Stringer Ply Splicing for Stiffness and Gap Elimination
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The construction of stringer sheets in aircraft and vehicle components faces challenges due to changes in ply layer dimensions when forming around contours, leading to gaps and increased weight from overlapping edges, which affects the structural integrity and stiffness of the final product.
Innovation Solution
A method and system for splicing ply layers by overlapping and staggering them on a tool surface with contours, ensuring edges are pressed into concavities to maintain desired dimensions and increase thickness within stringers, thereby enhancing stiffness and strength without adding unnecessary weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If plies are pressed into contours to form stringers, then the stringer shape is achieved, but the ply width changes and gaps occur between adjacent sheets
Solution Approach 1:
The patent divides the continuous ply into multiple separate plies that are positioned adjacent to each other. Each ply is independently laid and pressed into the contour, allowing precise control of each segment's width while maintaining the overall stringer shape. This segmentation resolves the contradiction by enabling individual ply width control without affecting adjacent plies.
Solution Approach 2:
The patent applies different width characteristics to different regions of the ply layout. The plies are configured with specific widths tailored to their local position on the contour, ensuring optimal fit and eliminating gaps. This local quality approach allows each ply to be precisely adapted to its specific location while maintaining overall structural integrity.
2Manufacturing precision
If edges of adjacent sheets are overlapped, then gaps between sheets are eliminated, but additional thickness is added which increases weight
Solution Approach 1:
Instead of overlapping edges, the patent uses adjacent segmentation where plies are placed edge-to-edge without overlap. This eliminates the additional thickness and weight associated with overlapping while still achieving gap-free coverage through precise positioning and width control of each individual ply.
3Area of stationary object
If a single large sheet spans multiple stringers, then coverage is complete, but the entire sheet moves when pushed into contours causing dimensional changes
Solution Approach 1:
The patent divides the large continuous sheet into multiple smaller adjacent plies. Each small ply is independently positioned and pressed into the contour, preventing the dimensional changes and movement that occur with large sheets. This segmentation maintains complete coverage while ensuring dimensional stability through localized control.
Solution Approach 2:
The patent enables dynamic positioning and adjustment of each individual ply during the forming process. Each ply can be independently manipulated and secured to the contour, allowing adaptive positioning that maintains dimensional stability throughout the forming operation, unlike rigid large sheets that move as a single unit.
Data Source
AI summary
A system and method for splicing multiple plies of material together during the construction of a stringer sheet. A first ply layer is laid onto a portion of a surface of a tool having a contour which defines a stringer, and the first ply layer is pressed down such that an edge of the first ply layer is located on the contour. A second ply layer is laid onto an adjacent portion of the surface, and the second ply layer is pressed down such that the edge of the second ply layer is located on the contour and overlaps the edge of the first ply layer. This process may be repeated for additional ply layers. The system may include an end-effector having a dispenser of the plies of material and a roller for pressing the plies, and a movement mechanism for moving the end-effector over the tool.