Automated Preform Forming Machine for Composite Stringers

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Solution Overview

Problem

Conventional methods for forming three-dimensional stringer preforms in composite structures require extensive skilled labor, leading to lengthy cycle times, high production costs, and significant dimensional variations, resulting in a high rejection rate.

Innovation Solution

A preform forming machine with a forming block assembly and clamping plate assembly that automates the folding and clamping of dry fabric plies to form a web, reducing the need for skilled labor and minimizing dimensional variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional manual methods are used to assemble, fold, and stitch dry fabric plies, then flexibility and adaptability in handling complex stringer geometries are maintained, but production cycle time increases significantly and labor costs increase

Engineering Contradiction:

Improveability to handle complex stringer geometriesVSAvoidproduction cycle time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The manual preform forming process is segmented into distinct operations (laying up, folding, stitching, debulking) that are then automated by separate modular machine components. This allows each function to be independently optimized for both complexity handling and speed, resolving the contradiction between adaptability and productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Manual mechanical operations are replaced with automated mechanical systems. The patent employs automated layup mechanisms, folding devices with controlled motion, and automated stitching systems that can handle complex geometries through programmable control while dramatically reducing cycle time compared to manual operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If extensive manual operations are performed to ensure high accuracy in preform formation, then dimensional precision is improved, but the rejection rate increases due to dimensional variation between preforms

Engineering Contradiction:

Improvedimensional accuracy of preformsVSAvoidconsistency between preforms

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The automated preform forming machine incorporates feedback control systems that monitor and adjust forming parameters in real-time. Sensors detect dimensional variations during the forming process and automatically compensate, ensuring consistent dimensional accuracy across all preforms and eliminating the rejection issues associated with manual variability.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The invention controls and standardizes critical forming parameters (temperature, pressure, folding angle, stitching tension) through automated systems. By maintaining parameters within tight controlled ranges, the process achieves both high dimensional accuracy and consistent results across multiple preforms, resolving the contradiction between precision and reliability.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If skilled touch labor is extensively used for manual preform formation, then operational flexibility is maintained, but production cost increases significantly

Engineering Contradiction:

Improveoperational flexibilityVSAvoidproduction cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The automated preform forming system is designed to be self-sufficient, with automated material handling, automated positioning, and automated quality monitoring. The system serves itself by automatically adjusting parameters and compensating for variations without requiring skilled operators, thereby eliminating high labor costs while maintaining operational flexibility through programmable control.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The automated machine is designed as a universal system capable of forming various stringer geometries and configurations through programmable control. A single multi-functional automated system replaces multiple specialized manual operations, reducing overall production cost while maintaining the flexibility to handle different preform designs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9278826B2System and method for producing a three-dimensional dry fiber preform

Publication Date: 2016.03.08 THE BOEING CO

AI summary

A preform forming machine for producing a three-dimensional dry fiber preform may include a forming block assembly and a clamping plate assembly. The forming block assembly may have a forming table and a forming block and may be positionable in a series of forming block assemblies. The clamping plate assembly may have a clamping table and a clamping plate and may be positionable in a series of clamping plate assemblies arranged in opposing relation to the series of forming block assemblies. Each forming block may be configured to fold a ply stack over onto itself to form a web of a preform. Each clamping plate may be configured to clamp the ply stack to the forming table during the folding of the ply stack.