Composite Layup Joining and Inspection for Faster Stringer Fabrication
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Solution Overview
Problem
The manufacturing process for composite stringers is time-consuming due to the manual or multi-device steps involved in laying up adhesive and plain weave fabric, which includes compaction and inspection of radius fillers and alignment of layers, leading to inefficiencies in production speed.
Innovation Solution
A multilayer composite layup system that integrates a joining system and a layup system to combine fiber product layers and adhesive into a single joined layer, which is then laid up on a composite workpiece in a single pass, incorporating automated inspection and compaction processes to ensure proper alignment and adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or multi-device steps are used for laying up adhesive and plain weave fabric, then manufacturing precision and quality control are maintained, but production speed decreases
Solution Approach 1:
The patent combines multiple discrete manufacturing steps (adhesive application, fabric laying, compaction, inspection) into a single integrated automated device that performs all operations in one pass, thereby increasing productivity while maintaining quality through consistent automated processes
Solution Approach 2:
The automated device is designed as a multi-functional system that can perform laying up, compaction, and inspection operations simultaneously, eliminating the need for multiple separate devices and manual operations, thus improving both speed and process integration
2Manufacturing precision
If multiple separate operations are performed for compaction and inspection of radius fillers and alignment of layers, then manufacturing precision is ensured, but time consumption increases
Solution Approach 1:
The device performs preliminary alignment and compaction actions automatically during the laying up process itself, rather than requiring separate subsequent operations, thereby maintaining precision while reducing overall production time
Solution Approach 2:
The automated system executes laying up, compaction, and inspection operations in continuous sequence without interruption or repositioning, eliminating idle time between operations while maintaining quality through consistent automated 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
This approach significantly increases the manufacturing speed of composite stringers by performing multiple operations, including compaction and inspection, in a single pass, thereby enhancing productivity and quality control.
Implementation Method 1
The layer heater heats the aligned layers to form heated aligned layers
Implementation Method 2
the compactor compacts the heated aligned layers to form a joined layer
Implementation Method 3
The layup roller causes the adhesive in the joined layer to contact the surface of the composite workpiece
Data Source
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AI summary
A multilayer composite layup system comprises a joining system and a layup system. The joining system is configured to join a fiber product layer and an adhesive to each other to form a joined layer. The layup system is configured to lay up the joined layer onto a surface of a composite workpiece.