Patent Description:
Formed composite structures are commonly used in applications where light weight and high strength are desired, such as in aircraft and vehicles. Often, these applications utilize contoured parts that must be formed and then cured. Conventional formation of composite structures, particularly relatively large composite structures or composite structures having a complex contour, requires extensive manual labor prior to curing. For example, composite fiber plies (e.g., pre-impregnated fiber plies or dry fabric) are laid by hand over a shaped forming tool or mandrel. The part is then cured, often by heating and pressure. The resulting part matches the shape of the forming tool. However, manual layup of the fiber plies is time consuming and laborious.

Some known composite manufacturing processes attempt to automate a portion of the formation operation. As an example, a drape forming process includes heating a laminate of pre-impregnated fiber plies ("composite charge") and forcing it around a mandrel with the use of a vacuum bag. However, this method has achieved limited success on thick laminates or structures with more complex shapes. As another example, a compactor may be used to compress the composite charge against a tool surface during fabrication. However, this method often requires supplemental manual formation after compaction when the tool surface and resulting structure is contoured. Accordingly, while such methods may be effective at forming relatively small and thin composite structures or composite structures with relatively simple shapes, they may be inefficient when applied to forming large composite structures or composite structures with more complex shapes.

Document <CIT>, with its abstract, discloses an apparatus for forming a material layer onto a form tool including at least one nosepiece configured to laterally sweep a ply carrier onto a form tool contour. The apparatus includes a pair of tension arm configured to support opposing lateral sides of a ply carrier having a material layer mounted to a lower surface thereof. The apparatus includes one or more actuators configured to position the tension arms during forming of the ply carrier to the form tool contour. The one or more actuators are configured to sense and control lateral tension in the ply carrier during forming of the ply carrier to the form tool contour.

Document <CIT>, with its abstract, discloses a draping tool having telescopic outer grippers for retaining a composite material mat i.e. composite material mat stack. Heating elements i.e. halogen radiators, perform partial heat treatment of the mat at the tool. The grippers are arranged at an elongated base body of the tool and pneumatically actuatable. The heating elements are arranged next to a base element. Form strips are movable relative to the base body, arranged at sides of the base body and movably activated by a position actuator. The grippers are designed as suction grippers, needle grippers and/or freezing grippers.

Document <CIT>, with its abstract, discloses a method for placing a piece of a composite material. The piece of the composite material is picked up from a source using an end effector. The piece is moved to a tool using the end effector. The piece is placed on the tool using the end effector. The piece is conformed to a shape of the tool using a roller system in the end effector, in which the roller system is moveable to conform the piece to a shape of the tool.

Accordingly, those skilled in the art continue with research and development efforts in the field of composite manufacturing and, more particularly, to the ply by ply manufacture of relatively large and/or relatively complex composite structures.

Disclosed is a forming apparatus having the features described at claim <NUM>. The dependent claims outline advantageous forms of embodiment of the apparatus.

Also disclosed is a method for forming a composite part comprising the steps described at claim <NUM>. Dependent claim <NUM> outlines an advantageous way of carrying out the method.

Examples of the forming apparatus <NUM>, method <NUM>, and system <NUM> enable automated forming of a composite part <NUM> and, more particularly, formation of at least one ply <NUM> of composite material <NUM> over a forming tool <NUM> for manufacture of the composite part <NUM>. Automation of the fabrication process provides a reduction in processing time, a reduction in labor and costs and a reduction of process variations (e.g., human error) that may lead to undesired inconsistencies in the finished composite structure as compared to conventional composite fabrication. The forming apparatus <NUM>, method <NUM>, and system <NUM> also enable ply-by-ply formation of the composite material <NUM> to fabricate the composite part <NUM>. Ply-by-ply formation facilitates fabrication of large composite structures, thick composite structures, and/or composite structures with complex shapes. Ply-by-ply formation also provides a reduction in buckling or wrinkling of plies within the composite structure as compared to conventional composite fabrication.

Generally, a composite ply includes a single ply (e.g., one layer of thickness) of composite material <NUM>. The composite material <NUM> may take the form of any one of various suitable types of composite material <NUM>. In one or more examples, the ply <NUM> of composite material <NUM> is formed by laminating multiple courses of unidirectional composite tape, which is pre-impregnated with a resin matrix. Throughout the present disclosure, the phrase "the ply" refers to at least one ply <NUM> of composite material <NUM>, unless explicitly stated otherwise. The ply <NUM> may also be referred to as a composite patch or a composite charge.

A composite manufacturing composite manufacturing system <NUM> includes a plurality of sub-systems, including a stationary forming system <NUM>, that facilitate and correspond to different fabrication operations associated with the manufacture of the composite part <NUM>. The sub-systems of the composite manufacturing composite manufacturing system <NUM> are interlinked and cooperate to automate at least a portion of the fabrication process. Throughout the present disclosure, the sub-systems of the disclosed composite manufacturing system <NUM> may be referred to as "systems" themselves or stations in which one or more fabrication operations occur. Among those sub-systems or stations is a system <NUM> for forming, which is shown and described in detail below.

