Patent Description:
Mandrels are often used to shape composite materials during manufacturing. For example, a mandrel may be used to define the shape of the composite materials during layup and curing. In some circumstances, it can be challenging to remove the composite materials from the mandrel after curing. To illustrate, when cured composite parts have certain shapes, there may be no simple way to pull the composite parts off of the mandrel without risking damage to the part, the mandrel, or both. For example, when a composite part fully encircles at least a portion of the mandrel, it can be challenging to remove the composite part from the mandrel.

Sometimes a breakdown mandrel is used to facilitate removal of a composite part from a mandrel without damaging the part or the mandrel. A breakdown mandrel includes several pieces that are assembled together to define the shape of the mandrel before composite materials are applied to the mandrel. After curing the composite materials, the mandrel is at least partially disassembled (e.g., one or more of the pieces of the mandrel are removed) to separate the cured composite part from the mandrel.

A breakdown mandrel is significantly more difficult to design and manufacture than a unitary or single-piece mandrel of the same size and shape and is therefore also significantly more expensive. Additionally, using a breakdown mandrel can increase fabrication times because the breakdown mandrel has to be disassembled, cleaned, and reassembled for each use whereas a unitary mandrel is ready for reuse after cleaning. Ill-fitting pieces, improper cleaning, or mis-assembly of the breakdown mandrel can also lead to defects in the composite part, which may require the composite part to be scrapped or reworked.

Another approach that may be used to remove a composite part from a mandrel is to cut the composite part into two or more pieces, and then reassemble the pieces. The pieces are subsequently joined together using two or more splice joints. Making each splice joint is time consuming, leading to higher manufacturing costs. Additionally, each splice joint adds additional weight to the composite part, which may be problematic when the final weight of the composite part is an important consideration, such as when the composite part is an aircraft component.

<CIT> states, in accordance with its abstract, that a flay assembly for separating a workpiece from a manufacturing fixture has a horizontal beam assembly and a pair of vertical beam assemblies. The horizontal beam assembly includes a horizontal beam having a horizontal drive motor. Each vertical beam assembly includes a vertical beam operably engaged to the horizontal drive motor and has a workpiece attachment assembly operably engaged to a vertical drive motor. The workpiece attachment assembly has an attachment mechanism attachable to the workpiece. The horizontal drive motor and the vertical drive motors are operable in a manner to move the vertical beams away from each other along a horizontal drive axis while simultaneously moving each workpiece attachment assembly along a vertical drive axis to cause the attachment mechanisms to pull the workpiece side portions away from the manufacturing fixture while a center support of the horizontal beam.

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

In a particular implementation, a demolding tool includes a first plurality of couplers arranged to couple to a first end of a workpiece disposed on a mandrel. The mandrel includes a first end disposed adjacent to the first end of the workpiece and a second end disposed adjacent to a second end of the workpiece. The first end of the mandrel has a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the mandrel. The demolding tool also includes a first plurality of actuators. Each actuator of the first plurality of actuators is coupled to at least one of the first plurality of couplers. The demolding tool further includes a second plurality of couplers arranged to couple to the workpiece at locations between the first end of the workpiece and the second end of the workpiece. The demolding tool also includes a second plurality of actuators. Each actuator of the second plurality of actuators is coupled to at least one of the second plurality of couplers. The demolding tool further includes a controller configured to, after a cut is formed in the workpiece along a longitudinal direction between the first end and the second end of the workpiece, cause the first plurality of actuators to apply, via the first plurality of couplers, first forces to the workpiece to deform the workpiece and at least partially disengage the first end of the workpiece from the first end of the mandrel. The controller is also configured to, after causing the first plurality of actuators to apply the first forces to the workpiece, cause the second plurality of actuators to apply, via the second plurality of couplers, second forces to the workpiece to further deform the workpiece and at least partially disengage the second end of the workpiece from the mandrel.

In another particular implementation, a method of removing from a mandrel a workpiece having a tubular shape defining a plurality of unequal circumferences spaced apart along a longitudinal axis is disclosed. The method includes, after the workpiece is cured on the mandrel, cutting the workpiece along a direction between a first end of the workpiece and a second end of the workpiece. The first end of the workpiece has a first circumference that is smaller than a second circumference of the second end of the workpiece. The method also includes applying first forces to the first end of the workpiece to deform the first end of the workpiece to at least partially disengage the first end of the workpiece from the first end of the mandrel. The method further includes, after applying the first forces, applying second forces to the second end of the workpiece to further deform the workpiece and at least partially disengage the second end of the workpiece from the mandrel.

In another particular implementation, a system includes a mandrel and a demolding tool. The mandrel is contoured to define a tapering tubular shape of a workpiece cured on the mandrel. The demolding tool is configured to remove the workpiece from the mandrel after the workpiece is cured on the mandrel and cut longitudinally. The demolding tool is configured to remove the workpiece from the mandrel by deforming a first end of the workpiece to at least partially disengage the first end of the workpiece from a first end of the mandrel, and subsequently, deforming a second end of the workpiece to at least partially disengage the second end of the workpiece from a second end of the mandrel. The first end of the workpiece has a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the workpiece.

In yet another particular implementation, a method of removing a workpiece from a mandrel includes applying forces to the workpiece while cutting the workpiece along a longitudinal direction between a first end of the workpiece and a second end of the workpiece. The method also includes, after cutting the workpiece, applying forces to disengage a first end of the workpiece from the mandrel. The method further includes, after disengaging the first end of the workpiece from the mandrel, applying forces to the second end of the workpiece to deform the workpiece and disengage the second end of the workpiece from the mandrel.

The features, functions, and advantages described herein can be achieved independently in various implementations or may be combined in yet other implementations, further details of which can be found with reference to the following description and drawings.

Aspects disclosed herein present systems and methods for demolding a composite part (e.g., a workpiece) that fully encircles at least a portion of a mandrel. The disclosed systems and methods enable use of a unitary mandrel (rather than a breakdown mandrel) and a single splice joint.

Particular implementations are described herein with reference to the drawings. In the description, common features are designated by common reference numbers throughout the drawings. The figures and the following description illustrate specific examples. It will 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 described herein and are included within the scope of the claims that follow this description. 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.

As used herein, various terminology is used for the purpose of describing particular implementations only and is not intended to be limiting. For example, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. Further, some features described herein are singular in some implementations and plural in other implementations. To illustrate, <FIG> depicts a system <NUM> including a mandrel <NUM> including one or more supports ("support(s)" <NUM> in <FIG>), which indicates that in some implementations the mandrel <NUM> includes a single support <NUM> and in other implementations the mandrel <NUM> includes multiple supports <NUM>. For ease of reference herein, such features are generally introduced as "one or more" features and are subsequently referred to in the singular unless aspects related to multiple of the features are being described.

