Patent Description:
Multi-layer laminates of constituent material (e.g., Carbon Fiber Reinforced Polymer (CFRP)) may be formed into any of a variety of shapes for hardening into a composite part. To facilitate the fabrication of composite parts, a robot such as an Automated Fiber Placement (AFP) machine may be utilized. For example, a large (e.g., multi-ton) AFP machine may occupy a cell, wherein the AFP machine lays up one or more layers of tows of constituent material that form a laminate which is then cured.

Fabrication of a composite part remains time consuming, however, because individual operations such as layup, consolidation, bagging, and curing are performed at different cells within the fabrication environment, and technicians must physically transport laminates on carts before proceeding with a next step of the fabrication process in another cell.

Therefore, it would be desirable to have a method and system that take into account at least some of the issues discussed above, as well as other possible issues.

The abstract of <CIT>, states: 'A manufacturing system includes a plurality of lamination heads (<NUM>) and a head-moving system defining a continuous loop lamination path (<NUM>) configured to move the lamination heads (<NUM>) in series along the lamination path (<NUM>). The manufacturing system also includes at least one lamination mandrel (<NUM>, <NUM>, <NUM>) positioned along a portion of the lamination path (<NUM>). The lamination heads (<NUM>) are each configured to dispense a layup material (<NUM>) onto the at least one lamination mandrel (<NUM>, <NUM>, <NUM>) or onto layup material (<NUM>) previously applied onto the lamination mandrel (<NUM>, <NUM>,<NUM>) while the lamination heads (<NUM>) are moved by the head-moving system through one or more revolutions of the lamination path (<NUM>) to lay up a composite laminate (<NUM>, <NUM>,<NUM>).

Embodiments described herein provide for lamination machines that actively lay up a laminate while a mandrel for the laminate (and the lamination machine itself) is being transported. This provides twin benefits of layup and transportation within a single station, and enables laminates to be fabricated as part of a continuous, moving line process. This arrangement also breaks down fabrication work into smaller portions, and enables immediate detection and response to out-of-tolerance conditions encountered during layup.

One embodiment is a method for forming a laminate. The method includes indexing a layup mandrel to a lamination station disposed at a first location, transporting the lamination station and the layup mandrel in a process direction from the first location towards a second location, laying up the laminate having layers of fiber-reinforced material onto the layup mandrel via a lamination machine while the lamination machine and the layup mandrel are transported in the process direction, removing the layup mandrel and the laminate at the second location, and returning the lamination station to the first location for laying up another laminate onto another mandrel.

A further embodiment is a non-transitory computer readable medium embodying programmed instructions which, when executed by a processor, are operable for performing a method for forming a laminate. The method includes indexing a layup mandrel to a lamination station disposed at a first location, transporting the lamination station and the layup mandrel in a process direction from the first location towards a second location, laying up the laminate having layers of fiber-reinforced material onto the layup mandrel via a lamination machine while the lamination machine and the layup mandrel are transported in the process direction, removing the layup mandrel and the laminate at the second location, and returning the lamination station to the first location for laying up another laminate onto another mandrel.

A further embodiment is a system for forming a laminate having multiple layers of fiber-reinforced material. The system includes a lamination station includes a layup mandrel having mandrel indexing elements. The lamination system further includes a shuttle having shuttle indexing elements for engaging the mandrel indexing elements of the layup mandrel. The lamination station further includes a lamination machine attached to the shuttle, and the lamination system further includes a drive system that transports the shuttle in a process direction while the lamination machine lays up the layers of the laminate onto the layup mandrel.

Other illustrative embodiments (e.g., methods and computer-readable media relating to the foregoing embodiments) may be described below. The features, functions, and advantages that have been discussed can be achieved independently in various embodiments or may be combined in yet other embodiments further details of which can be seen with reference to the following description and drawings.

The figures and the following description provide specific illustrative embodiments of the disclosure. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the disclosure and are included within the scope of the disclosure. Furthermore, any examples described herein are intended to aid in understanding the principles of the disclosure, and are to be construed as being without limitation to such specifically recited examples and conditions. As a result, the disclosure is not limited to the specific embodiments or examples described below, but by the claims.

Composite parts, such as CFRP parts, are initially laid-up in multiple layers that together are referred to as a laminate or "preform. " Individual fibers within each layer of the laminate are aligned parallel with each other, but different layers may exhibit different fiber orientations in order to increase the strength of the resulting composite part along different dimensions. The laminate may include a viscous resin that solidifies in order to harden the laminate into a composite part (e.g., for use in an aircraft). Carbon fiber that has been impregnated with an uncured thermoset resin or a thermoplastic resin is referred to as "prepreg. " Other types of carbon fiber include "dry fiber" which has not been impregnated with thermoset resin but may include a tackifier or binder. Dry fiber may be infused with resin prior to curing. For thermoset resins, the hardening is a one-way process referred to as curing, while for thermoplastic resins, the resin may reach a viscous form if it is re-heated.

<FIG> is a schematic diagram of a lamination system <NUM> for use within a manufacturing line <NUM>. The lamination system <NUM> can be one system in a series of systems that make up the manufacturing line <NUM>. For example, the manufacturing line <NUM> can further include a fastener installation system positioned after the lamination system <NUM>. The lamination system <NUM>, and more specifically the lamination station <NUM>, is used to form a laminate <NUM>. The laminate <NUM> includes at least a first layer <NUM> and a second layer <NUM> of fiber-reinforced material <NUM>.