The examples of the forming apparatus <NUM> (<FIG>), method <NUM> (<FIG>), and system <NUM> (<FIG>) described herein utilize a plurality of semi-automated or automated sub-systems to perform ply-by-ply formation and compaction of individual one or more ply <NUM> of composite material <NUM> on the forming tool <NUM>. Ply-by-ply formation refers to the laydown of one or more ply <NUM> of composite material <NUM> on the forming tool <NUM> in a predetermined sequence, and the one or more ply <NUM> of composite material <NUM> is compacted onto the forming tool <NUM> individually after each ply <NUM> of composite material <NUM> is laid down, or after more than one ply <NUM> of composite material <NUM> had been laid down.

Disclosed is a forming apparatus <NUM>, a method <NUM>, and a system <NUM> directed to ply by ply forming of a composite part <NUM> to apply pressure and manipulate plies on a forming tool <NUM>. The forming apparatus <NUM>, method <NUM>, and system <NUM> utilize a forming tool <NUM> to define the shape of the composite part <NUM>. The forming tool <NUM> may be any desired shape including a hat stringer forming tool <NUM>, a spar forming tool <NUM>, and a stringer forming tool <NUM>. The forming apparatus <NUM> is configured to apply pressure or compaction force <NUM> evenly across at least one ply <NUM> of composite material <NUM> over a forming surface <NUM> of a forming tool <NUM>. The forming apparatus <NUM> is further configured to deform <NUM> the at least one ply <NUM> of composite material <NUM> over the forming surface <NUM> of the forming tool <NUM> while eliminating any bubbles. The forming apparatus <NUM> is configured to move along the forming tool <NUM> at varying speeds, pressures, and angles to accommodate various geometries.

<FIG> and <FIG> illustrate an example composite manufacturing composite manufacturing system <NUM>. In an example, the composite manufacturing composite manufacturing system <NUM> includes a lamination system <NUM> (e.g., laminating sub-system or station), a transfer system <NUM> (e.g., transfer sub-system or station) and a forming system <NUM> (e.g., forming sub-system or station). In one or more examples, the composite manufacturing composite manufacturing system <NUM> also includes a trim system <NUM> (e.g., trim sub-system or station) and a scrap removal system <NUM> (e.g., a scrap removal sub-system of station). In one or more examples, the composite manufacturing composite manufacturing system <NUM> further includes a film removal system <NUM> (e.g., film removal sub-system or station). In one or more examples, the composite manufacturing composite manufacturing system <NUM> additionally includes a carrier preparation system <NUM> (e.g., carrier preparation sub-system or station). In one or more examples, the composite manufacturing composite manufacturing system <NUM> also includes a positioning system <NUM> (e.g., positioning sub-system).

In one or more examples, the composite manufacturing system <NUM> includes a tool transfer device <NUM>. The tool transfer device <NUM> is configured to convey the forming tool <NUM>. For example, the tool transfer device <NUM> includes, or takes the form of, a mobile platform that supports the forming tool <NUM> and moves the forming tool <NUM> between the sub-systems of the composite manufacturing system <NUM> that implement composite structure fabrication operations of the composite manufacturing process.

In an example, the composite manufacturing composite manufacturing system <NUM> for fabricating a composite part <NUM> includes a ply carrier <NUM> comprising a ply support surface <NUM> configured to support at least one ply <NUM> of composite material <NUM>. The composite manufacturing composite manufacturing system <NUM> further includes a carrier transfer device <NUM> configured to convey the ply carrier <NUM>, a lamination system <NUM> configured to selectively apply the at least one ply <NUM> of composite material <NUM> to the ply support surface <NUM> of the ply carrier <NUM>, a transfer system <NUM> configured to remove the ply carrier <NUM> from the carrier transfer device <NUM> and to apply the at least one ply <NUM> of composite material <NUM> to at least a portion of a forming surface <NUM> of a forming tool <NUM>, and a forming system <NUM> configured to form the at least one ply <NUM> of composite material <NUM> over the at least a portion of the forming surface <NUM> of the forming tool <NUM>. The forming system <NUM> comprises a forming apparatus <NUM>.

<FIG> and <FIG> illustrate a forming apparatus <NUM>. The forming apparatus <NUM> is located in the forming system <NUM>. In an example, the forming apparatus <NUM> includes a frame <NUM>. In an example, the frame <NUM> is generally rectangular in shape. The frame <NUM> defines a vertical axis <NUM>, a horizontal axis <NUM>, and a longitudinal axis <NUM>. The frame <NUM> surrounds a carriage <NUM> having a shape that is generally the same as the frame <NUM> but is smaller such that the carriage <NUM> nests within the frame <NUM>. In an example, the carriage <NUM> is movably connected to the frame <NUM> such that it may pivot or rotate along the vertical axis <NUM> and horizontal axis <NUM> to accommodate any specific geometry or configuration and achieve a best fit position.

In an example, the forming apparatus <NUM> includes a first end effector <NUM>. The first end effector <NUM> is movably connected to the carriage <NUM>. In an example, the first end effector <NUM> is movable or controlled via an actuator an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. in an example, the first end effector <NUM> is configured to skew along the vertical axis <NUM>. The first end effector <NUM> may include one or more sensor <NUM> configured to detect the location of a forming tool <NUM> along multiple axes including a vertical axis <NUM>, horizontal axis <NUM>, and longitudinal axis <NUM> for precise forming on a complex forming tool <NUM>. The one or more sensor <NUM> may be in communication with a controller <NUM>. The controller <NUM> is configured to receive data from the one or more sensor <NUM> and analyze that data to control movement of the first end effector <NUM>. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the first end effector <NUM>.