The terms "comprise," "comprises," and "comprising" are used interchangeably with "include," "includes," or "including. " Additionally, the term "wherein" is used interchangeably with the term "where. " As used herein, "exemplary" indicates an example, an implementation, and/or an aspect, and should not be construed as limiting or as indicating a preference or a preferred implementation. As used herein, an ordinal term (e.g., "first," "second," "third," etc.) used to modify an element, such as a structure, a component, an operation, etc., does not by itself indicate any priority or order of the element with respect to another element, but rather merely distinguishes the element from another element having a same name (but for use of the ordinal term). As used herein, the term "set" refers to a grouping of one or more elements, and the term "plurality" refers to multiple elements.

As used herein, "generating", "calculating", "using", "selecting", "accessing", and "determining" are interchangeable unless context indicates otherwise. For example, "generating", "calculating", or "determining" a parameter (or a signal) can refer to actively generating, calculating, or determining the parameter (or the signal) or can refer to using, selecting, or accessing the parameter (or signal) that is already generated, such as by another component or device. As used herein, "coupled" can include "communicatively coupled," "electrically coupled," or "physically coupled," and can also (or alternatively) include any combinations thereof. Two devices (or components) can be coupled (e.g., communicatively coupled, electrically coupled, or physically coupled) directly or indirectly via one or more other devices, components, wires, buses, networks (e.g., a wired network, a wireless network, or a combination thereof), etc. Two devices (or components) that are electrically coupled can be included in the same device or in different devices and can be connected via electronics, one or more connectors, or inductive coupling, as illustrative, non-limiting examples. In some implementations, two devices (or components) that are communicatively coupled, such as in electrical communication, can send and receive electrical signals (digital signals or analog signals) directly or indirectly, such as via one or more wires, buses, networks, etc. As used herein, "directly coupled" is used to describe two devices that are coupled (e.g., communicatively coupled, electrically coupled, or physically coupled) without intervening components.

<FIG> depicts an example of a system <NUM> that includes a mandrel <NUM> and a demolding tool <NUM>. The mandrel <NUM> is shaped to define the shape of a workpiece (e.g., workpiece <NUM> of <FIG>), and the demolding tool <NUM> is configured to facilitate removal of the workpiece <NUM> from the mandrel <NUM> after the workpiece <NUM> is at least partially cured on the mandrel <NUM>. <FIG> also illustrates a plurality of orthogonal axes <NUM>, including an X-axis, a Y-axis, and a Z-axis. Directions parallel to the X-axis are referred to herein as longitudinal directions <NUM>, directions parallel to the Y-axis are referred to herein as lateral directions, and directions parallel to the Z-axis are referred to herein as vertical directions. In <FIG>, the various components illustrated have orientations that are aligned with one another such that ends of the mandrel <NUM> are adjacent to corresponding ends of the demolding tool <NUM> and the workpiece <NUM>. For ease of reference, the ends are labeled in <FIG> as first ends <NUM> and second ends <NUM>. As used herein, a "first end" of the workpiece <NUM> is a portion of the workpiece <NUM> that is disposed adjacent to a "first end" of the mandrel <NUM>. Likewise, a "second end" of the workpiece <NUM> is a portion of the workpiece <NUM> that is disposed adjacent to a "second end" of the mandrel <NUM>. Thus, the designation of first ends <NUM> and second ends <NUM> is arbitrary but is used consistently herein.

In particular implementations, the workpiece <NUM> include a plurality of layers of laminate material <NUM>, such as a plurality of layers of polymer impregnated fiber tows (commonly referred to as "pre-preg" tows) or other fiber-reinforced polymer materials that are arranged on the mandrel <NUM> to define a skin <NUM> having a shape corresponding to a shape of the mandrel <NUM>. For certain applications, the workpiece <NUM> also includes stringers <NUM> (e.g., elongated structural members) that extend in one or more directions, such as in the longitudinal direction <NUM>, to stiffen or otherwise mechanically support the skin <NUM>. To shape the workpiece <NUM> for such applications, the mandrel <NUM> includes stringer troughs <NUM> to define shapes of the stringers <NUM>. The stringer troughs <NUM> are high aspect ratio (e.g., each having a length that is significantly greater than its width) channels defined in a surface of the mandrel <NUM> to shape (e.g., mold) and retain the stringers <NUM> during curing of the layers of laminate material <NUM>.

In some implementations, the workpiece <NUM>, when cured, fully encircles at least a portion of the mandrel <NUM>. For example, the workpiece <NUM>, or a portion of the workpiece <NUM>, defines a tubular shape around a portion of the mandrel <NUM>. The mandrel <NUM> and the workpiece <NUM> each have a tapered shape with uneven cross-sectional areas spaced apart along the longitudinal direction <NUM>. To illustrate, the cross-sectional area of the first end of the mandrel <NUM> is smaller than the cross-sectional area of the second end of the mandrel <NUM>. In some such implementations, the workpiece <NUM> is not moveable relative to the mandrel <NUM> after the workpiece <NUM> cures because the encircling portion of the workpiece <NUM> inhibits vertical movement (e.g., along the Z-axis in <FIG>) and lateral movement (e.g., along the Y-axis of <FIG>), and interaction of the stringers <NUM> and the stringer troughs <NUM> inhibits longitudinal movement (e.g., along the X-axis or along longitudinal direction <NUM> of <FIG>). Thus, while the mandrel <NUM> enables formation of a fully encircling or tubular workpiece <NUM>, it can be challenging to remove the workpiece <NUM> from the mandrel <NUM>.

The demolding tool <NUM> is configured to facilitate removal of the workpiece <NUM> from the mandrel <NUM> without disassembling the mandrel <NUM> by using a flay demolding process, which is described further below. Thus, the mandrel <NUM> can be a unitary or single-piece mandrel. The demolding tool <NUM> includes a frame structure <NUM> coupled to a first plurality of actuators <NUM> and a second plurality of actuators <NUM>. Each actuator of the first plurality of actuators <NUM> (such as representative actuator <NUM>) is coupled to at least one coupler of a first plurality of couplers <NUM> (such as to representative coupler <NUM>). Additionally, each actuator of the second plurality of actuators <NUM> (such as representative actuator <NUM>) is coupled to at least one coupler of a second plurality of couplers <NUM> (such as to representative coupler <NUM>).

The first plurality of couplers <NUM> are arranged to couple to a first end of the workpiece <NUM> while the workpiece <NUM> is disposed on the mandrel <NUM>. The second plurality of couplers <NUM> are arranged to couple to the workpiece <NUM> at locations between the first end of the workpiece <NUM> and the second end of the workpiece <NUM>. In some implementations, each of the couplers <NUM>, <NUM> is a surface coupler, such as a suction cup, a vacuum coupler, an adhesive coupler, or another coupler that attaches by contact with an external surface of the workpiece <NUM>. In other implementations, each of the couplers <NUM>, <NUM> is a subsurface coupler or a through coupler, such as a bolt, a pin, a threaded insert, or another coupler that extends past the external surface of the workpiece <NUM> into the workpiece <NUM>. In still other implementations, the couplers <NUM>, <NUM> include a mix of surface couplers, and subsurface couplers/through couplers.

