Rotatable Composite Stringer Tooling for Space-Efficient Layup
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Solution Overview
Problem
Conventional methods for manufacturing composite stringers require separate layup and cure tools, leading to high capital costs, large space requirements, limited access for vacuum bagging, and difficulties in removing cured stringers and cleaning tools, necessitating a more efficient and space-saving solution.
Innovation Solution
A tooling apparatus with independently rotatable elongated dies that form a composite stringer by rotating into side-by-side relation, allowing for back-to-back mating of stringer layup halves, vacuum bagging, and easy removal and cleaning, while reducing the footprint for increased production capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate layup and cure tools are used, then the manufacturing process can be divided into distinct stages, but capital costs increase and floor space requirements increase
Solution Approach 1:
The patent combines the layup tool and cure tool into a single integrated apparatus. The layup tool includes a layup surface for forming composite stringer halves and a cure surface for curing them, eliminating the need for separate tools and reducing floor space requirements while maintaining distinct manufacturing stages
2Reliability
If conventional cure tools are used, then curing can be performed, but access for vacuum bagging is limited
Solution Approach 1:
The cure surface is configured to be movable relative to the layup surface, allowing the cure tool to be positioned in different locations. This enables the vacuum bag to be applied to the composite stringer layup from an end of the layup tool, providing improved access for vacuum bagging while maintaining the curing function
3Reliability
If conventional cure tools are used, then curing can be performed, but removal of cured stringers and cleaning is difficult
Solution Approach 1:
The cure surface is configured to be movable relative to the layup surface, allowing the cure tool to be repositioned. After curing, the cure tool can be moved to a different location, providing improved access for removing the cured composite stringer and cleaning the layup surface, thereby facilitating easier maintenance and preparation for the next layup
4Productivity
If multiple tooling apparatuses are positioned in an autoclave, then production rate increases, but the footprint of each apparatus must be minimized
Solution Approach 1:
By combining the layup and cure tools into a single integrated apparatus with a reduced footprint, multiple tooling apparatuses can be positioned inside an autoclave simultaneously for curing composite stringer layups, thereby increasing production rate
Solution Approach 2:
The apparatus is designed with a compact configuration that minimizes its footprint, allowing it to be efficiently arranged within the autoclave volume. The movable cure surface allows the apparatus to assume different configurations (e.g., side-by-side or end-to-end) to optimize space utilization
Data Source
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AI summary
A tooling apparatus (200) may include a pair of elongated tooling dies (226) independently rotatable about a common central axis (220). Each tooling die (226) may have a layup surface (234) including a web layup surface (236) and at least one flange layup surface (238) oriented non-parallel to the web layup surface (236) and configured to receive at least one composite ply (136) to form a stringer layup half (150, 160) having a web (122) and at least one flange (124). The tooling dies (226) may be rotatable into side-by-side relation causing the webs (122) of the stringer layup halves (150, 160) to be positioned in back-to-back mating contact with one another.