The first end effector <NUM> includes a first forming feature <NUM>. In an example, the first forming feature <NUM> is a forming finger <NUM> (<FIG>). In an example, first forming feature <NUM> is an inflatable bladder <NUM>. The inflatable bladder <NUM> is configured to passively follow forming tool <NUM> contours by applying consistent compaction force <NUM>. Compaction force <NUM> may vary. In an example, compaction force <NUM> may be up to <NUM> per linear cm (20lbs per linear inch). The inflatable bladder <NUM> profile or orientation may be manipulated with one or more jacking screw 146a to conform to concave or convex profiles along the forming tool <NUM> length and to control the radius of the inflatable bladder <NUM>. <FIG> and <FIG> illustrate jacking screw 146a with respect to the inflatable bladder <NUM>.

In the exemplary embodiment of <FIG>, first end effector A 140a is movable along the horizontal axis <NUM> to accommodate a concave, convex, or linear configuration. The movement may be passive such that it moved based upon movement of one or more different first end effector <NUM> of the first plurality <NUM> of the first end effector <NUM>. The first end effector A 140a is connected to a first forming feature <NUM> comprising an inflatable bladder <NUM>. Any suitable means of connection and fastening may be used to secure the first forming feature <NUM> to the first end effector A 140a. In an example, a screw <NUM> is used to position and secure the forming feature <NUM> to the first end effector A 140a.

In an example, the first end effector B 140b is movable along the horizontal axis <NUM> and the vertical axis <NUM>. Movement along the horizontal axis <NUM> is passive. Movement along the vertical axis <NUM> is controlled by any suitable means. In an example, the movement of the first end effector B 140b is controlled by an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. Movement of the first end effector B 140b may be controlled by a controller <NUM>. The controller <NUM> is configured to receive data from one or more sensor <NUM> and analyze that data to control movement of the first end effector B 140b. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the first end effector B 140b to properly align with a forming tool <NUM>.

In an example, the first end effector C 140c is movable along the horizontal axis <NUM> and the vertical axis <NUM>. Movement along the vertical axis <NUM> is controlled by any suitable means. In an example, the movement of the first end effector C 140c is controlled by an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. Movement of the first end effector C 140c may be controlled by a controller <NUM>. The controller <NUM> is configured to receive data from one or more sensor <NUM> and analyze that data to control movement of the first end effector C 140c. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the first end effector C 140c to properly align with a forming tool <NUM>.

In an example, the first end effector D 140d is movable along the vertical axis <NUM>. Movement along the horizontal axis <NUM> is passive. Movement along the vertical axis <NUM> is controlled by any suitable means. In an example, the movement of the first end effector D 140d is controlled by an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. Movement of the first end effector D 140d may be controlled by a controller <NUM>. The controller <NUM> is configured to receive data from one or more sensor <NUM> and analyze that data to control movement of the first end effector D 140d. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the first end effector D 140d to properly align with a forming tool <NUM>.

In an example, first end effector E 140e is movable along the horizontal axis <NUM> to accommodate a concave, convex, or linear configuration. The movement may be passive such that it moved based upon movement of one or more different first end effector <NUM> of the first plurality <NUM> of the first end effector <NUM>. The first end effector E 140e is connected to a first forming feature <NUM> comprising an inflatable bladder <NUM>. Any suitable means of connection and fastening may be used to secure the first forming feature <NUM> to the first end effector E 140e.

In an example, the forming apparatus <NUM> includes a first stomp foot <NUM>. The first stomp foot <NUM> is movably connected to the carriage <NUM>. The first stomp foot <NUM> is movable along the vertical axis <NUM>. The first stomp foot <NUM> may have a flat or a curved design based upon the geometry of the forming tool <NUM>. In an example, the first stomp foot <NUM> is located adjacent to the first end effector <NUM>. The first stomp foot <NUM> is configured to move along the vertical axis <NUM> via any suitable means and is further configured to press one or more ply <NUM> of composite material <NUM> onto a forming surface <NUM> of a forming tool <NUM> and hold the one or more ply <NUM> of composite material <NUM> in place. In an example, the first stomp foot <NUM> movement is controlled by an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. In an example, the first stomp foot <NUM> movement is controlled by at least one magnetic switch <NUM> configured to detect travel and location of the first stomp foot <NUM> with respect to a forming tool <NUM>. The first stomp foot <NUM> is configured to apply compaction force <NUM> to a forming tool <NUM>. The applied compaction force <NUM> may be variable or may be consistent based upon the geometry of the forming tool <NUM>.

