Patent Description:
A composite structure is typically formed by placing plies or layers of composite material on a forming tool that sets forth the shape and/or contour of the composite structure. Once placed, composite material is then consolidated and/or cured to form the composite structure. However, known techniques for transporting a composite material to a forming tool, placing a composite material on a forming tool, and consolidating a composite material on a forming tool may be labor-intensive and time-consuming. Additionally, depending upon the degree of contour and geometry of the composite structure, special handling may be required to prevent introduction of defects during transfer and placement of the composite material. Document <CIT>, according to its abstract, states an apparatus and a method for producing a hollow structural component formed from a fibre composite plastic for a vehicle, in which a tube formed from the fibre composite plastic, from which the hollow structural component is produced, is held at points spaced apart from one another along the tube by means of respective robots, which each have a plurality of robot arms which are connected to one another in an articulated manner and are movable relative to one another, while the tube is heated in at least one partial region by means of a heating device, wherein the tube is bent into a two-dimensional or three-dimensional shape at least in the heated partial region by bending the tube, which is held during bending by means of the robots, around a bending head in the partial region by means of at least one of the robots. Accordingly, those skilled in the art continue with research and development efforts in the field of composite manufacturing.

According to the present disclosure, a method as defined in independent claim <NUM> and a system as defined in independent claim <NUM> are provided. Although the scope is only defined by the claims, the below embodiments, examples, and aspects are present for aiding in understanding the background and advantages.

Disclosed are examples of a method for shaping a composite structure, a system for forming a composite structure, and an automated method for shaping a composite structure. The following is a non-exhaustive list of examples, which may or may not be claimed, of the subject matter according to the present disclosure.

In an example, the disclosed method includes steps of: (<NUM>) holding a composite member in an initial contour along a length of the composite member; and (<NUM>) forming a final contour along the length of the composite member by:(<NUM>) sequentially shaping unformed portions of the composite member into formed portions of the composite member while holding remaining unformed portions of the composite member in the initial contour to form portions of the final contour; and (<NUM>) sequentially shaping the remaining unformed portions of the composite member to form other portions of the final contour.

In an example, the disclosed system includes a plurality of automated manipulators configured to manipulate a composite member. The system also includes a controller configured to execute instructions. Execution of the instructions causes the controller to perform operations using the automated manipulators. The operations including:(<NUM>) holding the composite member in an initial contour along a length of the composite member; (<NUM>) placing the composite member on a place tool; and (<NUM>) forming a final contour along the length of the composite member while placing the composite member on the place tool by: (<NUM>) sequentially shaping unformed portions of the composite member into formed portions of the composite member while holding remaining unformed portions of the composite member in the initial contour to form portions of the final contour; and (<NUM>) sequentially shaping the remaining unformed portions of the composite member to form other portions of the final contour.

In an example, the disclosed automated method includes steps of: (<NUM>) using a plurality of automated manipulators to hold a composite member in an initial contour along a length of the composite member; and (<NUM>) synchronizing motion of the automated manipulators to form a final contour along the length of the composite member, wherein the final contour is formed by: (<NUM>) sequentially shaping unformed portions of the composite member into formed portions of the composite member on a place tool while holding remaining unformed portions of the composite member in the initial contour to form portions of the final contour; and (<NUM>) sequentially shaping the remaining unformed portions of the composite member on the place tool to form other portions of the final contour.

Other examples of the disclosed method, system, and automated method will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

Referring generally to <FIG>, the present disclosure is directed to methods and systems for shaping composite structures. More particularly, the present disclosure is directed to a method <NUM> (<FIG>), a system <NUM> (<FIG>), and an automated method <NUM> (<FIG>) for retrieving a composite member <NUM>, having an initial contour <NUM>, and forming the composite member <NUM> into a desired, final contour <NUM> while placing the composite member <NUM>.

For the purpose of the present disclosure, the composite member <NUM> includes or is formed from an uncured composite material <NUM>. For the purpose of the present disclosure, the composite structure <NUM> includes or is formed by a cured composite material. In other words, the composite structure <NUM> refers to the composite member <NUM> after a curing operation.

Referring briefly to <FIG>, the uncured composite material <NUM> includes any suitable base materials used in composite manufacturing. Generally, the uncured composite material <NUM> and, thus, the cured composite material, includes a fiber reinforcement <NUM> and a matrix <NUM>. In one or more examples, the uncured composite material <NUM> may also include one or more additives, such as, but not limited to, thermoplastic toughening additives, curing agents, binders, and the like.

In one or more examples, the uncured composite material <NUM> includes the fiber reinforcement <NUM> that is impregnated with the matrix <NUM>, also referred to as a pre-preg. In these examples, the fiber reinforcement <NUM> is impregnated (e.g., pre-impregnated) with the matrix <NUM> before the placement on a forming tool (e.g., a place tool <NUM>).

In one or more examples, the uncured composite material <NUM> includes the fiber reinforcement <NUM> without the matrix <NUM>, also referred to dry fiber. In these examples, the fiber reinforcement <NUM> is infused with the matrix <NUM> after placement of the uncured composite material <NUM> on a forming tool (e.g., the place tool <NUM>).

The fiber reinforcement <NUM> includes any suitable type of reinforcement material, such as carbon fiber, glass fiber, aramid fiber, etc., having any suitable form, such as woven, nonwoven, fabric, tape, etc. The matrix <NUM> includes any suitable type of the matrix material, such as resin, epoxy, polymer, thermoplastic, thermoset, etc..

Referring still to <FIG>, the composite member <NUM> can take any one of various forms. In one or more examples, the composite member <NUM> includes a ply <NUM> of the uncured composite material <NUM>. As an example, the ply <NUM> is a single layer of the fiber reinforcement <NUM> pre-impregnated with the matrix <NUM>. As another example, the ply <NUM> is a single layer of the (e.g., dry) fiber reinforcement <NUM>.

In one or more examples, the composite member <NUM> includes a laminate <NUM> of the uncured composite material <NUM>. As an example, the composite member <NUM> includes a plurality of plies <NUM>. In one or more examples, the laminate <NUM> is laid up or otherwise formed on a forming tool (e.g., the place tool <NUM>). As an example, the laminate <NUM> is a wet layup (e.g., plies <NUM> of the fiber reinforcement <NUM> pre-impregnated with the matrix <NUM>). As another example, the laminate <NUM> is a dry layup (e.g., plies <NUM> of the fiber reinforcement <NUM> without the matrix <NUM>).

In one or more examples, the composite member <NUM> includes an assembly of composite components, referred to herein as a composite package <NUM>. As an example, the composite package <NUM> includes the laminate <NUM> (e.g., plies <NUM> of the fiber reinforcement <NUM> impregnated with the matrix <NUM>). In one or more examples, the composite package <NUM> also includes other components utilized in composite manufacturing.

In one or more examples, the laminate <NUM> has a cross-sectional shape <NUM> (e.g., an open cross-sectional shape) that forms a cavity <NUM> (e.g., shown in <FIG>). In one or more examples, the composite package <NUM> includes a bladder <NUM>. The bladder <NUM> is received by the cavity <NUM> formed by the cross-sectional shape <NUM> of the laminate <NUM>. The bladder <NUM> supports the cross-sectional shape <NUM> of the laminate <NUM> during placement and/or cure of the composite member <NUM>.

In one or more examples, the composite package <NUM> also includes one or more additional or auxiliary components used in a composite manufacturing or curing operation. As an example, the composite package <NUM> includes a radius filler (e.g., noodle) that fills an interface between plies in a laminated joint. As another example, the composite package <NUM> includes one or more additional uncured composite materials, which are co-cured with the laminate <NUM> to form a complex composite structure.

