Composite Forming Tool Shaping System for Ply Placement
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Solution Overview
Problem
Current methods for laying up composite materials in aircraft manufacturing are labor-intensive, time-consuming, and prone to inaccuracies, with manual processes and existing machinery being expensive and inefficient, leading to inconsistencies and increased costs due to the need for human intervention and the limitations of conventional equipment in producing high-quality female composite parts on female molds.
Innovation Solution
A method and apparatus that automate the laying up of composite plies using a composite forming tool with a shaping system that includes a centerline presser and compliant elongate members to uniformly apply prepreg material to a mold, minimizing human intervention and ensuring consistent and accurate placement, capable of forming composite parts on both female and male molds with reduced manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated fiber placement machines or tape laminating machines are used to lay up composite plies, then the automation level and manufacturing precision are improved, but the device complexity and cost increase significantly
Solution Approach 1:
The shaping system is divided into multiple independent components including a centerline presser mechanism and multiple compliant elongate members. Each component performs a specific function (centerline pressing, uniform force application, conforming to mold geometry) and can be independently controlled or replaced, simplifying the overall system while maintaining automation capability
Solution Approach 2:
The patent employs compliant elongate members that are flexible in nature, allowing them to conform to the specific geometry of the mold surface. These flexible members apply uniform force across the composite material without requiring complex rigid positioning mechanisms, thereby reducing device complexity while maintaining precision
2Manufacturing precision
If automated fiber placement machines are used to progressively lay up plies with smaller width than the completed ply, then the manufacturing precision is improved, but the productivity and manufacturing time are reduced
Solution Approach 1:
The composite material is prepared in advance as complete-width plies or sheets before being placed on the mold. This preliminary preparation of full-width material eliminates the need for progressive stitching together of narrower tapes during the forming process, significantly reducing manufacturing time while maintaining placement precision through the automated shaping system
Solution Approach 2:
The patent combines multiple functions into the shaping system: the centerline presser and compliant elongate members work together to simultaneously achieve precise positioning, uniform pressure distribution, and conforming to complex mold geometries. This integration allows complete-width plies to be placed and formed in a single operation rather than requiring multiple sequential steps
3Device complexity
If hand layup method is used to lay up whole prepreg sheets or plies, then the device complexity is reduced, but the productivity and manufacturing precision are significantly reduced
Solution Approach 1:
The shaping system is designed to automatically perform the laying up process without requiring manual intervention. The centerline presser and compliant elongate members self-adjust to apply uniform force across the composite material, eliminating the need for human operators while achieving both high productivity and consistent precision
Solution Approach 2:
The patent replaces the manual mechanical hand layup process with an automated shaping system that uses controlled mechanical forces. The centerline presser and compliant elongate members provide automated, repeatable force application that surpasses human capability in terms of speed and consistency, while the system remains relatively simple in design
4Device complexity
If hand layup method is used for composite ply placement, then the device complexity is reduced, but the manufacturing precision and consistency are significantly reduced
Solution Approach 1:
The shaping system incorporates control mechanisms that monitor and adjust the force application during the laying up process. The compliant elongate members provide feedback through their deformation, allowing the system to maintain uniform force distribution and consistent positioning across the composite material, achieving high precision without complex equipment
Solution Approach 2:
The patent utilizes the compliance (flexibility) of the elongate members as a key parameter, allowing them to adapt to varying mold geometries and material properties. This parameter change from rigid to compliant structures enables simple design to achieve high precision through automatic adaptation rather than complex positioning mechanisms
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
The solution enables efficient, accurate, and cost-effective automation of composite material placement, reducing inconsistencies and manufacturing time while allowing for the production of high-quality composite parts on female molds, thereby improving the efficiency and quality of composite part formation in aircraft manufacturing.
Implementation Method 1
a number of compliant elongate members of the shaping system to uniformly apply the prepreg material to the at least one mold
Implementation Method 2
applies pressure to the prepreg material with a centerline presser of the shaping system
Data Source
AI summary
A system and method for forming a composite part. The method comprises positioning a prepreg material relative to a composite forming tool. The composite forming tool comprises a frame associated with a shaping system, a base comprising at least one mold, and the shaping system associated with the frame and configured to move relative to the frame, the base, and the prepreg material. The method also lowers the shaping system of the composite forming tool towards the prepreg material. The method applies pressure to the prepreg material with a centerline presser of the shaping system. The method also applies a force to the prepreg material using a number of compliant elongate members of the shaping system to uniformly apply the prepreg material to the at least one mold of the base of the composite forming tool.