<FIG> and <FIG> illustrate an exemplary embodiment of the first stomp foot <NUM>. In an example, the first stomp foot <NUM> is configured to move along the vertical axis <NUM> and apply compaction force <NUM>. In an example, the first stomp foot <NUM> is configured to pivotably move along the horizontal axis <NUM>. The first stomp foot <NUM> may have a generally flat bottom surface or generally curved bottom surface based upon on the geometry of the forming tool <NUM>. <FIG> illustrates the first stomp foot <NUM> pivoting along the vertical axis <NUM> to accommodate forming tool <NUM> geometry. This configuration is ideal for outside forming of a stinger forming tool <NUM>. <FIG> illustrates the first stomp foot <NUM> positioned on the top surface of the forming tool <NUM> and first end effector <NUM> positioned lower along the vertical axis <NUM> along the outside surface of the forming tool <NUM>. The first stomp foot <NUM> is in communication with a controller <NUM> that may control the magnetic switch <NUM> and actuator <NUM> based upon one or more numerical control program <NUM> and data collected from one or more sensor <NUM>.

The forming apparatus <NUM> may include more than one pivoting bearing assembly <NUM> that is movably connected to the carriage <NUM> and a mounting beam <NUM> via a bearing mount 180a. The pivoting bearing assembly <NUM> is configured to have linear and radial configurations. The pivoting bearing assembly <NUM> allows for adjustments in yaw angle with respect to the first plurality <NUM> of first end effector <NUM> and second plurality <NUM> of the second end effector <NUM>. Adjustments in yaw angle allow for uniform compaction force <NUM> across a forming tool <NUM>, and particularly to a spar forming tool <NUM>.

<FIG>, <FIG>, and <FIG> illustrate a forming apparatus <NUM> having a first plurality <NUM> of the first end effector <NUM>. In an example, the first plurality <NUM> of the first end effector <NUM> extends along the longitudinal axis <NUM> of the forming apparatus <NUM>. In an example, each individual first end effector <NUM> of the first plurality <NUM> of the first end effector <NUM> includes a first forming feature <NUM>. In an example, each forming feature <NUM> of the first plurality <NUM> comprises an inflatable bladder <NUM> that collectively form a convex, concave, or generally linear shape based upon the geometry of the forming tool <NUM>. In an example, the inflatable bladder <NUM> abuts the first stomp foot <NUM>. In an example, each individual first end effector <NUM> of the first plurality <NUM> of the first end effector <NUM> is independently movable. This arrangement allows for the first plurality <NUM> of the first end effector <NUM> to form a convex, concave, or linear configuration with each first forming feature <NUM>.

<FIG> illustrates the first plurality <NUM> of the first end effector <NUM> moved to the edge of the forming tool <NUM>. In an example, the forming tool <NUM> is a stringer forming tool <NUM>. The forming tool <NUM> may be positioned on one or more movable form block. The one or more movable form block may be configured to move along the horizontal axis <NUM>.

<FIG> illustrates the first plurality <NUM> of the first end effector <NUM> moved to the side of the forming tool <NUM> along the outside edge. As illustrated in <FIG>, the forming tool <NUM> is a stringer forming tool <NUM>. The stringer forming tool <NUM> requires different first forming feature <NUM> configurations than a hat stringer forming tool <NUM> or spar forming tool <NUM> requires.

According to an embodiment, the forming apparatus <NUM> includes a second end effector <NUM>. The second end effector <NUM> is movably connected to the carriage <NUM>, said second end effector <NUM> is laterally opposed from said first end effector <NUM> relative to the longitudinal axis <NUM> such that it mirrors the configuration of the first end effector <NUM>. In an example, the second end effector <NUM> is movable or controlled via an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. In an example, the second end effector <NUM> is configured to skew along the vertical axis <NUM>. The second end effector <NUM> may include one or more sensor <NUM> configured to detect the location of a forming tool <NUM> along multiple axes including a vertical axis <NUM>, horizontal axis <NUM>, and longitudinal axis <NUM> for precise forming on a complex forming tool <NUM>. The one or more sensor <NUM> may be in communication with a controller <NUM>. The controller <NUM> is configured to receive data from the one or more sensor <NUM> and analyze that data to control movement of the first end effector <NUM>. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the first end effector <NUM>.

The second end effector <NUM> includes a second forming feature <NUM>. In an example, the second forming feature <NUM> is a forming finger <NUM>. In an example, second forming feature <NUM> is an inflatable bladder <NUM>. The inflatable bladder <NUM> is configured to passively follow forming tool <NUM> contours by applying consistent compaction force <NUM>. Compaction force <NUM> may vary. In an example, compaction force <NUM> may be up to <NUM> per linear cm (20lbs per linear inch). The inflatable bladder <NUM> profile or orientation may be manipulated with one or more jacking screw 146a to conform to concave or convex profiles along the forming tool <NUM> length and to control the radius of the inflatable bladder <NUM>. <FIG> and <FIG> illustrate jacking screw 146a with respect to the inflatable bladder <NUM>.

<FIG> illustrates a first plurality <NUM> of the first end effector <NUM> and a second plurality <NUM> of the second end effector <NUM>. The forming apparatus <NUM> comprises a second plurality <NUM> of the second end effector <NUM>. The second plurality <NUM> of the second end effector <NUM> extends along the longitudinal axis <NUM> and is laterally opposed from the first plurality <NUM> of the first end effector <NUM>. In an example, each individual second end effector <NUM> of the second plurality <NUM> of the second end effector <NUM> is independently movable. This arrangement allows for the second plurality <NUM> of the second end effector <NUM> to form a convex, concave, or linear configuration. In the exemplary embodiment of <FIG>, the second plurality <NUM> of the second end effector <NUM> includes five of the second end effector <NUM> that are movably connected to a mounting beam <NUM>. The mounting beam <NUM> is movably connected to the carriage <NUM> such that it may move along the vertical axis <NUM> and horizontal axis <NUM> in accordance with the shape and geometry of a forming tool <NUM>.

