Composite Stringer Handling Headers for Twist and Skew Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite fabrication processes for stringers in large structures like aircraft wings are time-consuming and expensive due to manual handling and lack of efficient methods to apply twist or skew, leading to undesired wrinkling and deformation.
Innovation Solution
An automated handling system with a rigid frame and movable handling headers that grip and lift longitudinal components, allowing simultaneous application of twist and skew to match the geometry of the target surface, using coordinated movement and stress distribution to prevent wrinkling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling methods (carts or overhead cranes) are used for composite stringers, then handling flexibility is maintained, but handling time increases and costs increase
Solution Approach 1:
The patent replaces traditional mechanical handling systems (overhead cranes and carts) with an automated robotic handling system that uses programmable controllers and automated grippers to manipulate composite stringers. This substitution eliminates manual operations, significantly reducing handling time and costs while maintaining precision through automated control systems.
2Ease of manufacture
If general contour geometries are applied to stringers during fabrication, then manufacturing simplicity is maintained, but twist or skew cannot be applied
Solution Approach 1:
The patent employs dynamic, adjustable support rollers that can be positioned at various locations along the stringer length and independently adjusted to apply specific angles of twist or skew. This dynamic adjustment capability allows the same fabrication system to handle both simple contour geometries and complex twisted/skewed geometries, providing versatility without sacrificing manufacturing ease.
3Device complexity
If uncured or partially cured stringers are handled manually, then handling equipment simplicity is maintained, but time consumption increases and costs increase
Solution Approach 1:
The patent replaces simple but inefficient manual handling equipment with an automated robotic system that uses programmable controllers, automated grippers, and coordinated motion systems. This increase in device complexity is justified by the substantial improvement in manufacturing efficiency, as the automated system can rapidly and precisely manipulate multiple stringers simultaneously without the time consumption and high costs associated with manual handling.
4Manufacturing precision
If automated handling system with multiple movable headers is used, then productivity increases and manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent divides the handling system into multiple independent, movable headers, each equipped with its own grippers and support rollers. This segmentation allows each header to independently apply specific conformations (twist, skew, contour) to different sections of the stringer, achieving high manufacturing precision through distributed, coordinated control while managing overall system complexity through modular architecture.
Data Source
AI summary
A method and a handling system for imparting a desired longitudinal conformation into a longitudinal component are presented. The handling system comprises a rigid frame and a plurality of handling headers movably connected to the rigid frame. The plurality of handling headers is configured to grip a longitudinal component, lift the longitudinal component, and cooperatively move to impart the desired longitudinal conformation into the longitudinal component.