Referring briefly to <FIG>, in one or more examples, the composite member <NUM> and, thus, the composite structure <NUM> formed from the composite member <NUM> is elongated along a length <NUM> (<FIG>). As an example, the composite member <NUM> has a relatively high aspect ratio and has a length dimension that is magnitudes of order greater than a width dimension.

Generally, the composite member <NUM> is provided in or has the initial contour <NUM> (e.g., as shown in <FIG>). The initial contour <NUM> refers to the curvature, bend, twist, or shape along a longitudinal axis A of the composite member <NUM> prior to retrieving and placing the composite member <NUM> on the place tool <NUM> (<FIG>). In one or more examples, the initial contour <NUM> is straight, such as at least approximately straight or substantially straight, in which the composite member <NUM> has little to no curvature, bend, or twist along the longitudinal axis A. In one or more examples, the initial contour <NUM> is not substantially straight or otherwise includes a minor or relatively low degree of curvature, bend, or twist along the longitudinal axis A. In other examples, the initial contour <NUM> includes other degrees of curvature, bend, or twist along the longitudinal axis A.

During and/or after placement of the composite member <NUM> on the place tool <NUM> (<FIG>), the composite member <NUM> has the final contour <NUM> (e.g., shown in <FIG>). The final contour <NUM> refers to the curvature, bend, twist, or shape along the longitudinal axis A of the composite member <NUM> after placing and shaping the composite member <NUM> on the place tool <NUM>. In one or more examples, the final contour <NUM> includes a relatively complex curvature or a relatively high degree of curvature, bend, or twist along the longitudinal axis A. The degree of curvature, bend, or twist of the final contour <NUM> depends on the contour of the place tool <NUM>, the desired final contour of the composite structure <NUM>, the intended use or application of the composite structure <NUM>, and the like. As examples, the final contour <NUM> can include one or more of a lengthwise (e.g., XZ-plane) bend or curvature, a side-to-side (e.g., XY-plane) bend or curvature, and a twist about the longitudinal axis A.

Referring now to <FIG>, which illustrates an example of the method <NUM> for shaping the composite structure <NUM>. The method <NUM> facilitates forming the composite member <NUM> from the initial contour <NUM> (e.g., as shown in <FIG>) to the final contour <NUM> (e.g., as shown in <FIG>).

In one or more examples, the method <NUM> includes a step of (block <NUM>) detecting or otherwise determining a location of the composite member <NUM>. Detecting the location of the composite member <NUM> enables automatic retrieval of the composite member <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) retrieving the composite member <NUM>. In one or more examples, the composite member <NUM> is provided in or otherwise has the initial contour <NUM> prior to and/or during the step of (block <NUM>) retrieving the composite member <NUM>.

In one or more examples, the composite member <NUM> has the initial contour <NUM> along the length <NUM> of the composite member <NUM> before the step of (block <NUM>) retrieving the composite member <NUM>. In one or more examples, the composite member <NUM> is formed, maintained, or otherwise held in the initial contour <NUM> during the step of (block <NUM>) retrieving the composite member <NUM>.

In one or more examples, the step of (block <NUM>) retrieving the composite member <NUM> includes a step of picking or otherwise removing the composite member <NUM> from a pick tool <NUM> (<FIG>). In one or more examples, the composite member <NUM> has the initial contour <NUM> on the pick tool <NUM> and is substantially maintained in the initial contour <NUM> during the step of picking.

In one or more examples, the step of (block <NUM>) retrieving the composite member <NUM> includes a step of transferring or otherwise moving the composite member <NUM> from the pick tool <NUM> to the place tool <NUM> (<FIG>). In one or more examples, the composite member <NUM> is maintained or otherwise held in the initial contour <NUM>, as picked, during the step of transferring. In one or more examples, the composite member <NUM> is formed in the initial contour <NUM>, after picking and during the step of transferring.

Referring briefly to <FIG>, in one or more examples, the composite member <NUM> is provided on the pick tool <NUM>. The pick tool <NUM> is configured to support the composite member <NUM> for retrieval. In one or more examples, the pick tool <NUM> supports and presents the composite member <NUM> in the initial contour <NUM>. As an example, the pick tool <NUM> includes a pick-tool surface <NUM> (e.g., as shown in <FIG> and <FIG>) that includes a contour that substantially matches and sets forth the initial contour <NUM> of the composite member <NUM>. In one or more examples, the pick tool <NUM> supports and presents the composite member <NUM> in a condition other than the initial contour <NUM>. In these examples, the composite member <NUM> is shaped in the initial contour <NUM> after being retrieved (e.g., picked and removed) from the pick tool <NUM>.

Referring again to <FIG>, in one or more examples, the method <NUM> includes a step of (block <NUM>) locating the composite member <NUM> relative to the place tool <NUM>. As an example, the composite member <NUM> is located (e.g., moved) relative to a first (e.g., initial) contact point 230A (<FIG>, <FIG>) of the place tool <NUM>. Locating the composite member <NUM> relative to the place tool <NUM>, such as relative to the initial contact point 230A on a place-tool surface <NUM> of the place tool <NUM>, properly positions the composite member <NUM> for shaping from the initial contour <NUM> to the final contour <NUM> while placing the composite member <NUM> on the place tool <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) detecting or otherwise determining a location of the place tool <NUM>. In one or more examples, the method <NUM> includes a step of adjusting the location of the composite member <NUM> relative to the place tool <NUM> based on the location detected. Detecting the location of the place tool <NUM> enables automatic locating of the composite member <NUM> relative to the place tool <NUM> prior to placement of the composite member <NUM> on the place tool <NUM>.

Referring to <FIG> and to <FIG>, <FIG>, in one or more examples, the method <NUM> includes a step of (block <NUM>) holding the composite member <NUM> in the initial contour <NUM> along the length <NUM> of the composite member <NUM>. In one or more examples, the composite member <NUM> is held in the initial contour <NUM> during and/or after the step of (block <NUM>) retrieving the composite member <NUM> and/or the step of (block <NUM>) locating the composite member <NUM>. As will be further described herein below, in one or more examples, portions of the composite member <NUM> are held in the initial contour <NUM> during placement of the composite member <NUM> on the place tool <NUM> and during formation of the final contour <NUM>.

Referring still to <FIG> and to <FIG>, <FIG>, in one or more examples, the method <NUM> includes a step of (block <NUM>) placing the composite member <NUM> on the place tool <NUM>. In one or more examples, a portion of the composite member <NUM> is placed on the place-tool surface <NUM> at the first contact point 230A (e.g., as shown in <FIG>, <FIG>).

As will be further described herein below, remaining portions of the composite member <NUM> are sequentially placed on subsequent contact points on the place-tool surface <NUM> of the place tool <NUM> (e.g., as shown in <FIG>, <FIG>, <FIG>, <FIG>, <FIG>, <FIG>) as the composite member <NUM> is formed into the final contour <NUM>.

Referring to <FIG>, in one or more examples, the method <NUM> includes a step of (block <NUM>) forming the final contour <NUM> along the length <NUM> of the composite member <NUM>. In one or more examples, the step of (block <NUM>) forming the final contour <NUM> is performed during the step of (block <NUM>) placing the composite member <NUM> on the place tool <NUM>.

Generally, the step of (block <NUM>) forming the final contour <NUM> includes sequentially forming portions of the final contour <NUM> by sequentially forming or shaping the composite member <NUM> into formed portions <NUM> on the place tool <NUM>, while holding unformed portions <NUM> of the composite member <NUM> in the initial contour <NUM>.