In <FIG>, the demolding tool <NUM> includes or is coupled to a controller <NUM>. The controller <NUM> includes special purpose circuitry and/or one or more processors coupled to a memory. The memory includes a non-transitory computer-readable medium that stores instructions that are executable by the processor(s). For example, the instructions are executable to initiate, perform or control operations to aid in removal of the workpiece <NUM> from the mandrel <NUM>. The processor(s) can be implemented as a single processor or as multiple processors, such as in a multi-core configuration, a multi-processor configuration, a distributed computing configuration, a cloud computing configuration, or any combination thereof. In some implementations, one or more portions of the controller <NUM> are implemented using dedicated hardware, firmware, or a combination thereof.

The controller <NUM> is configured to control operation of the actuators <NUM>, <NUM> (e.g., by sending control signals to the actuators <NUM>, <NUM>), and possibly other components, such as a cutter <NUM>, sensors, etc., during the flay demolding process. For example, in a particular implementation, the controller <NUM> is configured to send control signals to cause one or more of the actuators <NUM>, <NUM> to pre-tension one or more of the couplers <NUM>, <NUM> with respect to the workpiece <NUM> before the cutter <NUM> cuts the workpiece <NUM>. After the cutter <NUM> cuts the workpiece <NUM>, the controller <NUM> is configured to send control signals to cause one or more of the actuators <NUM>, <NUM> to apply forces to at least partially disengage the first end of the workpiece <NUM> from the first end of the mandrel <NUM>, and after at least partially disengaging the first end of the workpiece <NUM> from the first end of the mandrel <NUM>, to apply forces to at least partially disengage the second end of the workpiece <NUM> from the mandrel <NUM>. Controlling the flay demolding process in this manner has various benefits. For example, pre-tensioning one or more of the couplers <NUM>, <NUM> limits longitudinal movement of the workpiece <NUM> relative to the mandrel <NUM> during and after cutting the workpiece <NUM>. Such longitudinal movement could result in high contact pressure between ends of the stringers <NUM> and ends of the stringer troughs <NUM>, which could damage the workpiece <NUM>, the mandrel <NUM>, or both. Additionally, modeling has shown that at least partially disengaging the first end of the workpiece <NUM> (e.g., a smaller end of the workpiece <NUM>) from the first end of the mandrel <NUM> before applying forces to at least partially disengage the second end of the workpiece <NUM> (e.g., a larger end of the workpiece <NUM>) from the mandrel <NUM> limits stresses induced within the workpiece <NUM> and contact pressure between ends of the stringers <NUM> and ends of the stringer troughs <NUM> to within acceptable tolerances while deforming the workpiece <NUM> sufficiently to remove the workpiece <NUM> from the mandrel <NUM>.

In some implementation, one or more of the couplers <NUM>, <NUM> are positioned to couple to the workpiece <NUM> at locations that overlying ends of one or more of the stringers <NUM>. For example, in a particular implementation, each of the first plurality of couplers <NUM> is positioned to couple to the workpiece <NUM> at a location radially overlying a respective stringer of the plurality of stringers <NUM>. In such implementations, applying forces to at least partially disengaging the first end of the workpiece <NUM> from the first end of the mandrel <NUM> before applying forces to at least partially disengage the second end of the workpiece <NUM> from the mandrel <NUM> disengages the first ends of the stringers <NUM> from corresponding stringer troughs <NUM> early in the flay demolding process so that subsequent longitudinal movement between the workpiece <NUM> and the mandrel <NUM> does not damage the first ends of the stringers <NUM> or the stringer troughs <NUM>.

During operation, the layers of laminate material <NUM> are applied to the mandrel <NUM> to form the skin <NUM>. In some implementations, material is deposited or applied in the stringer troughs <NUM> before the layers of the laminate material <NUM> of the skin <NUM> are applied to the mandrel <NUM> so that the stringer <NUM> and the skin <NUM> cure together. In a particular implementation, layup of the layers of laminate material <NUM> is performed using one or more automated fiber placement tools. In this implementation, the automated fiber placement tool(s) may be too large to fit in the demolding tool <NUM>, in which case layup is performed remote from or outside of the demolding tool <NUM>. After layup is complete, the layers of laminate material <NUM> are cured or partially cured (e.g., sufficiently cured for the workpiece <NUM> to be mechanically stable), and the workpiece <NUM> and mandrel <NUM> are positioned in the demolding tool <NUM>. For example, the mandrel <NUM> or the demolding tool <NUM> may be mounted on rollers, tracks, or another mechanism to enable relative motion of the mandrel <NUM> and the demolding tool <NUM>.

After the mandrel <NUM> and the workpiece <NUM> are positioned relative to the demolding tool <NUM>, the couplers <NUM>, <NUM> are attached to the workpiece <NUM>. In some implementations, the couplers <NUM>, <NUM> include sub-surface or through couplers, in which case the couplers <NUM>, <NUM> or portions thereof (such as posts, bolts, washers, threaded inserts, are disposed in or through the workpiece <NUM> during the layup operation or after curing and before the couplers <NUM>, <NUM> are attached to the workpiece <NUM>. In some implementations, the couplers <NUM>, <NUM> include surface couplers which can be attached to the workpiece <NUM> while the workpiece <NUM> is in position relative to the demolding tool <NUM>. For example, when the couplers <NUM> include one or more vacuum couplers, a vacuum cup of the coupler <NUM> can be coupled to the surface of the workpiece <NUM> after the workpiece <NUM> is in position relative to the demolding tool <NUM>. In some implementations, the positions of at least some of the couplers <NUM>, <NUM> on the surface of the workpiece <NUM> are carefully controlled. For example, the coupler <NUM> can be coupled to the surface of the workpiece <NUM> at a location that radially overlies one of the stringers <NUM>.

In some implementations, the couplers <NUM>, <NUM> are de-attached from the actuators <NUM>, <NUM> during attachment to the workpiece <NUM>. In such implementations, the couplers <NUM>, <NUM> are attached to the actuators <NUM>, <NUM> after the couplers <NUM>, <NUM> are attached to the workpiece <NUM>. In other implementations, the couplers <NUM>, <NUM> remain attached to the actuators <NUM>, <NUM> during attachment of the couplers <NUM>, <NUM> to the workpiece <NUM>.

After the couplers <NUM>, <NUM> are coupled to the workpiece <NUM>, the controller <NUM> sends control signals to one or more of the actuators <NUM>, <NUM> to pre-tension the one or more of the actuators <NUM>, <NUM> and respective couplers <NUM>, <NUM>. As used herein, "pre-tensioning" refers to using an actuator to applying sufficient force to a coupler to remove slack between the workpiece <NUM> and the frame structure <NUM>, or put another way, to ensure that joints, couplings, and members between the frame structure <NUM> and the workpiece <NUM> are in tension. In a particular implementation, the controller <NUM> is configured to send control signals to a subset of the actuators <NUM>, <NUM> (such as to the first plurality of actuators <NUM>, to the second plurality of actuators <NUM>, or to some of each plurality of actuators <NUM>, <NUM>) to cause the subset of the actuators <NUM>, <NUM> to pre-tension respective ones of the couplers <NUM>, <NUM> with respect to the workpiece <NUM>. Pre-tensioning at least some of the couplers <NUM>, <NUM> inhibits movement of ends of the stringers <NUM> towards ends of the stringer troughs <NUM> when a cut is made in the workpiece <NUM>.

