Automated Film Applicator for Composite Stringer Adhesive Transfer
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Solution Overview
Problem
The aircraft industry faces challenges in efficiently applying film adhesive materials to elongate members like composite stringers, as manual handling and manipulation are tedious, time-consuming, and risk damaging the edges of the base flange, and transitioning between stringers is difficult, especially with heavy equipment.
Innovation Solution
A transfer system and method that includes a frame with a transfer fixture and a holding system, using pinch rollers to guide and index a film applicator along the elongate member, with a splice member for seamless transfer between stringers, and automated components for efficient film application and edge trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling and manipulation of the stringer is used, then workers can apply film adhesive material to the stringer, but the process becomes tedious, time-consuming, and risks damage to edges of the base flange
Solution Approach 1:
The patent replaces manual mechanical handling with an automated film applicator system that includes a film supply, applicator head with rollers, and drive mechanism. The applicator automatically feeds, applies, and trims film adhesive material along the entire length of the stringer without manual intervention, eliminating the tedious manual operations while maintaining or improving application quality.
Solution Approach 2:
The film applicator system is designed to be self-contained and self-operating, with the film supply feeding material through the applicator head, which automatically applies and trims the film along the stringer. The system serves itself by incorporating all necessary functions (feeding, applying, trimming) in one automated unit, eliminating the need for multiple workers performing sequential manual tasks.
2Ease of operation
If manual handling of the stringer is used, then workers can position and manipulate the stringer, but damage to edges of the base flange may occur
Solution Approach 1:
The patent replaces manual stringer handling with support rollers and a controlled positioning system that supports the stringer along its length. The automated film applicator moves along the stringer on guided rails or tracks, eliminating manual gripping and manipulation that could damage the base flange edges while maintaining ease of operation.
Solution Approach 2:
The patent introduces intermediary elements such as support rollers, guide rails, and protective fixtures between the workers and the stringer. These intermediaries bear the mechanical loads and positioning tasks, preventing direct manual contact that could cause damage to the base flange edges while still allowing workers to operate the system safely.
3Productivity
If heavy equipment is used for film application, then the application process can be automated, but transitioning between stringers becomes difficult and time-consuming
Solution Approach 1:
The patent designs the film applicator as a modular, segmented system with separate functional modules (film supply, applicator head, drive mechanism) that can be easily detached and repositioned. The applicator head itself is divided into independent components that can be quickly adjusted or replaced when transitioning between different stringers, reducing the complexity of equipment reconfiguration.
Solution Approach 2:
The patent incorporates dynamic, adjustable elements in the film applicator system, including movable support legs, adjustable film tensioning mechanisms, and reconfigurable guide rails. These dynamic features allow the equipment to adapt quickly to different stringer positions and configurations, making transitions between stringers simpler and faster despite the automated nature of the system.
Data Source
AI summary
A transfer system including a frame having an upper end portion and a lower end portion, a transfer fixture connected to the upper end portion, the transfer fixture defining a channel and including an elongate transfer member positioned in the channel, the elongate transfer member including a web and a base flange connected to the web.