Composite Forming Station for T-Profile Parts
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Solution Overview
Problem
The conventional manufacturing process of T-profile composite parts is labor-intensive, multi-step, and requires high precision, leading to delays and reduced production rates in the aeronautical industry.
Innovation Solution
A composite forming station that integrates all necessary means to form a T-profile composite part from a single planar laminate, using a series of rollers with increasing thickness and edge angle to bend the laminate into the desired shape, while also serving as a curing tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional multi-step process with separate L-profile formation and joining is used, then manufacturing precision can be maintained, but production rate decreases and lead time increases
Solution Approach 1:
The patent combines multiple separate operations (forming first L-profile, forming second L-profile, joining them, and curing) into a single integrated forming station that processes the entire T-profile composite part in one continuous operation, eliminating intermediate handling and joining steps
Solution Approach 2:
The forming station is designed to perform multiple functions simultaneously: it forms both L-profiles, joins them, cures the composite material, and positions the final T-profile all within a single device, replacing multiple dedicated stations
2Loss of time
If conventional separate forming and curing stations are used, then manufacturing precision is maintained, but lead time increases due to multiple transport steps
Solution Approach 1:
The forming and curing operations are merged into a single continuous process within one station, eliminating the need to transport formed L-profiles between separate forming and curing stations, thereby reducing lead time and intermediate handling
3Productivity
If manual positioning and joining of L-profiles is used, then alignment precision can be achieved, but labor intensity increases and production rate decreases
Solution Approach 1:
The patent replaces manual positioning and joining operations with an automated forming mechanism that uses a single planar laminate and integrated forming tools to automatically position, form, and join the T-profile components with precise alignment, eliminating labor-intensive manual operations
4Shape
If planar laminate is bent into L-profile shape, then desired geometry is achieved, but wrinkles or undulations may occur on the web
Solution Approach 1:
The patent uses a single planar laminate with a predetermined folding line that segments the material into first and second portions, which are then formed into L-profiles that are automatically joined, controlling the bending process to prevent wrinkles and undulations on the web
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 solution allows for the formation of T-profile composite parts in a single step, reducing lead time, increasing production rate, and eliminating misalignment risks, while maintaining high precision and avoiding wrinkles or undulations.
Implementation Method 1
The composite forming station further comprises heating means
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
The present invention provides a composite forming station (10) for forming a T-profile composite part (1) from a planar laminate (2) thereof. The composite forming station comprises a plurality of in-line rollers (13.1 - 13.6) arranged so as to follow a forming direction, wherein each roller comprises a thickness and an edge angle; such that the thickness and/or the edge angle of the rollers is successively increased along the forming direction; in such a way that the composite forming station gradually opens and forms the planar laminate into the T-profile composite part as it passes for subsequent in-line rollers.