With one or more of the actuators <NUM>, <NUM> pre-tensioned, the cutter <NUM> is activated to cut the workpiece <NUM> along the longitudinal direction <NUM>. In a particular implementation, the cutter <NUM> cuts the workpiece <NUM> end-to-end at or near a bottom (e.g., a lowest vertical or Z-axis location in <FIG>) of the workpiece <NUM>. As the cut is made, cut edges <NUM> of the workpiece <NUM> may be supported by the actuators <NUM>, <NUM>, or may be allowed to sag such that a portion of the workpiece <NUM> adjacent to the cut edges <NUM> at least partially disengages from the mandrel <NUM>. In some implementations, the mandrel <NUM> has a tapered shape along the longitudinal direction (e.g., the first end of the mandrel <NUM> has a cross-sectional area that is smaller than a cross-sectional area of the second end of the mandrel <NUM>). In such implementations, the stringer troughs <NUM> converge toward the first end of the mandrel <NUM>. Cutting the workpiece <NUM> can free the workpiece <NUM> from the mandrel <NUM> sufficiently to allow the workpiece <NUM> to shift toward the first end of the mandrel <NUM>, which can allow enough contact pressure between the ends of the stringers <NUM> and the stringer troughs <NUM> to damage or delaminate the stringers <NUM>. Pre-tensioned at least a subset of the actuators <NUM>, <NUM> before cutting the workpiece <NUM> inhibits such motion during and after the cutting operation and protects the stringers <NUM> from damage.

After the cut is formed in the workpiece <NUM>, the controller <NUM> sends control signals to cause the first plurality of actuators <NUM> to apply first forces to the workpiece <NUM> via the first plurality of couplers <NUM>. The first forces are sufficient to deform the workpiece <NUM> and at least partially disengage the first end of the workpiece <NUM> from the first end of the mandrel <NUM>. In some implementations, the first forces applied by the first plurality of actuators <NUM> have components along all three of the orthogonal axes <NUM> of <FIG>. For example, the first plurality of actuators <NUM> pull the workpiece <NUM> upward (along the Z-axis) to keep the stringers <NUM> aligned vertically with the stringer troughs <NUM>, pull the workpiece <NUM> longitudinal (e.g., toward the second ends <NUM> along the X-axis) to reduce contact pressure between first ends of the stringers <NUM> and first ends of the stringer troughs <NUM>, and pull the workpiece <NUM> laterally (e.g., along the Y-axis) to peel (or otherwise deform) the first end of the workpiece <NUM> away from the first end of the mandrel <NUM>.

After the first forces are applied and the first end of the workpiece <NUM> is at least partially disengaged from the mandrel <NUM>, the controller <NUM> sends control signals to cause the second plurality of actuators <NUM> to apply second forces to the workpiece <NUM> via the second plurality of couplers <NUM>. The second forces further deform the workpiece <NUM> and at least partially disengage the second end of the workpiece <NUM> from the mandrel <NUM>. In some implementations, the second forces applied by the second plurality of actuators <NUM> have components along two of the orthogonal axes <NUM> of <FIG>. For example, the second plurality of actuators <NUM> pull the workpiece <NUM> upward (along the Z-axis) and pull the workpiece <NUM> laterally (e.g., along the Y-axis) to peel (or otherwise deform) the second end of the workpiece <NUM> away from the second end of the mandrel <NUM>.

After the second forces are applied, vertical (e.g. along the Z-axis) movement is used to separate and fully disengage the workpiece <NUM> and the mandrel <NUM>. In some implementations, the actuators <NUM>, <NUM> apply third forces to lift the workpiece <NUM> from the mandrel <NUM>. In other implementations, the mandrel <NUM> is lowered to remove the mandrel <NUM> from the workpiece <NUM>. In still other implementations, the frame structure <NUM> is lifted to remove the workpiece <NUM> from the mandrel <NUM>.

After the workpiece <NUM> and the mandrel <NUM> are completely disengaged, longitudinal (e.g., along the X-axis) movement is used to fully remove the mandrel <NUM> from the interior of the workpiece <NUM>. For example, the same movement mechanism used to position the mandrel <NUM> and the workpiece <NUM> relative to the demolding tool <NUM> may be used to separate the mandrel <NUM> from the workpiece <NUM> and the demolding tool <NUM>. In some implementations, the mandrel <NUM> is moveable on wheels, rollers, tracks, etc. to enable the mandrel <NUM> to be moved away from the workpiece <NUM> and the demolding tool <NUM>. In other implementations, the demolding tool <NUM> is moveable on wheels, rollers, tracks, etc. to enable the demolding tool <NUM> and workpiece <NUM> to be moved away from the mandrel <NUM>. In either implementation, one or more of the support(s) <NUM> of the mandrel <NUM> may be moved between the cut edges <NUM> of the workpiece <NUM> as the mandrel <NUM> and the workpiece <NUM> are separated. Thus, the mandrel <NUM> can support at both ends <NUM>, <NUM> without interfering with removal of the workpiece <NUM> from the mandrel <NUM> after the workpiece <NUM> is cured.

After the mandrel <NUM> is removed from the workpiece <NUM>, the workpiece <NUM> may be stabilized and retained by the demolding tool <NUM> during post-processing operations, such as inspection and splicing the cut edges <NUM> together. In some implementations, support rings <NUM>, <NUM> are attached to one or both ends <NUM>, <NUM> of the workpiece <NUM> to stabilize and retain the workpiece <NUM>. In some such implementations, the support rings <NUM>, <NUM> fully support the workpiece <NUM> to allow the workpiece <NUM> to be decoupled from and removed from the demolding tool <NUM>.

Thus, a flay demolding process using the demolding tool <NUM> enables removing the workpiece <NUM> from the mandrel <NUM> without breaking down or disassembling the mandrel <NUM> even though the workpiece <NUM> fully encircles a portion of the mandrel <NUM>. Additionally, by using the flay demolding process with the demolding tool <NUM>, the workpiece <NUM> can be finished with a single splice joint to join the cut edges <NUM>.

<FIG> is flow chart of an example of a method <NUM> of using the demolding tool <NUM> of <FIG> to remove the workpiece <NUM> from the mandrel <NUM>. The method <NUM> begins after a workpiece is cured or at least partially cured on a mandrel. For example, layers of laminate material <NUM> of <FIG> can be applied to the mandrel <NUM> and cured or partially cured to conform to a shape defined by the mandrel <NUM>. In some implementations, the workpiece <NUM> fully encircles at least a portion of the mandrel <NUM>. Further, in some implementations, the mandrel <NUM> is tapered. For example, a first end of the mandrel <NUM> may have a smaller cross-sectional area than a second end of the mandrel <NUM>. In some implementations, the mandrel <NUM> also includes stringer troughs <NUM> to facilitate curing stringers <NUM> to a skin <NUM> of the workpiece <NUM>.

