Composite Stringer Compaction via Modular Vacuum System
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Solution Overview
Problem
The existing process of compacting stringers in aircraft manufacturing is time-consuming and complex, requiring the installation of vacuum bags and waiting for multiple stringers to be placed before compaction can begin, which delays the manufacturing process.
Innovation Solution
A system comprising a compacting structure and a compactor vacuum system that allows for individual compaction of stringer layers using a stringer processing device, which applies pressure to the layers of uncured composite material, and a carrier vacuum system to hold the material in place, enabling immediate compaction and reducing the need for traditional vacuum bags.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional vacuum bags are used for compaction, then the stringer layers can be compacted, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent divides the compaction system into modular components: a compaction device with vacuum ports that can be positioned at different locations along the stringer, allowing selective compaction of different stringer sections. This segmentation enables faster processing by working on multiple sections sequentially or in parallel, eliminating the need to wait for complete stringer assembly before starting compaction.
Solution Approach 2:
The compaction device is positioned and preliminary vacuum sealing is established before the stringer layers are fully laid up. This preliminary action allows the compaction process to begin while material placement is still in progress, reducing idle time and enabling overlapping operations between material layup and compaction.
2Manufacturing precision
If vacuum bags are installed for each stringer, then compaction can be performed, but the complexity and labor requirements increase
Solution Approach 1:
The patent extracts the compaction function from the traditional vacuum bag system and integrates it directly into a compaction device that applies vacuum through ports positioned against the stringer form. This eliminates the need for separate vacuum bag installation, sealing, and removal operations, significantly reducing procedural complexity and labor requirements while maintaining effective compaction.
Solution Approach 2:
The compaction device is designed to self-seal against the stringer form through vacuum pressure, eliminating the need for external sealing operations. The device automatically maintains its sealing relationship with the form during compaction, reducing the skill level and time required for operation compared to traditional vacuum bag systems that require careful sealing.
3Productivity
If multiple stringers are placed before compaction begins, then batch processing is achieved, but the overall manufacturing time increases
Solution Approach 1:
The compaction device is positioned and vacuum sealing is established on the stringer form before the stringer layers are fully laid up and while other stringers are still being placed. This preliminary compaction action allows the process to proceed without waiting for complete batch assembly, reducing waiting time and enabling overlapping operations.
Solution Approach 2:
The system transitions from static batch processing (where all stringers must be placed before any compaction begins) to dynamic processing (where compaction can begin on earlier stringers while later stringers are still being placed). The compaction device can be repositioned along the form to work on different stringers at different stages of completion, optimizing the workflow and reducing idle time.
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 reduces the time and complexity of the compaction process, allowing for faster processing of stringers and minimizing the need for labor-intensive vacuum bag installation, thereby streamlining the aircraft manufacturing process.
Implementation Method 1
The compactor vacuum system is configured to cause the compacting structure to apply a pressure to the layers of uncured composite material when a compactor vacuum is applied to the compactor vacuum system
Implementation Method 2
The carrier vacuum system is configured to hold the layers of uncured composite material against the compacting structure when a carrier vacuum is applied to the carrier vacuum system
Data Source
AI summary
A method and apparatus for compacting composite stringers. In one illustrative embodiment, an apparatus comprises a compacting structure, a compactor vacuum system, and a carrier vacuum system. The compacting structure has a shape configured to contact layers of uncured composite material for a composite stringer. The compactor vacuum system is associated with the compacting structure. The compactor vacuum system is configured to cause the compacting structure to apply a pressure to the layers of uncured composite material when a compactor vacuum is applied to the compactor vacuum system. The carrier vacuum system is associated with the compacting structure. The carrier vacuum system is configured to hold the layers of uncured composite material against the compacting structure when a carrier vacuum is applied to the carrier vacuum system.