Segmented Mandrel for Composite Fuselage Assembly
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Solution Overview
Problem
Current manufacturing systems for large composite structures, such as aircraft fuselage sections, are complex and labor-intensive, requiring extensive fixtures and time-consuming assembly procedures, which can lead to inconsistencies and increased maintenance needs.
Innovation Solution
A segmented mandrel system comprising a frame, connected segments, and a seal system, where segments are indexed to the frame for precise alignment and sealed at joints to form an inner mold line for laying up and curing composite materials, reducing assembly time and inconsistencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rotating mandrel is used to lay up composite materials, then the composite structure can be formed, but the assembly procedure becomes more complex and labor-intensive
Solution Approach 1:
The mandrel is divided into multiple segments that can be independently assembled and disassembled. Each segment is a separate component that connects to form the complete mandrel structure, allowing for simplified assembly procedures compared to a monolithic rotating mandrel while maintaining the necessary structural integrity for composite fabrication.
2Manufacturing precision
If extensive fixtures are used to manufacture large composite structures, then the structure can be formed with precision, but the assembly procedure becomes more complex and time-consuming
Solution Approach 1:
By segmenting the mandrel into modular sections, the system achieves the necessary precision for large composite structures without requiring extensive fixed fixtures. Each segment can be precisely positioned and connected to maintain structural accuracy while enabling faster assembly and disassembly operations.
Solution Approach 2:
The segmented mandrel system transitions from static, fixed fixtures to a dynamic, reconfigurable structure. The segments can be quickly assembled and disassembled without requiring time-consuming adjustment procedures, allowing the system to adapt to different composite structure sizes and configurations while maintaining precision.
3Productivity
If multiple layers of pre-preg are applied to a rotating mandrel, then the composite structure can be formed, but the assembly procedure becomes more complex and labor-intensive
Solution Approach 1:
The segmented mandrel design simplifies the operation of applying multiple layers of pre-preg by allowing operators to access different sections of the mandrel independently. Each segment can be operated on separately, reducing the complexity of handling and applying multiple layers compared to a single large rotating mandrel.
Data Source
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AI summary
A method, apparatus, and system for forming a composite structure. A mandrel system comprises a frame, segments, a connection system, and a seal system. The segments are connected to the frame. The segments provide an inner mold line for a composite structure. The connection system connects the segments to the frame. The seal system seals segment-to-segment joints in locations where the segments are joined to each other.