Reconfigurable Universal Dies for Composite Stringer Forming
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Solution Overview
Problem
The existing methods for forming composite stringers require unique and costly tool dies for different shapes, leading to high manufacturing expenses and labor-intensive die changes, limiting efficiency and throughput.
Innovation Solution
A reconfigurable forming apparatus using universal dies with flexible components and automated die-changing mechanisms, allowing quick adaptation to produce various stringer shapes without the need for multiple sets of uniquely configured dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If unique tool dies are used for different stringer shapes, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements a universal die system where a single base die can be used across multiple stringer shapes. The die is designed with modular components that can be reconfigured, allowing one die to serve multiple functions for different stringer cross-sections, thereby reducing the total number of unique dies required while maintaining manufacturing precision
Solution Approach 2:
The die structure is divided into segmented or modular components that can be independently adjusted or reconfigured. This segmentation allows the same base die to be adapted for different stringer shapes by changing or repositioning specific die segments, reducing device complexity while preserving shape accuracy
2Manufacturing precision
If multiple sets of uniquely configured dies are used, then manufacturing precision is improved, but loss of time increases due to die changes
Solution Approach 1:
By implementing a universal die that can produce multiple stringer shapes through reconfiguration, the patent eliminates the need to change entire die sets between different stringer types. The die can be adapted in-place, significantly reducing die change time while maintaining the precision required for different stringer geometries
Solution Approach 2:
The die system is designed with pre-configured modular components that can be quickly swapped or repositioned. This preliminary preparation of modular elements allows for rapid reconfiguration during die changes, minimizing production downtime while ensuring precision is maintained through pre-engineered positioning features
3Manufacturing precision
If multiple sets of uniquely configured dies are used, then manufacturing precision is improved, but loss of time increases due to labor requirements
Solution Approach 1:
The universal die system reduces the number of unique dies that need to be stored, handled, and installed. Fewer die sets mean less labor time spent on die management and changes, while the modular reconfiguration capability maintains the precision required for different stringer shapes
Solution Approach 2:
The die system incorporates self-aligning and self-latching features that reduce the skill level and time required for die changes. The modular components are designed to be easily reconfigured with minimal manual intervention, automatically positioning themselves to maintain precision without requiring extensive skilled labor
Data Source
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AI summary
Composite laminate stiffeners such as stringers (44) are punch formed between first (62) and second universal dies (57) respectively carried on first (84) and second trays (86). The second tray (86) is mounted for sliding movement relative to the first tray (84) between a punch position (87) and a compaction position (95). Parts of the first and second dies (62, 57) are easily reconfigurable, allowing different shapes of stiffeners (44) to be formed on the same forming apparatus.