In the exemplary embodiment of <FIG>, second end effector A 150a is movable along the horizontal axis <NUM> to accommodate a concave, convex, or linear configuration. The movement may be passive such that it moved based upon movement of one or more different second end effector <NUM> of the second plurality <NUM> of the second end effector <NUM>. The second end effector A 150a is connected to a second forming feature <NUM> comprising an inflatable bladder <NUM>. Any suitable means of connection and fastening may be used to secure the second forming feature <NUM> to the second end effector A 150a. In an example, a screw <NUM> is used to position and secure the second forming feature <NUM> to the second end effector A 150a.

In an example, the second end effector B 150b is movable along the horizontal axis <NUM> and the vertical axis <NUM>. Movement along the horizontal axis <NUM> is passive. Movement along the vertical axis <NUM> is controlled by any suitable means. In an example, the movement of the second end effector B 150b is controlled by an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. Movement of the second end effector B 150b may be controlled by a controller <NUM>. The controller <NUM> is configured to receive data from one or more sensor <NUM> and analyze that data to control movement of the second end effector B 150b. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the second end effector B 150b to properly align with a forming tool <NUM>.

In an example, the second end effector C 150c is movable along the horizontal axis <NUM> and the vertical axis <NUM>. Movement along the vertical axis <NUM> is controlled by any suitable means. In an example, the movement of the second end effector C 150c is controlled by an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. Movement of the second end effector C 150c may be controlled by a controller <NUM>. The controller <NUM> is configured to receive data from one or more sensor <NUM> and analyze that data to control movement of the second end effector C 150c. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the second end effector C 150c to properly align with a forming tool <NUM>.

In an example, the second end effector D 150d is movable along the vertical axis <NUM>. Movement along the horizontal axis <NUM> is passive. Movement along the vertical axis <NUM> is controlled by any suitable means. In an example, the movement of the second end effector D 150d is controlled by an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. Movement of the second end effector D 150d may be controlled by a controller <NUM>. The controller <NUM> is configured to receive data from one or more sensor <NUM> and analyze that data to control movement of the second end effector D 150d. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the second end effector D 150d to properly align with a forming tool <NUM>.

In an example, second end effector E 150e is movable along the horizontal axis <NUM> to accommodate a concave, convex, or linear configuration. The movement may be passive such that it moved based upon movement of one or more different second end effector <NUM> of the second plurality <NUM> of the second end effector <NUM>. The second end effector E 150e is connected to a second forming feature <NUM> comprising an inflatable bladder <NUM>. Any suitable means of connection and fastening may be used to secure the second forming feature <NUM> to the second end effector E 150e.

<FIG> illustrates a forming apparatus <NUM> having a first stomp foot <NUM> and a second stomp foot <NUM>. The forming apparatus <NUM> includes a second stomp foot <NUM>. The second stomp foot <NUM> is movably connected to the carriage <NUM>. The second stomp foot <NUM> is located between the first stomp foot <NUM> and the second end effector <NUM>. The first stomp foot <NUM> is movable along the vertical axis <NUM>. The first stomp foot <NUM> may have a flat or a curved design based upon the geometry of the forming tool <NUM>. In an example, the first stomp foot <NUM> is located adjacent to the first end effector <NUM>. The second stomp foot <NUM> is configured to move along the vertical axis <NUM> via any suitable means and is further configured to press one or more ply <NUM> of composite material <NUM> onto a forming surface <NUM> of a forming tool <NUM> and hold the one or more ply <NUM> of composite material <NUM> in place. In an example, the second stomp foot <NUM> movement is controlled by an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. In an example, the second stomp foot <NUM> movement is controlled by at least one magnetic switch <NUM> configured to detect travel and location of the second stomp foot <NUM> with respect to a forming tool <NUM>. The second stomp foot <NUM> is configured to apply compaction force <NUM> to a forming tool <NUM>. The applied compaction force <NUM> may be variable or may be consistent based upon the geometry of the forming tool <NUM>. The second stomp foot <NUM> is in communication with a controller <NUM> that may control the magnetic switch <NUM> and actuator <NUM> based upon one or more numerical control program <NUM> and data collected from one or more sensor <NUM>.

The forming apparatus <NUM> comprises a ply support feature <NUM>. Ply support feature <NUM> is located below the first stomp foot <NUM> and the second stomp foot <NUM>. Ply support feature <NUM> may be configured to support one or more ply <NUM> of composite material <NUM> prior to initiation of forming. Ply support feature <NUM> may further be configured to prevent the one or more ply <NUM> of composite material <NUM> from wrinkling prior to or during forming. The ply support feature <NUM> may be mechanical or may be air driven. In an example, the ply support feature <NUM> is an air knife.

