Automated Flange Forming Device for Composite Ply Compaction
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Solution Overview
Problem
The manual lay-up of pre-preg plies or dry fabric in composite structure manufacturing is time-consuming and laborious, leading to inconsistencies and inefficiencies, especially when forming complex contoured parts, and existing methods like drape forming are limited in success with thick laminates or complex shapes due to uncontrolled compression issues.
Innovation Solution
An automated flange forming device mounted on a movable chassis, with a forming tool having a web surface and flange surfaces, allows for precise ply-by-ply formation and compaction, using a pressurized contact element to apply uniform pressure and adjust to complex geometries, while a ply distribution apparatus provides plies on-demand to eliminate manual handling and sequencing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual lay-up of pre-preg plies is used, then flexibility in handling complex geometries is maintained, but productivity is reduced and labor time increases
Solution Approach 1:
The patent implements a dynamic compaction system where the compaction head can selectively rotate about a yaw axis to adjust its orientation relative to the forming tool. This dynamic positioning capability allows the automated system to adapt to complex contoured geometries while maintaining high productivity through automation. The chassis moves along the length dimension to position the compaction head at different locations, combining automated motion with geometric adaptability.
2Extent of automation
If drape forming with vacuum bagging is used, then automation is improved, but manufacturing precision deteriorates due to uncontrolled compression causing buckling or wrinkling
Solution Approach 1:
The patent applies local quality by providing selective compaction at different locations on the forming tool. The compaction head can be positioned at specific locations along the length dimension and rotated to specific orientations to apply controlled pressure where needed. This localized control prevents uncontrolled compression and buckling while maintaining automation, ensuring high manufacturing precision on complex contoured surfaces.
Solution Approach 2:
The system incorporates sensors to detect the position and orientation of the compaction head relative to the forming tool. This feedback mechanism allows the control system to adjust the compaction pressure and positioning in real-time, preventing buckling and wrinkling by maintaining precise control over the compression process throughout automation.
3Adaptability or versatility
If tool surfaces with complex geometries are used, then adaptability to contoured parts is improved, but device complexity increases requiring manual supplementation
Solution Approach 1:
The patent creates a universal compaction system that can handle various contoured geometries through the selective rotation capability about the yaw axis. The same compaction head design can be positioned and oriented to accommodate different flange surface configurations, eliminating the need for multiple specialized tools or manual supplementation while managing device complexity through standardized automated components.
4Ease of operation
If manual positioning and placement is used, then ease of operation is maintained, but loss of time increases and reliability decreases due to human factor variations
Solution Approach 1:
The system implements self-service through automated positioning and placement of the compaction head. The chassis automatically moves to required locations along the length dimension, and the compaction head automatically orients itself through selective rotation about the yaw axis based on sensor feedback. This eliminates manual positioning tasks while maintaining ease of operation through programmable control, significantly reducing labor time and eliminating human factor variations that affect reliability.
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 reduces ply wrinkling, minimizes manual labor, and enhances manufacturing efficiency by enabling semi-automated, error-reduced formation of composite structures with improved consistency and reduced production defects.
Implementation Method 1
an actuator coupled to the at least one mounting surface, wherein the actuator is configured to rotate the at least one mounting surface about a yaw axis
Implementation Method 2
a flange forming device coupled to, and rotatable with, the at least one mounting surface, wherein the flange forming device includes a forming head configured to apply pressure to a work surface
Data Source
AI summary
A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a chassis at a first location along a length dimension of the forming tool, selectively rotating a flange forming device, that is coupled to the chassis, about a yaw axis based on a relative orientation of the flange forming device to the at least one flange surface, applying, with the flange forming device, the ply of material onto the forming tool, moving the chassis relative to the forming tool to position the chassis at a second location along the length dimension of the forming tool, and repeating the selective rotation and the application steps at the second location.