Modular Tooling for Stiffened Composite Panels
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Solution Overview
Problem
Existing tooling for curing stiffened composite panels is large, heavy, and expensive, leading to increased capital costs and factory floor space requirements, with long work-in-process flow times and the need for multiple tool sets, and serial processing of layup, bond assembly, and bagging operations, which limits production flow rates.
Innovation Solution
The use of modular, reconfigurable tooling that allows for parallel processing of layup, forming, bonding, and bagging, with co-linearly arranged forming and cure tool segments that can be adjusted to accommodate different sizes and shapes, reducing tooling costs and floor space while enabling quicker engineering changes and lighter, more efficient curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing large, heavy tooling is used for curing stiffened composite panels, then the panels can be cured with proper support and shaping, but the capital costs and factory floor space requirements increase significantly
Solution Approach 1:
The tooling system is divided into multiple modular segments that can be independently positioned and configured. Each segment can be adjusted to support specific portions of the panel, allowing the overall tooling mass to be distributed and reduced while maintaining adequate support during curing.
Solution Approach 2:
The tooling segments are made adjustable and reconfigurable rather than fixed and static. This allows the same tooling system to adapt to different panel sizes and shapes, reducing the need for multiple heavy dedicated tool sets while maintaining curing quality across various configurations.
2Reliability
If existing tooling is used for curing stiffened composite panels, then the panels can be properly cured, but the work-in-process flow times become relatively long
Solution Approach 1:
The curing process is segmented into independent zones that can be prepared and positioned in advance. Multiple segments can be worked on simultaneously, allowing parallel processing of different portions of the panel or multiple panels, thereby reducing overall flow time while maintaining curing quality.
Solution Approach 2:
Tooling segments can be pre-positioned, pre-heated, or prepared in advance before the actual panel placement and curing begins. This preliminary preparation reduces the active curing time and allows for smoother workflow transitions, decreasing overall work-in-process flow time.
3Productivity
If multiple identical tool sets are required to achieve desired production rates, then the production flow rates can be increased, but the capital costs and factory floor space requirements increase
Solution Approach 1:
Each modular tooling segment is designed to perform multiple functions and can be reconfigured for different panel types and sizes. This universality allows a single set of modular segments to replace multiple dedicated tool sets, achieving the required production rates without proportionally increasing total tooling weight or capital costs.
Solution Approach 2:
The dynamic, reconfigurable nature of the modular segments enables rapid adaptation between different production runs. Instead of requiring multiple static tool sets for different products, one dynamic tooling system can be reconfigured for each product type, reducing total tooling inventory while maintaining high production flow rates.
4Manufacturing precision
If additional cure tooling and special tools are used for laying up and handling stringers, then the stringers can be accurately installed on skins, but the capital costs and tooling lead times increase
Solution Approach 1:
The functions of layup, handling, and positioning tools are merged into the modular cure tooling segments themselves. The segments incorporate features that directly support stringer placement and skin assembly, eliminating the need for separate special tools while maintaining manufacturing precision through integrated design.
Solution Approach 2:
The modular segments are designed with multi-functionality to handle various operations including layup support, stringer positioning, and curing. This reduces the total number of different tool types required, simplifying the overall tooling system while maintaining the precision needed for accurate stringer installation.
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 approach reduces tooling costs, shortens work-in-process flow times, and increases production flexibility by allowing simultaneous processing of multiple parts, thereby improving overall production efficiency and reducing capital expenditures.
Implementation Method 1
Each of the cure tool segments includes integral vacuum lines adapted to be coupled with a vacuum source for drawing a vacuum in the vacuum bag
Data Source
AI summary
A stiffened composite panel is fabricated using modular tooling. Composite pre-preg is laid up and formed over forming block modules each of which is assembled by co-linearly arranging a plurality of forming block segments. The formed stiffeners are respectively transferred to individual cure tool modules that are assembled by co-linearly arranging a plurality of cure tool module segments. The stiffeners are assembled by arranging the cure tool modules side-by-side, and a composite skin is placed on the assembled stiffeners. The panel is vacuum bagged using a segmented vacuum bag.