Composite Charge Positioning System for Automated Placement

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Solution Overview

Problem

Conventional automated 'pick and place' systems for composite layers are expensive, time-consuming to install, and not easily scalable or accurate enough for positioning composite charges onto forming tools, especially for larger or varying sizes of composite charges.

Innovation Solution

A composite charge positioning system using a pair of movable charge support arms that can be adjusted to position and align composite charges accurately on forming tools, allowing for flexible and precise placement without requiring significant infrastructure changes or high investment costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If conventional automated pick and place systems are used, then automation and placement capability are achieved, but the system becomes expensive and complex to install

Engineering Contradiction:

Improveautomation of composite layer placementVSAvoidsystem installation complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The system divides the composite charge into multiple layers that can be handled individually, with each layer being positioned using simple support arms rather than a complex automated system. This segmentation allows manual or semi-automated handling of smaller, more manageable units.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using a complex automated system to pick and place entire composite charges, the invention inverts the approach by using simple support arms to support the charge from below and lowering it into place. This reverses the conventional top-down placement method with a bottom-up support method.

Inventive Principle:

Principle #13The other way round (Inversion)

2Extent of automation

If conventional automated pick and place systems are used, then automated placement is achieved, but installation time increases

Engineering Contradiction:

Improveautomated composite charge positioningVSAvoidinstallation time

Core Design Contradiction:

Extent of automationVSLoss of time

Solution Approach 1:

The support arms are designed to be movable and adjustable, allowing the system to adapt to different composite charge sizes and positions dynamically. This flexibility eliminates the need for time-consuming reconfiguration of fixed automated systems when handling varying workpiece dimensions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system allows adjustment of support arm positions and configurations to match different composite charge parameters (size, shape, weight). This parameter adaptability enables the same simple system to handle various charges without requiring complex automated reprogramming or reconfiguration.

Inventive Principle:

Principle #35Parameter changes

3Extent of automation

If conventional automated pick and place systems are used, then automated handling is achieved, but scalability to larger composite charges is limited

Engineering Contradiction:

Improveautomated composite charge handlingVSAvoidscalability to varying charge sizes

Core Design Contradiction:

Extent of automationVSAdaptability or versatility

Solution Approach 1:

The support arm system is designed with universal applicability, where the same basic structure can support and position composite charges of various sizes by adjusting arm positions and configurations. This multi-functionality allows a single simple system to replace multiple specialized automated systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system adds dimensional flexibility by allowing support arms to extend and position themselves in multiple spatial dimensions. This enables the system to accommodate larger composite charges by distributing support across multiple points in three-dimensional space, rather than being constrained to fixed two-dimensional placement zones.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Ease of operation

If human operators manually place composite layers, then flexibility is maintained, but placement accuracy decreases

Engineering Contradiction:

Improvemanual placement flexibilityVSAvoidcomposite layer placement accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The support arms serve as an intermediary device between the operator and the composite charge. They provide mechanical assistance that enhances human capability, combining the flexibility of manual operation with the precision of mechanical positioning. The arms act as a mediator that translates human intent into accurate placement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The support arms are designed to be easily adjusted and repositioned by operators without requiring specialized training or complex procedures. The system enables operators to achieve high accuracy through intuitive, self-explanatory adjustments rather than requiring mastery of complex automated system controls.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS11951698B2Composite charge positioning system

Publication Date: 2024.04.09 THE BOEING CO

AI summary

A method of positioning a composite charge onto a forming tool using a composite charge positioning assembly. The composite charge is placed onto a first surface of a first charge support arm of the composite charge positioning assembly and a second surface of a second charge support arm of the composite charge positioning assembly. The composite charge is placed in contact with a portion of a forming surface of the forming tool.