Flexible Truss Mechanism for Composite Part Handling

Solution Overview

Problem

Handling large and flexible composite parts in aircraft manufacturing is challenging due to the difficulty in coordinating manual handling and the high cost and complexity of custom support fixtures.

Innovation Solution

A flexible truss system comprising a flexible truss mechanism with elongated members and slidable ribs, coupled with composite pick-and-place mechanisms, allows for the secure transfer and handling of flexible composite parts by bending to conform to the part's shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual handling with multiple operators is used, then the part can be supported at different locations, but coordination difficulty increases and damage risk increases

Engineering Contradiction:

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The support fixture is designed as a universal device that can accommodate multiple different composite parts through adjustable support elements, eliminating the need for multiple specialized fixtures and reducing coordination complexity while maintaining ease of handling

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If custom support fixtures are made for each part, then support precision improves, but manufacturing cost and logistics complexity increase

Engineering Contradiction:

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

A single universal support fixture design can be used across multiple part types and production lines, significantly reducing manufacturing costs and logistics complexity while maintaining the required support precision through adjustable configurations

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The support fixture incorporates adjustable and reconfigurable elements that allow it to adapt to different part geometries, maintaining high support precision without requiring custom-made fixtures for each part

Inventive Principle:

Principle #15Dynamics

3Stability of the object's composition

If rigid support structures are used, then structural stability improves, but adaptability to different part shapes decreases

Engineering Contradiction:

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The support fixture uses adjustable support elements that can be positioned and configured to match different part shapes, maintaining structural stability while providing adaptability to various composite part geometries

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP3932629B1Flexible truss systems and methods of transferring flexible composite parts using such systems

Publication Date: 2025.02.12

Figure 1A~1B
Figure 1C
Figure 1D

AI summary

Described herein are flexible truss systems (199) and methods (500) of transferring flexible composite parts using these systems. A flexible truss system (199) comprises a flexible truss mechanism (100) and composite pick-and-place mechanisms (190) supported on the flexible truss mechanism and designed to attach to various composite parts. The flexible truss mechanism comprises flexible elongated members (110) and slidable ribs (120) coupled to each flexible elongated member (110). Specifically, each rib is slidably coupled to at least one flexible elongated member (110). In some examples, each rib is also fixedly coupled to another flexible elongated member. The slidable coupling allows the flexible truss mechanism (100) to bend and follow the shape of a supported part (600), such that the composite pick-and-place mechanisms (190) are able to contact and support different areas of the composite part (600). As such, the same flexible truss mechanism is able to support flexible composite parts having different shapes.