Contoured Tool for Automated Composite Layup Placement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automated fiber placement machines struggle to efficiently form and apply composite layups, such as doublers, on structures with complex geometries, as existing methods are time-consuming and limited to flat or constantly curved surfaces.
Innovation Solution
A method and apparatus that use a multi-contoured tool with integrated layup, compaction, and location data generation to form and apply composite layups on complex surfaces, allowing for automated placement and compaction using an AFP machine, a manipulator, and inflatable bag or bladder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If preassembling doubler layups by hand, then layups can be applied to complex geometries, but the process becomes time consuming and difficult
Solution Approach 1:
The patent replaces manual mechanical assembly with an automated fiber placement machine that uses computer-controlled mechanisms to deposit composite material directly onto contoured tools. This substitution enables complex geometries to be formed automatically without time-consuming hand assembly while maintaining the adaptability to match various surface contours through programmable tool paths and multi-axis movement.
Solution Approach 2:
The patent changes the physical state and parameters of the composite material by using automated fiber placement to deposit pre-impregnated composite tapes in precise layers. The process controls parameters such as fiber orientation, layer thickness, and deposition speed to match complex surface geometries, thereby reducing assembly time while maintaining versatility for different contoured surfaces.
2Manufacturing precision
If using automated fiber placement machine for entire structure, then build rate is dependant on machine speed, but sequential ply formation limits productivity
Solution Approach 1:
The patent divides the composite structure into separate segments: doublers are preformed on dedicated contoured tools using automated fiber placement, then applied as preassembled kits to the main structure during the AFP build sequence. This segmentation allows parallel processing where doubler fabrication occurs independently offline, improving overall productivity without sacrificing the manufacturing precision achieved through automated fiber placement.
Solution Approach 2:
The patent performs preliminary action by preforming doubler layups on contoured tools before they are applied to the main structure. This advance preparation allows the doublers to be manufactured offline with high precision using automated fiber placement, then quickly integrated during assembly, thereby increasing the build rate without compromising the precision of the composite layup.
3Productivity
If preassembling doublers using automated equipment, then assembly is faster, but equipment is limited to flat or constant curvature surfaces
Solution Approach 1:
The patent employs contoured tools with multi-contoured faces that match the complex geometries of the target surfaces. These tools feature varying curvatures and contours that enable automated fiber placement equipment to form doublers on complex three-dimensional surfaces, not just flat or constant curvature surfaces. The contoured tools translate complex surface geometries into manufacturable forms that automated equipment can handle, thereby maintaining both productivity and adaptability.
Solution Approach 2:
The patent creates multi-functional contoured tools that can be used for both forming the doubler layup and serving as the substrate for application to the main structure. The tools are designed with surfaces that match various complex geometries, enabling a single automated system to handle multiple doubler configurations and surface types, thus achieving both high assembly speed and broad adaptability to complex geometries.
4Reliability
If fabricating layups off main assembly line, then rework and inspection are possible without slowing assembly, but requires additional equipment and process integration
Solution Approach 1:
The patent extracts the doubler fabrication process from the main assembly line by using separate contoured tools dedicated to doubler formation. This extraction allows doublers to be preformed, inspected, and reworked independently offline, improving reliability without adding significant complexity to the main assembly process. The separated process can be integrated through standardized interfaces and location data systems.
Solution Approach 2:
The patent uses contoured tools as intermediaries between the automated fiber placement machine and the final structure. These tools serve as temporary substrates for forming doublers and include integrated location data systems that facilitate their positioning and application to the main structure. The intermediary tools simplify the overall process by providing a standardized platform for doubler fabrication and application, reducing the complexity of direct integration.
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
Enables quick and accurate formation and application of composite layups on complex surfaces, allowing for off-line fabrication and rework without slowing down the assembly process, improving efficiency and accuracy.
Implementation Method 1
using the location data and a manipulator to move the tool into proximity to the part and place the contoured layup on the part
Implementation Method 2
The layup may be compacted against the part by inflating a bladder on the tool and/or by inflating a bag on the tool
Implementation Method 3
drawing a vacuum bag down onto a multi-contoured face of a tool substantially matching the contours of the part surface
Data Source
AI summary
A composite layup is formed on a tool and placed on a contoured part. The tool is contoured to substantially match the contour of the part. A set of location data is generated which represents the location of the part in space relative to the tool. An automated manipulator uses the location data to move the tool into proximity to the part and place the contoured layup on the part.