Composite Charge Shaping System for Stringer Formation
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Solution Overview
Problem
Conventional methods for forming composite stringers are time-consuming, complex, and lack the desired quality and consistency, especially in creating complex cross-sections and radii, and current robotic systems struggle to achieve the necessary precision and quality in laying up composite materials.
Innovation Solution
A method and apparatus that utilize a charge shaping system with placement end effectors and a contoured transfer tool to automate the stacking and shaping of composite charges, allowing for precise alignment and compaction to form contoured composite stringers with varying widths and radii, using a combination of 3-axis motion and a compactive roller to ensure accurate placement and void reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual laying up methods are used to form composite stringers, then flexibility and adaptability are maintained, but manufacturing time increases and quality consistency deteriorates
Solution Approach 1:
The patent replaces manual mechanical laying up with an automated robotic system that uses programmable motion control to place composite plies. The robotic system incorporates automated fiber placement technology with precision control mechanisms, substituting human operators with automated equipment that maintains both speed and quality consistency throughout the manufacturing process.
Solution Approach 2:
The patent implements programmable control parameters for the robotic system, allowing precise adjustment of ply placement parameters such as position, orientation, and spacing. By changing control parameters digitally rather than through manual adjustment, the system achieves both high productivity and consistent manufacturing quality across different stringer configurations.
2Extent of automation
If conventional robotic systems are used to lay up composite structures, then automation is increased, but manufacturing precision and quality deteriorate
Solution Approach 1:
The patent enhances conventional robotic systems by integrating automated fiber placement technology with precision control mechanisms. The system uses programmable motion control and automated tensioning systems to maintain precise ply placement, replacing less precise mechanical positioning with electronically controlled positioning that achieves both high automation and manufacturing precision.
Solution Approach 2:
The patent incorporates feedback control mechanisms in the robotic system, using sensors to monitor ply placement accuracy and automatically adjusting positioning parameters. The system includes real-time feedback on fiber tension, placement position, and layer alignment, enabling the automated system to maintain high manufacturing precision comparable to or exceeding manual methods while sustaining full automation.
3Shape
If complex cross-sections and radii are formed using conventional methods, then design versatility is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent uses dynamically controllable robotic arms with multiple degrees of freedom to form complex cross-sections and radii. The system can dynamically adjust the positioning and orientation of composite plies during the laying up process, enabling the creation of complex geometries through programmed motion paths rather than complex tooling or manual manipulation.
Solution Approach 2:
The patent employs programmable control parameters that can be easily modified to create different complex cross-sectional shapes and radii. By changing digital control parameters rather than physical tooling or manufacturing procedures, the system achieves design versatility without increasing manufacturing process complexity, allowing rapid reconfiguration for different stringer designs.
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 enables the efficient and precise formation of composite stringers with complex cross-sectional shapes, reducing manufacturing time and improving quality by allowing for in-situ shaping and compaction, thereby overcoming the limitations of conventional techniques.
Implementation Method 1
Upper plates of the plurality of placement end effectors are rotated along a first axis to cover the composite charge
Implementation Method 2
The contoured composite charge is compacted using a roller
Data Source
AI summary
A composite charge is positioned onto lower plates of a plurality of placement end effectors. Upper plates of the plurality of placement end effectors are rotated along a first axis to cover the composite charge. The composite charge is contoured to a tool using the plurality of placement end effectors to form a contoured composite charge. The contoured composite charge is compacted using a roller.