Automated Composite Forming Apparatus with Movable Stomp Feet

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Solution Overview

Problem

Conventional methods for forming composite structures, especially large and complex ones, are inefficient due to extensive manual labor and limited automation, leading to increased processing time, labor costs, and inconsistencies in the finished product.

Innovation Solution

A forming apparatus and system that enables automated ply-by-ply formation of composite parts using a frame with movable stomp feet and swing arms, allowing for precise application and compaction of composite material over a forming tool, reducing manual labor and process variations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual layup of fiber plies is used, then complex contoured parts can be formed, but processing time and labor costs increase significantly

Engineering Contradiction:

Improveability to form complex contoured partsVSAvoidprocessing time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The forming apparatus enables the composite plies to form themselves onto the mandrel through automated manipulation of the ply stack, eliminating the need for manual layup operations while maintaining the ability to create complex contoured parts

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical layup operations with an automated forming system that uses a movable carriage, stomp feet, and swing arms to manipulate the ply stack and force it around the mandrel

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Extent of automation

If drape forming process is used, then automation is achieved, but it fails on thick laminates or structures with complex shapes

Engineering Contradiction:

Improveautomation of formation operationVSAvoidability to form thick laminates and complex shapes

Core Design Contradiction:

Extent of automationVSAdaptability or versatility

Solution Approach 1:

The forming apparatus divides the automation process into discrete functional components: a movable carriage for positioning, stomp feet for applying localized force, and swing arms for manipulating the ply stack, allowing each component to address specific forming challenges

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs dynamic, movable components including a carriage that travels along the mandrel, stomp feet that move vertically to apply force, and swing arms that pivot to accommodate complex geometries, enabling adaptation to thick laminates and complex shapes while maintaining automation

Inventive Principle:

Principle #15Dynamics

3Stress or pressure

If compactor is used, then compression is achieved, but supplemental manual formation is still required for contoured surfaces

Engineering Contradiction:

Improvecompression forceVSAvoidautomation of formation operation

Core Design Contradiction:

Stress or pressureVSExtent of automation

Solution Approach 1:

The patent combines compression functionality with formation functionality by integrating stomp feet that can both compress the composite charge against the tool surface and manipulate it to conform to contoured surfaces, eliminating the need for separate manual formation operations

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12194693B2Forming apparatus, method, and system

Publication Date: 2025.01.14 THE BOEING CO

AI summary

A forming apparatus comprises a frame. The frame defines a vertical axis, a horizontal axis, and a longitudinal axis. A carriage is movably connected to the frame. A first stomp foot is movably connected to the carriage such that it may move along the vertical axis. A second stomp foot is movably connected to the carriage such that it may move along the vertical axis. A first swing arm is movably connected to the carriage and a second swing arm, movably connected to the carriage, is laterally opposed from the first swing arm relative to the longitudinal axis. A method includes applying at least one ply of composite material over a forming surface of a forming tool and deforming the at least one ply of composite material over the forming surface of the forming tool with the forming apparatus.