Integral Driver Blocks on Mold Lid for Aircraft Composite Fabrication
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Solution Overview
Problem
Conventional aircraft component molding techniques require significant manual effort and safety risks due to the separate insertion and removal of driver blocks, which are typically done at elevated temperatures, increasing operational complexity and safety hazards.
Innovation Solution
A toolset with integral driver blocks on the mold lid that projects from the interior surface, allowing for automatic extraction during mold opening, reducing manual handling and enhancing safety by integrating the driver blocks with the lid, thus eliminating the need for separate installation and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If driver blocks are inserted and removed separately from the mold base, then the mold can be assembled and disassembled, but the operational complexity increases and safety hazards arise due to manual handling at elevated temperatures
Solution Approach 1:
The driver blocks are merged with the mold lid by integrating them as integral portions of the lid structure. This combination eliminates the need for separate insertion and removal operations, as the driver blocks are automatically extracted when the mold lid is removed from the mold base. The integration resolves the technical contradiction by simplifying operations while maintaining the necessary mold assembly functionality.
Solution Approach 2:
The mold lid with integral driver blocks performs the function of both molding and driver block extraction. When the mold lid is removed, the driver blocks are automatically extracted along with it, eliminating the need for separate manual extraction operations. This self-service mechanism reduces operational complexity and safety hazards associated with manual handling at elevated temperatures.
2Productivity
If driver blocks are removed at elevated temperatures, then the driver blocks can be extracted from the mold base, but operator safety is compromised due to burning hazards
Solution Approach 1:
By merging the driver blocks with the mold lid, the extraction of driver blocks occurs simultaneously with the removal of the mold lid. This eliminates the need for separate driver block removal operations at elevated temperatures, thereby maintaining productivity while eliminating the safety hazard of operators handling hot driver blocks manually.
3Strength
If multiple driver blocks are individually pressed into place, then the mandrels can be clamped together, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The driver blocks are merged into the mold lid as integral structures, eliminating the need for individual installation of each driver block. The mold lid itself serves as the pressing mechanism that applies clamping force to the mandrels when closed, simplifying the manufacturing process while maintaining the necessary clamping strength.
4Adaptability or versatility
If driver blocks are discrete parts inserted separately, then the mold can be flexible in configuration, but the procedural steps increase and operational efficiency decreases
Solution Approach 1:
By merging the driver blocks with the mold lid, the number of procedural steps is significantly reduced. The driver blocks are automatically positioned and extracted as part of the mold lid assembly and disassembly operations, eliminating separate insertion and removal steps. This integration maintains configurational flexibility while dramatically reducing the time required for driver block operations.
Data Source
AI summary
Aspects of the disclosure are directed to a toolset configured to fabricate a component of an aircraft, the toolset comprising: a mold base configured to seat at least one mandrel, a mold lid configured to be coupled to the mold base, and at least one driver block that is integral with the mold lid and projects from an interior surface of the mold lid.