Mandrel Configuration Monitoring for Composite Part Precision
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Solution Overview
Problem
In aircraft manufacturing, mandrels often deform over time, leading to inconsistencies in composite parts, which can result in rework or discarding of parts, increasing production time and cost due to the difficulty in maintaining precise alignment and configuration during the manufacturing process.
Innovation Solution
A system comprising a mandrel with a plurality of transmitting devices that send signals to a receiving device to determine and monitor the mandrel's configuration, allowing for real-time adjustments to ensure alignment and precision, thereby reducing the need for rework and discarding parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mandrels are used repeatedly in composite part manufacturing, then production efficiency is improved, but mandrel deformation occurs leading to part inconsistencies
Solution Approach 1:
The system performs preliminary monitoring of mandrel configuration using transmitting devices and receiving devices before composite material is laid up on the mandrel. This allows detection of mandrel deformation early in the manufacturing process, enabling corrective action before parts are produced with incorrect dimensions, thus maintaining both productivity and precision.
Solution Approach 2:
The monitoring system establishes a feedback loop where transmitting devices attached to the mandrel continuously send signals to receiving devices that process the data to determine mandrel configuration. This real-time feedback enables operators to detect and correct mandrel deformation, ensuring part consistency while allowing repeated use of mandrels for efficient production.
2Manufacturing precision
If mandrels are monitored frequently to maintain precision, then part quality is improved, but system complexity increases
Solution Approach 1:
The system replaces complex mechanical measurement devices with electronic transmitting devices (such as RFID tags or sensors) that send signals wirelessly to receiving devices. This substitution simplifies the monitoring system while enabling frequent, non-intrusive checks of mandrel configuration, maintaining precision without adding mechanical complexity.
Solution Approach 2:
The transmitting devices attached to the mandrel serve multiple functions: they track mandrel configuration, monitor position, and provide data for quality control. This multi-functionality reduces the need for separate monitoring systems, decreasing overall system complexity while maintaining high manufacturing precision through continuous monitoring.
Data Source
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AI summary
A method and system for monitoring a mandrel (108). A first plurality of transmitting devices (134) is positioned with respect to the mandrel (108). Signals (136) from a portion (150) of the first plurality of transmitting devices (134) are received at a receiving device (114). The signals (148) are processed to determine a configuration (118) of the mandrel (108).