For the purpose of the present disclosure, an unformed portion of the composite member <NUM> refers to any portion of the composite member that has the initial contour <NUM>, that has yet to be formed into the final contour <NUM>, and/or that has yet to be placed on the place tool <NUM>. For the purpose of the present disclosure, a formed portion of the composite member <NUM> refers to any portion of the composite member that has been formed into a portion of the final contour <NUM> and/or that has been placed on the place tool <NUM>.

Referring now to <FIG> and to <FIG> and <FIG>, in one or more examples, the step of (block <NUM>) forming the final contour <NUM> includes a step of sequentially shaping or forming formed portions <NUM> of the composite member <NUM> on the place tool <NUM>.

Referring to <FIG> and to <FIG> and <FIG>, in one or more examples, the step of (block <NUM>) forming the final contour <NUM> includes a step of (block <NUM>) sequentially forming or shaping the unformed portions <NUM> of the composite member <NUM> into the formed portions <NUM> of the composite member <NUM>.

Referring to <FIG> and to <FIG> and <FIG>, the step of (block <NUM>) forming the final contour <NUM> also includes a step of (block <NUM>) holding remaining unformed portions <NUM> of the composite member <NUM> in the initial contour <NUM>.

In one or more examples, the step of (block <NUM>) holding the remaining unformed portions <NUM> in the initial contour <NUM> is performed during the step of (block <NUM>) sequentially forming or shaping the unformed portions <NUM> into the formed portions <NUM>. The step of (block <NUM>) sequentially forming or shaping the unformed portions <NUM> into the formed portions <NUM> and the step of (block <NUM>) holding the remaining unformed portions <NUM> in the initial contour <NUM> form or produce portions <NUM> of the final contour <NUM>.

Referring still to <FIG> and to <FIG>, <FIG>, the step of (block <NUM>) forming the final contour <NUM> further includes a step of (block <NUM>) sequentially forming or shaping the remaining unformed portions <NUM> of the composite member <NUM> into the formed portions <NUM> to form other portions <NUM> of the final contour <NUM>.

Generally, upon forming all of the unformed portions <NUM> into the formed portions <NUM>, an entirety of the final contour <NUM> is formed in the composite member <NUM>.

Referring to <FIG> and to <FIG>, in one or more examples, the method <NUM> includes a step of (block <NUM>) applying tension <NUM> to at least a portion of the composite member <NUM> during the step of (block <NUM>) forming the final contour <NUM> along the length <NUM> of the composite member <NUM>. As an example, the tension <NUM> is applied to at least one of the unformed portions <NUM> or at least one of the remaining unformed portions <NUM> of the composite member <NUM> while forming portions of the final contour <NUM> along the length <NUM> of the composite member <NUM>.

In one or more examples, the method <NUM> also includes a step of (block <NUM>) varying the tension <NUM> applied to at least a portion of the composite member <NUM> during the step of (block <NUM>) forming the final contour <NUM>. As an example, the tension <NUM> applied to the composite member <NUM> is varied or is selectively controlled and adjusted to at least one of the unformed portions <NUM> or at least one of the remaining unformed portions <NUM> of the composite member <NUM> while forming portions of the final contour <NUM> along the length <NUM> of the composite member <NUM>.

Applying the tension <NUM> and/or selectively controlling and/or adjusting the tension <NUM> applied to at least a portion of the composite member <NUM> while forming the final contour <NUM> advantageously reduces the likelihood of wrinkles to form in the composite member <NUM> while being placed and shaped on the place tool <NUM>.

As illustrated in <FIG>, the method <NUM> can have different sequences of placing and shaping portions of the composite member <NUM>. The composite member <NUM> includes a first end <NUM> and a second end <NUM>, opposite the first end <NUM> (<FIG> and <FIG>). As illustrated in <FIG>, in one or more examples, the placing and shaping sequence is performed from an intermediate portion of the composite member <NUM> outward along the length <NUM> toward the first end <NUM> and the second end <NUM>. As illustrated in <FIG>, in one or more examples, the placing and shaping sequence is performed from the first end <NUM> of the composite member <NUM> along the length <NUM> toward the second end <NUM>.

Referring to <FIG>, in one or more examples, the composite member <NUM> is held in the initial contour <NUM> relative to the place tool <NUM>. A first unformed portion 150A of the composite member <NUM>, located between the first end <NUM> and the second end <NUM>, is placed in contact with the place-tool surface <NUM> at the first contact point 230A, located between a first tool-end <NUM> and a second tool-end <NUM> of the place tool <NUM>. The composite member <NUM> is formed into the final contour <NUM> by sequentially shaping the unformed portions of the composite member <NUM> along the length <NUM> toward the first end <NUM> and toward the second end <NUM> while holding remaining unformed portions in the initial contour <NUM>.

Referring to <FIG>, in one or more examples, a first formed portion 148A of the composite member <NUM> is shaped on the place tool <NUM> to form a first contour portion <NUM> (<FIG>) of the final contour <NUM> while holding a first remaining unformed portion 174A of the composite member <NUM>, extending from the first formed portion 148A towards the first end <NUM>, and a second remaining unformed portion 174B, extending from the first formed portion 148A toward the second end <NUM>, in the initial contour <NUM>. For example, the composite member <NUM> is placed into contact with the place-tool surface <NUM> at a second contact point 230B and a third contact point 230C to shape the first formed portion 148A. The second contact point 230B is spaced away from the first contact point 230A toward the first tool-end <NUM>. The third contact point 230C is spaced away from the first contact point 230A toward the second tool-end <NUM>.

Referring to <FIG>, in one or more examples, a second formed portion 148B of the composite member <NUM>, extending from the first formed portion 148A, is shaped on the place tool <NUM> to from a second contour portion <NUM> (<FIG>) of the final contour <NUM> while holding a third remaining unformed portion 174C of the composite member <NUM>, extending from the second formed portion 148B toward the first end <NUM>, in the initial contour <NUM>. A third formed portion 148C of the composite member <NUM>, extending from the first formed portion 148A opposite the second formed portion 148B, is shaped to from a third contour portion <NUM> (<FIG>) of the final contour <NUM> while holding a fourth remaining unformed portion 174D of the composite member <NUM>, extending from the third formed portion 148C toward the second end <NUM>, in the initial contour <NUM>. For example, the composite member <NUM> is placed into contact with the place-tool surface <NUM> at a fourth contact point 230D and a fifth contact point 230E to shape the second formed portion 148B and the third formed portion 148C. The fourth contact point 230D is spaced away from the second contact point 230B toward the first tool-end <NUM>. The fifth contact point 230E is spaced away from the third contact point 230C toward the second tool-end <NUM>.

Referring to <FIG>, in one or more examples, a fourth formed portion 148D of the composite member <NUM>, extending from the second formed portion 148B, is shaped to from a fourth contour portion <NUM> (<FIG>) of the final contour <NUM>. A fifth formed portion 148E of the composite member <NUM>, extending from the third formed portion 148C, is shaped to from a fifth contour portion <NUM> (<FIG>) of the final contour <NUM>. For example, the composite member <NUM> is placed into contact with the place-tool surface <NUM> at a sixth contact point 230F and a seventh contact point <NUM> to shape the fourth formed portion 148D and the fifth formed portion 148E. The sixth contact point 230F is spaced away from the fourth contact point 230D toward the first tool-end <NUM>. The seventh contact point <NUM> is spaced away from the fifth contact point 230E toward the second tool-end <NUM>.

