Robotic Out-of-Autoclave Composite Repair System
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Solution Overview
Problem
Current methods for repairing damaged composite aircraft structures require multiple handling steps and lack the capability to both remove and restore damaged parts in situ efficiently, particularly in out-of-autoclave procedures.
Innovation Solution
A system comprising a fixing structure, a movable structure with rotating shafts for three-dimensional movement, and a patch manufacturing structure, allowing for scanning, removal, and in-situ restoration of damaged composite parts using tools like milling and patch cutting tools, enabling efficient in-service and production bonded repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional composite repair methods are used, then damaged parts can be restored, but multiple handling steps increase complexity and time required for repairs
Solution Approach 1:
The patent combines multiple repair operations (scanning, milling, patch manufacturing, and installation) into a single integrated robotic system. The robotic arm performs scanning to create a digital model, mills the damaged area, manufactures the patch, and installs it all in one continuous process, eliminating multiple handling steps and reducing complexity.
Solution Approach 2:
The robotic system is designed with multi-functionality, capable of performing scanning, material removal, patch manufacturing, and installation operations. The system can adapt to different repair scenarios by loading appropriate tools and parameters, making it a universal repair platform that reduces the need for multiple specialized devices.
2Loss of time
If out of autoclave bonded repair is implemented, then repair time is reduced, but precision in damage removal and patch manufacturing becomes more challenging
Solution Approach 1:
The system incorporates scanning technology that creates a digital model of the damaged area, providing feedback for precise milling operations. The robotic arm uses this digital model to guide the milling process and patch manufacturing with high precision, ensuring accurate reproduction of the original geometry while maintaining fast out of autoclave bonding processes.
Solution Approach 2:
The patent replaces manual mechanical operations with automated robotic control. The robotic arm performs scanning, milling, and patch manufacturing with computer-controlled precision, eliminating the variability and time-consuming nature of manual operations while maintaining or improving precision through automated feedback control.
3Ease of operation
If in-situ repair capability is added, then handling of composite parts is minimized, but system complexity increases
Solution Approach 1:
The patent integrates scanning, milling, patch manufacturing, and installation capabilities into a single robotic system that can perform all operations in-situ. This consolidation eliminates the need to move parts between different equipment stations, minimizing handling while the integrated design manages system complexity through unified control.
Data Source
AI summary
A system for out of autoclave bonded repairs which including a fixing structure (1) to the composite area to be repaired, including a frame (4) and fixing parts (5, 19) attached to the frame (4), a movable structure (2) able to be attached either to the fixing structure (1) or to the patch manufacturing table (3), which includes three shafts (6, 6′, 6″) and three engines (7, 7′, 7″) configured to be able to move the tooling support in the three axes X, Y and Z, and a tooling support of either scanning tool (9), milling tool (10), patch cutting tool (11) or composite patch handle tool (11), and a patch manufacturing structure (3).