Reconfigurable Mandrel for Composite Laminate Trimming and Forming
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Solution Overview
Problem
Conventional manufacturing methods for complex composite laminates face challenges such as the need for costly pick-and-place systems, accuracy issues due to partial support during trimming, and complexity in transferring composite laminates from trimming to forming surfaces.
Innovation Solution
A reconfigurable manufacturing system with a first and second mandrel, laminate securing and releasing mechanisms, allowing for continuous support and precise alignment during layup, trimming, and forming, eliminating the need for external pick-and-place systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pick-and-place system is used to transfer the composite laminate from the trimming surface to the forming surface, then the transfer capability is improved, but the device complexity and capital investment increase significantly
Solution Approach 1:
The patent combines the trimming surface and forming surface into a single integrated tool structure. The trimming surface is positioned on one side of the composite laminate while the forming surface is positioned on the opposite side, allowing both operations to be performed simultaneously without requiring separate transfer mechanisms. This merging eliminates the need for complex pick-and-place systems while maintaining operational capability.
Solution Approach 2:
The tool is designed with multi-functionality, serving both as a trimming surface and a forming surface through its dual-sided configuration. The same tool structure performs multiple functions (trimming and forming) by utilizing opposite faces of the composite laminate, thereby eliminating the need for separate dedicated tools for each operation.
2Ease of operation
If the composite laminate is transferred from the trimming surface to the forming surface, then the forming operation can be performed, but the positioning accuracy deteriorates due to disruption of vacuum pressure
Solution Approach 1:
By merging the trimming and forming operations into a single tool structure, the composite laminate remains continuously supported on the same tool throughout both operations. This eliminates the transfer step that causes vacuum pressure disruption and positioning accuracy loss, as the laminate never needs to be moved between separate tools.
Solution Approach 2:
The system maintains continuous support and vacuum pressure on the composite laminate throughout the entire process from trimming to forming. The useful action of holding the laminate in precise position continues uninterrupted, as both trimming and forming are performed while the laminate remains clamped to the same tool structure.
3Ease of manufacture
If the composite laminate is trimmed on a separate trimming surface before forming, then the trimming operation can be performed, but the device complexity increases due to multiple tools and transfer mechanisms
Solution Approach 1:
The patent merges the trimming function and forming function into a single dual-sided tool. The trimming surface and forming surface are integrated into one structure, allowing both operations to be performed on the same tool without requiring separate trimming tools, transfer mechanisms, or multiple tool changes.
Solution Approach 2:
The tool exhibits universality by performing both trimming and forming operations through its dual-sided design. One surface of the tool is configured for trimming while the opposite surface is configured for forming, allowing a single tool to replace multiple specialized tools and simplify the overall manufacturing system.
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 system enhances dimensional accuracy and reduces production costs by enabling trimming and forming on a single tool, maintaining composite laminate support and alignment throughout the process.
Implementation Method 1
A pick-and-place system is typically used to transfer the composite laminate from the trimming surface to the forming surface. However, pick-and-place systems require a significant capital investment to provide a machine that is capable of lifting the composite laminate, for example through the use of vacuum pressure
Implementation Method 2
forming the composite laminate by urging the composite laminate into the gap
Data Source
Figure 1
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AI summary
A manufacturing system includes a first mandrel (130), a second mandrel (150), and laminate securing mechanisms (190). The first mandrel (130) has a first mandrel surface (132) and a first mandrel surface edge (134). The second mandrel (150) has a second mandrel surface (152) and a second mandrel surface edge (154), and is positionable in a closed position in which the first mandrel surface edge and the second mandrel surface edge are in contact to form a continuous mandrel surface (162) collectively defined by the first mandrel surface and the second mandrel surface. The second mandrel translates to an open position defining a gap (166) between the first mandrel surface edge and the second mandrel surface edge for receiving a forming die (352,362). The laminate securing mechanisms (190) secure the composite laminate (400) on at least one of the first mandrel and the second mandrel during trimming and/or forming of the composite laminate.