Parallel Composite Barrel Panel Fabrication for High Throughput

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Solution Overview

Problem

Current manufacturing methods for composite fuselage components are time-consuming and require a large factory footprint, with laydown rates and takt times that are not sustainable in the long term, limiting the production of composite barrel structures.

Innovation Solution

The method involves fabricating multiple composite panels in parallel using a system with concurrent layup and heating stations, allowing for the simultaneous assembly and curing of composite material layers to form partial barrel sections, which can be quickly assembled into a full barrel structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional manufacturing methods are used for composite fuselage components, then manufacturing process simplicity is maintained, but production throughput is low (15 aircraft per month) and factory footprint is large

Engineering Contradiction:

Improveproduction throughputVSAvoidmanufacturing system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The manufacturing process is segmented into multiple parallel workstations, each capable of independently fabricating composite panels. This segmentation enables simultaneous production of multiple panels, increasing throughput from 15 to 80 aircraft per month while distributing complexity across modular units rather than requiring a single complex system

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent transitions from sequential processing to parallel processing by adding a temporal dimension to the manufacturing process. Multiple layup and heating stations operate concurrently, transforming a single-dimensional production flow into a multi-dimensional parallel architecture that significantly boosts productivity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Speed

If conventional manufacturing methods are used, then manufacturing time is long (takt time over 6 hours), but production speed is slow (laydown rate less than 1000 lbs. per hour)

Engineering Contradiction:

Improveproduction speedVSAvoidmanufacturing time

Core Design Contradiction:

SpeedVSLoss of time

Solution Approach 1:

Composite panels are fabricated and cured in advance at parallel workstations before final assembly. This preliminary action allows the heavy lifting and time-consuming curing processes to be completed separately, enabling rapid assembly operations and reducing overall takt time from over 6 hours to approximately 1.5 hours

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Multiple heating stations operate continuously and concurrently to cure multiple panels simultaneously, eliminating idle time between operations. This continuous useful action increases laydown rate from less than 1000 lbs. per hour to over 10,000 lbs. per hour by keeping all manufacturing resources continuously productive

Inventive Principle:

Principle #20Continuity of useful action

3Area of stationary object

If conventional manufacturing methods are used, then factory footprint is large, but space utilization is inefficient

Engineering Contradiction:

Improvefactory footprintVSAvoidproduction throughput

Core Design Contradiction:

Area of stationary objectVSProductivity

Solution Approach 1:

Multiple layup and heating operations that would traditionally require separate large facilities are merged into integrated parallel workstations. This combining of functions within compact modular units increases production throughput while reducing the overall factory footprint through efficient space utilization

Inventive Principle:

Principle #5Merging (Combining)

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 approach significantly increases production throughput, enabling the manufacturing of up to 80 aircraft per month within a reduced factory footprint, compared to the typical 15 aircraft per month, by utilizing parallel processing and panelized production concepts.

Implementation Method 1

The fabricating the first plurality of composite panels further includes heating the first layup together with the at least one additional layup

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS11911978B2Methods and associated systems for manufacturing composite barrel structures

Publication Date: 2024.02.27 THE BOEING CO

AI summary

A method for manufacturing a composite barrel structure includes fabricating a first plurality of composite panels that are assemblable into a first partial composite barrel section. The fabricating includes assembling a first layup of composite material and, concurrently, assembling at least one additional layup. The fabricating further includes heating the first layup with the at least one additional layup. A system for fabricating a plurality of panels that are assemblable into partial barrel sections includes a first workstation for fabricating a first plurality of composite panels that are assemblable into a first partial composite barrel section. The first workstation includes a first assembly station configured to concurrently assemble a first layup of composite material and at least one additional layup and a first heating station configured to heat the first layup concurrently with the at least one additional layup to yield the first plurality of composite panels.