Automated Composite Fabrication System for On-Demand Assembly
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Solution Overview
Problem
In vehicle manufacturing, the labor-intensive process of fabricating laminated composite components, such as frame fillers for aircraft fuselages, leads to inefficiencies and waste due to batch production and storage, especially when production is stopped or slowed, resulting in perishable parts becoming unusable.
Innovation Solution
An automated system comprising a cutting station, build station, and finishing station that uses robotic devices and vacuum conveyors to separate, stack, and compact composite layers according to predefined patterns and orientations, enabling on-demand fabrication of laminated composite components at the assembly site, reducing the need for storage and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If parts are fabricated in advance and stored in storage areas, then parts availability for vehicle assembly is improved, but storage space requirements increase and waste of perishable parts occurs when production is stopped or slowed
Solution Approach 1:
The system performs preliminary actions by preparing composite layers and stacking them in a controlled manner before final assembly, but only to the extent needed for immediate or near-term use. The automated stacking system allows parts to be prepared in advance under controlled conditions (maintaining perishability requirements) while enabling quick adjustment of production volume to match actual demand, thus reducing waste of perishable parts while ensuring availability.
Solution Approach 2:
The invention implements a dynamic production system where the automated composite fabrication system can adjust its output in real-time based on actual vehicle assembly needs. The system transitions from static batch production with fixed storage to a dynamic on-demand fabrication process, allowing the production rate to match the consumption rate and minimizing both storage requirements and waste of perishable parts.
2Productivity
If sufficiently sized storage area is maintained to keep stock of all parts, then productivity is ensured by part availability, but capital investment and storage space requirements increase
Solution Approach 1:
The invention extracts the fabrication process from centralized batch production locations and brings it directly to the vehicle assembly site through an automated composite fabrication system. This eliminates the need for large storage areas by producing parts on-demand at the point of use, while maintaining productivity through automated continuous operation.
Solution Approach 2:
The system performs preliminary fabrication actions directly at the assembly location rather than in advance at remote facilities. The automated stacking and consolidation of composite layers occurs just-in-time for assembly, eliminating the need for large storage areas while ensuring part availability for continuous productivity.
3Adaptability or versatility
If labor-intensive fabrication process is used by technicians, then manufacturing flexibility is maintained, but fabrication time and labor costs increase
Solution Approach 1:
The invention replaces manual mechanical fabrication processes performed by technicians with an automated composite fabrication system that uses computer-controlled cutting, stacking, and consolidation equipment. This substitution dramatically reduces fabrication time while maintaining manufacturing flexibility through programmable control that can adapt to different part designs and assembly requirements.
Solution Approach 2:
The system changes the control parameters from manual human decision-making to automated computer-controlled processes. The fabrication parameters (cutting patterns, stacking sequences, consolidation pressures) are programmatically adjusted to maintain manufacturing flexibility while achieving consistent, high-speed production that reduces fabrication time compared to manual processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The automated system allows for real-time fabrication of composite components, reducing storage needs, minimizing waste, and enabling immediate installation, thus improving productivity and reducing production delays and costs.
Implementation Method 1
a vacuum conveyor configured to hold the ply of composition material
Implementation Method 2
a compactor configured to compact the stack of component layers
Data Source
AI summary
A system and a method for manufacturing laminated composite components is described. The system may include a cutting station configured to separate component layers from a ply of composition material according to a predefined pattern, a build station configured to stack the component layers according to a predetermined orientation, and a finishing station configured to compact the stacked component layers and provide the laminated composite component to an installation station.