Forming End Effector With Sweepers for Complex Mandrel Layup

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Solution Overview

Problem

Gantry formers have a limited work envelope and cannot accommodate more than a few degrees of tool tilting, while robots are not as rigid and lack the precision needed for forming composite materials onto a mandrel.

Innovation Solution

A forming end effector with a frame, movable legs, and actuators connected to forming heads with sweepers, allowing for both rotational and translational sweeping of composite material onto a mandrel, and capable of connecting to and reacting loads into the mandrel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a gantry former is used to form composite material onto a mandrel, then rigidity and stability are improved, but the work envelope is limited and tool tilting capability is restricted to a few degrees

Engineering Contradiction:

ImproverigidityVSAvoidwork envelope

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The system is divided into a stationary gantry structure that provides rigidity and a movable end effector that provides adaptability. The end effector can be repositioned along the gantry rails to access different portions of the mandrel, effectively expanding the work envelope without compromising the structural stability of the gantry itself.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The end effector incorporates dynamic positioning capabilities with multiple degrees of freedom, including rotation and tilting movements. This allows the tool to adapt to various mandrel geometries and orientations while the gantry structure remains static and rigid, resolving the contradiction between structural stability and operational flexibility.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If a robot is used to form composite material, then adaptability and positioning capability are improved, but rigidity is reduced compared to gantries

Engineering Contradiction:

Improvepositioning capabilityVSAvoidrigidity

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The system uses the gantry structure as an intermediary that provides the rigid support framework, while the end effector acts as the adaptive component that interfaces with the composite material. This separation allows the rigid gantry to provide stable positioning without requiring the entire system to be rigid, enabling flexible composite forming operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If multiple robotic arms are used to form composite materials on complex surfaces, then adaptability is improved, but device complexity and cost increase

Engineering Contradiction:

Improvecoverage of complex surfacesVSAvoidnumber of robotic arms

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The end effector is designed as a universal tool that can form composite materials on various mandrel geometries through its multi-axis positioning and rotation capabilities. A single end effector can perform multiple forming operations on different portions of complex surfaces by repositioning along the gantry and adjusting its orientation, eliminating the need for multiple specialized robotic arms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12623412B2Forming end effector and methods of use

Publication Date: 2026.05.12 THE BOEING CO

AI summary

A forming end effector and methods of use are presented. Methods of forming a composite material onto a mandrel are presented. A forming end effector carrying the composite material is positioned over the mandrel. The forming end effector is connected to the mandrel. The composite material is swept onto the mandrel using sweepers of the forming end effector.