The method <NUM> includes, at block <NUM>, attaching couplers of a demolding tool to the workpiece on the mandrel. For example, the couplers <NUM>, <NUM> of <FIG> are coupled to the workpiece <NUM>. The couplers <NUM>, <NUM> include surface couplers, sub-surface couplers, through couplers, or a combination thereof. A first set of couplers <NUM>, <NUM> (e.g., the first plurality of couplers <NUM>) are coupled to a first end of the workpiece <NUM>, and a second set of the couplers <NUM>, <NUM> (e.g., the second plurality of couplers <NUM>) are coupled to the workpiece <NUM> between the first set of couplers and the second end of the workpiece <NUM>.

The method <NUM> also includes, at block <NUM>, pre-tensioning actuators coupled to the workpiece to inhibit movement of the workpiece toward a first end of the mandrel. For example, at least a subset of the couplers <NUM>, <NUM> are pre-tensioned by respective actuators <NUM>, <NUM> to removes slack from between the workpiece <NUM> and the frame structure <NUM>.

The method <NUM> also includes, at block <NUM>, after at least some of the couplers are pre-tensioned, cutting the workpiece along a direction between a first end of the workpiece and a second end of the workpiece. For example, while at least a subset of the couplers <NUM>, <NUM> of <FIG> are in tension, the cutter <NUM> is activated to cut the bottom of the workpiece <NUM> end-to-end along the longitudinal direction <NUM>. In some implementations, cutting the workpiece <NUM> allows at least a portion of the workpiece <NUM> to separate from the mandrel <NUM> due to sag at the cut edges <NUM> of the workpiece <NUM>.

The method <NUM> also includes, at block <NUM>, applying forces (e.g., first forces after pre-tensioning) to the first end of the workpiece to deform the first end of the workpiece to at least partially disengage the first end of the workpiece from the first end of the mandrel. For example, the first plurality of actuators <NUM> may be activated to apply the forces to the first end of the workpiece <NUM> via the first plurality of couplers <NUM>. In some implementations, the forces applied to the workpiece <NUM> by the first plurality of actuators <NUM> via the first plurality of couplers <NUM> have components along a lateral axis (e.g., the Y-axis in <FIG>), a vertical axis (e.g., the Z-axis in <FIG>), and the longitudinal axis (e.g., the X-axis in <FIG>).

The method <NUM> also includes, at block <NUM>, applying forces (e.g., second forces after pre-tensioning) to the second end of the workpiece to further deform the workpiece and at least partially disengage the second end of the workpiece from the mandrel. For example, the second plurality of actuators <NUM> may be activated to apply the forces to the second end of the workpiece <NUM> via the second plurality of couplers <NUM>. In some implementations, the forces applied to the workpiece <NUM> by the second plurality of actuators <NUM> via the second plurality of couplers <NUM> have components along the lateral axis (e.g., the Y-axis in <FIG>) and the vertical axis (e.g., the Z-axis in <FIG>). In some implementations, forces applied by the second plurality of actuators <NUM> also have components along the longitudinal axis (e.g., the X-axis in <FIG>); however, in other implementations, the forces applied by the second plurality of actuators <NUM> do not have components along the longitudinal axis.

The method <NUM> also includes, at block <NUM>, applying forces (e.g., third forces after pre-tensioning) to the workpiece to cause vertical displacement of the workpiece relative to the mandrel. For example, one or more actuators of the second plurality of actuators <NUM> may be coupled to an upper surface of the workpiece <NUM> and may lift the workpiece <NUM> away from the mandrel <NUM>. In some implementations, the mandrel <NUM> can be lowered to cause vertical displacement of the workpiece <NUM> relative to the mandrel <NUM>. In such implementations, lowering the mandrel <NUM> can be used in addition to applying lifting forces to the workpiece <NUM>, or lowering the mandrel <NUM> can be used instead of applying lifting forces to the workpiece <NUM>.

The method <NUM> also includes, at block <NUM>, after fully disengaging the workpiece from the mandrel, removing the mandrel from within the workpiece by moving the mandrel, the workpiece, or both, relative to the longitudinal direction. For example, the mandrel <NUM> can be moved along the longitudinal direction <NUM> to remove the mandrel <NUM> from within the workpiece <NUM>. In some implementations, one or more supports <NUM> of the mandrel <NUM> move between the cut edges <NUM> of the workpiece <NUM> as the mandrel <NUM> is removed from within the workpiece <NUM>.

The method <NUM> also includes, at block <NUM>, after removal of the mandrel from within the workpiece, coupling a first support ring to the first end of the workpiece and coupling a second support ring to the second end of the workpiece. For example, the first support ring <NUM> of <FIG> is coupled to the first end of the workpiece <NUM>, and the second support ring <NUM> is coupled to the second end of the workpiece <NUM>.

The method <NUM> also includes, at block <NUM>, after removal of the mandrel from within the workpiece, splicing cut edges of the workpiece together. For example, the cut edges <NUM> of the workpiece <NUM> can be joined together using a splice joint, as described further with reference to <FIG>.

Thus, the method <NUM> enables separation of the mandrel <NUM> and the workpiece <NUM> without disassembling the mandrel <NUM> and using a single splice joint to join the cut edges <NUM>.

<FIG> illustrate various examples of the components described with reference to <FIG> in the context of aircraft manufacturing. For example, in each of <FIG>, the workpiece <NUM> corresponds to a section of a structure of an aircraft, such as a portion of a fuselage of an aircraft. In other implementations, other aircraft components or workpieces unrelated to aircraft can be manufactured using the system <NUM> of <FIG>.

<FIG> illustrate a perspective view and a side view, respectively, of an example of the mandrel <NUM> of <FIG> according to a particular implementation. In <FIG>, a surface <NUM> of the mandrel <NUM> is shaped to form a portion of a fuselage of an aircraft, such as a forward section of the fuselage. For example, the mandrel <NUM> has a tapered shape such that the first end <NUM> of the mandrel <NUM> has a smaller cross-sectional area than the second end <NUM> of the mandrel <NUM>.

<FIG> also illustrate examples of the stringer troughs <NUM> of <FIG>. In <FIG>, the stringer troughs <NUM> extend longitudinally (e.g., along the X-axis) on the surface <NUM> of the mandrel <NUM>. In this example, due to the tapering shape of the mandrel <NUM>, the stringer troughs <NUM> converge toward the first end <NUM> of the mandrel <NUM>.

<FIG> also illustrate an example of the support(s) <NUM> of <FIG>. <FIG> illustrate only a single support <NUM> at the first end <NUM> of the mandrel <NUM>; however, in other examples, the mandrel <NUM> includes one or more additional supports <NUM> at the first end <NUM>, one or more supports <NUM> at the second end <NUM>, or both.

