Composite Skin Segment Assembly via Non-Planar Transfer

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Solution Overview

Problem

The construction and assembly of large and complex composite structures on an inner mold line (IML) layup mandrel is a time-consuming and costly process due to the serial nature of forming support structures and applying composite fibers.

Innovation Solution

The method involves receiving and assembling a plurality of ply kits to form skin segments, which are then affixed to the layup mandrel using a non-planar transfer tool and compaction bladders, allowing for concurrent processing and efficient attachment of multiple skin segments and stringers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a serial process is used to form support structures and apply composite fibers sequentially, then the manufacturing precision and quality control are maintained, but the assembly time and production cost increase significantly

Engineering Contradiction:

Improvequality controlVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The skin is divided into multiple skin segments, each formed from separate ply kits. This segmentation allows parallel processing of multiple segments simultaneously, reducing total assembly time while maintaining quality control through standardized formation procedures for each segment

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Ply kits are pre-formed and prepared before assembly. The plies are stacked and arranged in advance on a planar indexing surface, so that during assembly only the transfer and compaction steps are needed, significantly reducing on-site assembly time while ensuring consistent quality

Inventive Principle:

Principle #10Preliminary action

2Strength

If a serial process is used to form support structures and apply composite fibers, then the structural integrity is ensured, but the production cost becomes substantial

Engineering Contradiction:

Improvestructural integrityVSAvoidproduction cost

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

By dividing the skin into segments that can be processed in parallel, the production cost is reduced through more efficient use of labor and resources, while structural integrity is maintained through proper compaction and bonding of each segment

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple ply kits are combined to form complete skin segments that can be attached simultaneously to the layup mandrel. This merging of operations allows concurrent processing of multiple components, reducing overall production cost while ensuring structural integrity through integrated assembly

Inventive Principle:

Principle #5Merging (Combining)

3Shape

If ply kits are transferred from a planar surface to a non-planar transfer tool, then the skin segments can be compacted conformally, but the complexity of the transfer process increases

Engineering Contradiction:

Improveconformal compactionVSAvoidtransfer process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

A non-planar transfer tool serves as an intermediary between the planar ply kits and the curved layup mandrel. This intermediary tool allows the flat ply kits to be transferred and then compacted conformally to the curved surface, achieving the desired shape without excessive process complexity

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The transfer tool incorporates the required curvature to match the layup mandrel surface. By using a curved transfer tool instead of a flat one, the ply kits can be compacted conformally to the desired shape, simplifying the overall process while achieving the correct geometry

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 reduces the time and cost associated with assembling composite structures by enabling parallel processing and efficient attachment of skin segments and stringers, improving the efficiency of composite structure assembly.

Implementation Method 1

compacting the respective ply kit on the non-planar transfer tool

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

compressing the skin segment against the outer surface of the layup mandrel

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS9199418B1Systems and methods for assembling a skin of a composite structure

Publication Date: 2015.12.01 THE BOEING CO

AI summary

Systems and methods for assembling a skin of a composite structure on an outer surface of an inner mold line layup mandrel. The systems and methods include receiving a plurality of ply kits, assembling the plurality of ply kits to form a skin segment that defines a portion of the skin, and affixing the skin segment to the outer surface of the layup mandrel. The assembling includes transferring a respective ply kit of the plurality of ply kits to a non-planar transfer tool, compacting the respective ply kit on the non-planar transfer tool, and repeating the transferring and the compacting for each ply kit in the plurality of ply kits to form the skin segment.