Composite Structural Element Equipment With Retractable Laminating Mandrel
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Solution Overview
Problem
Existing processes for manufacturing structural elements in composite materials, such as aircraft fuselages, are inefficient, requiring multiple steps and equipment that is not adaptable to different dimensions, leading to increased production time and costs.
Innovation Solution
A modular equipment system comprising a support frame and a laminating mandrel with adjustable components, allowing for the integration of stringers and skin layers, which can be used in various sizes and configurations, and facilitates curing and finishing operations within an autoclave.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate equipment is used for making stringers and skin, then each component can be manufactured with dedicated tools, but the overall production time increases and multiple equipment setups are required
Solution Approach 1:
The patent combines the stringer forming tool and skin laminating mandrel into a single integrated equipment system. The mandrel includes both a stringer forming section with forming tools and a skin laminating section with laminating tools, allowing both operations to be performed on the same equipment without reconfiguration, thereby reducing production time and eliminating the need for multiple equipment setups.
2Adaptability or versatility
If fixed-size equipment is used, then manufacturing precision can be maintained for specific dimensions, but the equipment cannot be used for different sized structural elements
Solution Approach 1:
The equipment incorporates adjustable and reconfigurable components that can be dynamically adjusted to accommodate different structural element dimensions. The mandrel and forming tools can be repositioned and reconfigured for various sizes while maintaining manufacturing precision through controlled adjustment mechanisms and standardized interfaces.
Solution Approach 2:
The integrated mandrel is designed to perform multiple functions: forming stringers of different sizes, laminating skin layers for various dimensions, and supporting different structural configurations. This universal design allows a single equipment to handle diverse manufacturing requirements while maintaining precision through standardized tooling and adjustable fixtures.
3Ease of manufacture
If multiple separate processes are used for stringer making and skin bonding, then each process can be optimized independently, but the overall manufacturing cost increases
Solution Approach 1:
The patent merges the stringer forming process and skin laminating process into a single integrated manufacturing sequence on the same equipment. The mandrel first forms the stringers, then the same mandrel is used to laminate the skin layers directly over the formed stringers, eliminating the need for separate process equipment and reducing the total number of process steps while maintaining ease of manufacture through unified process control.
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 system enables efficient, cost-effective production of composite structural elements by reducing overall preparation times and allowing reuse of components for different applications, while ensuring flexibility in handling elements of varying dimensions.
Implementation Method 1
The assembly thus formed is then subjected to a co-curing operation in an autoclave by applying appropriate pressure and temperature, in order to cure the composite material, compact the aforementioned layers together and bond the stringers to the skin.
Implementation Method 2
The assembly thus formed is then subjected to a co-curing operation in an autoclave by applying appropriate pressure and temperature, in order to cure the composite material, compact the aforementioned layers together and bond the stringers to the skin.
Data Source
AI summary
The invention relates to equipment for making a structural element of composite material. The equipment comprises a frame and a laminating mandrel, which is mounted on the frame so that it can rotate about its own central axis; the support frame comprises two headers; the laminating mandrel comprises a central shaft, sectors angularly spaced apart about the central axis, and actuators extending between the central shaft and respective sectors to move the sectors between an expanded laminating position and a contracted position. The equipment further comprises first constraining means for connecting the sectors, arranged in the expanded position, to movable portions of the headers, and second constraining means connecting the actuators to the sectors so as to enable the extraction of the central shaft and actuators from the equipment when the sectors, in the expanded position, are connected to the movable portions of the headers by the first constraining means.