Composite Stringer Abrasion Assembly for Uniform Sanding Depth

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Solution Overview

Problem

Manual sanding of composite stringers is labor-intensive, time-consuming, and prone to inconsistencies in sanding depth across and between sections, posing ergonomic concerns and challenges in achieving uniform results.

Innovation Solution

An automated abrading apparatus with a frame, drive assembly, and abrasion assembly, including orbital and rotary sanders, that advances along the stringer's length, maintaining a uniform depth of cut and avoiding fiber damage, with a guard assembly to protect specific areas from abrasion, eliminating the need for separate masking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual sanding is used to prepare composite stringer surfaces, then flexibility and simplicity are maintained, but labor intensity increases, time consumption increases, and sanding depth consistency deteriorates

Engineering Contradiction:

Improveoperational simplicityVSAvoidsurface preparation efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent replaces manual mechanical sanding operations with an automated abrading apparatus that uses controlled mechanical abrasion elements. The system substitutes human labor with automated drive assemblies, abrasion assemblies, and controller systems that can precisely execute surface preparation tasks without the limitations of manual operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements precise control over abrasion parameters including depth of cut, travel speed, and abrasion pressure through the controller system. This allows optimization of the abrasion process to achieve consistent surface preparation while maintaining operational efficiency, resolving the contradiction between simplicity and productivity.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If manual sanding is used to prepare composite stringer surfaces, then equipment complexity is minimized, but sanding depth consistency and uniformity deteriorate

Engineering Contradiction:

Improveapparatus simplicityVSAvoidsanding depth uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The automated control system replaces manual judgment and skill with programmable parameters that ensure consistent depth of cut and uniform abrasion across the entire stringer surface. The controller manages multiple abrasion elements simultaneously to maintain precision without requiring complex manual coordination.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If automated abrading apparatus is used to prepare composite stringer surfaces, then productivity increases and sanding depth consistency improves, but device complexity increases

Engineering Contradiction:

Improvesurface preparation efficiencyVSAvoidapparatus structural complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The abrading apparatus is divided into modular functional assemblies including drive assembly, abrasion assembly, guard assembly, and controller system. Each assembly performs a specific function and can be independently managed, which reduces the operational complexity despite the overall system sophistication. The segmented design allows for easier maintenance and adaptation.

Inventive Principle:

Principle #1Segmentation

4Loss of time

If automated abrading apparatus is used to prepare composite stringer surfaces, then labor time is reduced, but device complexity and initial investment increase

Engineering Contradiction:

Improvesurface preparation timeVSAvoidapparatus system complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The automated apparatus enables continuous surface preparation operation along the entire length of the stringer without interruption. The drive assembly moves the abrasion elements continuously along the stringer, eliminating the start-stop nature of manual sanding and maximizing productivity while the controller manages the continuous process efficiently.

Inventive Principle:

Principle #20Continuity of useful action

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 apparatus significantly reduces labor and time required for surface preparation, ensures consistent sanding depth, and prevents damage to composite materials, improving efficiency and ergonomic safety.

Implementation Method 1

an orbital sander coupled to the first carriage and including a first orbital sander element having a first orbital sander surface... a second rotary sander coupled to the second carriage and including a second rotary sander element having a second rotary sander surface

Methodology Applied

Scientific EffectAbrasion: Abrasion

Data Source

PatentUS11413719B2Apparatus and method for abrading a composite material

Publication Date: 2022.08.16 THE BOEING CO

AI summary

Abrading apparatus and methods for treating opposing web surfaces of an elongate part include engaging the surfaces with first and second abrasion devices coupled to a frame. A drive assembly advances the frame along the part while the abrasion devices are operated to treat the surfaces. A guard assembly is coupled to the frame and includes first and second guards positioned to block portions of the contact areas of the first and second abrasion devices.