Composite Z-Profile Forming Mold for Automated Flange Bending
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Solution Overview
Problem
The production of aeronautical structural elements with a Z-shaped cross section in composite material faces challenges in automation, leading to increased costs and corrosion risks due to galvanic coupling with metallic elements.
Innovation Solution
A method and device for manufacturing a structural element in composite material with a Z-shaped cross section using automated processes, involving a forming mold and a movable portion to bend layers of fiber-reinforced composite material, allowing for automated lamination and shaping without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic elements are used for aeronautical structural elements, then strength and corrosion resistance are improved, but weight increases and galvanic coupling corrosion risks arise when in contact with composite material structures
Solution Approach 1:
The patent applies composite materials (fiber-reinforced plastics) to manufacture aeronautical structural elements with Z-shaped cross-sections, replacing traditional metallic elements. This resolves the contradiction by providing both the required mechanical strength and the weight reduction necessary for aircraft applications, while eliminating galvanic coupling corrosion issues between dissimilar metals and composite materials.
2Adaptability or versatility
If manual operations are used for manufacturing composite structural elements with Z-shaped profile, then flexibility and adaptability are improved, but productivity decreases and labor costs increase
Solution Approach 1:
The patent employs a movable portion that can be displaced between a rest position and a bending position to automatically form the Z-shaped profile during lamination. This dynamic mechanism enables automated manufacturing while maintaining the flexibility to produce complex geometries, thereby resolving the contradiction between manufacturing adaptability and productivity by eliminating manual intervention.
3Productivity
If automated processes are implemented for manufacturing composite structural elements, then productivity and cost-effectiveness are improved, but device complexity increases
Solution Approach 1:
The movable portion serves multiple functions: it acts as a forming tool during lamination, provides support during curing, and enables automated operation. This multi-functionality reduces the need for separate dedicated components, thereby implementing automated manufacturing with controlled device complexity while maintaining high productivity.
4Weight of moving object
If composite material is used instead of metallic material, then weight is reduced and corrosion resistance is improved, but manufacturing automation becomes more difficult
Solution Approach 1:
The patent uses a dynamic movable portion that automatically adapts its position and shape during the lamination process to form the Z-shaped profile. This enables full automation of composite material manufacturing, overcoming the difficulty of automating complex composite forming operations while achieving weight reduction and corrosion resistance benefits.
Data Source
AI summary
A method is described for manufacturing a structural element in composite material extending along a straight or curvilinear longitudinal direction, having a Z-shaped cross section and comprising, in its final configuration, a central web and two flanges extending at a given final angle from opposite end portions of the web in respective directions opposite to one another; the method including the steps of: arranging a plurality of layers of composite material on a shaped portion of a forming mold; laminating the layers on the shaped portion so that the web is arranged, at least partially, in its final configuration, that a first flange is arranged in its final configuration at the final angle with respect to the portion of the web arranged in its final configuration, and that a second flange is arranged in its initial configuration at an initial angle distinct from, and greater than, said final angle with respect to the portion of the web arranged in its final configuration; moving a movable portion of the forming mold, which is movable with respect to a fixed portion of the forming mold, from a rest position to a bending position; displacing the second flange from the initial configuration into a final configuration in which it is at said final angle with respect to the portion of the web arranged in its final configuration; the step d) of displacing being carried out by means of the step c) of moving.