Contoured Composite Pick-and-Place for Moving Mandrel Installation

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Solution Overview

Problem

Existing manufacturing systems face challenges in maintaining the complex curvatures of contoured composite structures, such as stringers, during transfer and installation onto a mandrel in a moving manufacturing line, leading to longer manufacturing times and increased costs.

Innovation Solution

A pick-and-place system comprising a tray station, installation station, gantry assembly, vacuum system, load balancer, and control system, which allows for precise transfer and installation of contoured composite structures onto a moving mandrel while maintaining curvature, using end effector assemblies and indexing mechanisms to align and secure the structures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If contoured composite structures are transferred in a stationary cell, then the curvature can be maintained, but the manufacturing time increases and costs increase

Engineering Contradiction:

Improvecurvature maintenanceVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The mandrel is made movable along the manufacturing line instead of being stationary, allowing the system to transition from static to dynamic operation. This enables continuous production while maintaining curvature through active positioning systems that adjust during movement.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

A specialized transfer mechanism acts as an intermediary between the forming station and the moving mandrel. This intermediary device includes curvature support features that maintain the contoured structure's shape during the transfer process, solving both the precision and productivity issues.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If a moving manufacturing line is used, then productivity increases, but it is difficult to maintain the curvature of contoured composite structures

Engineering Contradiction:

Improvemoving manufacturing lineVSAvoidcurvature maintenance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The contoured composite structure is pre-formed with its final curvature at the forming station before transfer. This preliminary shaping ensures the curvature is established early, and subsequent handling mechanisms are designed to preserve rather than alter this pre-established geometry during movement.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system controls the physical parameters of the transfer process, including movement speed, positioning accuracy, and support forces, to maintain the curvature. By carefully managing these parameters during the moving line operation, the system achieves both productivity and precision.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If complex alignment procedures are used, then installation precision improves, but the manufacturing time increases

Engineering Contradiction:

Improvealignment precisionVSAvoidalignment time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Manual or mechanical alignment procedures are replaced with automated positioning systems that use sensors, feedback control, and computerized coordination. This substitution maintains high alignment precision while dramatically reducing the time required for the alignment process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates self-aligning features where the contoured structure's geometry itself provides alignment cues, or where the positioning system automatically adjusts based on real-time feedback without requiring complex external alignment procedures.

Inventive Principle:

Principle #25Self-service

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 effectively maintains the complex curvatures of contoured composite structures during transfer and installation, reducing manufacturing time and costs by enabling efficient operation in a moving manufacturing line.

Implementation Method 1

a vacuum system coupled to the main beam and coupled to the plurality of end effector assemblies

Methodology Applied

Scientific EffectVacuum: Vacuum

Data Source

PatentEP4035876B1Pick-and-place system and method for transferring and installing a contoured composite structure

Publication Date: 2026.04.01 THE BOEING CO

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AI summary

There is provided a pick-and-place system (10) for transferring and installing a contoured composite structure (16) onto a mandrel (52), in a composite manufacturing system (12a). The pick-and-place system (10) includes a tray station (34) having a tray assembly (36) to hold the contoured composite structure (16), prior to transfer and installation onto the mandrel (52). The pick-and-place system (10) further includes an installation station (50) having the mandrel (52) and a pick-and-place assembly (60). The mandrel (52) is designed to receive the contoured composite structure (16), and designed to move along a moving manufacturing line (54), via a conveyor assembly (56). The pick-and-place assembly (10) includes a gantry assembly (70), a main beam (135) suspended from the gantry assembly (70), the main beam (135) having a plurality of end effector assemblies (160) and a plurality of indexing assemblies (154), a vacuum system (168) coupled to the main beam (135), a load balancer assembly (170) coupling the main beam (135) to the gantry assembly (70), and a control system (150) coupled to the pick-and-place assembly (60), to operably control the pick-and-place-assembly (60).