structure, according to an exemplary embodiment. The method 200 shown in Figure 13 presents one embodiment of a method that may be used, for example, with device 110 shown throughout the drawings or system 150 shown in Figure 10. Furthermore, the device or system may be used or configured to perform the logical functions presented in Figure 13. In some cases, components of the device and / or system may be configured to perform the above functions, and in fact, the components (together with hardware and / or software) may be designed and configured to enable such performance. In other embodiments, components of the device and / or system may be arranged to enable or be suitable for the performance of the above functions, for example, when operated in a particular manner. The method 200 may include one or more operations, functions, or actions, as shown by one or more of blocks 202-206. The blocks are shown in order, but these blocks may be performed in parallel and / or in an order different from that described herein. Furthermore, various blocks may be combined into fewer blocks, divided into further blocks, and / or removed based on the desired implementation.
[0049] Within the scope of the embodiments, one or more blocks of Method 200 may be represented in program code or circuitry used to control a robotic mechanism for performing functions related to forming a composite structure. At least some parts of Method 200 and its modifications may be performed automatically, for example, using one or more robotic armatures controlled by program code operating according to Method 200, although some tasks may be performed manually, or separately. Thus, certain functions described in relation to Method 200 may be performed automatically while other parts may be performed manually. Alternatively, all blocks of Method 200 may be performed automatically, or all blocks of Method 200 may be performed manually.
[0050] In this regard, a module, segment, or block or portion of a block representing a part of program code includes one or more instructions executable by a processor to implement a specific logical function or step in a process performed by a machine or device. Program code may be stored on any type of computer-readable medium or data storage, such as a storage device including a disk or hard drive. Furthermore, program code may be encoded in a machine-readable format on a computer-readable storage medium or on other non-transient medium or product. Computer-readable medium may include non-transient computer-readable medium or memory (e.g., computer-readable medium for short-term data storage, such as register memory, processor cache, and random access memory (RAM)). Computer-readable medium may also include non-transient media (e.g., secondary or persistent long-term storage devices, such as read-only memory (ROM), optical or magnetic disks, and compact disc read-only memory (CD-ROM)). Computer-readable medium may also be any other volatile or non-volatile storage system. Computer-readable media can be considered, for example, tangible computer-readable storage media.
[0051] Furthermore, some blocks or portions of blocks in Figure 13 may represent circuits wired to perform specific logical functions within a process, within the scope of other processes and methods disclosed herein. Alternative implementations are included within the scope of the embodiments of this disclosure. In embodiments of this disclosure, functions may be performed in an order different from that shown or described (including substantially simultaneous or reversed order), depending on the relevant functionality, as will be understood by those skilled in the art.
[0052] In block 202, method 200 includes adding the stacked charge 116 onto the expandable pallet 112.
[0053] In block 204, method 200 includes moving an expandable pallet 112 in linear motion against a plurality of rollers 118. Within the scope of the embodiment, one of the rollers 118 defines a contour that complements the desired shape of the composite structure 100. Furthermore, in one embodiment, the composite structure 100 is a stringer.
[0054] In block 206, method 200 includes progressively pressing a laminated charge 116 into a continuously expanding recess 120 defined by an expandable pallet 112 using a plurality of rollers 118. The plurality of rollers 118 are oriented into a series of configurations to shape the laminated charge 116 into at least a portion of the shape of the composite structure 100.
[0055] In one embodiment, each subsequent roller of the plurality of rollers 118 is oriented progressively deeper than the previous roller, and progressively pressing the laminated charge 116 into a continuously expanding recess 120 defined by the expandable pallet using the plurality of rollers 118 includes gradually pressing the laminated charge 116 into the recess 120 by the plurality of rollers 118, with each subsequent roller of the plurality of rollers 118 pressing the laminated charge 116 deeper into the recess 120.
[0056] In one embodiment, the expandable pallet 112 is moved in a linear motion against a plurality of rollers 118, and the plurality of rollers 118 are used to progressively press the stacked charge 116 into a continuously expanding recess 120 defined by the expandable pallet 112, thereby progressively expanding the expandable pallet 112 from a first end 130 to a second end 132 opposite the first end 130.