<FIG> and <FIG> illustrate an end view and a perspective view, respectively, of an example of the demolding tool <NUM> of <FIG> according to a particular implementation. The demolding tool <NUM> in <FIG> and <FIG> includes the frame structure <NUM>, the first plurality of actuators <NUM>, and the second plurality of actuators <NUM>. The first plurality of couplers <NUM> are attached to the first plurality of actuators <NUM>, and the second plurality of couplers <NUM> are attached to the second plurality of actuators <NUM>. <FIG> also illustrates a gap <NUM> of the frame structure <NUM>. The gap <NUM> enables one or more of the supports <NUM> of the mandrel <NUM> to pass between members of the frame structure <NUM> as the mandrel <NUM> is moved relative to the demolding tool <NUM>.

<FIG> illustrates a coupler <NUM> attached to an actuator <NUM>. In the example illustrated in <FIG>, the coupler <NUM> and the actuator <NUM> are located forward of the second plurality of couplers <NUM> and the second plurality of actuators <NUM> (e.g., closer to the first end <NUM> than the second end). In some implementations, the coupler <NUM> and the actuator <NUM> are considered members of the second plurality of couplers <NUM> and the second plurality of actuators <NUM>, respectively. For example, the actuator <NUM> can be controlled by the controller <NUM> of <FIG> when the controller <NUM> controls the second plurality of actuators <NUM>. Alternatively, in some implementations, the coupler <NUM> and the actuator <NUM> are distinct from (e.g., not members of) the second plurality of couplers <NUM> and the second plurality of actuators <NUM>, respectively. For example, the controller <NUM> may control the actuators <NUM> independently of the first and second pluralities of actuators <NUM>, <NUM>. To illustrate, the actuator <NUM> can be used to lift the workpiece <NUM> from the mandrel <NUM> after the first and second pluralities of actuators <NUM>, <NUM> have been actuated to disengage the ends <NUM>, <NUM> of the workpiece <NUM> from the mandrel <NUM>.

<FIG> illustrates a perspective view of an example of the demolding tool <NUM> and the workpiece <NUM> of <FIG> according to a particular implementation. The example illustrated in <FIG> illustrates the couplers <NUM>, <NUM> coupled to the workpiece <NUM>, which is supported in the frame structure <NUM>.

<FIG> illustrates a perspective view of an example of the workpiece <NUM> and couplers <NUM>, <NUM>, <NUM> and actuators <NUM>, <NUM>, <NUM> of the demolding tool <NUM> according to a particular implementation. <FIG> also illustrates examples of the stringers <NUM> extending longitudinally from the first end <NUM> toward the second end <NUM> of the workpiece <NUM>.

<FIG> illustrates a coupler <NUM> attached to an actuator <NUM>. In the example illustrated in <FIG>, the coupler <NUM> and the actuator <NUM> are located forward of the second plurality of couplers <NUM> and the second plurality of actuators <NUM> (e.g., closer to the first end <NUM> than the second end <NUM>). In some implementations, the coupler <NUM> and the actuator <NUM> are consider members of the first plurality of couplers <NUM> and the first plurality of actuators <NUM>, respectively. For example, the actuator <NUM> can be controlled by the controller <NUM> of <FIG> when the controller <NUM> controls the first plurality of actuators <NUM>. Alternatively, in some implementations, the coupler <NUM> and the actuator <NUM> are consider members of the second plurality of couplers <NUM> and the second plurality of actuators <NUM>, respectively. In another alternative, in some implementations, the coupler <NUM> and the actuator <NUM> are distinct from (e.g., not members of) the first or second plurality of couplers <NUM>, <NUM> and the first or second plurality of actuators <NUM>, <NUM>, respectively. For example, the controller <NUM> may control the actuators <NUM> independently of the first and second pluralities of actuators <NUM>, <NUM>.

<FIG> illustrates a perspective view of an example of the workpiece <NUM> and components of force applied to the workpiece <NUM> by the actuators <NUM>, <NUM> of the demolding tool <NUM> of <FIG> during a demolding process according to a particular implementation. The illustrated components of force include first components of force <NUM> applied by the first plurality of actuators <NUM>, second components of force <NUM> applied by the second plurality of actuators <NUM>, third components of force <NUM> applied by the actuator <NUM> of <FIG>, and fourth components of force <NUM> applied by the actuator <NUM> of <FIG>. In the example illustrated in <FIG>, the first components of force <NUM> are along all three of the orthogonal axes <NUM> (e.g., the X-axis, the Y-axis, and the Z-axis), whereas the second components of force <NUM>, the third components of force <NUM>, and the fourth components of force <NUM> are along two of the three orthogonal axes <NUM> (e.g., the Y-axis and the Z-axis).

<FIG> illustrate deformation of the workpiece <NUM> during various stages of a demolding process according to a particular implementation. Each of <FIG>, <FIG>, <FIG> and <FIG> illustrates an end view of an example of the workpiece <NUM> disposed in the demolding tool <NUM> during a respective stage of the demolding process. Each of <FIG>, <FIG>, <FIG> and <FIG> illustrates a top view of an example of the workpiece <NUM> disposed in the demolding tool <NUM> during a respective stage of the demolding process. <FIG> illustrate a first stage of the demolding process, <FIG> illustrate a second stage of a demolding process that is subsequent to the first stage. <FIG> illustrate a third stage of a demolding process that is subsequent to the second stage. <FIG> illustrate a fourth stage of a demolding process that is subsequent to the third stage.

<FIG>, <FIG> and <FIG> illustrate a first end view, a second end view, and a cutaway perspective second end view, respectively, of an example of the workpiece <NUM> as deformed during various stages of the demolding process of <FIG>. For example, in <FIG>, the skin <NUM> is shown in five configurations. A first configuration of the skin 126A illustrates a shape of the workpiece <NUM> while the workpiece <NUM> is on the mandrel <NUM> and before the workpiece <NUM> is cut. A second configuration of the skin 126B illustrates a shape of the workpiece <NUM> while the workpiece <NUM> is on the mandrel <NUM> and after the workpiece <NUM> is cut and the cut edges <NUM> are allowed to sag apart. The first configuration of the skin 126A and the second configuration of the skin 126B are also illustrated in <FIG>.

<FIG> also illustrate a third configuration of the skin 126C which illustrates a shape of the workpiece <NUM> after the first plurality of actuators <NUM> apply first forces to the first end <NUM> of the workpiece <NUM> to at least partially disengage the first end <NUM> of the workpiece <NUM> from the first end <NUM> of the mandrel <NUM>. The second configuration of the skin 126B and the third configuration of the skin 126C are also illustrated in <FIG>.

<FIG> also illustrate a fourth configuration of the skin 126D which illustrates a shape of the workpiece <NUM> after the second plurality of actuators <NUM> apply second forces to the second end <NUM> of the workpiece <NUM> (or between the first plurality of couplers <NUM> and the second end <NUM>) to at least partially disengage the second end <NUM> of the workpiece <NUM> from the second end <NUM> of the mandrel <NUM>. The third configuration of the skin 126C and the fourth configuration of the skin 126D are also illustrated in <FIG>.