The examples described above and depicted in <FIG> are illustrative of a forming sequence that begins at an intermediate portion of the composite member <NUM> and that shapes sequential portions of the composite member <NUM> along the length <NUM> toward opposing ends of the composite member <NUM>. While the illustrate examples describe and depict a number of (e.g., five) portions of the composite member <NUM> being sequentially placed on the place tool <NUM> and formed into portions of the final contour <NUM>, the disclosed method <NUM> is not limited to any particular number of portions. For example, the placing and forming steps describe above can be applied to any number of (e.g., less than five or greater than five) portions of the composite member <NUM>.

In one or more examples, the tension <NUM> is applied and/or selectively controlled along the length <NUM> of the composite member <NUM> between the first end <NUM> and the second end <NUM>. In one or more examples, the tension <NUM> is applied and/or selectively controlled along a portion of the length <NUM> of the composite member <NUM>, such as between one of the formed portions <NUM> and an adjacent one of the remaining unformed portions <NUM> or between one of the formed portions <NUM> and at least one of the first end <NUM> and the second end <NUM>.

As an example, the tension <NUM> can be selectively controlled and applied along at least a portion of the length <NUM> of the composite member <NUM> between the first end <NUM> and the second end <NUM> while forming (e.g., placing and/or shaping) the first formed portion 148A. As another example, the tension <NUM> can be applied along at least a portion of the length <NUM> of the composite member <NUM> between the first formed portion 148A and the first end <NUM> while forming (e.g., placing and/or shaping) at least one of the second formed portion 148B, the fourth formed portion 148D, and any other formed portions <NUM> between the first formed portion 148A and the first end <NUM>. As another example, the tension <NUM> can be applied along at least a portion of the length <NUM> of the composite member <NUM> between the first formed portion 148A and second end <NUM> while forming (e.g., placing and/or shaping) at least one of the third formed portion 148C, the fifth formed portion 148E, and any other formed portions <NUM> between the first formed portion 148A and the second end <NUM>. As another example, the tension <NUM> can be applied along a portion of the length <NUM> of the composite member <NUM> between any two of the contact points on the place-tool surface <NUM>.

In one or more examples, more than one portion of the composite member <NUM> is formed (e.g., placed and/or shaped) on the place tool <NUM> concurrently or approximately simultaneously. As an example, the second formed portion 148B of the composite member <NUM> and the third formed portion 148C of the composite member <NUM> can be formed (e.g., placed and/or shaped) at least approximately concurrently. As another example, the fourth formed portion 148D of the composite member <NUM> and the fifth formed portion 148E of the composite member <NUM> can be formed (e.g., placed and/or shaped) at least approximately concurrently.

In one or more examples, each portion of the composite member <NUM> is formed (e.g., placed and/or shaped) on the place tool <NUM> consecutively or successively. As an example, the second formed portion 148B of the composite member <NUM> and the third formed portion 148C of the composite member <NUM> are formed (e.g., placed and/or shaped) consecutively. As another example, the fourth formed portion 148D of the composite member <NUM> and the fifth formed portion 148E of the composite member <NUM> are formed (e.g., placed and/or shaped) consecutively.

Referring to <FIG>, in one or more examples, the composite member <NUM> is held in the initial contour <NUM> relative to the place tool <NUM>. A first unformed portion 150A of the composite member <NUM>, located proximate (e.g., at or near) the first end <NUM>, is placed in contact with the place-tool surface <NUM> at the first contact point 230A, located proximate (e.g., at or near) the first tool-end <NUM> of the place tool <NUM>. The composite member <NUM> is formed into the final contour <NUM> by sequentially shaping the unformed portions of the composite member <NUM> along the length <NUM> toward the first end <NUM> and toward the second end <NUM> while holding remaining unformed portions in the initial contour <NUM>.

Referring to <FIG>, in one or more examples, a first formed portion 148A of the composite member <NUM> is shaped on the place tool <NUM> to form the first contour portion <NUM> (<FIG>) of the final contour <NUM> while holding a first remaining unformed portion 174A of the composite member <NUM>, extending from the first formed portion 148A towards the second end <NUM>, in the initial contour <NUM>. For example, the composite member <NUM> is placed into contact with the place-tool surface <NUM> at the second contact point 230B to shape the first formed portion 148A. The second contact point 230B is spaced away from the first contact point 230A toward the second tool-end <NUM>.

Referring to <FIG>, in one or more examples, a second formed portion 148B of the composite member <NUM>, extending from the first formed portion 148A, is shaped on the place tool <NUM> to from a second contour portion <NUM> (<FIG>) of the final contour <NUM> while holding a second remaining unformed portion 174B of the composite member <NUM>, extending from the second formed portion 148B toward the second end <NUM>, in the initial contour <NUM>. For example, the composite member <NUM> is placed into contact with the place-tool surface <NUM> at a third contact point 230C to shape the second formed portion 148B. The third contact point 230C is spaced away from the second contact point 230B toward the second tool-end <NUM>.

Referring to <FIG>, in one or more examples, a third formed portion 148C of the composite member <NUM>, extending from the second formed portion 148B, is shaped to from a third contour portion <NUM> (<FIG>) of the final contour <NUM>. For example, the composite member <NUM> is placed into contact with the place-tool surface <NUM> at a fourth contact point 230D to shape the third formed portion 148C. The fourth contact point 230D is spaced away from the third contact point 230C toward the second tool-end <NUM>.

The examples described above and depicted in <FIG> are illustrative of a forming sequence that begins at one end of the composite member <NUM> and that shapes sequential portions of the composite member <NUM> along the length <NUM> toward an opposing end of the composite member <NUM>. While the illustrate examples describe and depict a number of (e.g., three) portions of the composite member <NUM> being sequentially placed on the place tool <NUM> and formed into portions of the final contour <NUM>, the disclosed method <NUM> is not limited to any particular number of portions. For example, the placing and forming steps describe above can be applied to any number of (e.g., less than three or greater than three) portions of the composite member <NUM>.

As an example, the tension <NUM> can be selectively controlled and applied along at least a portion of the length <NUM> of the composite member <NUM> between the first end <NUM> and the second end <NUM> while forming (e.g., placing and/or shaping) the first formed portion 148A. As another example, the tension <NUM> can be applied along at least a portion of the length <NUM> of the composite member <NUM> between the first formed portion 148A and the second end <NUM> while forming (e.g., placing and/or shaping) at least one of the second formed portion 148B, the third formed portion 148C, and any other formed portions <NUM> between the first formed portion 148A and the second end <NUM>. As another example, the tension <NUM> can be applied along a portion of the length <NUM> of the composite member <NUM> between any two of the contact points on the place-tool surface <NUM>.

Referring again to <FIG>, in one or more examples, the method <NUM> includes a step of (block <NUM>) applying heat <NUM> to the composite member <NUM>. In one or more examples, the step of (block <NUM>) applying heat <NUM> to the composite member <NUM> is performed before the step of (block <NUM>) placing and/or the step of (block <NUM>) forming the final contour <NUM>. In one or more examples, the step of (block <NUM>) applying heat <NUM> to the composite member <NUM> is performed during the step of (block <NUM>) placing and/or the step of (block <NUM>) forming the final contour <NUM>. while forming the final contour <NUM>. In one or more examples, the step of (block <NUM>) applying heat <NUM> to the composite member <NUM> is performed after the step of (block <NUM>) placing and/or the step of (block <NUM>) forming the final contour <NUM>. while forming the final contour <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) compacting the composite member <NUM>. Generally, the step of (block <NUM>) compacting includes applying a compaction pressure or force to at least a portion of the composite member <NUM> to compact or compress the composite member <NUM> against the place-tool surface <NUM>. In one or more examples, the step of (block <NUM>) compacting the composite member <NUM> is performed during the step of (block <NUM>) placing and/or the step of (block <NUM>) forming the final contour <NUM>. In one or more examples, the step of (block <NUM>) compacting the composite member <NUM> is performed after the step of (block <NUM>) placing and/or the step of (block <NUM>) forming the final contour <NUM>.

