Adjustable Laminating Mandrel Equipment for Composite Structural Elements
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Solution Overview
Problem
The existing processes for manufacturing structural elements in composite materials, such as aircraft fuselages, are time-consuming and require multiple equipment setups for different dimensions, lacking a unified, efficient, and cost-effective solution.
Innovation Solution
A modular equipment system comprising a support frame and a laminating mandrel with adjustable components, allowing for the integration of stringers and skin layers, followed by curing in an autoclave, which can be adapted for various dimensions and reused for different applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple equipment setups are used for different dimensions, then manufacturing precision is improved, but device complexity and loss of time increase
Solution Approach 1:
The mandrel is designed with adjustable components including movable support rollers and可变 positioning systems that allow a single mandrel to accommodate multiple structural element dimensions. The support rollers can be repositioned along the mandrel length, and the positioning system can adjust to different geometries, enabling one mandrel to perform multiple functions for different product sizes.
Solution Approach 2:
The mandrel incorporates dynamic positioning mechanisms and movable support elements that can be adjusted during the manufacturing process. The support rollers are mounted on movable carriages that can slide along the mandrel, allowing the equipment to adapt its configuration for different structural element dimensions and geometries.
2Manufacturing precision
If multiple equipment setups are used for different dimensions, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The mandrel is designed with adjustable components including movable support rollers and可变 positioning systems that allow a single mandrel to accommodate multiple structural element dimensions. The support rollers can be repositioned along the mandrel length, and the positioning system can adjust to different geometries, enabling one mandrel to perform multiple functions for different product sizes.
Solution Approach 2:
The mandrel incorporates dynamic positioning mechanisms and movable support elements that can be adjusted during the manufacturing process. The support rollers are mounted on movable carriages that can slide along the mandrel, allowing the equipment to adapt its configuration for different structural element dimensions and geometries.
3Manufacturing precision
If traditional multi-step processes are used, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The equipment integrates multiple manufacturing operations into a single unified system. The mandrel simultaneously performs shaping, positioning, and support functions during the autoclave curing process. The integrated design combines what were previously separate operations (forming, positioning, and support) into one coordinated system that operates throughout the entire curing cycle.
Solution Approach 2:
The mandrel is pre-configured with the correct geometry and positioning before the autoclave cycle begins. All support rollers and positioning elements are arranged in advance to match the required structural element geometry, eliminating the need for adjustments or reconfigurations during the curing process.
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
This system optimizes production time and cost by enabling the completion of manufacturing, finishing, and quality checks on a single equipment, facilitating reuse for different sizes and autoclave compatibility, thus enhancing efficiency and flexibility.
Implementation Method 1
The assembly thus formed is then subjected to a co-curing operation in an autoclave by applying appropriate pressure and temperature, in order to cure the composite material, compact the aforementioned layers together and bond the stringers to the skin.
Implementation Method 2
The assembly thus formed is then subjected to a co-curing operation in an autoclave by applying appropriate pressure and temperature, in order to cure the composite material, compact the aforementioned layers together
Implementation Method 3
the skin, made by laminating together a plurality of layers of uncured composite material, is bonded, by means of a structural adhesive, to the stringers which have been previously pre-cured after their forming
Data Source
Figure 1~2
Figure 3A~3B
Figure 4~5
AI summary
The invention relates to equipment (10) for making a structural element (1) of composite material having a longitudinal axis (A) and an axial cavity (2). The equipment (10) comprises a support frame (11) and a laminating mandrel (12), which is mounted on the support frame (11) so that it can rotate about its own central axis (B) and defines an outer laminating surface (13); the support frame (11) comprises two vertical headers (14, 15), facing each other and parallel to each other, and longitudinal connecting means (16) for longitudinally connecting the headers (14, 15); each header (14, 15) comprises a fixed portion (17) and a movable portion (18), coaxially receiving the laminating mandrel (12) and rotatable about the central axis (B) in relation to the fixed portion (17); the laminating mandrel (12) comprises a central shaft (26, 26' ), a plurality of sectors (30) angularly spaced apart about the central axis (B), and a plurality of linear actuators (31) extending between the central shaft (26, 26' ) and respective sectors (30) to move the sectors (30) themselves between an expanded laminating position and a contracted position; the equipment (10) further comprises first constraining means (35) for connecting in a releasable manner the sectors (30), arranged in the expanded laminating position, to the movable portions (18) of the headers (14, 15), and second constraining means (36) connecting the linear actuators (31) to the sectors (30) in a releasable manner so as to enable the extraction of the central shaft (26, 26' ) and linear actuators (31) from the equipment (10) in the condition in which the sectors (30), in the expanded position, are connected to the movable portions (18) of the headers (14, 15) by means of the first constraining means (35).