Elongate End Effector Tensioning Composite Material

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Solution Overview

Problem

Forming elongate composite parts, especially those with bends or complex shapes, is challenging due to difficulties in precisely positioning and layering elongate charges of composite material without introducing defects like wrinkles, particularly when fibers extend longitudinally along bends.

Innovation Solution

The use of an elongate forming tool with a corresponding forming surface and an elongate end effector that includes a porous vacuum region and a friction surface to tension and position the composite material, utilizing a vacuum to retain the material and resist sliding motion, allowing for precise shaping and tensioning across the forming surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional forming methods are used for elongate composite parts with bends, then the forming process can be completed, but wrinkles and defects are introduced into the composite part

Engineering Contradiction:

Improvesurface qualityVSAvoidforming difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by transitioning from conventional static forming to dynamic tensioning during the forming process. The end effector applies controlled tension to the composite material as it is formed around bends, changing the stress state parameters to prevent wrinkle formation while maintaining manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional mechanical clamping or manual positioning with an automated end effector system that applies distributed tension through a vacuum interface. This substitution of mechanical action reduces human intervention and improves consistency in preventing defects during forming.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If elongate charges of composite material are positioned and layered manually, then flexibility in positioning is maintained, but manufacturing efficiency decreases

Engineering Contradiction:

Improveforming efficiencyVSAvoidpositioning system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The end effector system is designed to be self-adjusting through vacuum distribution, where the vacuum pressure automatically distributes and holds the elongate charge in the correct position during forming. This self-service mechanism eliminates the need for complex external positioning systems while maintaining high productivity.

Inventive Principle:

Principle #25Self-service

3Reliability

If fibers are allowed to slide during forming, then the forming process is simpler, but fiber alignment and material integrity are compromised

Engineering Contradiction:

Improvematerial integrityVSAvoidforming operation simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The vacuum interface acts as an intermediary between the end effector and the composite material. It provides a controlled friction interface that prevents fiber sliding and maintains material integrity during forming, while the overall system operation remains simple through automated vacuum application and end effector movement.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method enables efficient and precise formation of elongate composite parts by maintaining tension and preventing defects such as wrinkling, particularly for zero-degree plies, while reducing the risk of damage during the forming process.

Implementation Method 1

The porous elongate vacuum region is configured to receive the applied vacuum from the vacuum outlet and to generate a pressure differential that is configured to retain the elongate charge of composite material in contact with the porous elongate vacuum region

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

The elongate friction surface extends along a length of the porous elongate vacuum region and is configured to generate a frictional force that resists a sliding motion between the elongate end effector and the elongate charge of composite material

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS20240181726A1Forming systems and methods for forming an elongate charge of composite material

Publication Date: 2024.06.06 THE BOEING CO

AI summary

Forming systems and methods for forming an elongate charge of composite material are disclosed herein. The forming systems include an elongate forming tool having an elongate forming surface with a forming surface shape. The forming systems also include an elongate end effector, which is configured to tension the elongate charge of composite material across the elongate forming surface. The elongate end effector includes an elongate vacuum distribution manifold, a porous elongate vacuum region that is defined by a strip of porous material, and an elongate friction surface that is defined by a strip of friction material. The strip of friction material is proximate a trailing edge of the elongate end effector relative to the strip of porous material. The methods include tensioning an elongate charge of composite material across an elongate forming surface of an elongate forming tool utilizing an elongate end effector.