In one or more examples, according to the method <NUM>, the step of (block <NUM>) applying heat <NUM> to the composite member <NUM> and the step of (block <NUM>) compacting the composite member <NUM> are performed at least approximately concurrently. In one or more examples, according to the method <NUM>, the step of (block <NUM>) applying heat <NUM> to the composite member <NUM> is performed before the step of (block <NUM>) compacting the composite member <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) maintaining the cross-sectional shape <NUM> of the composite member <NUM> during the step of (block <NUM>) placing the composite member <NUM> on the place tool <NUM> and/or the step of (block <NUM>) forming the final contour <NUM> in the composite member <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) curing the composite member <NUM> to form the composite structure <NUM>. The composite structure <NUM> includes the final contour <NUM>.

In one or more examples, the composite structure <NUM> is a composite stiffener <NUM>, such as a composite stiffener utilized in the manufacture of an aircraft. In one or more examples, the composite structure <NUM> is a composite stringer <NUM>, such as a composite stringer utilized in the manufacture of an aircraft.

Referring now to <FIG>, which schematically illustrate examples of the system <NUM> for forming the composite structure <NUM>. In one or more examples, the system <NUM> operates in a manufacturing environment <NUM> (<FIG>) and is configured to shape the composite member <NUM> and form the composite structure <NUM>. In one or more examples, the system <NUM> performs one or more operations of or is used to implement the method <NUM> (<FIG>).

In one or more examples, the system <NUM> includes a plurality of automated manipulators <NUM>. The automated manipulators <NUM> are configured to manipulate the composite member <NUM>. In one or more examples, as illustrated in <FIG>, one or more of the automated manipulators <NUM> includes or takes the form of an independently movable robotic manipulator <NUM> (<FIG>) or robotic arm having multiple (e.g., six) degrees of freedom. In these examples, the robotic manipulators <NUM> can be floor-mounted (e.g., <FIG> and <FIG>) or ceiling-mounted (e.g., <FIG>). In one or more examples, as illustrated in <FIG>, the automated manipulators <NUM> include or take the form of an overhead gantry <NUM>. In these examples, each one of the automated manipulators <NUM> is independently movable via the gantry <NUM> and has multiple (e.g., three) degrees of freedom.

In one or more examples, the automated manipulators <NUM>, in unison, pick the composite member <NUM> from a pick position on the pick tool <NUM>. The automated manipulators <NUM> move in a coordinated fashion to place the composite member <NUM> into a place position on the place tool <NUM>. During approach to the place position, each automated manipulator <NUM> moves along a pre-programmed motion profile, or path, to form or shape the composite member <NUM> to match the contour of the place-tool surface <NUM> at the place position. This is done in a synchronized, coordinated motion to prevent damaging the composite member <NUM> and to ensure that the composite member <NUM> is properly placed in the place position on the place tool <NUM>.

In one or more examples, the system <NUM> includes the pick tool <NUM>. The pick tool <NUM> supports the composite member <NUM>, for example, in the initial contour <NUM>, for retrieval by the automated manipulators <NUM>.

In one or more examples, the system <NUM> includes the place tool <NUM>. The place tool <NUM> supports the composite member <NUM> after forming the final contour <NUM>. In one or more examples, the place tool <NUM> defines or sets forth the final contour <NUM> as the composite member <NUM> is placed and formed on the place tool <NUM>. As an example, the place tool <NUM> includes the place-tool surface <NUM> (e.g., as shown in <FIG> and <FIG>) that includes a contour that substantially matches and sets forth the final contour <NUM> of the composite member <NUM>.

As illustrated in <FIG> and <FIG>, in one or more examples, the place tool <NUM> includes a groove, a cavity, recess, or other feature that is formed (e.g., machined) in the place-tool surface <NUM> and the is shaped to receive at least a portion of the cross-sectional shape of the composite member <NUM>.

Referring to <FIG> and to <FIG>, in one or more examples, the system <NUM> includes a controller <NUM>. The controller <NUM> is configured to execute instructions <NUM>. Execution of the instructions <NUM> causes the controller <NUM> to perform operations using the automated manipulators <NUM>. Generally, as described herein below, execution of the instructions <NUM> causes the controller <NUM> to direct preprogrammed and synchronized movement of the automated manipulators <NUM> to perform a series of operational steps.

As illustrated in <FIG> and <FIG>, in one or more examples, the operations include retrieving the composite member <NUM> using the automated manipulators <NUM>. As an example, the operations include picking the composite member <NUM> from the pick tool <NUM> and moving the composite member <NUM> from the pick tool <NUM> to the place tool <NUM> using the automated manipulators <NUM>.

As illustrated in <FIG> and <FIG>, in one or more examples, the operations include holding the composite member <NUM> in the initial contour <NUM> using the automated manipulators <NUM> (<FIG>). In one or more examples, the operations include placing the composite member <NUM> on the place tool <NUM> using the automated manipulators <NUM> (<FIG>). In one or more examples, the operations include forming the final contour <NUM> along the length <NUM> of the composite member <NUM> while placing the composite member <NUM> on the place tool <NUM> using the automated manipulators <NUM>. Generally, the final contour <NUM> is formed by sequentially forming or shaping the composite member <NUM> into the formed portions <NUM> on the place tool <NUM> using synchronized movement of ones of the automated manipulators <NUM>, while holding unformed portions <NUM> of the composite member <NUM> in the initial contour <NUM> using synchronized movement of other ones of the automated manipulators <NUM>.

As an example, portions <NUM> of the final contour <NUM> are formed in the composite member <NUM> by sequentially forming or shaping the unformed portions <NUM> into the formed portions <NUM> on the place tool <NUM> using ones of the automated manipulators <NUM>, while holding the remaining unformed portions <NUM> of the composite member <NUM> in the initial contour <NUM> using other ones of the automated manipulators <NUM>. Other portions <NUM> of the final contour <NUM> are formed in the composite member <NUM> by then sequentially forming or shaping the remaining unformed portions <NUM> into the formed portions <NUM> on the place tool <NUM> using ones of the automated manipulators <NUM>.

In one or more examples, the operations include applying tension <NUM> along at least a portion of the length <NUM> of the composite member <NUM>, such as to at least one of the formed portions <NUM>, the unformed portions <NUM>, and/or the remaining unformed portions <NUM> of the composite member <NUM> using ones of the automated manipulators <NUM>, while forming the final contour <NUM> along the length <NUM> of the composite member <NUM> using other ones of the automated manipulators <NUM>.

In one or more examples, the operations include selectively controlling or otherwise varying the tension <NUM> applied to at least one of the remaining unformed portions <NUM> of the composite member <NUM> using ones of the automated manipulators <NUM>, while forming the final contour <NUM> along the length <NUM> of the composite member <NUM> using other ones of the automated manipulators <NUM>.

Referring now to <FIG> and <FIG>, in one or more examples, each one of the automated manipulators <NUM> includes a gripper <NUM>. The gripper <NUM> is configured to selectively hold or release the composite member <NUM>, for example, upon direction from the controller <NUM>. In one or more examples, the gripper <NUM> includes or takes the form of a vacuum gripper <NUM>. In other examples, the gripper <NUM> includes or takes the form of any other suitable gripper mechanism, such as a mechanical gripper, an electrostatic gripper, an adhesive gripper, and the like.