In an example, the forming apparatus <NUM> includes a first plurality <NUM> of the first end effector <NUM> and a second plurality <NUM> of the second end effector <NUM>. The first plurality <NUM> of the first end effector <NUM> and the second plurality <NUM> of the second end effector <NUM> are laterally opposed from each other with a first stomp foot <NUM> and a second stomp foot <NUM> located between.

The configuration of the first plurality <NUM> of the first end effector <NUM> and the second plurality <NUM> of the second end effector <NUM> to accommodate a stinger forming tool <NUM> is illustrated in FIG. 20a and FIG. In this example, the first plurality <NUM> of the first end effector <NUM> is convex and the second plurality <NUM> of the second end effector <NUM> is concave. 15a-15d illustrate various concave and convex configurations that the first plurality <NUM> of the first end effector <NUM> and the second plurality <NUM> of the second end effector <NUM> can achieve to match the geometry of a forming tool <NUM>. The first forming feature <NUM> and second forming feature <NUM> are an inflatable bladder <NUM>.

<FIG> illustrates an exemplary embodiment of the forming apparatus <NUM> comprising a protective slip film <NUM>. The protective slip film <NUM> may be of any suitable material including a polymer material such as PTFE or FEP. The protective slip film <NUM> is connected to at least one retractable spool <NUM>. The retractable spool <NUM> is configured to provide constant tension to the protective slip film <NUM>. The protective slip film <NUM> is advantageous in prevention of bunching of composite material <NUM> material during the forming process.

<FIG> illustrates a method <NUM>. Disclosed is a method <NUM> for forming a composite part <NUM>. The method <NUM> comprises applying <NUM> at least one ply <NUM> of composite material <NUM> over a forming surface <NUM> of a forming tool <NUM>. The method <NUM> further comprises deforming <NUM> the at least one ply <NUM> of composite material <NUM> over the forming surface <NUM> of the forming tool <NUM> with a forming apparatus <NUM>. The method <NUM> further comprises advancing <NUM> the composite part <NUM> to a subsequent process. In an example, the forming apparatus <NUM> of the method <NUM> includes a frame <NUM>. In an example, the frame <NUM> is generally rectangular in shape. The frame <NUM> defines a vertical axis <NUM>, a horizontal axis <NUM>, and a longitudinal axis <NUM>. The frame <NUM> surrounds a carriage <NUM> having a shape that is generally the same as the frame <NUM> but is smaller such that the carriage <NUM> nests within the frame <NUM>. In an example, the carriage <NUM> is movably connected to the frame <NUM> such that it may pivot or rotate along the vertical axis <NUM> and horizontal axis <NUM> to accommodate any specific geometry or configuration and achieve a best fit position.

In an example, the forming apparatus <NUM> of the method <NUM> includes a first end effector <NUM>. The first end effector <NUM> is movably connected to the carriage <NUM>. In an example, the first end effector <NUM> is movable or controlled via an actuator an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. in an example, the first end effector <NUM> is configured to skew along the vertical axis <NUM>. The first end effector <NUM> may include one or more sensor <NUM> configured to detect the location of a forming tool <NUM> along multiple axes including a vertical axis <NUM>, horizontal axis <NUM>, and longitudinal axis <NUM> for precise forming on a complex forming tool <NUM>. The one or more sensor <NUM> may be in communication with a controller <NUM>. The controller <NUM> is configured to receive data from the one or more sensor <NUM> and analyze that data to control movement of the first end effector <NUM>. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the first end effector <NUM>.

The first end effector <NUM> includes a first forming feature <NUM>. In an example, the first forming feature <NUM> is a forming finger <NUM>. In an example, first forming feature <NUM> is an inflatable bladder <NUM>. The inflatable bladder <NUM> is configured to passively follow forming tool <NUM> contours by applying consistent compaction force <NUM>. Compaction force <NUM> may vary. In an example, compaction force <NUM> may be up to <NUM> per linear cm (20lbs per linear inch). The inflatable bladder <NUM> profile or orientation may be manipulated with one or more jacking screw 146a to conform to concave or convex profiles along the forming tool <NUM> length and to control the radius of the inflatable bladder <NUM>. <FIG> and <FIG> illustrate jacking screw 146a with respect to the inflatable bladder <NUM>.

<FIG> illustrates a system <NUM>. The system <NUM> comprises a forming apparatus <NUM>, a forming tool <NUM>, and at least one ply <NUM> of composite material <NUM>. In an example, the forming tool <NUM> is a spar forming tool <NUM>. In an example, the forming tool <NUM> is a stringer forming tool <NUM>. In an example, the forming tool <NUM> is a hat stringer forming tool <NUM>.

The forming apparatus <NUM> of system <NUM> includes a frame <NUM>. In an example, the frame <NUM> is generally rectangular in shape. The frame <NUM> defines a vertical axis <NUM>, a horizontal axis <NUM>, and a longitudinal axis <NUM>. The frame <NUM> surrounds a carriage <NUM> having a shape that is generally the same as the frame <NUM> but is smaller such that the carriage <NUM> nests within the frame <NUM>. In an example, the carriage <NUM> is movably connected to the frame <NUM> such that it may pivot or rotate along the vertical axis <NUM> and horizontal axis <NUM> to accommodate any specific geometry or configuration and achieve a best fit position.

