Elastically Deformable Mounting Shell for Composite Demoulding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing technologies face challenges in producing large-area, two-dimensionally curved structural components from fiber composite materials due to the 'undercut problem' during demoulding, which limits the degree of curvature and requires complex mechanisms for mobility, especially in aircraft construction where half-shell construction is prevalent.
Innovation Solution
A device featuring a mounting shell with articulated actuators that can be elastically deformed inwardly, allowing the assembly shell to be moved between extended and retracted positions without undercuts, enabling efficient automation and reducing weight by forming a compact mechanism with radially aligned actuators and molded receiving channels for stringers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rigid mounting surface is used to maintain structural integrity during production, then manufacturing precision is improved, but device complexity increases due to the need for complex mechanisms to overcome undercuts during demoulding
Solution Approach 1:
The mounting shell is designed to be elastically deformable rather than rigid, allowing it to dynamically change its shape during the production cycle. The shell can be deformed into an extended position for demoulding and a retracted position for component production, eliminating the need for complex mechanisms to overcome undercuts while maintaining structural integrity during the critical production phase
Solution Approach 2:
The physical state of the mounting shell is changed from a fixed rigid structure to an elastically deformable structure whose shape parameter can be changed. By controlling the elastic deformation of the shell between extended and retracted positions, the system achieves both high manufacturing precision during production and simplified demoulding without complex mechanisms
2Ease of operation
If the mounting shell is deformed inwardly at the edges to enable separation from the mould, then ease of operation is improved, but manufacturing precision may worsen due to potential deformation of the structural component
Solution Approach 1:
The mounting shell's elastic deformability allows it to dynamically adapt its shape during different phases of the production cycle. During demoulding, the shell deforms inwardly at the edges to clear undercuts and facilitate separation. During component production, the shell maintains its precise contoured shape to ensure manufacturing accuracy. The dynamic nature of the deformation ensures that precision is maintained when needed while enabling ease of operation when required
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
This solution allows for the efficient production of large-area, two-dimensionally curved structural components by overcoming the undercut issue, enabling the assembly shell to be separated from the mould without undercuts, reducing weight, and simplifying the mechanism for storage and transport, while maintaining the structural integrity and curvature of the components.
Implementation Method 1
a mounting shell (3), which can be elastically deformed inwardly at the edges
Implementation Method 2
A vacuum is applied to the cavity formed by the receiving channels in such a way that the film is sucked smoothly onto the mounting surface
Data Source
Figure 1~2
Figure 3~6
AI summary
The invention relates to an installation and a method for producing structural components from a fiber composite material, said structural components being essentially two-dimensionally curved over a large surface, comprising a jig (ARV) having a convex mounting surface (3) which has receiving channels (4) for structural components to be inserted, said channels extending longitudinally at a distance to each other, and which can be loaded with auxiliary materials, the loaded jig (ARV) interacting with a lamination bonding device (LKV) having a corresponding shape for forming the structural component under the impact of pressure. The jig (ARV) has a mounting shell (3), the edges of which can be elastically deformed inwards. Said mounting shell can be displaced by means of a plurality of actuators (5a, 5b) between deployed position (A) and at least one retracted position (B) in which the jig (ARV) can be deployed from the lamination bonding device (LKV) without creating undercuts relative to the longitudinally extending receiving channels (4) without undercuts, the actuators being articulated to the interior of the shell.