The lamination system <NUM> has a lamination station <NUM> and a layup mandrel <NUM>. The lamination system <NUM> can include more than one lamination station <NUM> such that a first lamination station <NUM> and a second lamination station <NUM>' are in series along a process direction <NUM> of the manufacturing line <NUM>. In such an embodiment, the lamination system <NUM> further includes a transfer machine <NUM> that can move between the lamination stations <NUM>, <NUM>' of the lamination system <NUM>. The transfer machine <NUM> is configured to remain stationary during transfer of the layup mandrel <NUM>, as described in more detail with respect to <FIG>.

Referring still to <FIG>, the lamination system <NUM> further includes a drive system <NUM>. The drive system <NUM> moves the lamination station <NUM> and/or the layup mandrel <NUM> to perform the methods described herein. More specifically, the drive system <NUM> moves the lamination station <NUM> from a first location <NUM> to or toward a second location <NUM> along the process direction <NUM>. In the examples described herein, the drive system <NUM> moves the shuttle <NUM> of the lamination station <NUM> from the first location <NUM> toward the second location <NUM>. The lamination system <NUM> can further include a track system <NUM>. When the lamination system <NUM> includes the track system <NUM>, the drive system <NUM> moves the lamination station <NUM> and/or the layup mandrel <NUM> along the track system <NUM> at least from the first location <NUM> toward the second location <NUM>. Further, the drive system <NUM> can include an electrified/powered rail <NUM>. The powered rail <NUM> can be integrated into a track on the track system <NUM> or can be separate from the tracks of the track system. When the powered rail <NUM> is included in the lamination system <NUM>, the drive system <NUM> moves the shuttle <NUM> along the powered rail <NUM> to transport the lamination station <NUM>.

Further, the lamination system <NUM> can include more than one layup mandrel <NUM>, such as including the layup mandrel <NUM> and anew layup mandrel <NUM>'. The layup mandrels <NUM>, <NUM>' can be used within the same lamination station <NUM> or can each be used with a respective lamination station <NUM>, <NUM>'. The layup mandrel <NUM> includes mandrel indexing elements <NUM>, as will be explained in more detail below. When the lamination system <NUM> includes more than one layup mandrel <NUM>, <NUM>', each layup mandrel <NUM>, <NUM>' includes the mandrel indexing elements <NUM>.

<FIG> is a schematic block diagram of the lamination station <NUM> than can be used in the lamination system <NUM>. Lamination station <NUM> comprises any system, device, or component operable lay up a laminate <NUM> onto the layup mandrel <NUM> while the layup mandrel <NUM> is moving continuously in the process direction <NUM>. As described in more detail with respect to <FIG>, <FIG>, and <FIG>, the lamination station <NUM> can also move in a counter process direction <NUM> through the lamination system <NUM>. Referring to <FIG>, the lamination station <NUM> includes a shuttle <NUM> and a lamination machine <NUM>. In this embodiment, the lamination station <NUM> is associated with the track system <NUM> along which a shuttle <NUM> is transported by the drive system <NUM>. The drive system <NUM> can include a chain drive <NUM> that is coupled with the track system <NUM> or an engine <NUM> that moves along the track system <NUM>. In such embodiments, power may be provided to the shuttle <NUM> (e.g., a platen, vacuum platen, flat surface, etc.) (or the engine <NUM> that drives shuttle <NUM>) via the electrified or powered rail <NUM> of the track system <NUM>. In still further embodiments, shuttle <NUM> is transported by an Autonomous Guided Vehicle (AGV) or other automated device acting as the drive system <NUM>, and the track system <NUM> is not used. The shuttle <NUM> includes shuttle indexing elements <NUM>, such as cups of a cup-and-cone indexing system.

Shuttle indexing elements <NUM> enable the layup mandrel <NUM> to be removably placed at shuttle <NUM> at a known offset from the lamination machine <NUM>. The layup mandrel <NUM> includes mandrel indexing elements <NUM>, which are complementary to shuttle indexing elements <NUM>. The shuttle indexing elements <NUM> are configured to engage, such as receive, the mandrel indexing elements <NUM>. The engagement of the shuttle indexing elements <NUM> and the mandrel indexing elements <NUM> align the layup mandrel <NUM> to the shuttle <NUM>. For example, in an embodiment as shown in <FIG> where the shuttle indexing elements <NUM> are cups, the mandrel indexing elements <NUM> are cones having a shape complementary to a shape of the cups. This enables indexing the layup mandrel <NUM> to the shuttle <NUM> via complementary indexing elements disposed at the layup mandrel <NUM> and the shuttle <NUM>.

The lamination machine <NUM> is disposed on/affixed to the shuttle <NUM>, which is driven in the process direction <NUM>. Lamination machine <NUM> lays up the laminate <NUM> having layers <NUM>, <NUM> of a fiber-reinforced material <NUM> including resin <NUM> reinforced by fibers <NUM>. In one embodiment, each layer <NUM>, <NUM> laid-up by the lamination machine <NUM> includes a tow of unidirectional fiber-reinforced polymer. The lamination machine <NUM> includes an end effector <NUM>. The end effector <NUM> can be driven by a kinematic chain <NUM>. In some embodiments, the kinematic chain <NUM> and the end effector <NUM> are a robot arm. The end effector <NUM> includes a head <NUM>, which is capable of dispensing fiber-reinforced material <NUM> stored in a spool <NUM> at desired fiber orientations (e.g., zero degrees, plus forty-five degrees, minus forty-five degrees, and ninety degrees).

