Automated Assembly Table for Composite Structure Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual fabrication of composite aircraft stringers is labor-intensive, time-consuming, and prone to quality control issues due to the need for manual layering and assembly of materials, which limits efficiency and consistency.
Innovation Solution
A modular, automated structure assembly table with multiple devices for positioning, compacting, and rotating composite subassemblies, including flipper and flopper assemblies, to facilitate the automated assembly of composite structures like aircraft wing stringers, allowing for precise alignment and joining of subassemblies while accommodating variations in taper and ply thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual layering and assembly of composite materials is used, then flexibility in handling complex shapes is improved, but labor intensity and fabrication time increase significantly
Solution Approach 1:
The automated cutting machine performs cutting operations autonomously based on digital designs, eliminating the need for manual cutting and positioning of each prepreg layer. The system self-regulates the cutting process, material feed, and layer placement, significantly reducing labor intensity while maintaining the ability to handle complex stringer geometries through computer-controlled operations.
2Adaptability or versatility
If manual placement of prepreg layers on lay-up mandrels is used, then adaptability to various stringer configurations is improved, but manufacturing precision and quality control deteriorate
Solution Approach 1:
The automated system incorporates adjustable and reconfigurable tooling fixtures that can dynamically adapt to different stringer configurations and geometries. The cutting machine and positioning systems are computer-controlled and can be reprogrammed for various stringer types, maintaining versatility while ensuring consistent, precise alignment through automated guidance and control mechanisms.
3Productivity
If automated cutting and assembly equipment is introduced, then productivity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The automated cutting machine and assembly system are designed as multi-functional units that can handle multiple operations including cutting, positioning, and monitoring of composite layer assembly. This consolidation of functions into integrated automated equipment improves productivity and precision while managing system complexity through unified control architectures and standardized interfaces.
4Ease of operation
If manual conformance of prepreg layers to mandrel contours is used, then ease of operation is improved, but time consumption and labor costs increase
Solution Approach 1:
The system replaces manual mechanical operations of conforming prepreg layers to mandrel contours with automated mechanical systems. Computer-controlled positioning mechanisms and automated handling equipment perform the conformance operation, eliminating manual labor while maintaining the ability to achieve proper contour alignment, thereby reducing assembly time without sacrificing ease of operation.
Data Source
AI summary
A method of assembling a composite structure is disclosed. An illustrative embodiment of the method includes receiving and positioning at least two composite structure subassemblies on a structure assembly table by operation of at least one first device and at least one second device and compacting the at least two composite structure subassemblies into a composite structure by operation of a third device.