Integrally laminated composite stringer laminate manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing composite laminates in aircraft construction are labor-intensive and time-consuming due to the manual fabrication and installation of individual frame fillers, which significantly impact production rate and cost.
Innovation Solution
A manufacturing system and method that uses a plurality of lamination heads to dispense composite material and laminate plies on a lamination surface, including frame filler outer, inner, and stringer body lamination heads to create an uncured stringer laminate with integrally laminated frame filler portions protruding laterally, reducing the need for separate frame filler fabrication and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manual methods are used to fabricate and install individual frame fillers, then the structural integrity and gap-filling function are achieved, but the production time and labor cost increase significantly
Solution Approach 1:
The patent merges the frame filler fabrication and installation processes into a single automated lamination operation. The lamination heads deposit frame filler plies directly onto the lamination surface at predetermined locations during the stringer laminate manufacturing process, eliminating the need for separate manual fabrication and installation steps. This integration directly resolves the technical contradiction by achieving both structural integrity and high productivity.
Solution Approach 2:
The patent applies preliminary action by pre-positioning the frame filler plies during the lamination process itself, before the stringer laminate is completed. The frame filler portions are laid up at predetermined locations on the lamination surface as part of the initial manufacturing process, rather than being installed later as separate components. This advance preparation eliminates subsequent installation time and labor while maintaining the required gap-filling function.
2Ease of manufacture
If multiple separate components (stringer laminate and frame fillers) are manufactured and assembled, then the structural requirements are met, but the quantity of parts and assembly complexity increase
Solution Approach 1:
The patent combines multiple separate components into a single integrated structure. The frame filler plies are manufactured as an integral part of the stringer laminate by depositing them on the lamination surface during the lamination process. This merging eliminates the need for separate frame filler components and their subsequent assembly, directly reducing part quantity and assembly complexity while maintaining structural requirements.
Solution Approach 2:
The lamination process is designed to perform multiple functions simultaneously: it lays up the stringer laminate body plies and deposits frame filler plies at predetermined locations in a single operation. The lamination heads serve both to create the main structural laminate and to position the gap-filling frame filler portions, reducing the need for separate manufacturing and assembly operations.
Data Source
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AI summary
A manufacturing system for laying up a stringer laminate includes a lamination surface and a plurality of lamination heads including a frame filler outer ply lamination head for laying up (e.g., laminating) frame filler bottom ply at a plurality of frame filler locations. Also included is at least one frame filler inner ply lamination head for laying up one or more frame filler inner plies over a protruding portion of the frame filler bottom ply at each frame filler location. Further included is at least one stringer body lamination head laying up one or more stringer body plies defining a stringer body portion extending along the lamination surface. A frame filler outer ply lamination head is configured to lay up a frame filler top ply at each frame filler location such that the frame filler inner plies are captured between a frame filler bottom ply and a frame filler top ply.