Composite Transfer Flippers for Automated Stringer Positioning
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Solution Overview
Problem
Current methods for manufacturing composite stringers, such as aircraft stringers, are slow and costly due to hand lay-up and crane handling, necessitating a more flexible, faster, and less costly composite handling system.
Innovation Solution
A composite transfer cell with a delivery system, tool, and a composite transfer system comprising flipper arms that are vertically and rotationally movable to lift and place composite charges, utilizing a pneumatic and mechanical connector for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hand lay-up and crane handling are used for composite stringers, then manufacturing flexibility is maintained, but manufacturing speed is slow and cost is high
Solution Approach 1:
The composite handling system is divided into separate functional modules: a delivery system for transporting composite charges, a composite transfer system with multiple flipper arms for positioning, and a tool for receiving the composite charge. This segmentation allows each module to be optimized independently and enables automated operation while maintaining flexibility in handling different composite configurations.
Solution Approach 2:
The composite transfer system employs multiple flipper arms that can independently move in vertical directions and rotate, providing dynamic positioning capability. This dynamic structure enables the system to adapt to different composite charge positions and orientations automatically, increasing manufacturing speed without sacrificing flexibility.
2Adaptability or versatility
If crane systems are used for material handling, then lifting capability is provided, but flexibility and speed are reduced
Solution Approach 1:
The handling system is segmented into multiple independent flipper arms rather than using a single crane mechanism. Each flipper arm can independently lift, rotate, and position composite charges, providing both the lifting capability of cranes and the flexible, coordinated positioning of multiple actuators, thereby increasing overall handling speed and adaptability.
Solution Approach 2:
The flipper arms serve multiple functions: they lift composite charges vertically, rotate them to different orientations, and position them precisely on the tool. This multi-functionality replaces the need for separate crane operations and positioning mechanisms, enhancing both flexibility and productivity.
3Productivity
If automated composite positioning systems are implemented, then manufacturing speed increases, but system complexity increases
Solution Approach 1:
The automated positioning system is divided into modular components: a delivery system, a composite transfer system with multiple flipper arms, and a tool. Each module performs a specific function and can be independently controlled, which simplifies the overall system architecture while maintaining high positioning speed and automation capability.
Data Source
AI summary
A composite transfer cell and associated components and methods are presented. The composite transfer cell comprises a delivery system on a first side of the composite transfer cell; a tool on a second side of the composite transfer cell; and a composite transfer system between the first side and the second side of the composite transfer cell, the composite transfer system comprising a plurality of flipper arms independently movable in a vertical direction and rotatingly movable to lift and place a composite charge from the delivery system to the tool.