Modular Composite Manufacturing for Aircraft Fuselage
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Solution Overview
Problem
The existing advanced fiber placement (AFP) methods for aircraft component fabrication require high capital investment, extensive factory space, and skilled operators, limiting production rate and efficiency.
Innovation Solution
A modular composite manufacturing method utilizing a plurality of composite modules that are inspected and placed on a curing tool, allowing for high manufacturing rates with reduced capital investment and operational complexity, using right-sized equipment for parallel processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If advanced fiber placement (AFP) machines are used for aircraft component fabrication, then manufacturing precision and component quality are improved, but capital investment requirements and device complexity increase significantly
Solution Approach 1:
The patent divides the aircraft fuselage skin into multiple composite modules that can be manufactured separately using simpler equipment and then assembled together. This segmentation allows each module to be produced with less complex machinery while maintaining overall component quality through controlled module fabrication and precise assembly processes.
Solution Approach 2:
The patent transitions from traditional single-piece AFP manufacturing to a modular assembly approach, adding the dimension of modularity to the manufacturing process. This allows parallel production of multiple modules using simpler equipment, reducing overall device complexity and capital investment while maintaining manufacturing precision through standardized module fabrication procedures.
2Manufacturing precision
If traditional AFP machines operate at baseline lay-down rates, then manufacturing precision is maintained, but production rate and productivity are limited
Solution Approach 1:
By dividing the fuselage skin into multiple modules, the patent enables parallel manufacturing of several modules simultaneously using multiple simpler AFP machines or other composite fabrication methods. This segmentation multiplies the effective production rate while each individual module maintains manufacturing precision through controlled fabrication processes.
Solution Approach 2:
The patent implements preliminary manufacturing of multiple composite modules in parallel before final assembly. This preliminary action allows production to scale beyond the capacity of a single AFP machine, increasing overall productivity while each module is fabricated with adequate precision control during its preliminary production phase.
3Productivity
If multiple AFP machines are deployed to increase production rate, then productivity is improved, but factory floor space and device complexity increase
Solution Approach 1:
The patent segments the manufacturing process into module fabrication and final assembly phases. Multiple smaller modules can be produced in compact fabrication areas using simpler equipment, then consolidated during assembly. This segmentation reduces the total factory floor space required compared to deploying multiple full-scale AFP machines simultaneously.
Solution Approach 2:
The patent uses simpler composite fabrication equipment to produce copies of standardized modules rather than requiring multiple expensive AFP machines. These copied modules are then assembled to form the complete fuselage skin, achieving increased productivity with reduced factory space and device complexity.
4Manufacturing precision
If traditional AFP processes are used, then manufacturing precision is achieved, but the need for skilled operators and programmers increases
Solution Approach 1:
By dividing the fuselage into standardized modules, the patent reduces the complexity of individual manufacturing operations. Each module uses simpler fabrication processes that require less skilled operation, while overall precision is maintained through standardized procedures and controlled assembly of the segmented modules.
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 method significantly reduces capital investment, factory space requirements, and the need for skilled operators, while increasing production rates by enabling parallel processing of composite materials, thus efficiently fabricating aircraft components like fuselage skins.
Implementation Method 1
placing the composite modules on the curing tool
Data Source
AI summary
A modular composite manufacturing method, including providing a plurality of composite modules (18); providing a curing tool (54); and placing the composite modules on the curing tool, such that edges of adjacent composite modules are disposed in overlapping relationship with respect to each other.