Film Applicator Transfer System for Composite Stringers
Find Innovative SolutionsGenerate Solutions
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, labor-intensive, and prone to damage, and transitioning between stringers is difficult and time-consuming, especially with heavy equipment.
Innovation Solution
A film applicator system with a carriage and pinch rollers that guides and indexes along the elongate member, including a film feed roll, compaction roller, backer take-up reel, and cutter assembly, mounted on a holding fixture that stabilizes the stringer, allowing automated or manual movement and precise edge trimming, with a transfer system for efficiently moving the applicator between stringers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling and manipulation of the stringer is used to apply film adhesive material, then the process is flexible and adaptable, but the operation becomes tedious, labor-intensive, and prone to damage to edges
Solution Approach 1:
A transfer member is introduced as an intermediary component between the stringer and the film applicator. The transfer member receives the film applicator from the stringer and facilitates its movement to the next stringer, reducing direct manual handling of the heavy stringer while maintaining process flexibility
Solution Approach 2:
The transfer member acts as a surrogate or copy of the stringer's interface, providing a standardized means to transfer the film applicator without requiring direct manipulation of the actual stringer, thereby reducing labor intensity and risk of damage
2Manufacturing precision
If heavy equipment is used for film application, then application precision is improved, but transitioning between stringers becomes difficult and time-consuming
Solution Approach 1:
The system is divided into separate functional components: the film applicator (for precise application), the stringer (workpiece), and the transfer member (for movement). This segmentation allows the heavy precision equipment to remain stationary while only the lighter transfer member moves between stringers, improving transition speed
Solution Approach 2:
The transfer member serves as a mediator that decouples the precision film application function from the heavy stringer manipulation. The film applicator maintains precise application capability while the transfer member handles the movement between stringers, resolving the contradiction between precision and transition efficiency
3Stability of the object's composition
If multiple workers manually hold and manipulate the stringer, then the stringer position can be controlled, but the process becomes labor-intensive and presents damage risk
Solution Approach 1:
The transfer member acts as a mechanical intermediary that provides stable support and positioning for the film applicator during transfer operations. This reduces the need for multiple workers to manually hold and position components, decreasing labor intensity and damage risk while maintaining position control
Solution Approach 2:
The transfer member is designed to self-stabilize and self-position during the transfer process, reducing the need for external manual intervention. The system performs part of its own positioning and support function, thereby reducing the number of workers required
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A transfer system including a frame having an upper end portion (100) and a lower end portion (84), a transfer fixture connected to the upper end portion (100), the transfer fixture defining a channel and including an elongate transfer member (34) positioned in the channel, the elongate transfer member (34) including a web (64) and a base flange (60) connected to the web(64).