In one or more examples, each one of the automated manipulators <NUM> includes a compactor <NUM>. The operations include compacting the composite member <NUM> using the compactor <NUM>, after forming the final contour <NUM> along the length <NUM> of the composite member <NUM>. In one or more examples, the compactor <NUM> includes or takes the form of a vacuum compactor <NUM>. In one or more examples, the compactor <NUM> includes or takes the form of a roller compactor <NUM>.

In one or more examples, the vacuum gripper <NUM> and the vacuum compactor <NUM> are integrated into a single, unitary vacuum unit. As an example, the vacuum unit includes a plurality of vacuum zones that are selectively activated. In these examples, a central vacuum zone is activated to pick, move, and hold the composite member <NUM> during retrieval, placement, and formation. After placement of the composite member <NUM> on the place tool <NUM> and formation of a portion of the final contour <NUM>, additional vacuum zones are then activated to compact a portion of the composite member <NUM> against the place-tool surface <NUM>.

In one or more examples, each one of the automated manipulators <NUM> includes a heater <NUM>. The operations include applying heat <NUM> to the composite member <NUM> using the heater <NUM>, while forming the final contour <NUM> along the length <NUM> of the composite member <NUM>. In one or more examples, the operations include applying heat <NUM> to the composite member <NUM> while compacting the composite member <NUM>.

In one or more examples, each one of the automated manipulators <NUM> includes an end effector <NUM>. In one or more examples, the gripper <NUM>, the compactor <NUM>, and the heater <NUM> are integrated into the end effector <NUM>. As an example, the end effector <NUM> is coupled to the automated manipulator <NUM> by a rotary coupling <NUM> that is configured to rotate or otherwise move the end effector <NUM> relative to the automated manipulator <NUM> to selectively utilize one or more of the gripper <NUM>, the compactor <NUM>, and the heater <NUM>.

In one or more examples, the end effector <NUM> is self-aligning. As an example, the end effector <NUM> is coupled to the automated manipulator <NUM> by a joint coupling <NUM> that is configured to selectively enable free linear and/or angular motion of the end effector <NUM> relative to the automated manipulator <NUM> and to selectively lock a linear position and/or angular orientation of the end effector <NUM> relative to the automated manipulator <NUM>.

In other examples, the compactor <NUM> and/or the heater <NUM> are not integrated into an end effector with the gripper <NUM> or are otherwise independent devices. In these examples, the compactor <NUM> and/or the heater <NUM> are coupled to a dedicated automated manipulator for selective positioning during the compacting and/or heating operations.

In one or more examples, synchronized motion of the automated manipulators <NUM> is selectively controlled to sequentially place portions of the composite member <NUM> on the place tool <NUM>, form portions of the final contour <NUM> in the composite member <NUM> while being placed on the place tool <NUM>, and hold portions of the composite member <NUM> in the initial contour <NUM>. As described above and illustrated in <FIG>, synchronized motion of the automated manipulators <NUM> can utilize different sequences of placing and shaping portions of the composite member <NUM>.

Referring now to <FIG> and <FIG>, in one or more examples, the system <NUM> includes a sensor <NUM>. In one or more examples, the sensor <NUM> is configured to detect a location of the composite member <NUM>. In one or more examples, the sensor <NUM> is configured to detect a location of the place tool <NUM>. The sensor <NUM> can include one or more suitable sensor devices.

As an example, the sensor <NUM> is configured to detect a location of the composite member <NUM> relative to the pick tool <NUM>, for example, prior to and/or during the picking operation. As an example, the sensor <NUM> is configured to detect a location of the composite member <NUM> relative to the place tool <NUM>, for example, during the moving operation, the holding operation, the placing operation, and the forming operation. As an example, the sensor <NUM> is configured to detect a location of the place tool <NUM>, for example, prior to and/or during the placing operation and the forming operation.

In one or more examples, the operations include locating at least a portion of the composite member <NUM> relative to the place tool <NUM> before placing the composite member <NUM> on the place tool <NUM> using the locations detected by the sensor <NUM>. In one or more examples, the operations include adjusting a location of the composite member <NUM> relative to the place tool <NUM> based on a location detected by the sensor <NUM>. As an example, the sensor <NUM> detects at least a portion of the place tool <NUM>, such as at least one of the first tool-end <NUM> and the second tool-end <NUM> of the place tool <NUM>, to determine a location of the place-tool surface <NUM>. The automated manipulators <NUM> suitably locate the composite member <NUM> relative to the place-tool surface <NUM> such that a proper portion of the composite member <NUM> is initially placed on the place-tool surface <NUM> at the first contact point 230A.

Referring now to <FIG>, which illustrates an example of the automated method <NUM> for shaping the composite structure <NUM>. In one or more examples, the method <NUM> is implemented using the system <NUM> (<FIG>).

Referring to <FIG> and to <FIG>, in one or more examples, the automated method <NUM> includes a step of (block <NUM>) using the automated manipulators <NUM>, under direction from the controller <NUM>, to retrieve the composite member <NUM>. As an example, the automated manipulators <NUM>, under direction from the controller <NUM>, pick the composite member <NUM>, for example, in the initial contour <NUM>, from the pick tool <NUM> and move the composite member <NUM>, in the initial contour <NUM>, to the place tool <NUM>.

Referring to <FIG> and to <FIG>, in one or more examples, the automated method <NUM> includes a step of (block <NUM>) using the automated manipulators <NUM> to hold the composite member <NUM> in the initial contour <NUM> along the length <NUM> of the composite member <NUM>.

Referring to <FIG> and to <FIG> and <FIG>, in one or more examples, the automated method <NUM> includes a step of (block <NUM>) using the sensor <NUM> to detect a location of the composite member <NUM>. In one or more examples, the automated method <NUM> includes a step of (block <NUM>) using the sensor <NUM> to detect a location of the place tool <NUM>. In one or more examples, the automated method <NUM> includes a step of (block <NUM>) using the automated manipulators <NUM> to locate the composite member <NUM> or adjust the location of the composite member <NUM> relative to the place tool <NUM> based on locations detected by the sensor <NUM>.

Referring to <FIG> and to <FIG>, in one or more examples, the automated method <NUM> includes a step of (block <NUM>) synchronizing motion of the automated manipulators <NUM> to sequentially place the composite member <NUM> on the place tool <NUM>. In one or more examples, the automated method <NUM> includes a step of (block <NUM>) synchronizing motion of the automated manipulators <NUM> to form the final contour <NUM> along the length <NUM> of the composite member <NUM>. Generally, the step of (block <NUM>) synchronizing motion of the automated manipulators <NUM> to sequentially place the composite member <NUM> on the place tool <NUM> and the step of (block <NUM>) synchronizing motion of the automated manipulators <NUM> to form the final contour <NUM> in the composite member <NUM> are performed concurrently.

In one or more examples, the final contour <NUM> is formed by sequentially shaping the formed portions <NUM> of the composite member <NUM> on the place tool <NUM>, while holding the unformed portions <NUM> of the composite member <NUM> in the initial contour <NUM> to form portions <NUM> of the final contour <NUM>. The final contour <NUM> is further formed by sequentially shaping the unformed portions <NUM> of the composite member <NUM> on the place tool <NUM> to form other portions <NUM> of the final contour <NUM>.