[0057] In one embodiment, the expandable pallet 112 includes a pair of interconnected pallet members 134a-b that define a recess 120 between them, and progressively pressing the laminated charge 116 into the continuously expanding recess 120 defined by the expandable pallet 112 includes a plurality of rollers 118 pressing the laminated charge 116 into the continuously expanding recess 120, causing the pair of pallet members 134a-b to move outward relative to each other and continuously expanding the recess 120.
[0058] In one embodiment, a plurality of rollers 118 are held stationary at their respective heights, and Method 200 further includes moving an expandable pallet 112 in linear motion beneath the plurality of rollers 118. A further feature of Method 200 also includes the plurality of rollers 118 pressing a stacked charge 116 into a continuously expanding recess 120, thereby expanding the expandable pallet 112 in a direction substantially perpendicular to the linear motion.
[0059] In some embodiments, Method 200 optionally includes progressively pressing the laminated charge 116 into a continuously expanding recess 120 defined by the expandable pallet 112 using a plurality of rollers 118, and then applying a bladder 144 over the laminated charge 116 in a cavity 160 formed by the plurality of rollers 118. Furthermore, Method 200 may optionally include installing R-filler 162 inside the laminated charge 116 after applying the bladder 144. Furthermore, Method 200 may optionally include compacting the laminated charge 116 after installing the R-filler 162 inside the laminated charge 116. In these embodiments, the process of adding the laminated charge 116 onto the expandable pallet 112, progressively pressing the laminated charge 116 into a continuously expanding recess 120 defined by the expandable pallet 112 using a plurality of rollers 118, attaching a bladder 144 to the laminated charge 116, installing R-filler 162 within the laminated charge 116, and compacting the laminated charge 116 is performed along the supply assembly line 152 by continuously moving the expandable pallet 112 in linear motion.
[0060] In some embodiments, Method 200 optionally includes attaching a forming block 136 to the lamination charge 116 after it has been added to the expandable pallet 112, the forming block 136 comprising a base 138 and projections 140 extending from the base 138 that define a contour complementing the desired shape of the composite structure 100. In this embodiment, progressively pressing the lamination charge 116 into a continuously expanding recess 120 defined by the expandable pallet 112 using a plurality of rollers 118 includes progressively pressing the forming block 136 downward, thereby continuously expanding the recess 120 and pressing the lamination charge 116 into the recess 120.
[0061] The exemplary devices, systems, and methods described herein support the fabrication of composite structures along a continuously moving production line. This significantly improves efficiency, drastically reduces the time required to form composite structures, and drastically reduces the space required for fabrication. At the same time, the exemplary devices, systems, and methods described herein can also be used to reduce the cost of fabricating composite structures.
[0062] As used herein, the terms “substantially” or “about” mean that the described characteristics, parameters, or values do not need to be strictly realized, but deviations or variations may occur, including tolerances, measurement errors, measurement accuracy limits, and other factors known to those skilled in the art, not to negate the effects that the characteristics are intended to produce.
[0063] Various embodiments of the (one or more) systems, (one or more) devices, and (one or more) methods disclosed herein include a wide variety of components, features, and functions. It should be understood that various embodiments of the (one or more) systems, (one or more) devices, and (one or more) methods disclosed herein may include, in any combination or subcombination, any component, features, and functions of any of the other embodiments of the (one or more) systems, (one or more) devices, and (one or more) methods disclosed herein, and all such possibilities are intended to be within the scope of this disclosure.