The lamination machine <NUM> further includes a controller <NUM> and a memory <NUM>. The controller <NUM> operates the kinematic chain <NUM> to control the movements of the end effector <NUM>, according to instructions stored in a Numerical Control (NC) program in the memory <NUM>. Upon depletion of the fiber-reinforced material <NUM> from the spool <NUM>, the controller <NUM> operates the kinematic chain <NUM> and the end effector <NUM> to remove the head <NUM> and acquire a spare <NUM> of spare head <NUM>' and/or to remove the spool <NUM> and replace the spool <NUM> with a spare spool <NUM>' that is fully loaded with fiber-reinforced material <NUM>. The spare(s) <NUM> (e.g., spare head <NUM>', spare spool <NUM>') may be stored on the shuttle <NUM>, on a second shuttle <NUM>', or at a known location along the track system <NUM>. The controller <NUM> may be implemented, for example, as custom circuitry, as a hardware processor executing programmed instructions, or some combination thereof.

In further embodiments, a power supply <NUM> and/or a gas supply <NUM> are disposed upon the shuttle <NUM> for powering and supplying pressurized gas to the lamination machine <NUM>. In still further embodiments, the shuttle <NUM> includes an interface (I/F) <NUM> that couples with the powered rail <NUM> of the drive system <NUM>. The interface <NUM> is configured to acquire power from the electrified/powered rail <NUM> of the track system <NUM>. That is, the interface <NUM> couples with the powered rail <NUM> along which the drive system <NUM> transports the shuttle <NUM> to deliver power to shuttle <NUM> of components thereon, such as delivering power to the lamination machine <NUM> on the shuttle <NUM>.

During operation, the layup mandrel <NUM> is loaded onto the shuttle <NUM>, and the shuttle <NUM> moves in the process direction <NUM> while lamination machine <NUM> lays up the laminate <NUM> on the layup mandrel <NUM>. The layup mandrel <NUM> (and the laminate <NUM>) then proceed to second lamination station <NUM>' in the lamination system <NUM> or to another system in the manufacturing line <NUM> (show in <FIG>) for additional lamination (if needed), to be consolidated, bagged, and cured, or otherwise prepared for fabrication into a composite part.

<FIG> is a perspective view of the shuttle <NUM> carrying the lamination machine <NUM> and the layup mandrel <NUM> in an illustrative embodiment. In this embodiment, the lamination machine <NUM> moves along path <NUM> attached to or defined in a body <NUM> of the shuttle <NUM>. The path <NUM> enables the lamination machine <NUM> to move a first direction <NUM> that is the same as the process direction <NUM> or in a second direction <NUM> opposite of the process direction <NUM>. The lamination machine <NUM> can move either first direction <NUM> or second direction <NUM> in the path <NUM> regardless of which direction <NUM> or <NUM> the shuttle <NUM> is moving in. Accordingly, the lamination machine <NUM> can move in the first direction <NUM> to lay up the first layer <NUM> on the layup mandrel <NUM> and move in the second direction <NUM> to lay up the second layer <NUM> on the first layer <NUM>. The lamination machine <NUM> can move back and forth in the path <NUM> to lay up the layers <NUM>, <NUM> of the laminate <NUM> while the shuttle <NUM> moves in the process direction <NUM>, the counter process direction <NUM>, or is stationary.

For example, the lamination machine <NUM> moves along the path <NUM> during operation at the shuttle <NUM>, which enables an end effector <NUM>, such as the head <NUM> of the end effector <NUM>, of the lamination machine <NUM> to lay up layers <NUM>, <NUM>, such as tows, of fiber-reinforced material <NUM> along a length L of a laminate <NUM>. Body <NUM> of the shuttle <NUM> may be carried by the track system <NUM> (shown in <FIG> and <FIG>), driven by a tug platform along the track system <NUM>, carried by an AGV, or otherwise transported between locations within the lamination station <NUM>, lamination system <NUM>, and/or manufacturing line <NUM>. However, the possible variations of transportation of the shuttle <NUM> are not illustrated in <FIG> for the sake of brevity. This transportation process helps to facilitate handing-off of the laminate <NUM> between lamination stations <NUM>, <NUM>' that perform repetitive or different actions upon the laminate <NUM>.

<FIG> is a section cut view of the shuttle <NUM> of <FIG> in an illustrative embodiment. <FIG> illustrates that the shuttle <NUM> includes a mechanical coupling <NUM> (e.g., a hook) for engaging with the drive system <NUM> (shown in <FIG>), such as a chain drive, in order to be transported along the track system <NUM> (shown in <FIG> and <FIG>). <FIG> further illustrates that the layup mandrel <NUM> includes cones <NUM> as the mandrel indexing elements <NUM>, and the shuttle <NUM> includes cups <NUM> as the shuttle indexing elements <NUM>. The cones <NUM> engage with (i.e., receive) the cups <NUM> to facilitate indexing the layup mandrel <NUM> to the shuttle <NUM>. The geometry of the shuttle indexing element <NUM> and mandrel indexing element <NUM> automatically aligns the layup mandrel <NUM> with the shuttle <NUM> when the layup mandrel <NUM> is placed at the shuttle <NUM> (so long as a tip of each cone <NUM> is placed anywhere within its corresponding cups <NUM>). That is, the weight of the layup mandrel <NUM> pushes the layup mandrel <NUM> into place such that the cones <NUM> are centered on the cups <NUM> when the layup mandrel <NUM> is released.

With a discussion of the design of the shuttle <NUM> and constituent components provided above with regard to <FIG> and <FIG>, further discussion in <FIG> and <FIG> focuses upon the arrangement of the track system <NUM> and shuttles <NUM> within a lamination station <NUM> in a manner that facilitates fabrication processes.

