Weight-Neutral Holding Fixture for Composite Stringer Bonding
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Solution Overview
Problem
The aircraft industry faces challenges in efficiently processing elongate members like composite stringers during adhesive bonding, requiring manual labor that is labor-intensive, time-consuming, and prone to errors, with a need for a system that reduces manual handling and improves process flow.
Innovation Solution
A modular holding fixture with linear actuators that adjusts the vertical position of elongate members to a weight-neutral state, combined with a material applicator that uses pinch rollers and a heater to apply adhesive film consistently, reducing the need for manual labor and fixture clamps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual labor is used to hold and manipulate the stringer during adhesive bonding, then flexibility and adaptability are maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The stringer support system automatically adjusts and maintains the stringer in a weight-neutral position through self-adjusting support rollers and positioning mechanisms, eliminating the need for continuous manual manipulation while maintaining operational flexibility throughout the adhesive bonding process
Solution Approach 2:
Manual mechanical manipulation of the stringer is replaced with an automated support system comprising adjustable support rollers, positioning fixtures, and height-adjustment mechanisms that automatically maintain the stringer in the desired weight-neutral position during adhesive application
2Stability of the object's composition
If fixture clamps are used to hold the stringer, then positioning stability is improved, but the risk of damage to edges increases and manual labor is still required
Solution Approach 1:
The harmful clamping function is extracted and replaced with a non-contact support system using rollers and friction-based positioning mechanisms that maintain stringer stability without applying concentrated forces that could damage the edges or composite structure
Solution Approach 2:
The support system uses compliant support elements and friction-based positioning that gently constrain the stringer without rigid clamping, preventing edge damage while maintaining positioning stability throughout the adhesive bonding process
3Manufacturing precision
If the stringer is held in a fixed position during adhesive application, then consistency of adhesive placement is improved, but the system complexity and setup time increase
Solution Approach 1:
The support system creates a weight-neutral equilibrium position for the stringer where gravitational forces are balanced by the support mechanisms, allowing the stringer to remain stable and consistent during adhesive application without requiring complex active positioning or control systems
Solution Approach 2:
The system achieves precise positioning by adjusting support heights and positions to create optimal weight-neutral conditions, using simple parameter adjustments rather than complex mechanical fixtures or active control systems
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
The system significantly reduces manual labor requirements, improves process flow times, and ensures consistent adhesive application to elongate members, minimizing damage and errors while accommodating varying lengths.
Implementation Method 1
The holding fixture may include linear actuators that adjust the vertical position of the stringer such that it is weight neutral
Implementation Method 2
The material applicator may include a heater for heating a surface of the elongate member
Implementation Method 3
The material applicator includes pinch rollers capable of holding the elongate member in a substantially weight neutral condition on the elongate member support surface area
Data Source
AI summary
A holding system holds an elongate member in a desired position as a process operation is carried out on the member. The elongate member is held in a weight neutral position in a holding fixture without the need for clamps.