Gap Filler Roller Assembly for Variable Curvature Composite Fabrication
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Solution Overview
Problem
Existing methods for fabricating composite gap fillers struggle to reliably form gap fillers with changing sizes and radii of curvature, often resulting in abrupt surface changes and suboptimal fits within the gaps they are intended to fill, particularly in aircraft stringer applications where load demands vary.
Innovation Solution
A roller assembly with two rollers supported by rotatable support members, allowing for simultaneous rotation and translation of the rollers' axes to smoothly transition the size and radius of curvature of the gap filler, ensuring continuous and optimal fit with the changing gap configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional fabrication methods are used to form composite gap fillers, then the manufacturing process is simple, but the gap filler cannot accommodate changing gap sizes and radii of curvature along the stringer length
Solution Approach 1:
The fabrication system uses adjustable rollers with variable positions and radii that can be dynamically reconfigured along the stringer length. The rollers are mounted on adjustable supports that allow changing their position and the gap filler is formed by pulling it through the rollers, enabling the radius of curvature to vary continuously along the length rather than being fixed
Solution Approach 2:
The system changes geometric parameters (roller position, roller radius, support member position) to accommodate varying gap configurations. By adjusting these parameters, the fabrication system can produce gap fillers with different sizes and radii of curvature at different locations along the stringer to match the changing gap dimensions
2Manufacturing precision
If fixed radius rollers are used to form gap filler surfaces, then the manufacturing process is straightforward, but abrupt surface changes occur when transitioning between different radius sections
Solution Approach 1:
The support members are made rotatable about transverse axes, allowing the rollers to be dynamically repositioned. This enables smooth transitions between different radius sections by gradually changing the roller positions rather than making abrupt changes, eliminating surface discontinuities while maintaining a manageable assembly structure
Solution Approach 2:
The system adds rotational freedom to the support members, introducing a new degree of freedom (rotation about transverse axis) that allows the rollers to be positioned at multiple orientations. This enables continuous surface formation by transitioning through intermediate positions rather than jumping between fixed positions
3Reliability
If the gap filler size and radius are increased to accommodate maximum load conditions, then the fit is optimal for high-load sections, but excessive material is used in low-load sections
Solution Approach 1:
The gap filler is formed with locally varying properties - the radius of curvature and cross-sectional dimensions change along the length of the gap filler to match the local gap configuration and load requirements. High-load sections receive larger radius and size, while low-load sections have smaller dimensions, optimizing material distribution rather than using uniform dimensions throughout
Solution Approach 2:
The fabrication system dynamically adjusts the roller configuration along the length of the gap filler to create varying dimensions. The rollers can be positioned to produce different radii and sizes at different locations, allowing the gap filler to be tailored to local structural requirements rather than being uniformly sized
Data Source
AI summary
A roller assembly for forming adjacent curved surfaces in a composite gap filler member includes a first roller supported by a first support member wherein the first roller rotates relative to the first support member about a first axis of rotation. A second roller is supported by a second support member wherein the second roller rotates relative to the second support member about a second axis of rotation. First support member is rotatable about a third axis of rotation and the third axis of rotation extends in a direction transverse to the first axis of rotation. Second support member is rotatable about a fourth axis of rotation. The fourth axis of rotation extends in a direction transverse to the second axis of rotation.