<FIG> is a top view of the lamination station <NUM> that includes the shuttle <NUM> of <FIG> in an illustrative embodiment. As shown in <FIG>, the track system <NUM> can include a first track <NUM>, a second track <NUM>, and a third track <NUM>. The track system <NUM> further includes a first switch track <NUM> and a second switch track <NUM> extending between at least two tracks <NUM>, <NUM> of the track system <NUM>. In <FIG>, the shuttle <NUM> traverses between the first track <NUM> and the second track <NUM> via the switch tracks <NUM> and <NUM>. The lamination machine <NUM> performs layup while shuttle <NUM> proceeds along the first track <NUM>. The lamination machine <NUM> may be recharged, restocked, or otherwise replenished before proceeding via the first switch track <NUM> and the second track <NUM> to receive another mandrel (e.g., the new layup mandrel <NUM>' shown in <FIG>) for layup. Upon reaching the first switch track <NUM>, the lamination machine <NUM> may be disconnected from umbilicals or other components that provide power and pressurized gas to the lamination machine <NUM>. In further embodiments, however, the lamination machine <NUM> is powered by self-contained power and pressure sources within or on the shuttle <NUM>, such as the power supply <NUM> and/or the gas supply <NUM>.

During operation as the layup mandrel <NUM> proceeds in the process direction <NUM> atop the shuttle <NUM>, a second shuttle <NUM> is transported across the third track <NUM> at the same rate as the shuttle <NUM> is transported across the first track <NUM>. A second lamination machine <NUM> at the second shuttle <NUM> proceeds to perform layup in tandem with the lamination machine <NUM>. For example, both of these lamination machines <NUM>, <NUM> may be operated according to the same NC program.

In short, as shown in <FIG>, fabrication processes can include transporting an additional, second lamination machine <NUM> in the process direction <NUM> from a first location <NUM> towards a second location <NUM>, and laying up the laminate <NUM> can be performed via coordinated action of the lamination machine <NUM> and the additional, second lamination machine <NUM>. In such circumstances, the fabrication rate is increased by the use of two of end effector <NUM> (e.g., the heads <NUM> of the end effectors <NUM>) working to build the laminate <NUM> simultaneously. In this manner, multiple lamination machines <NUM>, <NUM> may be operated simultaneously to apply the layers <NUM>, <NUM> of fiber-reinforced material <NUM> (shown in <FIG> and <FIG>) onto the same layup mandrel <NUM>. For example, the lamination machine <NUM> lays up the first layer <NUM> on to the layup mandrel <NUM>, and the second lamination machine <NUM> follows the lamination machine <NUM> to lay up the second layer <NUM> on to the first layer <NUM> to form the laminate <NUM>.

The embodiment in <FIG> also allows the lamination system <NUM> to form at least two different portions <NUM>, <NUM>, <NUM>, <NUM> of the laminate <NUM> simultaneously using different lamination machines <NUM>, <NUM> at the same lamination station <NUM>. Alternatively, the different portions <NUM>, <NUM>, <NUM>, <NUM> of the laminate <NUM> can be simultaneously formed by different lamination machines <NUM>, <NUM>' in different lamination stations <NUM>, <NUM>'. In the example shown in <FIG>, the first lamination machine <NUM> forms a first axial portion <NUM>/<NUM> of the laminate <NUM>, and the second lamination machine <NUM> forms a second axial portion <NUM>/<NUM> of the laminate <NUM>. Alternatively, the first lamination machine <NUM> forms a first longitudinal portion <NUM>/<NUM> of the laminate <NUM>, and the second lamination machine <NUM> forms a second longitudinal portion <NUM>/<NUM> of the laminate <NUM>. The portions <NUM>, <NUM>, <NUM>, and/or <NUM> can also be individual layers or subsets of layers that make up the laminate <NUM>.

<FIG> is a top view of the lamination system <NUM> having multiple lamination stations <NUM>, <NUM>', <NUM>" that interact with each other in an illustrative embodiment. The lamination stations <NUM>, <NUM>', <NUM>" may interact with each other to hand-off laminates <NUM> (or hardened composite parts) in order to perform different tasks, such as lamination, consolidation, bagging, curing, etc., as the layup mandrel <NUM> is transported (e.g., along the track system <NUM>) in the process direction <NUM>. Each lamination station <NUM>, <NUM>', <NUM>" can be configured similarly (e.g., has the same components), as described with respect to <FIG>. However, in the embodiment of <FIG>, each lamination station <NUM> is slightly differently configured. For example, a first lamination station <NUM> is a lamination station <NUM> as described above, a second lamination station <NUM>' is a consolidation station <NUM>, and a third lamination station <NUM>" is a bagging station <NUM>.

In the embodiment of <FIG>, the first lamination station <NUM> lays up the laminate <NUM> on to the layup mandrel <NUM>, and the second consolidation station <NUM> receives the laminate <NUM> by picking up the layup mandrel <NUM> from the first lamination station <NUM> and consolidates the laminate <NUM>. The third bagging station <NUM> receives the consolidated laminate <NUM> by picking up the layup mandrel <NUM> and applies a vacuum bag <NUM> atop the consolidated laminate <NUM>. The layup mandrel <NUM> may then be moved to a heater (e.g., an autoclave) and hardened.

