Flay Beam Assembly for Mandrel-Free Workpiece Removal

Solution Overview

Problem

The existing manufacturing processes for removing workpieces from layup mandrels are time-consuming and costly due to the need for disassembling the mandrel, which complicates the process and increases costs.

Innovation Solution

A flay system comprising a horizontal beam assembly and paired vertical beam assemblies, with drive motors and track systems that coordinate to move the vertical beams apart and attachment mechanisms to deflect the workpiece side portions away from the mandrel, allowing for removal without disassembling the fixture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the mandrel is disassembled to remove skin panels, then the workpiece can be removed from the fixture, but the operation becomes time-consuming and complex

Engineering Contradiction:

Improveworkpiece removalVSAvoiddisassembly time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The flay system performs preliminary actions by positioning multiple attachment mechanisms at predetermined locations on the mandrel before the workpiece is fully cured. The system maintains continuous contact with the workpiece during curing and performs preliminary separation movements before complete curing, eliminating the need for later disassembly operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flay system introduces an intermediary mechanism that acts between the workpiece and the mandrel. The attachment mechanisms serve as intermediaries that can be detached from the workpiece and repositioned, allowing removal without disassembling the mandrel itself. This intermediary system transfers the removal function from the mandrel structure to a separate, reusable device.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the mandrel is formed as multiple sections to facilitate removal, then the workpiece can be accessed, but the device complexity and cost increase

Engineering Contradiction:

Improveworkpiece accessVSAvoidmandrel structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The flay system applies segmentation by dividing the removal function into multiple independent attachment mechanisms that can be individually positioned and operated. Rather than segmenting the mandrel itself, the system segments the removal apparatus into multiple units that work in coordination, maintaining mandrel integrity while achieving workpiece access.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flay system introduces an intermediary mechanism that acts between the workpiece and the mandrel. The attachment mechanisms serve as intermediaries that can be detached from the workpiece and repositioned, allowing removal without disassembling the mandrel itself. This intermediary system transfers the removal function from the mandrel structure to a separate, reusable device.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If the stringers are engaged in grooves for structural integrity, then the skin panel is securely held, but the workpiece cannot be lifted off the mandrel

Engineering Contradiction:

Improvestructural integrityVSAvoidworkpiece removal

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The flay system applies dynamics by transitioning the attachment mechanisms from a static engagement state during curing to a dynamic separation state during removal. The system uses controlled movement to gradually lift the workpiece edges while maintaining engagement at other points, creating a dynamic removal process that overcomes the static structural engagement without compromising integrity during curing.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flay system performs preliminary actions by positioning multiple attachment mechanisms at predetermined locations on the mandrel before the workpiece is fully cured. The system maintains continuous contact with the workpiece during curing and performs preliminary separation movements before complete curing, eliminating the need for later disassembly operations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentEP3552773B1System and method for removing a workpiece from a manufacturing fixture

Publication Date: 2022.06.08 THE BOEING CO

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AI summary

A flay assembly (102) for separating a workpiece (400) from a manufacturing fixture (500) has a horizontal beam assembly (108) and a pair of vertical beam assemblies (150). The horizontal beam assembly includes a horizontal beam (110) having a horizontal drive motor (136). Each vertical beam assembly includes a vertical beam (152) operably engaged to the horizontal drive motor and has a workpiece attachment assembly (200) operably engaged to a vertical drive motor (170). The workpiece attachment assembly has an attachment mechanism (202) attachable to the workpiece. The horizontal drive motor and the vertical drive motors are operable in a manner to move the vertical beams away from each other along a horizontal drive axis (134) while simultaneously moving each workpiece attachment assembly along a vertical drive axis (168) to cause the attachment mechanisms to pull the workpiece side portions away from the manufacturing fixture while a center support (114) of the horizontal beam maintains a workpiece crown (416) in contact with the manufacturing fixture.