Abstract:
Systems for forming composite parts, methods of forming composite parts, and methods of precisely performing a plurality of operations on a composite part. The systems include a layup mandrel that includes a mandrel body and a plurality of regions of isotropic surface finish. The methods of forming the composite part include positioning a plurality of plies of composite material on a layup mandrel, conforming the plurality of plies of composite material to a layup surface shape of the layup mandrel, and curing the plurality of plies of composite material. The methods of precisely performing the plurality of operations on a composite part include detecting a corresponding imprinted feature of a plurality of imprinted features, aligning an operating assembly of an end effector relative to the corresponding imprinted feature, and performing a corresponding operation of the plurality of operations on the composite part.
Abstract:
A manufacturing system includes a cutting machine, an adhesion machine, and a pick-and-place system. The cutting machine sequentially cuts a continuous length of a unidirectional prepreg into prepreg segments. Each prepreg segment has an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The adhesion machine has a conveyor belt and an adhesion station. The pick-and-place system sequentially picks up the prepreg segments from the cutting machine, and places the prepreg segments in end-to-end relation on the conveyor belt, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The conveyor belt feeds the prepreg segments to the adhesion station. The adhesion station adheres the prepreg segments to a continuous length of a backing material, thereby resulting in a continuous length of a backed cross-ply prepreg.
Abstract:
A method forms a multi-ply laminate. A first cutting system cuts and moves a first group of courses into staging positions. Placement robots pick up and place the first group of courses from the staging positions to a layup surface to form a first ply of the multi-ply laminate, changing an orientation of fibers from an initial orientation to a desired orientation for the first ply. A second cutting system cuts and moves a second group of courses into the staging positions while the placement robots are picking up and placing the first group of courses. The placement robots pick up and place the second group of courses from the staging positions to the layup surface to form a second ply of the multi-ply laminate after the first ply has been formed, changing the orientation of the fibers from the initial orientation to the desired orientation for the second ply.
Abstract:
A backing film removal system including a substrate support member configured to support a substrate, where a backing film is attached to the substrate, a backing film separating member arranged operatively with respect to the substrate support member such that at least a portion of the backing film separating member is positionable between at least one portion of the substrate and backing film when the substrate is disposed on the substrate support member, a backing film holding member configured to maintain a separation between the substrate and backing film at the at least one portion of the substrate and backing film, and at least one drive unit connected to one or more of the substrate support member and the backing film separating member and operable to cause relative movement between the substrate support member and the backing film separating member.
Abstract:
A method for initial separation of an adhered backing film from an uncured pre-impregnated composite lamina having an edge includes exposing and supporting the edge of the composite lamina, and applying an impact force to the exposed edge with an automated tool. The impact force is sufficient to cause delamination of the backing film from the composite lamina without damaging the lamina.
Abstract:
A method of manufacturing a backed cross-ply prepreg comprises cutting, using a cutting machine, a first continuous length of a unidirectional prepreg into first prepreg segments, each having an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The method also includes picking up, using a pick-and-place system, the first prepreg segments off of the cutting machine, and placing the first prepreg segments in end-to-end relation onto a conveyor belt of an adhesion machine, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The method also includes feeding, using the conveyor belt, the first prepreg segments to an adhesion station of the adhesion machine, and adhering, using the adhesion station, the first prepreg segments to a continuous length of a backing material.
Abstract:
A backing film removal system including a substrate support member configured to support a substrate, where a backing film is attached to the substrate, a backing film separating member arranged operatively with respect to the substrate support member such that at least a portion of the backing film separating member is positionable between at least one portion of the substrate and backing film when the substrate is disposed on the substrate support member, a backing film holding member configured to maintain a separation between the substrate and backing film at the at least one portion of the substrate and backing film, and at least one drive unit connected to one or more of the substrate support member and the backing film separating member and operable to cause relative movement between the substrate support member and the backing film separating member.
Abstract:
A method for initial separation of an adhered backing film from an uncured pre-impregnated composite lamina having an edge includes exposing and supporting the edge of the composite lamina, and applying an impact force to the exposed edge with an automated tool. The impact force is sufficient to cause delamination of the backing film from the composite lamina without damaging the lamina.
Abstract:
A method of manufacturing a backed cross-ply prepreg comprises cutting, using a cutting machine, a first continuous length of a unidirectional prepreg into first prepreg segments, each having an opposing pair of segment cut edges that are non-parallel to a lengthwise direction of the unidirectional prepreg. The method also includes picking up, using a pick-and-place system, the first prepreg segments off of the cutting machine, and placing the first prepreg segments in end-to-end relation onto a conveyor belt of an adhesion machine, and in an orientation such that the segment cut edges are generally parallel to a lengthwise direction of the conveyor belt. The method also includes feeding, using the conveyor belt, the first prepreg segments to an adhesion station of the adhesion machine, and adhering, using the adhesion station, the first prepreg segments to a continuous length of a backing material.
Abstract:
The magnetic handling systems comprise a bladder and a magnetic carriage system. The bladder is configured to be received within a stringer interior volume of a hat stringer and comprises a magnetic insert having a plurality of magnetic walls, each configured to align with a respective wall portion of the hat stringer. The magnetic carriage system comprises a carriage having a magnetic head that comprises a bracket and a plurality of magnetic sources supported by the bracket. Each magnetic source is configured to magnetically couple with a respective magnetic wall of the magnetic insert to produce an attractive magnetic force therebetween. The methods comprise disposing a bladder having a plurality of the magnetic inserts within the hat stringer, magnetically engaging a plurality of the magnetic heads with the plurality of magnetic inserts, and conforming the hat stringer by moving at least one magnetic head relative to another magnetic head.