The first end effector <NUM> includes a first forming feature <NUM>. In an example, the first forming feature <NUM> is a forming finger <NUM>. In an example, first forming feature <NUM> is an inflatable bladder <NUM>. The inflatable bladder <NUM> is configured to passively follow forming tool <NUM> contours by applying consistent compaction force <NUM>. Compaction force <NUM> may vary. In an example, compaction force <NUM> may be up to 20lbs per linear inch. The inflatable bladder <NUM> profile or orientation may be manipulated with one or more jacking screw 146a to conform to concave or convex profiles along the forming tool <NUM> length and to control the radius of the inflatable bladder <NUM>. <FIG> and <FIG> illustrate jacking screw 146a with respect to the inflatable bladder <NUM>.

<FIG> illustrates a flowchart of a manufacturing composite manufacturing method <NUM>. Disclosed is a manufacturing composite manufacturing method <NUM> of fabricating a composite part <NUM>. In an example, the manufacturing composite manufacturing method <NUM> comprises various steps. In an example, the manufacturing composite manufacturing method <NUM> includes conveying a ply carrier <NUM> to a lamination system <NUM> using a carrier transfer device <NUM>. The manufacturing composite manufacturing method <NUM> includes selectively applying at least one ply <NUM> of composite material <NUM> to a ply support surface <NUM> of the ply carrier <NUM> using the lamination system <NUM>. The manufacturing composite manufacturing method <NUM> includes conveying the ply carrier <NUM> from the lamination system <NUM> to a transfer system <NUM> using the carrier transfer device <NUM>. In an example, the manufacturing composite manufacturing method <NUM> includes the step of removing the ply carrier <NUM> from the carrier transfer device <NUM> and applying the at least one ply <NUM> of composite material <NUM> to at least a portion of a forming surface <NUM> of a forming tool <NUM> using the transfer system <NUM>. The manufacturing composite manufacturing method <NUM> includes the step of forming the at least one ply <NUM> of composite material <NUM> over the at least a portion of the forming surface <NUM> of the forming tool <NUM> using a forming system <NUM>. In an example, the forming system <NUM> comprises a forming apparatus <NUM>.

In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) preparing the ply carrier <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) selectively applying the retention vacuum to retain the protective slip film <NUM> on the base plate <NUM> using the carrier transfer device <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) conveying the ply carrier <NUM> to the lamination system <NUM> using the carrier transfer device <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) selectively applying one or more ply <NUM> of composite material <NUM> to the ply support surface <NUM> of the ply carrier <NUM> using the lamination system <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) conveying the ply carrier <NUM> from the lamination system <NUM> to the trim system <NUM> using the carrier transfer device <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) selectively cutting the one or more ply <NUM> of composite material <NUM> into the predetermined shape using the trim system <NUM>.

In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) removing a remnant of the one or more ply <NUM> of composite material <NUM> from the ply support surface <NUM> using the scrap removal system <NUM>, after the step of (block <NUM>) selectively cutting the one or more ply <NUM> of composite material <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of selectively removing the retention vacuum from select areas of the protective slip film <NUM> using the carrier transfer device <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> also includes a step of (block <NUM>) conveying the ply carrier <NUM> from the trim system <NUM> to the transfer system <NUM> using the carrier transfer device <NUM>.

In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) removing the ply carrier <NUM> from the carrier transfer device <NUM> and a step of (block <NUM>) reorienting (e.g., rotating) the ply carrier <NUM> using the transfer system <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) maintaining the retention vacuum to retain the protective slip film <NUM> on the base plate <NUM> using the transfer system <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) conveying the forming tool <NUM> to the transfer system <NUM> using the tool transfer device <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) applying the one or more ply <NUM> of composite material <NUM> to at least a portion of the forming surface <NUM> of the forming tool <NUM> using the transfer system <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of releasing the protective slip film <NUM> from the base plate <NUM> and a step of removing the ply carrier <NUM> (e.g., the base plate <NUM>) from the forming tool <NUM> using the transfer system <NUM>, and after the step of (block <NUM>) applying the one or more ply <NUM> of composite material <NUM> to at least a portion of the forming surface <NUM> of the forming tool <NUM>. For example, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) selectively removing the retention vacuum to release the protective slip film <NUM> from the base plate <NUM> while retaining the base plate <NUM> using the transfer system <NUM>.

In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) conveying the forming tool <NUM> from the transfer system <NUM> to the forming system <NUM> using the tool transfer device <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) forming the one or more ply <NUM> of composite material <NUM> over the at least a portion of the forming surface <NUM> of the forming tool <NUM> using the forming system <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) removing the protective slip film <NUM> from the one or more ply <NUM> of composite material <NUM> using the film removal system <NUM>. In one or more examples, the manufacturing composite manufacturing method <NUM> includes a step of (block <NUM>) returning the ply carrier <NUM> (e.g., the base plate <NUM>) to the carrier transfer device <NUM> using the transfer system <NUM>. In one or more examples, the above operations are repeated a number of times to fully form the composite part <NUM> (block <NUM>), at which point the process terminates.

