Contoured Composite Charge Forming for Faster Stringer Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing large composite structures with complex geometries are time-consuming, require significant manufacturing space, and involve the use of expensive and inefficient tape laying machines, leading to inconsistencies during contour formation.
Innovation Solution
A composite structure forming system with multiple parallel charge forming stations and conveyor systems that form and transport contoured elongate composite structures in a continuous process, using composite tape laying heads and adjustable support rollers to introduce curvature and flexibility in the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional tape laying machines are used to form composite structures with complex geometries, then manufacturing precision can be maintained, but manufacturing time increases significantly and manufacturing space requirements increase
Solution Approach 1:
The system divides the composite structure into multiple separate charges (first charge, second charge, third charge) that are formed independently in parallel stations. Each charge forming station operates autonomously to create a portion of the final structure, which are then joined together. This segmentation allows simultaneous production of multiple charges, dramatically reducing total manufacturing time while maintaining precision through dedicated forming stations for each charge.
Solution Approach 2:
The patent combines multiple charge forming stations and conveyor systems into a single integrated system that operates in parallel. The first, second, and third charge forming stations work simultaneously, each with its own conveyor system, to produce multiple charges at the same time. These charges are then joined together to form the complete composite structure, merging the output of multiple parallel processes into one unified product.
2Ease of manufacture
If traditional methods are used to manufacture large composite structures, then complete structure formation is achieved, but manufacturing floor space requirements become excessive
Solution Approach 1:
The manufacturing system is segmented into multiple discrete charge forming stations (first, second, and third stations) that can be arranged in a compact configuration. Each station forms a separate charge that is then joined with others, eliminating the need for a single large-forming area. This segmentation allows the manufacturing system to fit within smaller floor spaces while still producing large composite structures through assembly of multiple charges.
Solution Approach 2:
The system transitions from forming complete structures in a single planar space to forming multiple smaller charges in parallel stations arranged in three-dimensional space. The charges are formed vertically or in stacked configurations and then joined, utilizing vertical space and multiple dimensions rather than requiring extensive horizontal floor space for a single large structure formation area.
3Shape
If multiple uncured composite charges are joined to form large composite structures, then structural complexity is achieved, but manufacturing time increases undesirably
Solution Approach 1:
Multiple composite charges are formed in advance in parallel charge forming stations before final assembly. Each charge is prepared independently with its complete contour and geometry predetermined, allowing simultaneous preparation of all charges that will be joined. This preliminary parallel formation of charges eliminates sequential processing time and allows rapid assembly of the final complex structure.
Solution Approach 2:
The system maintains continuous operation across all charge forming stations, with each station continuously forming charges that are immediately conveyed to joining areas. The parallel stations operate simultaneously without idle time, and the conveyor systems continuously transport charges through the forming and joining processes, eliminating interruptions and maintaining uninterrupted productive action throughout the manufacturing system.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A composite structure forming system (102) configured to form a contoured elongate composite structure (104) in a continuous process is presented. The composite structure forming system comprises a plurality of charge forming stations (108) and a plurality of conveyor systems (110). The plurality of charge forming stations is configured to operate in parallel, each charge forming station of the plurality of charge forming stations is configured to form a respective composite charge (118, 124, 130) of the contoured elongate composite structure. Each conveyor system (110) of the plurality of conveyor systems is configured to transport a respective composite charge (118, 124, 130) through a respective charge forming station (108).