Composite Component Tape Lay-Up Optimization
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Solution Overview
Problem
Current manufacturing processes for composite material components with a C-shaped profile in the aeronautical industry are inefficient, as they often underutilize tape lay-up machines when producing single components and result in excessive material costs and waste when producing multiple components, due to the need for separate templates and material for each component.
Innovation Solution
A method that optimizes the tape lay-up process by using a single orientation dial for complete layers and individual orientation dials for local layers, allowing for the simultaneous production of pairs of components with a conical tendency, which reduces material waste and optimizes the use of tape lay-up machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate templates and material are used for each component, then manufacturing precision is maintained, but material waste increases and production cost increases
Solution Approach 1:
The patent combines multiple identical or symmetrical components into a single integrated mold, allowing simultaneous production of multiple components from one mold cavity. This merging approach eliminates the need for separate molds for each component, reducing material waste while maintaining manufacturing precision through unified mold design and consistent curing conditions.
Solution Approach 2:
The mold design incorporates universal features that can produce multiple components with identical or symmetrical geometries simultaneously. The mold structure is configured to accommodate multiple cavities or symmetric configurations, enabling one mold to serve the function of producing several components that would traditionally require separate molds, thereby reducing material consumption and production costs.
2Manufacturing precision
If tape lay-up machines are used for single component production, then manufacturing precision is maintained, but machine capacity utilization decreases
Solution Approach 1:
The patent merges multiple component production into a single tape lay-up operation by using an integrated mold that accommodates multiple components simultaneously. This allows the tape lay-up machine to produce multiple components in one cycle, significantly improving machine capacity utilization while maintaining manufacturing precision through consistent process parameters applied across all components.
Solution Approach 2:
The continuous tape lay-up process is optimized to continuously fill multiple mold cavities simultaneously, maximizing the productive use of the machine throughout the entire cycle. The process eliminates idle time between components by arranging the mold configuration to allow continuous material deposition across all component areas, thereby improving overall machine utilization while maintaining precision.
3Productivity
If multiple components are produced simultaneously, then productivity increases, but material cost increases
Solution Approach 1:
By merging multiple component production into a single integrated mold, the patent achieves economies of scale where the total material cost for producing multiple components simultaneously is less than the sum of producing them separately. The shared mold structure and simultaneous curing process reduce overall material consumption and eliminate redundant setup materials, lowering the cost per component while increasing productivity.
Solution Approach 2:
The patent optimizes material usage by precisely controlling the tape lay-up process to minimize excess material for each component within the integrated mold. Any excess material or symmetric components that are not needed for a particular production run can be recovered or repurposed, reducing overall material cost while maintaining high productivity through efficient resource utilization.
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 method enables the efficient production of pairs of composite material components with a conical tendency, optimizing material usage and machine capacity, thereby reducing production costs and minimizing material waste while maintaining the mechanical properties of the components.
Implementation Method 1
a hot forming process is carried out, which consists basically of positioning the flat laminate resulting from the first stage on a jig or mandrel with a suitable geometry and applying heat and vacuum according to a defined cycle, so that said laminate adapts to the shape of the jig
Implementation Method 2
applying heat and vacuum according to a defined cycle, so that said laminate adapts to the shape of the jig
Implementation Method 3
a final curing process is carried out in an autoclave with temperature and vacuum, until the component reaches its finished state
Implementation Method 4
a final curing process is carried out in an autoclave with temperature and vacuum
Data Source
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AI summary
Method of manufacture of one or more pairs of components in composite material (11, 13; 11', 13') intended to form part of aerofoils located on both sides of the axis of symmetry of an aircraft whose shape has a conical tendency in the longitudinal direction, the angle of conicity being less than 10°, that comprises the following stages: a) Lay-up of layers on a flat tape lay-up table forming the laminate of a hypothetical component formed by all of the components of said pairs (11, 13; 11', 13'), the components of each pair being arranged adjacently and the first components (11, 11') and the second components (13, 13') of each pair being arranged alternately, and the whole being arranged symmetrically relative to a hypothetical horizontal axis X-X of the tape lay-up jig; b) Cutting of the flat laminates corresponding to each of said components); c) Forming and curing said components.