Automated Mandrel Preparation for Composite Stringers
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Solution Overview
Problem
Conventional methods for preparing mandrels for composite stringer manufacturing are labor-intensive and time-consuming, requiring significant production floor space due to manual application of breather layers and release films.
Innovation Solution
A system comprising a U-shaped chute, feeder mechanisms, a sock application assembly, and a film application assembly that progressively applies a breather sock and film over the mandrel as it exits the chute, forming a film-sock-mandrel assembly, reducing labor and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual methods are used to apply breather layer and release film over mandrel, then labor flexibility is maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical application methods with an automated system that uses a chute to guide the mandrel and mechanical assemblies to apply breather and film layers. The system substitutes human labor with automated mechanical components including a mandrel guide chute, breather application mechanism, and film application mechanism, thereby increasing productivity while maintaining controlled application quality
Solution Approach 2:
The mandrel serves itself by being automatically guided through the chute and having materials applied to it as it moves through the system. The continuous motion of the mandrel through the automated assembly allows for self-service application without requiring external manual intervention at each step of the process
2Area of stationary object
If manual application processes are used, then equipment complexity is reduced, but production floor space requirements increase
Solution Approach 1:
The patent combines multiple functions into a single integrated automated system. The chute structure simultaneously serves as a mandrel guide, a material delivery channel, and a support structure for the application mechanisms. The breather application and film application are merged into a continuous process within the same chute structure, reducing the overall space footprint compared to separate manual operations
Solution Approach 2:
The system transitions from horizontal spread-out manual operations to a vertical or compact linear arrangement within the chute. By organizing the application processes in sequence along the mandrel's path through the chute, the system compresses the spatial requirements into a more compact configuration, effectively utilizing the third dimension (depth/length of chute) rather than requiring extensive floor space
3Loss of time
If conventional manual preparation methods are used, then process simplicity is maintained, but time consumption and labor costs increase
Solution Approach 1:
The system performs preliminary actions by pre-positioning the breather and film materials in the chute structure before the mandrel arrives. The materials are staged and ready for immediate application as the mandrel moves through, eliminating setup time during the actual application process and reducing overall preparation time
Solution Approach 2:
The patent implements continuous action by maintaining constant motion of the mandrel through the chute and continuous application of materials without interruption. The automated system eliminates the start-stop nature of manual operations, keeping all components in continuous productive action throughout the mandrel preparation process, thereby reducing total cycle time
Data Source
AI summary
A system includes a U-shaped chute, one or more feeder mechanisms, a sock application assembly, and a film application assembly. The chute has a chute inlet and a chute outlet and is configured to receive a mandrel having a mandrel length. The one or more feeder mechanisms are configured to move the mandrel into the chute inlet and through the chute. The sock application assembly has a sock material spool containing a breather sock in tubular form. The sock application assembly is configured to progressively apply the breather sock over the mandrel length as the mandrel exits the chute outlet. The film application assembly has a film material spool containing a film in tubular form. The film application assembly is configured to progressively apply the film over the breather sock covering the mandrel exiting the sock application assembly to thereby form a film-sock-mandrel assembly.