Filler Location Tool for Stiffened Composite Assembly
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Solution Overview
Problem
The assembly of stiffened composite structures, such as aircraft fuselages, is labor and time intensive due to the manual placement and vacuum compacting of stringer mandrels and noodles, which requires significant effort and resources, especially for large commercial aircraft.
Innovation Solution
A method and system that includes providing a supply of stiffeners and filler structures, loading and positioning them onto an inner mold line layup mandrel using a filler location tool, and affixing a skin segment over the filler structures to form a stiffened composite structure, which streamlines the assembly process by automating the placement and compaction of filler structures within stiffener cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual placement and vacuum compacting of stringer mandrels and noodles is used, then the assembly process can be performed with simple equipment, but the labor and time requirements increase significantly
Solution Approach 1:
The system enables self-service automation where the filler location tool automatically positions filler structures within stiffener cavities without requiring manual intervention. The tool self-adjusts to locate and place fillers accurately, reducing labor intensity while maintaining equipment simplicity.
Solution Approach 2:
The patent replaces manual mechanical placement with an automated filler location tool that uses mechanical guidance and positioning mechanisms. This substitution eliminates the need for labor-intensive hand positioning while keeping the overall equipment complexity manageable through modular design.
2Device complexity
If manual placement and vacuum compacting of stringer mandrels and noodles is used, then the equipment requirements remain simple, but the time consumption increases
Solution Approach 1:
The filler location tool performs preliminary positioning of filler structures before the skin application process. By pre-locating fillers accurately within stiffener cavities, the system eliminates time-consuming manual adjustments during subsequent assembly steps, reducing overall assembly time without complex equipment.
3Productivity
If automated placement and compaction of filler structures is implemented, then labor and time requirements are reduced, but the device complexity increases
Solution Approach 1:
The filler location tool acts as an intermediary device between the simple vacuum compaction system and the filler structures. This intermediary component automates the positioning function while maintaining compatibility with existing simple equipment, achieving productivity improvement without proportionally increasing overall system complexity.
4Productivity
If automated placement and compaction of filler structures is implemented, then the assembly process becomes more efficient, but the equipment complexity increases
Solution Approach 1:
The automated system is segmented into modular functional components: the filler location tool, the positioning mechanism, and the integration interface with existing vacuum compaction equipment. This segmentation allows the automated features to be added as discrete modules, improving productivity while keeping equipment complexity manageable through modular architecture.
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 approach reduces labor and time requirements, enhances efficiency, and facilitates the assembly of large composite structures by mechanizing the placement and compaction of filler structures, thereby improving the overall production process.
Implementation Method 1
A vacuum is then applied between the sheet of material and the inner mold line layup mandrel to compress the stringer mandrels into the stringers.
Data Source
AI summary
Methods of assembling a stiffened composite structure include loading a stiffener onto an inner mold line layup mandrel; positioning a filler structure on an upper side of a filler location tool; following the loading and the positioning, locating, with the filler location tool, the filler structure within the stiffener cavity of the stiffener; repeating the loading, the positioning, and the locating to load a plurality of stiffeners and filler structures; and following the repeating, affixing a skin segment over the plurality of filler structures and to the plurality of stiffeners to form at least a portion of the stiffened composite structure. Systems for assembling stiffened composite structures include a supply of stiffeners; a supply of filler structures; an inner mold line layup mandrel; and a filler location tool configured to locate a filler structure within the stiffener cavity of a stiffener that is loaded onto the mandrel.