In an example, the forming apparatus <NUM> of the manufacturing composite manufacturing method <NUM> includes a frame <NUM>. In an example, the frame <NUM> is generally rectangular in shape. The frame <NUM> defines a vertical axis <NUM>, a horizontal axis <NUM>, and a longitudinal axis <NUM>. The frame <NUM> surrounds a carriage <NUM> having a shape that is generally the same as the frame <NUM> but is smaller such that the carriage <NUM> nests within the frame <NUM>. In an example, the carriage <NUM> is movably connected to the frame <NUM> such that it may pivot or rotate along the vertical axis <NUM> and horizontal axis <NUM> to accommodate any specific geometry or configuration and achieve a best fit position.

In an example, the forming apparatus <NUM> includes a first end effector <NUM>. The first end effector <NUM> is movably connected to the carriage <NUM>. In an example, the first end effector <NUM> is movable or controlled via an actuator an actuator <NUM>. In an example, the actuator <NUM> is a pneumatically actuated forming cylinder 147a. In an example, the first end effector <NUM> is configured to skew along the vertical axis <NUM>. The first end effector <NUM> may include one or more sensor <NUM> configured to detect the location of a forming tool <NUM> along multiple axes including a vertical axis <NUM>, horizontal axis <NUM>, and longitudinal axis <NUM> for precise forming on a complex forming tool <NUM>. The one or more sensor <NUM> may be in communication with a controller <NUM>. The controller <NUM> is configured to receive data from the one or more sensor <NUM> and analyze that data to control movement of the first end effector <NUM>. The controller <NUM> may utilize one or more numerical control program <NUM> in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the first end effector <NUM>.

Examples of the disclosure may be described in the context of an aircraft manufacturing and service method <NUM>, as shown in <FIG>, and an aircraft <NUM>, as shown in <FIG>. During pre-production, the aircraft manufacturing and service method <NUM> may include specification and design <NUM> of the aircraft <NUM> and material procurement <NUM>. During production, component/subassembly manufacturing <NUM> and system integration <NUM> of the aircraft <NUM> takes place. 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 maintenance and service <NUM>, which may also include modification, reconfiguration, refurbishment and the like.

Each of the steps of method <NUM> 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 aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.

As shown in <FIG>, the aircraft <NUM> produced by example method <NUM> may include an airframe <NUM> with a plurality of systems <NUM> and an interior <NUM>. Examples of the plurality of systems <NUM> may 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.

The disclosed methods and systems may be employed during any one or more of the stages of the aircraft manufacturing and service method <NUM>. As one example, components or subassemblies corresponding to component/subassembly manufacturing <NUM>, system integration <NUM> and/or maintenance and service <NUM> may be assembled using the disclosed methods and systems. As another example, the airframe <NUM> may be constructed using the disclosed methods and systems. Also, one or more apparatus examples, method examples, or a combination thereof may be utilized during component/subassembly manufacturing <NUM> and/or system integration <NUM>, for example, by substantially expediting assembly of or reducing the cost of an aircraft <NUM>, such as the airframe <NUM> and/or the interior <NUM>. Similarly, one or more of system examples, method examples, or a combination thereof may be utilized while the aircraft <NUM> is in service, for example and without limitation, to maintenance and service <NUM>.

Aspects of disclosed examples may be implemented in software, hardware, firmware, or a combination thereof. The various elements of the system, either individually or in combination, may be implemented as a computer program product tangibly embodied in a machine-readable storage device for execution by a processor. Various steps of examples may be performed by a computer processor executing a program tangibly embodied on a computer-readable medium to perform functions by operating on input and generating output. The computer-readable medium may be, for example, a memory, a transportable medium such as a compact disk or a flash drive, such that a computer program embodying aspects of the disclosed examples can be loaded onto a computer.

The above-described methods and systems are described in the context of an aircraft. However, one of ordinary skill in the art will readily recognize that the disclosed methods and systems are suitable for a variety of applications, and the present disclosure is not limited to aircraft manufacturing applications. For example, the disclosed methods and systems may be implemented in various types of vehicles including, for example, helicopters, passenger ships, automobiles, marine products (boat, motors, etc.) and the like. Non-vehicle applications are also contemplated.

Claim 1:
A forming apparatus (<NUM>) comprising:
a frame (<NUM>) defining a vertical axis (<NUM>), a horizontal axis (<NUM>), and a longitudinal axis (<NUM>);
a carriage (<NUM>) movably connected to the frame (<NUM>);
a first stomp foot (<NUM>) movably connected to the carriage (<NUM>);
a first end effector (<NUM>) movably connected to the carriage (<NUM>), said first end effector (<NUM>) controlled by an actuator (<NUM>);
further comprising a second end effector (<NUM>) movably connected to the carriage (<NUM>), said second end effector (<NUM>) is laterally opposed from said first end effector (<NUM>) relative to the longitudinal axis;
a second stomp foot (<NUM>) movably connected to the carriage (<NUM>), said second stomp foot (<NUM>) located between the first stomp foot (<NUM>) and the second end effector (<NUM>);
a ply support feature (<NUM>) located below the first stomp foot (<NUM>) and the second stomp foot (<NUM>); and
wherein the first end effector (<NUM>) comprises a first forming feature (<NUM>) and the second end effector (<NUM>) comprises a second forming feature (<NUM>).