Abstract:
An aircraft part manufacturing device for automated composite lamination on a mandrel surface of a tool having a rotational axis includes a mechanical supporting structure that supports multiple material delivery heads. The tool is moveable and rotatable relative to the mechanical supporting structure. The mechanical supporting structure provides for axial translation of the material delivery heads relative to the mandrel surface while the mandrel surface is rotated for laying down courses of composite material over the entire mandrel surface of the tool. The position and movement of each of the plurality of material delivery heads is individually adjustable. Arm mechanisms provide motion of each material delivery head in a direction normal to the mandrel surface; rotation about an axis normal to the mandrel surface; circumferential position adjustment in a hoop direction relative to the mandrel surface; and axial position adjustment relative to the other material delivery heads.
Abstract:
An aircraft part manufacturing device for automated composite lamination on a mandrel surface of a tool having a rotational axis includes a mechanical supporting structure that supports multiple material delivery heads. The tool is moveable and rotatable relative to the mechanical supporting structure. The mechanical supporting structure provides for axial translation of the material delivery heads relative to the mandrel surface while the mandrel surface is rotated for laying down courses of composite material over the entire mandrel surface of the tool. The position and movement of each of the plurality of material delivery heads is individually adjustable. Arm mechanisms provide motion of each material delivery head in a direction normal to the mandrel surface; rotation about an axis normal to the mandrel surface; circumferential position adjustment in a hoop direction relative to the mandrel surface; and axial position adjustment relative to the other material delivery heads.
Abstract:
A method is provided for making a composite laminate aircraft skin for a fuselage in multiple composite panels. A resin-impregnated composite tape is placed on a lay-up surface of a mandrel tool to form the composite laminate aircraft skin as a barrel that is substantially the shape of a fuselage section. The barrel is cut into a plurality of panels on the mandrel tool, and at least one panel of the plurality of panels is transferred, individually and independently of all other of the plurality of panels, from the lay-up surface of the mandrel tool to a first cure tool of a plurality of cure tools having an aero surface tooled to an outer mold line. The at least one of the panels is cured on the first cure tool to form a cured composite panel. The first cure tool defines and controls the outer mold line of the at least one panel. The cured composite panel is removed from the first cure tool.
Abstract:
A method of transferring an uncured composite laminate skin from a lay-up surface of a male mandrel tool to a female cure tool includes defining multiple vacuum zones on the lay-up surface, each zone corresponding to one of a multiple of portions into which the skin is to be separated. For example, to separate the skin into two portions, a low profile seal of a first membrane to the lay-up surface is formed at a first vacuum zone and a second low profile seal for a second membrane is formed at a second vacuum zone. The method further includes laying up a composite laminate skin over all the vacuum zones; separating the composite laminate skin into portions, for example, a first portion over the first vacuum zone and a second portion over the second vacuum zone; and releasing the portions individually into cure tools having an outside mold line surface.
Abstract:
A composite structure is fabricated by laying up at least one ply of fiber reinforcement and at least one layer of resin on a tool. The resin film layer is formed by laying strips of resin film. The fiber reinforcement is infused with resin from the resin layer.
Abstract:
A method for fabricating a grid-stiffened structure from fiber-reinforced composite materials. A skin is applied to a smooth, hard base tool. Ribs comprised of carbon-fiber tows are formed on the skin, and shallow cavities are formed between the ribs and the skin. An expansion block is placed in each of the cavities, and is held in place by an elastomeric contact adhesive having adhesive properties that are substantially diminished when the adhesive is heated to an elevated curing temperature. The assembly is then autoclave cured. After cooling, the formed structure is separated from the base tool and the expansion blocks are removed from the cavities. A grid-stiffened sandwich structure is formed by applying an outer skin over the ribs and expansion blocks, before curing the assembly. After cooling, the outer skin is removed to allow extraction of the blocks, and subsequently bonded to the ribs.
Abstract:
A method for fabricating a grid-stiffened structure from fiber-reinforced composite materials. Ribs are formed on a smooth hard base tool. Expansion blocks are placed in the shallow cavities formed by the ribs and the base tool, and held in place by a synthetic elastomer-based adhesive while a skin is placed over the ribs, expansion blocks, and base tool. The assembly is then placed in a vacuum bag and autoclave cured. After cooling, the expansion blocks are removed and the formed structure is removed from the hard base tool. This abstract is provided to comply with the rules requiring an abstract, and is intended to allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
Abstract:
A method for fabricating a grid-stiffened structure from fiber-reinforced composite materials. Ribs are formed on a smooth hard base tool. Expansion blocks are placed in the shallow cavities formed by the ribs and the base tool, and held in place by one of several means while a skin is placed over the ribs, expansion blocks, and base tool. The assembly is then placed in a vacuum bag and autoclave cured. After cooling, the formed structure is separated from the base tool and the expansion blocks are removed from the cavities. This abstract is provided to comply with the rules requiring an abstract, and is intended to allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.
Abstract:
Systems and methods for the dynamic control of task assignments in a fabrication process that employs a plurality of machines to fabricate a manufactured component. These systems and methods may include executing a plurality of task assignments with an available portion of the plurality of machines, monitoring a process variable that defines the available portion of the plurality of machines, and adjusting the plurality of task assignments to create a plurality of adjusted task assignments based upon the monitoring. The plurality of task assignments may include a plurality of tasks that are to be completed during fabrication of the manufactured component, and the executing may include initiating a respective task assignment of the plurality of task assignments with each machine in the available portion of the plurality of machines, thereby fabricating at least a portion of the manufactured component.
Abstract:
A method for fabricating a grid-stiffened structure from fiber-reinforced composite materials. A skin is applied to a smooth, hard base tool. Ribs comprised of carbon-fiber tows are formed on the skin, and shallow cavities are formed between the ribs and the skin. An expansion block is placed in each of the cavities, and is held in place by an elastomeric contact adhesive having adhesive properties that are substantially diminished when the adhesive is heated to an elevated curing temperature. The assembly is then autoclave cured. After cooling, the formed structure is separated from the base tool and the expansion blocks are removed from the cavities. A grid-stiffened sandwich structure is formed by applying an outer skin over the ribs and expansion blocks, before curing the assembly. After cooling, the outer skin is removed to allow extraction of the blocks, and subsequently bonded to the ribs.