[0064] Furthermore, this disclosure includes embodiments as stipulated below. Article 1. A method (200) for forming a composite material structure (100), Adding stacked charges (116) to an expandable pallet (202), Moving the expandable pallet (112) in a linear motion relative to a plurality of rollers (118) (204), and A method comprising using the plurality of rollers (118) to progressively press the laminated charge (116) into a continuously expanding recess (120) defined by the expandable pallet (112), wherein the plurality of rollers (118) are oriented into a series of configurations to shape the laminated charge (116) into at least a portion of the shape of the composite structure (100). Article 2. The method according to Clause 1, wherein one of the plurality of rollers (118) defines a contour that complements the desired shape of the composite material structure (100). Article 3. The method according to clause 1 or 2, wherein the composite material structure (100) is a stringer. Article 4. Each of the plurality of rollers (118) in a sequence is oriented progressively deeper than the previous roller, and the plurality of rollers (118) are used to progressively press the stacked charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112). The method according to any one of claims 1 to 3, comprising gradually pressing the laminated charge (116) into the recess (120) by the plurality of rollers (118), wherein each successive roller of the plurality of rollers (118) presses the laminated charge (116) more deeply into the recess (120). Article 5. The plurality of rollers (118) are held stationary at their respective heights, and the method is as follows: The method according to any one of the claims 1 to 3, further comprising moving the expandable pallet (112) in linear motion under the plurality of rollers (118). Article 6. The method according to Clause 5, further comprising the plurality of rollers (118) pressing the stacked charge (116) into the continuously expanding recess (120) and causing the expandable pallet (112) to expand in a direction substantially perpendicular to the linear motion. Article 7. The expandable pallet (112) is moved in the linear motion relative to the plurality of rollers (118), and the plurality of rollers (118) are used to gradually press the stacked charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112). The method according to any one of the claims 1 to 6, further comprising progressively extending the expandable pallet (112) from a first end (130) to a second end (132) opposite the first end. Article 8. The expandable pallet (112) includes a pair of interconnected pallet members (134a-b) that define the recess (120) between the pair of pallet members (134a-b), and progressively pressing the stacked charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112) is performed as follows: The method according to any one of claims 1 to 7, comprising pressing the stacked charge (116) into the continuously expanding recess (120) with the plurality of rollers (118), moving the pair of pallet members outward relative to each other, and continuously expanding the recess (120). Article 9. The method according to any one of claims 1 to 8, further comprising using the plurality of rollers (118) to progressively press the laminated charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112), and then placing a bladder (144) over the laminated charge (116) in the cavity formed by the plurality of rollers (118). Article 10. The method according to Clause 9, further comprising placing the bladder on top of the laminated charge (116) and then installing the R-shaped filler (162) inside the laminated charge (116). Article 11. The method according to clause 10, further comprising compacting the laminated charge (116) after installing the R-shaped filler within the laminated charge (116). Article 12. The method according to Clause 11, wherein the steps of adding the laminated charge (116) onto the expandable pallet (112), progressively pressing the laminated charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112) using the plurality of rollers (118), attaching the bladder onto the laminated charge (116), installing the R-filler within the laminated charge (116), and compacting the laminated charge (116) are performed along a supply assembly line (152) by continuously moving the expandable pallet (112) in the linear motion. Article 13. The method according to any one of claims 1 to 12, further comprising adding a forming block (136) on the lamination charge (116) after adding the lamination charge (116) on the expandable pallet (112), wherein the forming block comprises a base (138) and a projection (140) extending from the base that defines a contour that complements the desired shape of the composite structure (100). Article 14. Using the plurality of rollers (118), the stacked charge (116) is gradually pressed into the continuously expanding recess (120) defined by the expandable pallet (112). The method according to Clause 13, comprising progressively pressing the forming block downward, thereby continuously expanding the recess (120) and pressing the laminated charge (116) into the recess (120). Article 15. A device (110) for forming a composite material structure (100), An expandable pallet (112) having a forming surface configured to receive a stacked charge (116) on top, and A device comprising a plurality of rollers (118) oriented in a series configuration for progressively pressing the laminated charge (116) into a continuously expanding recess (120) defined by the expandable pallet (112) as the