Multi-Head AFP Composite Preform Assembly
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Solution Overview
Problem
Current methods for fabricating aircraft airframe components are labor-intensive and inefficient, particularly in the use of Automated Fiber Placement (AFP) machines that require a single head to trace the contour of components, limiting the speed and scalability of the manufacturing process.
Innovation Solution
A method and apparatus for assembly line fabrication of airframe components using fiber-reinforced broad goods, where sheets are cut into layup pieces, rotated, and synchronized across multiple stations to form a layup pattern, which is then placed and compacted onto a mandrel to create a composite preform, allowing for rapid preparation and hardening of parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single head AFP machine is used to trace the contour of airframe components, then manufacturing precision can be maintained, but productivity is limited and the process becomes labor-intensive
Solution Approach 1:
The patent divides the airframe component into multiple zones and uses multiple AFP heads to work simultaneously on different zones. Each head is responsible for a specific segment of the component, allowing parallel fabrication operations that significantly increase productivity while maintaining precision through dedicated control of each head
Solution Approach 2:
The patent transitions from a single-head sequential approach to a multi-head parallel approach by adding spatial dimensionality to the fabrication system. Multiple heads are positioned at different locations and angles, enabling simultaneous deposition on different portions of the component, effectively moving from one-dimensional sequential processing to multi-dimensional parallel processing
2Productivity
If hand-layup processes are used, then flexibility and adaptability are maintained, but labor intensity increases and efficiency decreases
Solution Approach 1:
The patent implements automated fiber placement systems that self-regulate and self-position multiple heads according to pre-programmed paths and parameters. The system automatically manages the complex coordination of multiple heads, resin delivery, and contour following without requiring manual intervention, thereby increasing efficiency while keeping the manufacturing process manageable through automation
Solution Approach 2:
The patent replaces manual hand-layup mechanical operations with automated AFP machine systems. The mechanical actions of cutting, positioning, and placing fiber reinforcements are performed by automated mechanisms controlled by computer systems, eliminating labor-intensive operations while maintaining or improving precision and efficiency
3Productivity
If broad goods are cut and arranged using synchronized multi-station operations, then productivity increases, but device complexity increases
Solution Approach 1:
The patent divides the layup preparation process into distinct segments handled by separate stations: cutting station for trimming broad goods, rotation station for orienting pieces, and assembly station for arranging pieces into layup patterns. This segmentation allows each station to specialize in one function and operate in parallel, increasing overall productivity while managing complexity through functional decomposition
Solution Approach 2:
The patent performs preliminary actions at dedicated stations before final assembly: broad goods are pre-cut to required dimensions at the cutting station, pre-rotated to correct orientations at the rotation station, and pre-positioned on carriers. These preliminary preparations are done in advance and in parallel, reducing the complexity and time of the final assembly operation
Data Source
AI summary
A method for fabricating a preform for a portion of an aircraft includes acquiring a sheet of broad good fiber reinforced material, trimming the sheet to form layup pieces having boundaries, placing the boundaries into alignment, arranging the layup pieces in a layup pattern to form a ply, performing a placement operation that transports the layup pattern onto a layup mandrel, and shaping the layup pattern into conformance with a contour of the layup mandrel.