Reconfigurable Composite Stringer Dies for Fast Shape Changeovers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for forming composite stringers require unique and costly dies for different shapes, leading to high manufacturing expenses and labor costs due to the need for frequent die changes and modifications.
Innovation Solution
A reconfigurable pallet system with universal dies and a punch forming apparatus that allows for easy adaptation to produce various stringer shapes by using interchangeable upper and lower dies, and a method involving a punch to form and compact composite charges into different stringer shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If unique dies are used for each stringer shape, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements a universal die system where a single base die can be used across multiple stringer shapes. The die is divided into a base portion and interchangeable profile portions, allowing the same base die to produce different stringer cross-sections by swapping profile portions. This eliminates the need for completely unique dies for each stringer shape while maintaining manufacturing precision.
Solution Approach 2:
The die is segmented into modular components: a base die portion and interchangeable profile portions. This segmentation allows independent replacement of profile portions without affecting the base die structure, enabling quick reconfiguration for different stringer shapes while preserving the precision of the base die.
2Adaptability or versatility
If frequent die changes are performed, then adaptability is improved, but loss of time and productivity decrease
Solution Approach 1:
Multiple profile portions are pre-configured and ready for interchange on the universal die. The profile portions are designed to be quickly swapped without requiring complete die removal or complex reconfiguration. This preliminary preparation of interchangeable components minimizes die change time and maintains high productivity while enabling production of various stringer shapes.
3Manufacturing precision
If unique dies are manufactured for each shape, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The universal die system allows a single base die to serve multiple stringer shape requirements. By making the base die universal and only replacing the profile portions, the manufacturing cost is significantly reduced compared to creating entirely unique dies for each shape, while the precision is maintained through the carefully designed profile portions.
Solution Approach 2:
The profile portions are designed as replaceable, relatively simple components that can be manufactured at lower cost compared to complete unique dies. When a profile portion wears or needs modification, only that specific component is replaced rather than the entire die assembly, reducing manufacturing expenses.
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 labor required for stringer production, minimizes the need for unique dies, and automates the die-changing process, thereby lowering costs and increasing throughput.
Implementation Method 1
compression forming a flat stack of composite plies between a pair of tool dies placed in a press or similar device that compresses the dies together
Implementation Method 2
The die blocks are movable laterally on the bottom plate
Data Source
AI summary
Composite laminate stiffeners such as stringers are punch formed between first and second universal dies respectively carried on first and second trays. The second tray is mounted for sliding movement relative to the first tray between a punch position and a compaction position. Parts of the first and second dies are easily reconfigurable, allowing different shapes of stiffeners to be formed on the same forming apparatus.