<FIG> also illustrate a fifth configuration of the skin 126E which illustrates a shape of the workpiece <NUM> after the workpiece <NUM> is fully disengaged from the mandrel <NUM> and retained by the demolding tool <NUM>. The fourth configuration of the skin 126D and the fifth configuration of the skin 126E are also illustrated in <FIG>.

The order of the stages of the demolding process of <FIG> have been shown by modeling to result in deformations of the workpiece <NUM> that are within manufacturing and structural limitations of the workpiece <NUM>. For example, the order in which the forces are applied in the example of <FIG> inhibits movement of the workpiece <NUM> toward the first end <NUM>, which could subject ends of the stringers <NUM> to excessive contact pressure with the stringer troughs <NUM>.

<FIG> illustrate a perspective view of an example of a post-processing fixture <NUM> disposed within the workpiece <NUM> after the mandrel <NUM> has been removed and while the workpiece <NUM> is retained by the demolding tool <NUM> according to a particular implementation. In the example illustrated in <FIG>, the post-processing fixture <NUM> includes or is coupled to one or more post-processing tools <NUM>. For example, the post-processing tool(s) <NUM> may include non-destructive inspection tools that facilitate inspection of an interior surface of the workpiece <NUM>, through inspection of the workpiece walls, or both. To illustrate, the non-destructive inspection tools can include laser measurement tools to measure interior dimensions of the workpiece <NUM> or cameras to check for surface defects. In some implementations, non-destructive inspection tools on the post-processing fixtures <NUM> interact with non-destructive inspection tools external to the workpiece <NUM> to gather data. To illustrate, ultrasound emitters or an x-ray source may be mounted to the post-processing fixture <NUM> to generate signals that are detected by detectors outside the workpiece <NUM> for gathering non-destructive inspection data about the skin <NUM>, the stringers <NUM>, or both. In other examples, the post-processing tool(s) <NUM> may include surface finishing equipment, such as painters, drills, cutters, or polishers. The post-processing tool(s) <NUM> can include any tool that facilitates preparation of the workpiece <NUM> for subsequent manufacturing steps.

<FIG> illustrate an end view of an example of a ring fixture <NUM> coupled to the workpiece of <FIG> after the mandrel <NUM> has been removed and while the workpiece <NUM> is disposed with the demolding tool <NUM> according to a particular implementation. <FIG> illustrate a perspective view of an example of the ring fixture <NUM> coupled to the workpiece <NUM> after the workpiece <NUM> has been removed from the demolding tool <NUM> according to a particular implementation.

In the example illustrated in <FIG> and <FIG>, the ring fixture <NUM> includes a plurality of support rings, including the first support ring <NUM> and the second support ring <NUM>. In the example illustrated in <FIG>, the ring fixture <NUM> also includes a first set of rollers <NUM> to enable movement of the ring fixture <NUM> relative to the frame structure <NUM> of the demolding tool <NUM>.

In some implementations, the ring fixture <NUM> includes a second set of rollers <NUM> and a third set of rollers <NUM> (shown in <FIG>) to enable rotation of the workpiece <NUM> while the workpiece <NUM> is supported by the ring fixture <NUM>. In the example illustrated in <FIG>, the third set of rollers <NUM> directly supports a third support ring <NUM>, which is coupled via an axle <NUM> to the first support ring <NUM>.

In addition to supporting the weight of the workpiece <NUM> on the ring fixture <NUM>, the support rings <NUM>, <NUM> retain the shape of the workpiece <NUM>. For example, the support rings <NUM>, <NUM> attach to the workpiece <NUM> such that the cut edges <NUM> of the workpiece <NUM> are positioned to be spliced together (e.g., touching or nearly touching each other).

<FIG> illustrate a bottom exterior view of the workpiece <NUM> and indicates a cut line <NUM> used for the demolding process according to a particular implementation. Cutting along the cut line <NUM> separates the skin <NUM> at the cut edges 128A and 128B. After the demolding process, the cut edges <NUM> are reattached to one another using a splice joint. <FIG> illustrate an interior view of the workpiece <NUM> at the cut line <NUM>.

<FIG> shows details of a splice used to join the cut edges <NUM> together according to a particular implementation. In <FIG>, a splice fitting <NUM> is coupled to a rib <NUM> on an interior surface of the workpiece <NUM> to join the cut edges <NUM> together. In some implementations, the rib <NUM> is formed in the same manner as the stringers <NUM>. For example, the rib <NUM> may include laminate material that is disposed in a rib forming feature (e.g., a channel) in the surface of the mandrel <NUM> during layup and is subsequently cured with the layers of laminate material <NUM> of the skin <NUM> to form the workpiece <NUM>. In other implementations, the rib <NUM> is attached to the interior surface of the workpiece <NUM> during post-processing of the workpiece <NUM>. After the splice joint is complete, the workpiece <NUM> is ready for subsequent processing, such as assembly with one or more other components to manufacture a fuselage or other structure of an aircraft.

There is disclosed a demolding tool comprises a first plurality of couplers arranged to couple to a first end of a workpiece disposed on a mandrel, the mandrel having a first end disposed adjacent to the first end of the workpiece and having a second end disposed adjacent to a second end of the workpiece, wherein the first end of the mandrel has a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the mandrel; a first plurality of actuators, each actuator of the first plurality of actuators coupled to at least one of the first plurality of couplers; a second plurality of couplers arranged to couple to the workpiece at locations between the first end of the workpiece and the second end of the workpiece; a second plurality of actuators, each actuator of the second plurality of actuators coupled to at least one of the second plurality of couplers; and a controller configured to, after a cut is formed in the workpiece along a longitudinal direction between the first end and the second end of the workpiece: cause the first plurality of actuators to apply, via the first plurality of couplers, first forces to the workpiece to deform the workpiece and at least partially disengage the first end of the workpiece from the first end of the mandrel; and after causing the first plurality of actuators to apply the first forces to the workpiece, cause the second plurality of actuators to apply, via the second plurality of couplers, second forces to the workpiece to further deform the workpiece and at least partially disengage the second end of the workpiece from the mandrel.

Preferably, the workpiece comprises layers of laminate material cured on the mandrel to define a skin having a shape corresponding to a shape of the mandrel.

In particular, the mandrel defines a plurality of stringer troughs and the workpiece further comprises a plurality of stringers coupled to the skin and cured within the plurality of stringer troughs.

Preferably, the plurality of stringer troughs converge toward the first end of the mandrel.

In particular, the controller is further configured to, before causing the first plurality of actuators to apply the first forces, cause the first plurality of actuators to pre-tension the first plurality of couplers with respect to the workpiece to inhibit movement of ends of the stringers towards ends of the stringer troughs.

Preferably, each of the first plurality of couplers is positioned to couple to the workpiece at a location radially overlying a respective stringer of the plurality of stringers.

In particular, one or more of the first plurality of couplers includes a suction cup or vacuum coupler.

Preferably, the first plurality of actuators and the first plurality of couplers are configured to apply forces having components along at least three orthogonal axes to the workpiece, and wherein the second plurality of actuators and the second plurality of couplers are configured to apply forces having components along at least two of the three orthogonal axes of the workpiece.

