Curved Composite Preform Fabrication via Concentric Rail Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for fabricating aircraft components, particularly curved composite parts, face challenges in achieving efficient production rates due to limitations in assembly line efficiency and space utilization, leading to potential delays in aircraft fabrication.
Innovation Solution
The implementation of a dynamic assembly line system that uses a rail system with concentric circles and spurs to efficiently route and form plies into curved preforms, allowing for Just-in-Time delivery and increased work density by clustering Ply-By-Ply forming stations, thereby enhancing the fabrication of curved composite parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional assembly techniques are used to fabricate curved composite parts, then production capacity is maintained, but space requirements on the factory floor increase and production rate decreases
Solution Approach 1:
The assembly line is segmented into multiple specialized stations (layup station, forming station, curing station, inspection station) that process different aspects of preform fabrication. This segmentation allows each station to be optimized for its specific function and enables parallel processing of multiple plies simultaneously, increasing production rate while compacting the overall footprint through efficient space utilization.
Solution Approach 2:
The patent transitions from traditional linear or radial assembly layouts to a concentric circular track system. Multiple plies are delivered along concentric circles (inner circle for PBP stations, outer circle for lamination station) and can be routed to different forming stations based on their destination. This dimensional reorganization allows greater work density and reduces the radial space requirement while maintaining high production capacity.
2Area of stationary object
If multiple forming stations are clustered together to increase work density, then space efficiency improves, but system complexity increases
Solution Approach 1:
The rail system is designed as a universal infrastructure that serves multiple functions: it transports plies from the lamination station to any of the multiple PBP forming stations, provides routing flexibility based on ply characteristics, and enables dynamic allocation of plies to different stations. This multi-functional rail system consolidates what would otherwise require multiple separate material handling systems, reducing overall complexity while enabling station clustering.
Solution Approach 2:
The patent introduces a controller as an intermediary that manages the complex interactions between multiple forming stations, the rail system, and the lamination station. The controller receives information about ply characteristics, determines optimal routing and station assignment, and coordinates the timing of ply delivery. This centralized intelligence simplifies the control architecture compared to distributed control at each station while enabling the clustered configuration.
3Productivity
If Just-in-Time delivery is implemented for plies, then production efficiency increases, but timing precision requirements increase
Solution Approach 1:
The lamination station prepares plies in advance and loads them onto carriers that are then transported along the outer concentric circle. This preliminary preparation and staged transport allow plies to be ready for Just-in-Time delivery to the inner-circle PBP forming stations when needed. The concentric circle design inherently provides timing control as plies travel at controlled speeds along predetermined paths, reducing the need for complex real-time timing adjustments.
Data Source
AI summary
Systems and methods are provided for fabricating curved preforms of fiber reinforced material. Methods include laying up at least one ply onto a carrier of flexible material at a lamination station, loading the carrier onto a rail system, routing the carrier to a particular Ply-By-Ply (PBP) forming station at the rail system, separating the at least one ply from the carrier, and making the at least one ply into the preform via the particular PBP forming station.