Coupled Mobile Platforms for Continuous Composite Part Layup

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Solution Overview

Problem

Conventional manufacturing techniques for large composite parts, such as aircraft structures, are limited by their fixed nature, hindering the adoption of continuous flow manufacturing and restricting production rate increases.

Innovation Solution

An apparatus and method involving mobile platforms for automated machines and tools, allowing them to couple and travel along a production line, enabling continuous movement and precise control for composite material deposition and lamination, facilitated by a motion controller and coupling features like grippers and latches.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If fixed-base machines and fixed-base tooling are used for manufacturing composite parts, then manufacturing stability and precision are maintained, but production rate and continuous flow capability are limited

Engineering Contradiction:

Improveproduction rateVSAvoidsystem flexibility

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies the dynamics principle by transforming fixed-base machines and tools into mobile platforms that can move along a production line. The automated machine and tool are mounted on mobile platforms with wheels or tracks, allowing them to travel to different workstations and return, converting static manufacturing equipment into dynamic systems capable of continuous flow production while maintaining manufacturing precision through controlled movement and positioning mechanisms.

Inventive Principle:

Principle #15Dynamics

2Productivity

If batch processing with stationary machines is used, then manufacturing precision is maintained, but continuous flow manufacturing cannot be achieved

Engineering Contradiction:

Improvecontinuous flow capabilityVSAvoidprocess continuity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent applies preliminary action by having mobile platforms pre-positioned at various locations along the production line and systematically scheduled to move to specific workstations in advance. The controller coordinates the movement of multiple mobile platforms beforehand, ensuring that machines and tools are positioned at the correct locations before needed, enabling continuous flow operations without disrupting manufacturing precision or process control.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If mobile platforms are introduced for continuous flow manufacturing, then production efficiency is improved, but system complexity and control requirements increase

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidcontrol system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing mobile platforms that serve multiple functions: they transport both automated machines and tools, provide positioning capabilities, and integrate with the production line infrastructure. The controller system manages multiple mobile platforms simultaneously, coordinating their movement, coupling, and uncoupling operations. This multi-functional approach consolidates several system components into unified mobile units, reducing overall system complexity despite the introduction of motion capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent introduces a controller as an intermediary that mediates between the mobile platforms, workstations, and production line. The controller receives commands, determines optimal movement sequences, coordinates coupling and uncoupling operations, and ensures synchronization between multiple mobile platforms. This centralized control intermediary simplifies the management of complex mobile platform operations by providing a single point of coordination rather than requiring direct complex interactions between all system components.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Adaptability or versatility

If automated machines and tools remain stationary, then manufacturing precision is maintained, but adaptability to different production configurations is limited

Engineering Contradiction:

Improveproduction line flexibilityVSAvoidpositioning accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical positioning systems with controlled mobile platform movement. Instead of having fixed machines at predetermined locations, the system uses mobile platforms equipped with motion control mechanisms that can precisely position themselves at required workstations. The controller manages the movement and positioning, substituting rigid mechanical fixed-positioning with flexible controlled motion, thereby maintaining manufacturing precision while achieving adaptability to different production configurations and product types.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4001549A1Continuous-line manufacturing system and method for composite parts

Publication Date: 2022.05.25 THE BOEING CO

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AI summary

A method for depositing composite material onto a tool using an automated machine. The method includes coupling a first mobile platform with a second mobile platform to form a coupled system, the first mobile platform supporting the automated machine and the second mobile platform supporting the tool. The method further includes indexing the automated machine relative to the tool. The method further includes depositing composite material from the automated machine onto the tool while the coupled system moves along a production line.