Variable Thickness Composite Spar Braiding
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Solution Overview
Problem
Conventional composite spar manufacturing techniques, such as the ply-drop method, are costly, labor-intensive, and prone to defects when producing complex shapes with varying thicknesses, leading to potential delamination and stress points due to resin pockets and braided fibre misalignment.
Innovation Solution
A method and apparatus using a braiding machine with a non-cylindrical mandrel and variable position shuttle to create a variable thickness composite spar component by braiding fibers, flattening, and cutting the preform, eliminating the need for the ply-drop technique and allowing for automated production without skilled operator dependency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the ply-drop technique is used to manufacture composite spars with varying thickness, then complex shapes can be formed, but the manufacturing process becomes labor-intensive, costly, and slow
Solution Approach 1:
The patent replaces the manual mechanical ply-drop technique with an automated braiding machine system. The braiding machine uses mechanical automation to lay down fibers in the desired pattern, eliminating the need for skilled operators to manually place and shape fabric layers. This substitution of manual mechanical work with automated mechanical systems directly addresses the productivity issue while maintaining the ability to create complex varying thickness shapes.
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from manual layer-by-layer fabric placement to automated fiber braiding. By transitioning from a process controlled by operator skill to one controlled by machine parameters (braiding pattern, tension, speed), the manufacturing speed and consistency are dramatically improved while still achieving the required complex geometries.
2Shape
If the ply-drop technique is used to manufacture composite spars, then complex shapes can be formed, but the manufacturing costs increase due to expensive materials and skilled labor
Solution Approach 1:
The patent replaces the manual mechanical ply-drop technique with an automated braiding machine system. The braiding machine uses mechanical automation to lay down fibers in the desired pattern, eliminating the need for skilled operators to manually place and shape fabric layers. This substitution of manual mechanical work with automated mechanical systems directly addresses the productivity issue while maintaining the ability to create complex varying thickness shapes.
Solution Approach 2:
The patent employs a disposable or consumable mandrel system that can be easily removed after braiding. The mandrel serves its purpose during manufacturing and is then discarded or reused, eliminating the need for expensive, precision-machined tooling that would be required for traditional molding methods. This reduces the capital equipment cost while maintaining the ability to produce complex shapes.
3Shape
If the ply-drop technique is used to manufacture composite spars, then complex shapes can be formed, but the quality control becomes difficult due to resin pockets and fibre misalignment
Solution Approach 1:
The patent replaces the manual mechanical ply-drop technique with an automated braiding machine system. The braiding machine uses mechanical automation to lay down fibers in the desired pattern, eliminating the need for skilled operators to manually place and shape fabric layers. This substitution of manual mechanical work with automated mechanical systems directly addresses the productivity issue while maintaining the ability to create complex varying thickness shapes.
Solution Approach 2:
The braiding process is self-regulating in terms of fiber placement and tension control. The machine automatically maintains consistent fiber tension and spacing throughout the braiding process, eliminating the variability introduced by manual operations. The system monitors and adjusts parameters automatically, ensuring consistent quality without requiring continuous human intervention or inspection.
Data Source
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AI summary
According to one aspect, the present invention relates to a method 200 of manufacturing at least one non-uniform thickness composite spar component 152. The method comprises braiding 202 a plurality of fibres 126 over a non-cylindrical mandrel 140 to form a variable thickness shaped fibre preform 150, flattening the shaped fibre preform 150 and cutting the flattened shaped fibre preform 150 to obtain the at least one non-uniform thickness composite spar component 152. Spars 152 made according to various embodiments of the present invention are faster and less expensive to manufacture than conventional composite spar components.