Automated Composite Noodle Manufacturing for Structural Joints
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Solution Overview
Problem
Conventional methods for manufacturing noodles for structural joints in complex structures, such as aircraft, are cumbersome and labor-intensive due to the need for manual cutting and alignment of composite plies and separate manufacturing of bases and tips, which complicates the production of noodles with narrow tips and requires non-automated processes.
Innovation Solution
A method and system that automate the manufacturing process by cutting, aligning, heating, and shaping composite sheets into continuous noodles with specific cross-sectional shapes, allowing for concurrent cutting of both base and tip portions to the desired length, using a series of stations including splitting, alignment, heating, forming, and cooling to produce a continuous noodle that can be rapidly cooled and cut to size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manual manufacturing processes are used to create noodles with narrow tips, then the noodles can be produced, but the manufacturing process becomes cumbersome and labor-intensive
Solution Approach 1:
The manufacturing process is divided into distinct functional stations (splitting station, alignment station, heating station, forming station, cutting station) that operate sequentially. Each station performs a specific operation on the composite sheet to transform it into the final noodle shape with narrow tip, eliminating the need for manual manipulation while achieving precise geometric control
Solution Approach 2:
The composite material undergoes parameter changes through controlled heating at the heating station, transitioning from a rigid state to a more formable state. This thermal parameter change enables the material to be shaped into complex cross-sections with narrow tips without manual intervention, as the heated material becomes more pliable and responsive to the forming station's geometric constraints
2Manufacturing precision
If separate manufacturing processes are used for base and tip portions, then the noodle components can be produced, but the assembly process becomes time-consuming
Solution Approach 1:
The base and tip portions of the noodle are manufactured in a single continuous operation through the integrated station system. The composite sheet flows continuously through splitting, alignment, heating, forming, and cutting stations, with the forming station simultaneously creating both the base geometry and the narrow tip geometry in one pass. This merging of operations eliminates separate manufacturing and assembly steps, achieving both precision and high productivity
Solution Approach 2:
The manufacturing process maintains continuous motion of the composite sheet through all stations without interruption. The sheet is continuously fed, continuously heated, continuously formed, and continuously cut, eliminating idle time between operations. This continuous action ensures high production rate while maintaining precision through consistent process parameters throughout the entire manufacturing sequence
3Manufacturing precision
If manual cutting and aligning of composite plies are used, then the noodle plies can be prepared, but the process becomes labor-intensive
Solution Approach 1:
Manual mechanical operations of cutting and aligning composite plies are replaced by an automated system of stations. The splitting station uses mechanical cutting apparatus to automatically divide the composite sheet into plies of precise widths. The alignment station uses mechanical guides and positioning mechanisms to automatically align and stack plies with high precision. This substitution of manual mechanical operations with automated mechanical systems achieves both accuracy and reduced labor intensity
Solution Approach 2:
The composite sheet and plies are self-aligned through the designed geometry of the alignment station fixtures and guides. The splitting station automatically produces plies with consistent dimensions based on pre-set cutting positions. The system is designed so that the material itself, through its interaction with the station fixtures, achieves proper alignment and stacking without requiring manual positioning, thereby reducing labor while maintaining precision
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 streamlines the noodle manufacturing process, reducing labor and time while enabling precise control over the shape and size of the noodle, improving the efficiency and accuracy of producing noodles for structural joints, enhancing the structural integrity and performance of the joints.
Implementation Method 1
pulling the first stacked composite layup through a first heating station to heat the first stacked composite layup
Implementation Method 2
The first heating station heats the first stacked composite layup to a melting temperature of the thermoplastic adhesive
Implementation Method 3
pulling at least the first portion and the second portion of the continuous noodle through a first cooling station to rapidly cool at least the first portion and the second portion of the continuous noodle
Implementation Method 4
pulling the first heated composite layup through a first forming station to shape the first heated composite layup into a first pre-selected cross-sectional shape
Data Source
AI summary
A method of manufacturing a noodle of a structural joint that comprises pulling a first composite sheet through a first splitting station to cut the first composite sheet into a plurality of first composite plies, pulling the plurality of first composite plies through a first alignment station to stack the plurality of first composite plies on top of each other to form a first stacked composite layup, pulling the first stacked composite layup through a first heating station to heat the first stacked composite layup to form a first heated composite layup, pulling the first heated composite layup through a first forming station to shape the first heated composite layup into a first pre-selected cross-sectional shape to form at least a first portion of a continuous noodle, and pulling at least the first portion of the continuous noodle through a cutting station to cut at least the first portion of the continuous noodle to a pre-selected length.