Referring to <FIG> and to <FIG>, in one or more examples, the step of (block <NUM>) synchronizing motion of the automated manipulators <NUM> to form the final contour <NUM> in the composite member <NUM> includes a step of (block <NUM>) synchronizing motion of the automated manipulators <NUM> to sequentially form or shape the unformed portions <NUM> of the composite member <NUM> into the formed portions <NUM> of the composite member <NUM>, a step of (block <NUM>) synchronizing motion of the automated manipulators <NUM> to hold the remaining unformed portions <NUM> of the composite member <NUM> in the initial contour <NUM>, and a step of (block <NUM>) synchronizing motion of the automated manipulators <NUM> to sequentially form or shape the remaining unformed portions <NUM> of the composite member <NUM> into the formed portions <NUM>.

In one or more examples, the automated method <NUM> includes a step of (block <NUM>) moving at least one of the automated manipulators <NUM> relative to at least another one of the automated manipulators <NUM> to apply the tension <NUM> to at least a portion of the composite member <NUM>, while forming the final contour <NUM> along the length <NUM> of the composite member <NUM>.

Referring to <FIG> and to <FIG> and <FIG>, in one or more examples, the automated method <NUM> includes a step of (block <NUM>) using the heater <NUM> of at least one of the automated manipulators <NUM> to apply heat <NUM> to the composite member <NUM>, for example, before and/or while forming the final contour <NUM> along the length <NUM> of the composite member <NUM>.

In one or more examples, the automated method <NUM> includes a step of (block <NUM>) using the compactor <NUM> of at least one of the automated manipulators <NUM> to compact the composite member <NUM>, after forming the final contour <NUM> along the length <NUM> of the composite member <NUM>.

In one or more examples, the automated method <NUM> includes a step of (block <NUM>) curing the composite member <NUM> to form the composite structure <NUM>. The composite structure <NUM> having the final contour <NUM>. In one or more examples, the composite member <NUM> is cured on the place tool <NUM>. In other examples, the composite member <NUM>, having the final contour <NUM>, is moved from the place tool <NUM> to a dedicated cure tool for curing.

Referring now to <FIG>, in one or more examples, the controller <NUM> (<FIG>) includes a data processing system <NUM>. In one or more examples, the data processing system <NUM> includes a communications framework <NUM>, which provides communications between at least one processor <NUM>, one or more storage devices <NUM>, such as memory <NUM> and/or persistent storage <NUM>, a communications unit <NUM>, an input/output unit <NUM> (I/O unit), and a display <NUM>. In this example, the communications framework <NUM> takes the form of a bus system.

The processor <NUM> serves to execute the instructions <NUM> (<FIG>) for software that can be loaded into the memory <NUM>. In one or more examples, the processor <NUM> is a number of processor units, a multi-processor core, or some other type of processor, depending on the particular implementation.

The memory <NUM> and the persistent storage <NUM> are examples of the storage devices <NUM>. A storage device is any piece of hardware that is capable of storing information, such as, for example, without limitation, at least one of data, program code in functional form, or other suitable information either on a temporary basis, a permanent basis, or both on a temporary basis and a permanent basis. The storage devices <NUM> may also be referred to as computer readable storage devices in one or more examples. The memory <NUM> is, for example, a random-access memory or any other suitable volatile or non-volatile storage device. The persistent storage <NUM> can take various forms, depending on the particular implementation.

For example, the persistent storage <NUM> contains one or more components or devices. For example, the persistent storage <NUM> is a hard drive, a solid-state hard drive, a flash memory, a rewritable optical disk, a rewritable magnetic tape, or some combination of the above. The media used by the persistent storage <NUM> also can be removable. For example, a removable hard drive can be used for the persistent storage <NUM>.

The communications unit <NUM> provides for communications with other systems or devices, such as the automated manipulators <NUM>, the grippers <NUM>, the compactors <NUM>, the heaters <NUM>, and the sensors <NUM> (<FIG>). In one or more examples, the communications unit <NUM> is a network interface card.

Input/output unit <NUM> allows for input and output of data with other devices that can be connected to the data processing system <NUM>. As an example, the input/output unit <NUM> provides a connection for user input through at least one of a keyboard, a mouse, or some other suitable input device. Further, the input/output unit <NUM> can send output to a printer. The display <NUM> provides a mechanism to display information to a user.

Instructions (e.g., instructions <NUM>) for at least one of the operating system, applications, or programs can be located in the storage devices <NUM>, which are in communication with the processor <NUM> through the communications framework <NUM>. The processes of the various examples and operations described herein can be performed by the processor <NUM> using computer-implemented instructions, which can be located in a memory, such as the memory <NUM>.

The instructions <NUM> are referred to as program code, computer usable program code, or computer readable program code that can be read and executed by a processor of the processor <NUM>. The program code in the different examples can be embodied on different physical or computer readable storage media, such as the memory <NUM> or the persistent storage <NUM>.

In one or more examples, the program code <NUM> is located in a functional form on computer readable media <NUM> that is selectively removable and can be loaded onto or transferred to the data processing system <NUM> for execution by the processor <NUM>. In one or more examples, the program code <NUM> and computer readable media <NUM> form the computer program product <NUM>. In one or more examples, the computer readable media <NUM> is computer readable storage media <NUM>.

In one or more examples, the computer readable storage media <NUM> is a physical or tangible storage device used to store the program code <NUM> rather than a medium that propagates or transmits the program code <NUM>.

Alternatively, the program code <NUM> can be transferred to the data processing system <NUM> using a computer readable signal media. The computer readable signal media can be, for example, a propagated data signal containing the program code <NUM>. For example, the computer readable signal media can be at least one of an electromagnetic signal, an optical signal, or any other suitable type of signal. These signals can be transmitted over at least one of communications links, such as wireless communications links, optical fiber cable, coaxial cable, a wire, or any other suitable type of communications link.

The different components illustrated for data processing system <NUM> are not meant to provide architectural limitations to the manner in which different examples can be implemented. The different examples can be implemented in a data processing system including components in addition to or in place of those illustrated for the data processing system <NUM>. Other components shown in <FIG> can be varied from the examples shown. The different examples can be implemented using any hardware device or system capable of running the program code <NUM>.

Additionally, various components of the controller <NUM> and/or the data processing system <NUM> may be described as modules. For the purpose of the present disclosure, the term "module" includes hardware, software or a combination of hardware and software. As an example, a module can include one or more circuits configured to perform or execute the described functions or operations of the executed processes described herein (e.g., the method <NUM> and/or the automated method <NUM>). As another example, a module includes a processor, a storage device (e.g., a memory), and computer-readable storage medium having instructions that, when executed by the processor causes the processor to perform or execute the described functions and operations. In one or more examples, a module takes the form of the program code <NUM> and the computer readable media <NUM> together forming the computer program product <NUM>.

Referring now to <FIG>, examples of the method <NUM>, the automated method <NUM>, and/or the system <NUM> described herein, may be related to, or used in the context of, an aircraft manufacturing and service method <NUM>, as shown in the flow diagram of <FIG> and an aircraft <NUM>, as schematically illustrated in <FIG>. For example, the aircraft <NUM> and/or the aircraft production and service method <NUM> may utilize composite structures <NUM> (<FIG>) shaped and/or formed using the system <NUM> and/or according to the method <NUM> or the method <NUM>.

