Composite Layup Tool Concavity Alignment and On-Mold Trimming
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Solution Overview
Problem
The existing methods for constructing composite structures, such as composite helicopter rotor blades, are costly and time-consuming due to the need for predetermining and cutting precise dimensions of material plies and stacks, often requiring complex equipment and programming for laser projection and pattern flattening.
Innovation Solution
A method involving a layup tool with concavities and material strips cut from rolls, where the strips are aligned and machined to form mating interfaces without projecting visual representations, using a router to remove excess material and create a composite structure with reduced tolerance variables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If material plies are precut to appropriate dimensions using laser projection and flat pattern conversion, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the complex laser projection and flat pattern conversion equipment from the manufacturing process. Instead of using these complex devices to predetermine ply dimensions, the invention applies material plies directly to the mold surface and trims excess material on-mold, thereby removing the disturbing complex equipment while maintaining dimensional accuracy.
Solution Approach 2:
The patent segments the manufacturing process into distinct phases: first applying material plies to the mold surface without complex pre-cutting, then trimming excess material on-mold. This segmentation allows the use of simpler equipment for each step while achieving the same overall precision as the integrated laser projection system.
2Manufacturing precision
If complex three-dimensional surface areas are converted to flat patterns for material cutting, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The patent performs preliminary preparation of the mold surface with reference markings and guidelines before material application. This preliminary action eliminates the need for time-consuming flat pattern generation and laser programming, as the mold itself provides the reference framework for direct material placement and on-mold trimming.
Solution Approach 2:
The patent removes the time-consuming flat pattern conversion and laser projection programming steps from the process. By applying material directly to the three-dimensional mold surface and trimming on-mold, the invention extracts these time-consuming intermediate steps while maintaining dimensional accuracy through direct mold reference.
3Manufacturing precision
If laser projection tools are used to outline material plies on the layup tool, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces the optical laser projection system with a mechanical reference system consisting of markings, guidelines, and alignment features directly on the mold surface. This mechanical substitution maintains alignment accuracy while eliminating the need for complex laser projection equipment and programming.
Solution Approach 2:
The patent extracts and removes the laser projection equipment from the manufacturing system. Instead of using optical projection to outline material plies, the invention uses direct visual alignment with mold markings and guidelines, thereby eliminating the disturbing complex equipment while maintaining alignment precision.
4Manufacturing precision
If material plies are precut to fit complex three-dimensional surfaces, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent inverts the traditional sequence by applying material plies to the three-dimensional mold surface first, then trimming excess material on-mold, rather than pre-cutting to fit the complex surface. This inversion simplifies the manufacturing process by using the mold itself as the reference framework, making material application more straightforward while maintaining dimensional conformity through on-mold trimming.
Data Source
Figure 1~2A
Figure 2B~3
Figure 4~5
AI summary
A method of constructing a composite component includes at least one of laterally and longitudinally aligning a material strip relative to a concavity of a layup tool, at least one of laterally and longitudinally extending the material strip to a predetermined location relative to the layup tool, wherein the material strip is substantially rectangular, and vertically abutting the material strip to the concavity of the layup tool, wherein the longitudinally extending the material strip includes at least one of (1) measuring a longitudinal distance of the material strip and (2) aligning a longitudinal end of the material strip with a longitudinal distance indicium and wherein the laterally extending the material strip includes at least one of (1) measuring a lateral distance of the material strip and (4) aligning a lateral end of the material strip with a lateral distance indicium.