<FIG> is a top view of a transfer of the layup mandrel <NUM> between lamination stations <NUM>, <NUM>' using the transfer machine <NUM>. In the illustrative embodiment of <FIG>, the transfer machine <NUM> transfers the layup mandrel <NUM> between the shuttle <NUM> of the first lamination station <NUM> and a second shuttle <NUM>' of the second lamination station <NUM>'. According to <FIG>, the transfer machine <NUM> is stationary while the shuttles <NUM>, <NUM>' move with respect to the transfer machine <NUM> to transfer the layup mandrel <NUM> between shuttles <NUM> and <NUM>'. The transfer machine <NUM> has arms <NUM> that can be inserted into the layup mandrel <NUM>, and moves the arms <NUM> in a transfer direction <NUM>. The transfer direction <NUM> can be the same as the process direction <NUM>; however, the transfer direction <NUM> can be opposite the process direction <NUM>. This transfers the layup mandrel <NUM> from the shuttle <NUM> on the left, first lamination station <NUM> to a second shuttle <NUM>' on the right, second lamination station <NUM>' for continuing layup of the laminate <NUM>.

<FIG> is a top view of top view of the lamination system <NUM> having multiple lamination stations <NUM>, <NUM>', <NUM>", <NUM>‴ that fabricate laminates <NUM> in two directions <NUM> and <NUM> in an illustrative embodiment. Embodiments that utilize multiple lamination stations <NUM>, working in two directions <NUM>, <NUM> provide a technical benefit by enhancing throughput and/or ensuring that work is performed during all movements of the lamination stations <NUM>. Further, each of the lamination stations <NUM> can operate on the same track system <NUM> or at least one of the lamination stations <NUM> operates on a separate track system or AGV. Each of the first lamination station <NUM>, the second lamination station <NUM>', the third lamination station <NUM>", and a fourth lamination station <NUM>‴ include at least some similar components to perform similar lamination processes simultaneously to form respective laminate <NUM>. Alternatively, lamination stations <NUM> on the same track, first track <NUM> or second track <NUM> of the track system <NUM> work together to perform different parts of the composite fabrication process to form a laminate <NUM> or <NUM>". The laminates <NUM> and <NUM>" can be the same type or different types of laminates. In such an embodiment, the lamination stations <NUM> can be similarly configured with end effectors <NUM> capable of performing multiple different composite fabrication processes and/or forming more than one type of laminate.

According to <FIG>, the shuttle <NUM> of the first lamination station <NUM> and the second shuttle <NUM>' operate to layup a first laminate <NUM> while proceeding rightward along the first track <NUM>. Third shuttle <NUM>" of the third lamination station <NUM>" and the fourth shuttle <NUM>‴ of the fourth lamination station <NUM>‴ operate to layup a second laminate <NUM>" while proceeding leftward along the second track <NUM>. The shuttles <NUM> and <NUM>" move in a loop from the first track <NUM>, to the first switch track <NUM>, to the second track <NUM>, to the second switch track <NUM>, and back to the first track <NUM>.

The first lamination station <NUM> operates the lamination machine <NUM> to place the first laminate <NUM> onto the layup mandrel <NUM>, and third lamination station <NUM>" operates a lamination machine <NUM>" to place the second laminate <NUM>" onto a mandrel <NUM>". The first laminate <NUM> is transferred from the shuttle <NUM> to the second shuttle <NUM>' (e.g., using the transfer machine <NUM>) and proceeds rightward (e.g., in the process direction <NUM>), while second laminate <NUM>" is transferred from the third shuttle <NUM>" to the fourth shuttle <NUM>‴ (e.g., using a second transfer machine <NUM>'), and proceeds leftward (e.g., in the counter process direction <NUM>). In this manner, by operating iteratively, the lamination stations <NUM>, <NUM>', <NUM>", <NUM>‴ can fabricate two separate types of laminates <NUM>, <NUM>' along the process direction <NUM> and an opposite, counter process direction <NUM>.

Illustrative details of the operation of the lamination system <NUM> and the lamination station <NUM> will be discussed with regard to <FIG>. Assume, for this embodiment, that a layup mandrel <NUM> is disposed proximate to shuttle <NUM> within reach of end effector <NUM>, such as within reach of an actuated arm of the end effector <NUM>.

<FIG> is a flowchart illustrating a method <NUM> for operating the lamination system <NUM> and the lamination station <NUM> shown in <FIG> to form the laminate <NUM>. The steps of method <NUM> are described with reference to the lamination station <NUM>, but those skilled in the art will appreciate that method <NUM> may be performed in other systems. The steps of the flowcharts described herein are not all inclusive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

Referring to <FIG>, <FIG>, and <FIG>, the method <NUM> includes indexing <NUM> the layup mandrel <NUM>, transporting <NUM> the lamination station <NUM> and the layup mandrel <NUM>, and laying up <NUM> the laminate <NUM> onto the layup mandrel <NUM> via the lamination machine <NUM>. The method <NUM> further includes removing <NUM> the layup mandrel <NUM> and the laminate <NUM> and returning the lamination station <NUM> to the first location <NUM>.

When the lamination system <NUM> is configured as in <FIG>, the method <NUM> can start by subdividing <NUM> the laminate <NUM> into portions <NUM>, <NUM>, <NUM>, and/or <NUM>. The indexing <NUM>, transporting <NUM>, laying up <NUM>, removing <NUM>, and returning <NUM> are performed independently at each of multiple lamination machines <NUM>, <NUM> arranged along the process direction <NUM>. Each of the multiple lamination machines <NUM>, <NUM> forms one of the portions <NUM>, <NUM>, <NUM>, and/or <NUM> of the laminate <NUM>. In one embodiment, the laminate <NUM> is subdivided <NUM> into portions <NUM>, <NUM>, <NUM>, and/or <NUM> (e.g., lengthwise portions, specific subsets of layers, etc.), and the indexing <NUM>, transporting <NUM>, laying up <NUM>, removing <NUM>, and returning <NUM> is performed independently at each of multiple lamination machines <NUM>, <NUM>' and/or multiple lamination stations <NUM>, <NUM>' arranged along the process direction <NUM>. Each of the multiple lamination machines <NUM>, <NUM>' lays up <NUM> one of the portions <NUM>, <NUM>, <NUM>, and/or <NUM> of the laminate <NUM> that was subdivided <NUM>, and the in-process laminate <NUM> is handed-off between the lamination machines <NUM>, <NUM>'.

