Non-Rotating Tooling Tablet for Automated Fiber Placement

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Solution Overview

Problem

The use of rotating mandrels in automated fiber placement machines increases cycle times and costs due to the need to heat the mandrel for curing, limits the ability to form non-symmetrical or planar parts, and results in material waste when trying to remove the mandrel from complex shapes.

Innovation Solution

A non-rotating tooling tablet with oppositely facing surfaces is used, allowing pre-impregnated fibers or tapes to be applied to form composite structures, which can then be cured in an autoclave without the need for a rotating mandrel, enabling the formation of complex shapes like aircraft wing skins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a rotating mandrel is used for automated fiber placement, then cylindrical parts can be formed efficiently, but cycle time increases due to heating the mandrel for curing

Engineering Contradiction:

Improvecycle timeVSAvoidenergy for heating mandrel

Core Design Contradiction:

ProductivityVSUse of energy by stationary object

Solution Approach 1:

The patent extracts the mandrel from the curing process by using a mandrel-less forming approach. The composite structure is formed directly on a tool surface without requiring a rotating mandrel to be heated in the autoclave, thereby eliminating the energy-intensive heating of a large mass object while maintaining the ability to form curved surfaces

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of heating the mandrel to cure the composite, the patent inverts the approach by heating only the composite material directly on the tool surface. This reverses the traditional sequence where the mandrel serves as the heating medium, and instead uses the tool surface as a passive form that requires minimal thermal mass

Inventive Principle:

Principle #13The other way round (Inversion)

2Adaptability or versatility

If a rotating mandrel is used, then full revolution parts can be manufactured, but non-symmetrical and planar parts cannot be formed

Engineering Contradiction:

Improveability to form various part geometriesVSAvoidmandrel rotation mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent inverts the traditional approach by making the tool surface movable rather than rotating the mandrel. The tool surface can be positioned and oriented in different configurations to form planar, curved, or complex geometries, eliminating the need for rotational symmetry and enabling versatile part formation without complex rotation mechanisms

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent employs dynamic positioning of the tool surface that can be adjusted during the fiber placement process. This allows the same tooling system to adapt to different part geometries including planar wings, curved fuselages, and complex structures by dynamically repositioning the tool surface rather than requiring different fixed mandrels

Inventive Principle:

Principle #15Dynamics

3Ease of manufacture

If a rotating mandrel is used for complex shapes, then parts can be cured, but mandrel removal becomes difficult and material waste increases

Engineering Contradiction:

Improvepart removal from toolingVSAvoidmaterial waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent extracts the mandrel from the process entirely, forming the composite structure directly on a tool surface that can be easily separated. This eliminates the removal difficulties associated with mandrels embedded in complex shapes and prevents material waste that occurs when mandrels prevent complete utilization of the formed structure

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent segments the tooling system into a separable tool surface that can be easily detached from the cured composite structure. This segmentation allows the tool surface to be removed cleanly without damaging the part or requiring excessive material clearance, thereby reducing material waste

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method reduces cycle times, eliminates unnecessary costs, and allows for the efficient formation of composite structures with complex geometries, such as aircraft wing skins, by eliminating the need for a rotating mandrel and simplifying the manufacturing process.

Implementation Method 1

an automated placement head for placing pre-impregnated fiber or pre-impregnated tape onto a tool surface of a tooling tablet

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 2

the tablet, with the pre-impregnated composite material deposited on the tooling surface thereof, is placed into an autoclave for curing of the composite structure

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS8003034B2Forming a composite structure by filament placement on a tool surface of a tablet

Publication Date: 2011.08.23 INGERSOLL MACHINE TOOLS INC

AI summary

A method and apparatus are provided for forming a composite structure with an automatic placement head, through the use of a non-rotating tooling tablet having first and second substantially oppositely facing surfaces thereof, joined around the peripheries thereof by a side surface of the tablet, with at least one of the first or second surfaces forming a tool surface of the tablet. Layers of pre-impregnated fiber or tape are applied to the tool surface of the tablet by the automated fiber placement head.