Laminate Shear Forming Pressure Feedback for Composite Uniformity

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Solution Overview

Problem

Laminate shear forming machines face challenges in ensuring precise and consistent pressure application along the length of complex composite parts, particularly in aerospace applications, leading to potential wrinkles and weak spots due to inconsistent force distribution.

Innovation Solution

Incorporating pressure sensing strips between forming members and the composite charge, coupled with a forming controller that dynamically adjusts the position of forming members to maintain pressure within a target range, ensuring even pressure application along the layup mandrel.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If pressure sensing strips and dynamic adjustment mechanisms are added to the laminate shear forming machine, then manufacturing precision and reliability of pressure application are improved, but device complexity increases

Engineering Contradiction:

Improvepressure application precisionVSAvoidmachine structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Pressure sensing strips are integrated between the forming members and composite charge to provide real-time feedback on pressure distribution. The forming controller receives this feedback and dynamically adjusts forming member positions to maintain uniform pressure, resolving the contradiction by using closed-loop control to achieve precision without excessive complexity

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system transitions from static pressure application to dynamic adjustment, where forming member positions are continuously modified based on real-time pressure measurements. This dynamic approach enables precise pressure control while using straightforward actuation mechanisms rather than complex mechanical systems

Inventive Principle:

Principle #15Dynamics

2Device complexity

If forming members are statically positioned to apply pressure, then device complexity is reduced, but manufacturing precision and consistency of pressure application deteriorate

Engineering Contradiction:

Improvemachine structure complexityVSAvoidpressure distribution consistency

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

Pressure sensing strips provide continuous feedback on pressure distribution along the composite charge. The forming controller uses this feedback to dynamically adjust forming member positions, ensuring consistent pressure application without requiring complex mechanical positioning systems

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses self-regulating feedback where pressure sensing strips automatically detect pressure variations and trigger corresponding adjustments in forming member positions, enabling the system to self-correct pressure distribution without external intervention or complex control mechanisms

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables precise and consistent pressure application, enhancing the reliability and reproducibility of composite part formation by dynamically adjusting forming member positions based on real-time pressure measurements, thereby improving the quality of composite parts with complex geometries.

Implementation Method 1

pressure sensing strips configured to measure pressure between the forming members and the composite charge

Methodology Applied

Scientific EffectPressure sensing:

Data Source

PatentUS11179900B2Laminate shear forming machine with dynamic pressure adjustment

Publication Date: 2021.11.23 THE BOEING CO

AI summary

Systems and methods are provided for designing composite parts. One embodiment is a laminate shear forming machine configured to shape a composite charge. The laminate shear forming machine includes a layup mandrel including a surface for shaping the composite charge, forming members configured to press the composite charge against the surface of the layup mandrel to shape the composite charge, and pressure sensing strips configured to measure pressure between the forming members and the composite charge. The laminate shear forming machine also includes a forming controller coupled to the pressure sensing strips and configured to determine that at least one forming member is applying pressure to the composite charge outside a pressure range, and to direct the at least one forming member to adjust from a first position to a second position to apply pressure to the composite charge within the pressure range.