In particular, the workpiece corresponds to a section of a structure of an aircraft.

Preferably, the demolding tool further comprises a frame structure coupled to the first plurality of actuators and the second plurality of actuators.

Further, there is describes a method of removing from a mandrel a workpiece having a tubular shape defining a plurality of unequal circumferences spaced apart along a longitudinal axis, the method comprising: after the workpiece is cured on the mandrel, cutting the workpiece along a direction between a first end of the workpiece and a second end of the workpiece, wherein the first end of the workpiece has a first circumference that is smaller than a second circumference of the second end of the workpiece; applying first forces to the first end of the workpiece to deform the first end of the workpiece to at least partially disengage the first end of the workpiece from the first end of the mandrel; and after applying the first forces, applying second forces to the second end of the workpiece to further deform the workpiece and at least partially disengage the second end of the workpiece from the mandrel.

Preferably, the first forces are applied after at least a portion of the workpiece separates from the mandrel due to sag at cut edges of the workpiece.

In particular, the method further comprises, before applying the first forces, pre-tensioning actuators coupled to the workpiece to inhibit movement of the workpiece toward the first end of the mandrel.

Preferably, the method further comprises, after applying the second forces, applying third forces to the workpiece to cause vertical displacement of the workpiece relative to the mandrel.

In particular, the method further comprises, after fully disengaging the workpiece from the mandrel, removing the mandrel from within the workpiece by moving the mandrel, the workpiece, or both, relative to the longitudinal axis.

Preferably, the mandrel comprises a support coupled to the first end of the mandrel and wherein the support moves between cut edges of the workpiece during removal of the mandrel from within the workpiece.

In particular, the method further comprises, after removing the mandrel from within the workpiece, coupling a first support ring to the first end of the workpiece and coupling a second support ring to the second end of the workpiece.

Preferably, the method further comprises, after removing the mandrel from within the workpiece, splicing cut edges of the workpiece together.

In particular, the first forces have components along a lateral axis, a vertical axis, and the longitudinal axis, and wherein the second forces have components along the lateral axis and the vertical axis.

Also, there is disclosed a system comprising: a mandrel contoured to define a tapering tubular shape of a workpiece cured on the mandrel; and a demolding tool configured to remove the workpiece from the mandrel after the workpiece is cured on the mandrel and cut longitudinally, wherein the demolding tool is configured to remove the workpiece from the mandrel by deforming a first end of the workpiece to at least partially disengage the first end of the workpiece from a first end of the mandrel, and subsequently, deforming a second end of the workpiece to at least partially disengage the second end of the workpiece from a second end of the mandrel, wherein the first end of the workpiece has a first cross-sectional area that is smaller than a second cross-sectional area of the second end of the workpiece.

Preferably, the demolding tool comprises: a first plurality of couplers arranged to couple to a first end of the workpiece; a first plurality of actuators, each actuator of the first plurality of actuators coupled to at least one of the first plurality of couplers; a second plurality of couplers arranged to couple to the workpiece at locations between the first end of the workpiece and the second end of the workpiece; and a second plurality of actuators, each actuator of the second plurality of actuators coupled to at least one of the second plurality of couplers.

Furthermore, there is described a method of removing a workpiece from a mandrel, the method comprising: applying forces to the workpiece while cutting the workpiece along a longitudinal direction between a first end of the workpiece and a second end of the workpiece; after cutting the workpiece, applying forces to disengage a first end of the workpiece from the mandrel; and disengaging the first end of the workpiece from the mandrel, applying forces to the second end of the workpiece to deform the workpiece and disengage the second end of the workpiece from the mandrel.

Preferably, the method further comprises, after disengaging the second end of the workpiece from the mandrel, applying forces to the workpiece to cause vertical displacement of the workpiece relative to the mandrel.

In particular, the method further comprises, after fully disengaging the workpiece from the mandrel, removing the mandrel from within the workpiece by moving the mandrel, the workpiece, or both, relative to the longitudinal direction.

In some implementations, a non-transitory, computer readable medium stores instructions that, when executed by one or more processors, cause the one or more processors to initiate, perform, or control operations to perform part or all of the functionality described above. For example, the instructions may be executable to implement one or more of the operations or methods of <FIG>. In some implementations, part or all of one or more of the operations or methods of <FIG> may be initiated, performed, or controlled by one or more processors (e.g., one or more central processing units (CPUs), one or more graphics processing units (GPUs), one or more digital signal processors (DSPs)) executing instructions, by dedicated hardware circuitry, or any combination thereof.

The illustrations of the examples described herein are intended to provide a general understanding of the structure of the various implementations. Many other implementations may be apparent to those of skill in the art upon reviewing the disclosure. Other implementations may be utilized and derived from the disclosure, such that structural and logical substitutions and changes may be made without departing from the scope of the disclosure.

Moreover, although specific examples have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar results may be substituted for the specific implementations shown. This disclosure is intended to cover any and all subsequent adaptations or variations of various implementations. Combinations of the above implementations, and other implementations not specifically described herein, will be apparent to those of skill in the art upon reviewing the description.

Claim 1:
A demolding tool (<NUM>) comprising:
a first plurality of couplers (<NUM>) arranged to couple to a first end of a workpiece (<NUM>) disposed on a mandrel (<NUM>), the mandrel (<NUM>) having a first end (<NUM>) disposed adjacent to the first end of the workpiece (<NUM>) and having a second end (<NUM>) disposed adjacent to a second end of the workpiece (<NUM>), wherein the first end (<NUM>) of the mandrel (<NUM>) has a first cross-sectional area that is smaller than a second cross-sectional area of the second end (<NUM>) of the mandrel (<NUM>);
a first plurality of actuators (<NUM>), each actuator (<NUM>) of the first plurality of actuators (<NUM>) coupled to at least one (<NUM>) of the first plurality of couplers (<NUM>);
a second plurality of couplers (<NUM>) arranged to couple to the workpiece (<NUM>) at locations between the first end of the workpiece (<NUM>) and the second end of the workpiece (<NUM>);
a second plurality of actuators (<NUM>), each actuator of the second plurality of actuators (<NUM>) coupled to at least one (<NUM>) of the second plurality of couplers (<NUM>); and
a controller (<NUM>) configured to, after a cut is formed in the workpiece (<NUM>) along the longitudinal direction (<NUM>) between the first end and the second end of the workpiece (<NUM>):
cause the first plurality of actuators (<NUM>) to apply, via the first plurality of couplers (<NUM>), first forces to the workpiece (<NUM>) to deform the workpiece (<NUM>) and at least partially disengage the first end of the workpiece (<NUM>) from the first end (<NUM>) of the mandrel (<NUM>); and
after causing the first plurality of actuators (<NUM>) to apply the first forces to the workpiece (<NUM>), cause the second plurality of actuators (<NUM>) to apply, via the second plurality of couplers, second forces to the workpiece to further deform the workpiece and at least partially disengage the second end of the workpiece from the mandrel.