In indexing <NUM>, the layup mandrel <NUM> is indexed to the lamination station <NUM>. More specifically, the layup mandrel <NUM> is indexed <NUM> to the shuttle <NUM> of the lamination station <NUM> while the lamination station <NUM> is at a first location <NUM> (e.g., a left side of the track system <NUM>). Indexing <NUM> the layup mandrel <NUM> to the lamination station <NUM> also indexes the layup mandrel <NUM> to the lamination machine <NUM>. Indexing <NUM> the layup mandrel <NUM> to the lamination machine <NUM> happens when the layup mandrel <NUM> is indexed to the shuttle <NUM>, on which the lamination machine <NUM> is disposed. Indexing <NUM> the layup mandrel <NUM> to the lamination machine <NUM> includes indexing the layup mandrel <NUM> to the shuttle <NUM> via mandrel indexing elements <NUM> and shuttle indexing elements <NUM> disposed at the layup mandrel <NUM> and the shuttle <NUM>.

Indexing <NUM> the layup mandrel <NUM> may include lifting or sliding the layup mandrel <NUM> into a position wherein the mandrel indexing elements <NUM> align and/or engage with the shuttle indexing elements <NUM>. The indexing <NUM> may be performed by an actuated arm (e.g., the kinematic chain <NUM> and the end effector <NUM> of the lamination machine <NUM>, or another robot arm outside of the lamination station <NUM>) picking up and placing the layup mandrel <NUM> into position on the shuttle <NUM> based on instructions in an NC program. In a further embodiment, pick up by a robot is not necessary, as joining via indexing <NUM> may occur where a platform track and a mandrel track intersect and shuttle indexing elements <NUM> and mandrel indexing element <NUM> align and/or engage.

In transporting <NUM>, the lamination machine <NUM> and the layup mandrel <NUM> are transported in the process direction <NUM> from the first location <NUM> towards a second location <NUM> (e.g., a final location at a right side of the track system <NUM> when viewing the figures). For example, the shuttle <NUM> is driven in the process direction <NUM> to transport <NUM> the lamination machine <NUM> and the layup mandrel <NUM>. To perform the transport <NUM> operation, the controller <NUM> may direct the drive system <NUM> to move the shuttle <NUM> along the track system <NUM> at a desired rate of speed. In embodiments where the drive system <NUM> comprises an AGV, the drive system <NUM> may be independently operated by another controller. In embodiments where the drive system <NUM> comprises a chain drive, a mechanical coupling <NUM> (shown in <FIG>) at the shuttle <NUM> may engage with the chain drive in order to transport <NUM> the shuttle <NUM> at the desired rate of speed. In examples of the lamination system <NUM> as shown in <FIG>, shuttles <NUM> at each of multiple lamination station <NUM> may be transported via the drive system <NUM> in order to ensure that the lamination station <NUM> operate at a uniform rate of speed.

In laying up <NUM>, the lamination machine <NUM> lays up the laminate <NUM> having layers <NUM>, <NUM> of fiber-reinforced material <NUM> onto the layup mandrel <NUM>. In the exemplary embodiment, the laying up <NUM> occurs while the lamination station <NUM> and the layup mandrel <NUM> are transported <NUM> in the process direction <NUM>. When the lamination system <NUM> is configured as in <FIG>, the transporting <NUM> and laying up <NUM> are also performed when the lamination station <NUM> and the layup mandrel <NUM> are moving in the counter process direction <NUM>. Laying up <NUM> includes laying the first layer <NUM> on to the layup mandrel <NUM>, laying the second layer <NUM> on the first layer <NUM>, and so on until the layers of the laminate <NUM> are laid up <NUM> on the layup mandrel <NUM>.

In one embodiment, laying up <NUM> the laminate <NUM> includes operating <NUM> the lamination machine <NUM> in the first direction <NUM> in the process direction <NUM> to lay up <NUM> the first layer <NUM> and operating <NUM> the lamination machine <NUM> in the second direction <NUM> opposed to the process direction <NUM> to lay up <NUM> the second layer <NUM>. The operating steps <NUM>, <NUM> are repeated to add more layers to build up the laminate <NUM>. That is, during laying up <NUM> the lamination machine <NUM> moves <NUM> independently of the process direction <NUM> and may move in any suitable direction to perform laying up <NUM>.

Laying up <NUM> the laminate <NUM> includes moving <NUM> the lamination machine <NUM> independently of the process direction <NUM>. More specifically, the lamination machine <NUM> is moved <NUM> independently of the direction the shuttle <NUM> of the lamination station <NUM> moves because the lamination machine <NUM> moves <NUM> along the path <NUM> with respect to the shuttle <NUM>, as described in more detail with respect to <FIG>.

When the lamination system <NUM> includes multiple lamination machines <NUM>, <NUM> as shown in <FIG>, laying up <NUM> the laminate <NUM> includes operating <NUM> the multiple lamination machines <NUM>, <NUM> simultaneously to apply the layers <NUM>, <NUM> of the fiber-reinforced material <NUM> onto the layup mandrel <NUM>.

