Metal Beam Bending Control to Reduce Stringer Twisting
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Solution Overview
Problem
The manual bending process for aircraft stringers is slow, requires significant operator expertise, results in high scrap rates due to overloads, and has a long cycle time, necessitating a more efficient and automated method for forming metal beams.
Innovation Solution
An automated apparatus and method for forming metal beams, utilizing a platform with fixed and bending clamp members, actuators, and a linkage assembly to apply controlled bending forces through the shear center and principal axes, reducing twisting and out-of-plane deformation, and incorporating a control system for precise contouring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual bending process is used, then operator control and flexibility are maintained, but cycle time increases and productivity decreases
Solution Approach 1:
The patent replaces manual mechanical bending operations with an automated computer-controlled bending system. The control system automatically positions and applies bending forces to the metal beam according to pre-programmed parameters, eliminating the need for manual measurement, marking, and bending operations while significantly reducing cycle time and increasing productivity.
Solution Approach 2:
The automated bending system performs self-positioning and self-adjustment through computer control. The system automatically calculates bend parameters, positions the beam, applies appropriate forces, and monitors the bending process without requiring continuous manual intervention, thereby maintaining quality control while improving efficiency.
2Ease of manufacture
If manual bending process is used, then flexibility in handling different part configurations is maintained, but operator expertise requirements increase and manufacturing complexity increases
Solution Approach 1:
The patent replaces skilled manual operations with computer-controlled automation. The control system contains embedded knowledge and algorithms that automatically determine bending parameters, force applications, and positioning requirements for various part configurations, eliminating the need for highly skilled operators while standardizing the manufacturing process.
Solution Approach 2:
The system handles different part configurations by dynamically adjusting bending parameters such as force magnitude, application points, duration, and sequences based on pre-programmed data for each part type. This allows the same automated equipment to efficiently produce various stringer configurations without requiring operator expertise or manual reconfiguration.
3Manufacturing precision
If manual bending process is used, then real-time adjustment capability is maintained, but measurement precision and manufacturing precision decrease due to human error
Solution Approach 1:
The patent replaces manual measurement and adjustment operations with automated computer-controlled positioning and force application. The system uses precise sensors and actuators to execute bending operations with high accuracy, eliminating human measurement errors and ensuring consistent manufacturing precision across all parts.
Solution Approach 2:
The automated bending system incorporates feedback mechanisms that monitor bending progress and beam position in real-time. The control system receives feedback from sensors and automatically adjusts bending parameters to maintain precision, ensuring that each bend is executed accurately according to specifications without requiring manual measurement and correction.
4Productivity
If manual bending process is used, then adaptability to different part geometries is maintained, but loss of time increases due to iterative measurement and adjustment
Solution Approach 1:
The patent performs preliminary programming of all bending parameters, positions, and sequences before the actual bending operation. The control system is pre-loaded with the complete bending schedule and parameters for each part type, allowing the automated system to execute the entire bending sequence without iterative measurement and adjustment, thereby significantly reducing cycle time while maintaining precision.
Solution Approach 2:
The system uses real-time feedback from position sensors and force sensors to monitor bending progress and ensure contour accuracy during the automated process. This allows the system to maintain high precision while eliminating the need for repeated manual measurements and adjustments that extend cycle time in manual operations.
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
The solution significantly reduces cycle time, minimizes operator expertise requirements, lowers scrap rates, and ensures accurate bending of metal beams with reduced risk of damage, enabling efficient production of symmetrical and unsymmetrical cross-sections like aircraft stringers.
Implementation Method 1
a first bend actuator connected to the rotatable bending frame and configured to apply a first bending force to the rotatable bending frame. The bending clamp member may include a second bend actuator connected to the rotatable bending frame and configured to apply a second bending force to the rotatable bending frame
Implementation Method 2
a linkage assembly that may be interposed between the first bend actuator and the rotatable bending frame. The linkage assembly may be provided to translate the first bending force to the rotatable bending frame and modulate the angle at which the first bending force is applied to the rotatable bending frame
Implementation Method 3
The fixed clamp member may include a first locking clamp for releasably locking a first portion of the metal beam. The bending clamp member may include a rotatable bending frame having a second locking clamp for releasably locking a second portion of the metal beam
Data Source
AI summary
A method for forming a metal beam may comprise: clamping first and second portions of the metal beam in a substantially fixed and in a position whereat the metal beam is rotatable about three axes; applying a net bending force to the clamped second portion of the metal beam at a predetermined angle; sensing twisting of the second portion of the metal beam resulting from the net bending force; and modulating the angle at which the net force is applied to reduce the twisting of the metal beam. As a result, the net bending force is moved toward the shear center and toward being along the principal axis of the metal beam.