expandable pallet (112) is moved in linear motion against a plurality of rollers (118), wherein the plurality of rollers (118) mold the laminated charge (116) into at least a portion of the shape of the composite structure (100). Article 16. The device according to Clause 15, wherein each successive roller of the plurality of rollers (118) is oriented progressively deeper than the previous roller, and the plurality of rollers (118) gradually press the laminated charge (116) into the recess (120) such that each successive roller of the plurality of rollers (118) presses the laminated charge (116) deeper into the recess (120). Article 17. The device according to Clause 15, wherein the plurality of rollers (118) are held stationary at their respective heights, and the expandable pallet (112) moves in the linear motion beneath the plurality of rollers (118) so as to progressively expand from a first end of the expandable pallet (112) to a second end of the expandable pallet (112) opposite the first end. Article 18. A system (150) for forming a composite material structure (100), An expandable pallet (112) having a forming surface configured to receive a stacked charge (116) on top, A plurality of rollers (118) oriented in a configuration for progressively pressing a laminated charge (116) into a continuously expanding recess (120) defined by the expandable pallet (112), wherein the plurality of rollers (118) shape the laminated charge (116) into at least a portion of the shape of the composite structure (100), and A supply assembly line (152) on which the expandable pallet (112) having the stacked charge (116) is positioned, the supply assembly line comprising the supply assembly line for continuously moving the expandable pallet (112) in linear motion relative to the plurality of rollers (118). Article 19. The system according to Clause 18, further comprising a bladder station (158) positioned after the plurality of rollers (118) within the range of the supply assembly line, wherein a bladder (144) is placed over the stacked charge (116) in a cavity formed by the plurality of rollers (118) as the expandable pallet (112) moves through the bladder station. Article 20. The system according to Clause 19, further comprising an R-section filling station (161) located after the bladder station within the range of the supply assembly line, wherein the R-section filler is placed in the stacked charge (116) as the expandable pallet (112) moves through the R-section filling station.
[0065] The descriptions of various advantageous configurations are presented for illustrative and explanatory purposes only and are not intended to be complete or to limit the embodiments of the disclosed form. Many modifications and variations will be obvious to those skilled in the art. Furthermore, various advantageous embodiments may represent different advantages compared to other advantageous embodiments. One or more selected embodiments have been chosen and described to illustrate the principle of the embodiment, its practical applications, and to facilitate the understanding of the disclosure of various embodiments and the various modifications suitable for the specific applications considered by those skilled in the art.
Claims
1. A method (200) for forming a composite material structure (100), Adding stacked charges (116) on an expandable pallet (202), Moving the expandable pallet (112) in a linear motion relative to a plurality of rollers (118) (204), and A method comprising using the plurality of rollers (118) to progressively press the laminated charge (116) into a continuously expanding recess (120) defined by the expandable pallet (112), wherein the plurality of rollers (118) are oriented into a series of configurations to shape the laminated charge (116) into at least a portion of the shape of the composite structure (100).
2. The method according to claim 1, wherein one of the plurality of rollers (118) defines a contour that complements the desired shape of the composite material structure (100).
3. The method according to claim 1 or 2, wherein the composite material structure (100) is a stringer.
4. Each of the plurality of rollers (118) in a sequence is oriented progressively deeper than the previous roller, and the plurality of rollers (118) are used to progressively press the stacked charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112), The method according to claim 1, comprising gradually pressing the stacked charge (116) into the recess (120) by the plurality of rollers (118), wherein each of the plurality of rollers (118) in a continuous manner presses the stacked charge (116) more deeply into the recess (120).
5. The plurality of rollers (118) are held stationary at their respective heights, and the method is as follows: The method according to claim 1, further comprising moving the expandable pallet (112) in linear motion under the plurality of rollers (118).
6. The method according to claim 5, further comprising the plurality of rollers (118) pressing the stacked charge (116) into the continuously expanding recess (120) and causing the expandable pallet (112) to expand in a direction substantially perpendicular to the linear motion.
7. The expandable pallet (112) is moved in the linear motion relative to the plurality of rollers (118), and the plurality of rollers (118) are used to gradually press the stacked charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112). The method according to claim 1, further comprising progressively extending the expandable pallet (112) from a first end (130) to a second end (132) opposite the first end.