Because the layup mandrel <NUM> is indexed <NUM> to the shuttle <NUM>, and because the lamination machine <NUM> is affixed to the shuttle <NUM>, any offset between the lamination machine <NUM> and the layup mandrel <NUM> is known. This means that, regardless of the location of the shuttle <NUM> along the track system <NUM>, the lamination machine <NUM> continues to operate in accordance with an NC program without interruption.

Referring again to transporting <NUM>, in a further embodiment, the end effector <NUM> consolidates <NUM> the laminate <NUM> while the lamination station <NUM> and the layup mandrel <NUM> are transported <NUM> in the process direction <NUM> (and/or the counter process direction <NUM> when the lamination system <NUM> is configured as in <FIG>). The consolidation <NUM> is performed by applying pressure to the laminate <NUM> while the lamination station <NUM> and the layup mandrel <NUM> are transported <NUM> in the process direction <NUM> (and/or the counter process direction <NUM> when the lamination system <NUM> is configured as in <FIG>). The rate of transportation <NUM> of the shuttle <NUM> may be any desired speed, such as a tenth of one mile per hour (<NUM> meters per second), or other speeds.

During laying up <NUM>, the spool <NUM> at the head <NUM> may run out of fiber-reinforced material <NUM> or the lamination machine <NUM> may be programmed to perform a subsequent process using a different head. In such instances, the method <NUM> includes replacing <NUM> the head <NUM> and/or the spool <NUM> during the transporting <NUM>. For example, the head <NUM> is replaced <NUM> with the spare head <NUM>' and/or the spool <NUM> is replaced <NUM> with the spare spool <NUM>' as the lamination station <NUM> is transported <NUM> in the process direction <NUM> or in the counter process direction <NUM>. In a particular example, the controller <NUM> may operate the kinematic chain <NUM> and the end effector <NUM> to replace <NUM> the head <NUM> (or spool <NUM>) of the lamination machine <NUM> during transport <NUM>. The replacement <NUM> may include acquiring a spare <NUM>, such as the spare head <NUM>' and/or the spare spool <NUM>', from the shuttle <NUM>, or from a second shuttle <NUM>' traveling at the same speed in the same direction, and/or at an off-shuttle location at a known offset from the shuttle <NUM> and/or track system <NUM>.

In removing <NUM>, the layup mandrel <NUM> and the laminate <NUM> are removed at the second location <NUM>. More specifically, the layup mandrel <NUM> having the laminate <NUM> thereon is removed <NUM> from the lamination station <NUM> at the second location <NUM>. In one embodiment, the removing <NUM> includes operating a robot arm (e.g., at the lamination machine <NUM>) and/or the transfer machine <NUM> to move the layup mandrel <NUM> (and hence the laminate <NUM>) from the lamination station <NUM> to another station in the lamination system <NUM> or in the manufacturing line <NUM>. The other station may lay up <NUM> another portion of the laminate <NUM>, may consolidate <NUM> the laminate <NUM> by applying pressure, may apply a vacuum bag <NUM> to the laminate <NUM>, or may even cure the laminate <NUM> via the application of heat.

In returning <NUM>, the lamination station <NUM> is returned to the first location <NUM> for forming an additional laminate <NUM>' onto a new layup mandrel <NUM>'. For example, the lamination machine <NUM> is carried upon the shuttle <NUM>, which is transported <NUM> along the track system <NUM> (such as along parallel tracks <NUM>, <NUM>, <NUM>) to return <NUM> to the first location <NUM>. In one embodiment, the track system <NUM> forms a loop, or includes switch tracks <NUM>, <NUM> for ferrying the shuttle <NUM> to a return track, such as the second track <NUM>. In this manner, multiple shuttles <NUM>, <NUM>' may consistently travel back and forth between the first location <NUM> and the second location <NUM> without interfering with each other.

In one embodiment, before or while returning <NUM> on a loop, the new layup mandrel <NUM>' is indexed <NUM> to the lamination station <NUM>. The indexing <NUM> of the new layup mandrel <NUM>' is similar to the indexing <NUM> of the first layup mandrel <NUM>. For example, mandrel indexing elements <NUM> of the new layup mandrel <NUM>' are aligned and/or engaged with the shuttle indexing elements <NUM> to index <NUM> the new layup mandrel <NUM>' to the shuttle <NUM>. In a particular example, the new layup mandrel <NUM>' is indexed <NUM> to the lamination machine <NUM> while the lamination station <NUM> is at the second location <NUM>.

When the lamination station <NUM> is provided the new layup mandrel <NUM>', the lamination machine <NUM> can continue to perform the laying up <NUM> to form the additional laminate <NUM>' on the new layup mandrel <NUM>'. In such an embodiment, after removing <NUM> the first layup mandrel <NUM>, the lamination station <NUM> and the new layup mandrel <NUM>' are transported <NUM> in the counter process direction <NUM>, opposed to the process direction <NUM>, from the second location <NUM> towards the first location <NUM>. The lamination machine <NUM> lays up <NUM> the additional laminate <NUM>' having layers <NUM>, <NUM> of fiber-reinforced material <NUM> onto the new layup mandrel <NUM>' while the lamination station <NUM> and the new layup mandrel <NUM>' are transported <NUM> opposed to the process direction <NUM>. The transporting <NUM> in the counter process direction <NUM> can be substantially similar to the transporting <NUM> described above. For example, the laying up <NUM>, consolidation <NUM>, and/or replacement <NUM> can occur during the transporting <NUM> in the counter process direction <NUM>.