Referring to <FIG>, which illustrates an example of the aircraft <NUM>. The aircraft <NUM> also includes an airframe <NUM> having an interior <NUM>. The aircraft <NUM> includes a plurality of onboard systems <NUM> (e.g., high-level systems). Examples of the onboard systems <NUM> of the aircraft <NUM> include propulsion systems <NUM>, hydraulic systems <NUM>, electrical systems <NUM>, and environmental systems <NUM>. In other examples, the onboard systems <NUM> also includes one or more control systems coupled to an airframe <NUM> of the aircraft <NUM>, such as for example, flaps, spoilers, ailerons, slats, rudders, elevators, and trim tabs. In yet other examples, the onboard systems <NUM> also includes one or more other systems, such as, but not limited to, communications systems, avionics systems, software distribution systems, network communications systems, passenger information/entertainment systems, guidance systems, radar systems, weapons systems, and the like. The aircraft <NUM> may include various composite structures <NUM> having desired final contours and that form a portion of the airframe <NUM>, the interior <NUM>, and/or one or more of the onboard systems <NUM>, such as composite stiffeners <NUM>, composite stringers <NUM>, and the like.

Referring to <FIG>, during pre-production of the aircraft <NUM>, the method <NUM> includes specification and design of the aircraft <NUM> (block <NUM>) and material procurement (block <NUM>). During production of the aircraft <NUM>, component and subassembly manufacturing (block <NUM>) and system integration (block <NUM>) of the aircraft <NUM> take place. Thereafter, the aircraft <NUM> goes through certification and delivery (block <NUM>) to be placed in service (block <NUM>). Routine maintenance and service (block <NUM>) includes modification, reconfiguration, refurbishment, etc. of one or more systems of the aircraft <NUM>.

Each of the processes of the method <NUM> illustrated in <FIG> may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of spacecraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.

Examples of the method <NUM>, the method <NUM>, and the system <NUM> shown and described herein, may be employed during any one or more of the stages of the manufacturing and service method <NUM> shown in the flow diagram illustrated by <FIG>. In an example, shaping and forming composite structures having a desired final (e.g., complex) contour using the system <NUM> and/or according to the method <NUM> or the method <NUM> may form a portion of component and subassembly manufacturing (block <NUM>) and/or system integration (block <NUM>). Further, shaping and forming composite structures having a desired final (e.g., complex) contour using the system <NUM> and/or according to the method <NUM> or the method <NUM> may be implemented in a manner similar to components or subassemblies prepared while the aircraft <NUM> is in service (block <NUM>). Also, composite structures having a desired final (e.g., complex) contour that are shaped and formed using the system <NUM> and/or according to the method <NUM> or the method <NUM> may be utilized during system integration (block <NUM>) and certification and delivery (block <NUM>). Similarly, composite structures having a desired final (e.g., complex) contour that are shaped and formed using the system <NUM> and/or according to the method <NUM> or the method <NUM> may be utilized, for example and without limitation, while the aircraft <NUM> is in service (block <NUM>) and during maintenance and service (block <NUM>).

<FIG>, <FIG> and <FIG>, referred to above, may represent functional elements, features, or components thereof and do not necessarily imply any particular structure. Accordingly, modifications, additions and/or omissions may be made to the illustrated structure. Additionally, those skilled in the art will appreciate that not all elements, features, and/or components described and illustrated in <FIG>, <FIG> and <FIG>, referred to above, need be included in every example and not all elements, features, and/or components described herein are necessarily depicted in each illustrative example. Accordingly, some of the elements, features, and/or components described and illustrated in <FIG>, <FIG> and <FIG> may be combined in various ways without the need to include other features described and illustrated in <FIG>, <FIG> and <FIG>, other drawing figures, and/or the accompanying disclosure, even though such combination or combinations are not explicitly illustrated herein. Similarly, additional features not limited to the examples presented, may be combined with some or all of the features shown and described herein. Unless otherwise explicitly stated, the schematic illustrations of the examples depicted in <FIG>, <FIG> and <FIG>, referred to above, are not meant to imply structural limitations with respect to the illustrative example. Rather, although one illustrative structure is indicated, it is to be understood that the structure may be modified when appropriate. Accordingly, modifications, additions and/or omissions may be made to the illustrated structure. Furthermore, elements, features, and/or components that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each of <FIG>, <FIG> and <FIG>, and such elements, features, and/or components may not be discussed in detail herein with reference to each of <FIG>, <FIG> and <FIG>. Similarly, all elements, features, and/or components may not be labeled in each of <FIG>, <FIG> and <FIG>, but reference numerals associated therewith may be utilized herein for consistency.

In <FIG>, <FIG> and <FIG>, referred to above, the blocks may represent operations, steps, and/or portions thereof and lines connecting the various blocks do not imply any particular order or dependency of the operations or portions thereof. It will be understood that not all dependencies among the various disclosed operations are necessarily represented. <FIG>, <FIG> and <FIG> and the accompanying disclosure describing the operations of the disclosed methods set forth herein should not be interpreted as necessarily determining a sequence in which the operations are to be performed. Rather, although one illustrative order is indicated, it is to be understood that the sequence of the operations may be modified when appropriate. Accordingly, modifications, additions and/or omissions may be made to the operations illustrated and certain operations may be performed in a different order or simultaneously. Additionally, those skilled in the art will appreciate that not all operations described need be performed.

There is provided a method for shaping a composite structure, the method comprising steps of:.

The method further comprises selectively applying tension along at least a portion of the length of the composite member while forming the final contour along the length of the composite member or more than one of the unformed portions are concurrently shaped into the formed portions.

Preferably, each one of the unformed portions is consecutively shaped into one of the formed portions.

Preferably, the method further comprises applying heat to the composite member while forming the final contour along the length of the composite member.

Preferably, the method further comprises compacting the composite member after forming the final contour along the length of the composite member.

Preferably, the step of forming the final contour along the length of the composite member is performed while placing the composite member on a place tool.

Preferably, the method further comprises:.

There is further provided a system for forming a composite structure, the system comprising:.

The operations further comprise selectively applying tension along at least a portion of length of the composite member while forming the final contour along the length of the composite member.

Preferably, the system further comprises a sensor configured to detect a location of the composite member relative to the place tool,
wherein the operations further comprise:.

There is further provided an automated method for shaping a composite structure, the automated method comprising steps of:.

Preferably, the automated method further comprises moving at least one of the automated manipulators relative to at least another one of the automated manipulators to apply tension along at least a portion of the length of the composite member while forming the final contour along the length of the composite member.

Preferably, the automated method further comprises using a heater of at least one of the automated manipulators to apply heat to the composite member while forming the final contour along the length of the composite member.

Preferably, the automated method further comprises using a compactor of at least one of the automated manipulators to compact the composite member after forming the final contour along the length of the composite member.

Preferably, the automated method further comprises:.

Further, references throughout the present specification to features, advantages, or similar language used herein do not imply that all of the features and advantages that may be realized with the examples disclosed herein should be, or are in, any single example. Rather, language referring to the features and advantages is understood to mean that a specific feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussion of features, advantages, and similar language used throughout the present disclosure may, but do not necessarily, refer to the same example.

Claim 1:
A method (<NUM>) for shaping a composite structure (<NUM>), the method (<NUM>) comprising steps of:
holding a composite member (<NUM>) in an initial contour (<NUM>) along a length (<NUM>) of the composite member (<NUM>);
forming a final contour (<NUM>) along the length (<NUM>) of the composite member (<NUM>) by:
sequentially shaping unformed portions (<NUM>) of the composite member (<NUM>) into formed portions (<NUM>) while holding remaining unformed portions (<NUM>) of the composite member (<NUM>) in the initial contour (<NUM>); and
sequentially shaping the remaining unformed portions (<NUM>) of the composite member (<NUM>);
selectively applying tension (<NUM>) along at least a portion of the length (<NUM>) of the composite member (<NUM>) while forming the final contour (<NUM>) along the length (<NUM>) of the composite member (<NUM>); and
varying the tension (<NUM>) applied to at least a portion of the composite member (<NUM>) during the step of forming the final contour (<NUM>).