8. The expandable pallet (112) includes a pair of interconnected pallet members (134a to b) that define the recess (120) between the pair of pallet members (134a to b), and progressively pressing the stacked charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112) is performed as follows: The method according to claim 1, comprising the plurality of rollers (118) pressing the stacked charge (116) into the continuously expanding recess (120), moving the pair of pallet members outward relative to each other, and continuously expanding the recess (120).
9. The method according to claim 1, further comprising using the plurality of rollers (118) to progressively press the laminated charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112), and then placing a bladder (144) on top of the laminated charge (116) in the cavity formed by the plurality of rollers (118).
10. The method according to claim 9, further comprising placing the bladder on top of the laminated charge (116) and then installing the R-shaped filler (162) inside the laminated charge (116).
11. The method according to claim 10, further comprising compacting the laminated charge (116) after installing the R-shaped filler in the laminated charge (116).
12. The method according to claim 11, wherein the steps of adding the laminated charge (116) onto the expandable pallet (112), progressively pressing the laminated charge (116) into the continuously expanding recess (120) defined by the expandable pallet (112) using the plurality of rollers (118), attaching the bladder onto the laminated charge (116), installing the R-shaped filler into the laminated charge (116), and compacting the laminated charge (116) are performed along a supply assembly line (152) by continuously moving the expandable pallet (112) in the linear motion.
13. The method according to claim 1, further comprising adding a forming block (136) on the forming block (116) after adding the lamination charge (116) on the expandable pallet (112), wherein the forming block comprises a base (138) and a projection (140) extending from the base that defines a contour that complements the desired shape of the composite structure (100).
14. Using the plurality of rollers (118), the stacked charge (116) is gradually pressed into the continuously expanding recess (120) defined by the expandable pallet (112). The method according to claim 13, comprising progressively pressing the forming block downward, thereby continuously expanding the recess (120) and pressing the laminated charge (116) into the recess (120).
15. A device (110) for forming a composite material structure (100), An expandable pallet (112) having a forming surface configured to receive a stacked charge (116) on top, and A device comprising a plurality of rollers (118) oriented in a series configuration for progressively pressing the laminated charge (116) into a continuously expanding recess (120) defined by the expandable pallet (112) as the expandable pallet (112) is moved in linear motion against a plurality of rollers (118), wherein the plurality of rollers (118) mold the laminated charge (116) into at least a portion of the shape of the composite structure (100).
16. The device according to claim 15, wherein each of the plurality of rollers (118) in a sequence is oriented progressively more deeply than the previous roller, and the plurality of rollers (118) gradually press the stacked charge (116) into the recess (120) such that each of the plurality of rollers (118) in a sequence presses the stacked charge (116) more deeply into the recess (120).
17. The device according to claim 15, wherein the plurality of rollers (118) are held stationary at their respective heights, and the expandable pallet (112) moves in the linear motion beneath the plurality of rollers (118) so as to progressively expand from a first end of the expandable pallet (112) to a second end of the expandable pallet (112) opposite the first end.
18. A system (150) for forming a composite material structure (100), An expandable pallet (112) having a forming surface configured to receive a stacked charge (116) on top, A plurality of rollers (118) oriented in a series configuration for progressively pressing a laminated charge (116) into a continuously expanding recess (120) defined by the expandable pallet (112), wherein the plurality of rollers (118) shape the laminated charge (116) into at least a portion of the shape of the composite structure (100), and A supply assembly line (152) on which the expandable pallet (112) having the stacked charge (116) is positioned, the supply assembly line comprising the supply assembly line for moving the expandable pallet (112) continuously in linear motion relative to the plurality of rollers (118).
19. The system according to claim 18, further comprising a bladder station (158) located behind the plurality of rollers (118) within the range of the supply assembly line, wherein a bladder (144) is placed over the stacked charge (116) in a cavity formed by the plurality of rollers (118) as the expandable pallet (112) moves through the bladder station.
20. The system according to claim 19, further comprising an R-section filling station (161) located after the bladder station within the range of the supply assembly line, wherein the R-section filler is placed in the stacked charge (116) as the expandable pallet (112) moves through the R-section filling station.