For the lamination machine <NUM> to perform the steps of method <NUM>, the lamination machine <NUM> is powered <NUM>. More specifically, the lamination machine <NUM> is powered <NUM> by the power supply <NUM> disposed at the shuttle <NUM>. Additionally or alternatively, the lamination machine <NUM> is powered <NUM> via the powered rail <NUM> along which the lamination station <NUM> travels during the transporting <NUM>. The powering <NUM> occurs at least during laying up <NUM> and can also occur during the transporting <NUM> (e.g., to perform the consolidation <NUM> and/or replacement <NUM>) or any other step of the method <NUM> where the lamination machine <NUM> is performing an action or is in an inactive, but ready, state.

Method <NUM> provides an advantage over prior systems and techniques because the method <NUM> can enable continuous, in-line fabrication techniques to be applied to composite parts, such as stringers or frames of an aircraft (e.g., the aircraft <NUM> shown in <FIG>), while laminates for those parts are in motion through the manufacturing line <NUM> (shown in <FIG>). Furthermore, the method <NUM> does not require specialized, heavy machinery such as an AFP machine. Hence, if one lamination machine <NUM> requires maintenance during the performance of method <NUM>, the lamination machine <NUM>, end effector <NUM>, head <NUM>, or spool <NUM> may be rapidly replaced by a technician (or another AFP machine) without disrupting the fabrication process.

In the following examples, additional processes, systems, and methods are described in the context of continuous-line fabrication process for composite parts.

Referring more particularly to the drawings, embodiments of the disclosure may be described in the context of aircraft manufacturing and service in method <NUM> as shown in <FIG> and an aircraft <NUM> as shown in <FIG>. During pre-production, method <NUM> may include specification and design <NUM> of the aircraft <NUM> and material procurement <NUM>. During production, component and subassembly manufacturing <NUM> and system integration <NUM> of the aircraft <NUM> takes place. The method <NUM> (shown in <FIG>) may be performed during the component and subassembly manufacturing <NUM> to produce a portion of the aircraft <NUM>. Thereafter, the aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service by a customer, the aircraft <NUM> is scheduled for routine work in maintenance and service <NUM> (which may also include modification, reconfiguration, refurbishment, and so on).

Systems and methods embodied herein may be employed during any one or more suitable stages of the production and service described in method <NUM> (e.g., specification and design <NUM>, material procurement <NUM>, component and subassembly manufacturing <NUM>, system integration <NUM>, certification and delivery <NUM>, service <NUM>, maintenance and service <NUM>) and/or to produce any suitable component of aircraft <NUM> (e.g., airframe <NUM>, systems <NUM>, interior <NUM>, propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, environmental system <NUM>).

As shown in <FIG>, the aircraft <NUM> produced by method <NUM> may include an airframe <NUM> with a plurality of systems <NUM> and an interior <NUM>. Examples of systems <NUM> include one or more of a propulsion system <NUM>, an electrical system <NUM>, a hydraulic system <NUM>, and an environmental system <NUM>. Any number of other systems may be included. Although an aerospace example is shown, the principles of the disclosure may be applied to other industries, such as the automotive industry.

As already mentioned above, lamination systems <NUM> and methods <NUM> (shown in FIGS. <NUM>) embodied herein may be employed during any one or more of the stages of the production and service described in method <NUM>. For example, components or subassemblies corresponding to component and subassembly manufacturing <NUM> may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft <NUM> is in service. Also, one or more system embodiments, method embodiments, or a combination thereof may be utilized during the subassembly manufacturing <NUM> and system integration <NUM>, for example, by substantially expediting assembly of or reducing the cost of an aircraft <NUM>.

Similarly, one or more of system embodiments, method embodiments, or a combination thereof may be utilized while the aircraft <NUM> is in service, for example and without limitation during the maintenance and service <NUM>. For example, the method <NUM> and lamination system <NUM> described herein may be used for material procurement <NUM>, component and subassembly manufacturing <NUM>, system integration <NUM>, service <NUM>, and/or maintenance and service <NUM>, and/or may be used for airframe <NUM> and/or interior <NUM>. These method <NUM> and lamination system <NUM> may even be utilized to create any suitable part for the systems <NUM>, including, for example, propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and/or environmental system <NUM>.

In one embodiment, a part comprises a portion of airframe <NUM> and is manufactured during component and subassembly manufacturing <NUM> using the method <NUM> and the lamination system <NUM>. The part may then be assembled into the aircraft <NUM> in system integration <NUM>, and then be utilized in service <NUM> until the part is to be replaced. Then, in maintenance and service <NUM>, the part may be discarded and replaced with a newly manufactured part made using any suitable method, such as the method <NUM>. Inventive systems and methods may be utilized throughout component and subassembly manufacturing <NUM> in order to manufacture new parts.

Claim 1:
A method (<NUM>) for forming a laminate (<NUM>), the method (<NUM>) comprising:
indexing (<NUM>) a layup mandrel (<NUM>) to a lamination station (<NUM>) disposed at a first location (<NUM>);
transporting (<NUM>) the lamination station (<NUM>) and the layup mandrel (<NUM>) in a process direction (<NUM>) from the first location (<NUM>) towards a second location (<NUM>);
laying up (<NUM>) the laminate (<NUM>) having layers (<NUM>, <NUM>) of fiber-reinforced material (<NUM>) onto the layup mandrel (<NUM>) via a lamination machine (<NUM>) while the lamination machine (<NUM>) and the layup mandrel (<NUM>) are transported in the process direction (<NUM>);
removing (<NUM>) the layup mandrel (<NUM>) and the laminate (<NUM>) at the second location (<NUM>); and
returning (<NUM>) the lamination station (<NUM>) to the first location (<NUM>) for laying up an additional laminate (<NUM>') onto a new layup mandrel (<NUM>').