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 stack of pre-impregnated fiber plies ("composite charge") and forcing it around a mandrel with the use of a vacuum bag or rubber bladder. 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. Specifically, forming composite material to complex and intricate contours of a forming tool may be challenging.

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

Document <CIT>, according to its abstract, states a tape laying machine, more particularly a tape laying head assembly is provided for laying plastic tape onto a work surface to produce a reinforced plastic structure. Means for transferring the vertical movement of at least one segment of a stacked plate segmented shoe presser member, of the head assembly, as it engages the work surface to a non-terminal segment of the stacked plate segmented shoe and a sensor means, e.g. a linear variable differential transformer, sensing the movement of the non-terminal segment to produce a signal related to the movement of the non-terminal segment that can be employed to control and direct the movement of the head assembly and/or presser member are provided.

Document <CIT>, according to its abstract, states an apparatus and method for shaping an airfoil. A prepreg assembly is positioned relative to a part in a plurality of parts for a tool for the airfoil using a positioning section for a frame. The positioning section is configured to move relative to the tool and a base of the frame and move a number of parts in the plurality of parts for the tool relative to each other. A number of sections in the prepreg assembly are heated. A force is applied to the number of sections in the prepreg assembly that have been heated to conform to the tool to cause the number of sections in the prepreg assembly that have been heated to conform to the tool with a shape for a component of the airfoil.

Document <CIT>, according to its abstract, states a machine comprising a solid matrix, a deformable body joined to the surface of said matrix, a shaping mould and a securing system for the fibre structure. The matrix is a solid element having a functional face, the geometry of which depends on the part to be manufactured. The deformable body has an initial geometry that depends on the geometry to be given to the fibre structure. The shaping mould has the geometry to be given to the fibre structure during the process of adaptation to the shaping mould, and the shaping mould is located such that the deformable body is located between said shaping mould and the matrix.

Disclosed are composite forming apparatus.

In one example, the disclosed composite forming apparatus includes an end effector and a forming feature that is coupled to the end effector. The forming feature sweeps into engagement with and across a composite ply relative to a forming tool to form the composite ply over one of a forming surface of the forming tool when the forming surface is free from composite material and at least one previously formed ply over the forming surface of the forming tool when the forming surface includes at least one previously formed ply. The composite forming apparatus further includes a positioning member that is engageable with the forming feature. Engagement between the positioning member and the forming feature facilitates a position between the forming feature and the composite ply to promote uniform application of compaction force over the forming surface of the forming tool, wherein the positioning member controls a position and an orientation of the forming feature.

In another example, the disclosed composite forming apparatus includes an end effector, a forming feature that is coupled to the end effector, the forming feature sweeps into engagement with a composite ply relative to a forming tool to form the composite ply over one of a forming surface of the forming tool and at least one previously formed ply over the forming surface of the forming tool, and a positioning member that is engageable with the forming feature, wherein engagement between the positioning member and the forming feature facilitates a position between the forming feature and the composite ply.

Also disclosed are methods for forming a composite part.

In one example, the disclosed method for forming a composite part includes applying at least one ply of composite material over a forming surface of a forming tool. The method further includes positioning a positioning member into engagement with a forming feature. The method further includes, after the positioning, forming the at least one ply of composite material over the forming surface of the forming tool and/or prior formed substrate plies with the forming feature.

Also disclosed are methods for manipulating a composite material on a tool.

In one example, the disclosed method for manipulating a composite material on a tool includes positioning a positioning member into engagement with a forming feature to manipulate a position of the forming feature, wherein the positioning member controls a position and an orientation of the forming feature. The method further includes moving the forming feature into engagement with the composite material, wherein the moving includes sweeping the forming feature across the composite material to conform the composite material to the geometry of the forming tool.

Also disclosed are composite forming systems.

In one example, the disclosed composite forming system includes a movement mechanism, an end effector that is coupled to the movement mechanism, a forming feature that is coupled to the end effector, and a positioning member that is coupled to the forming feature. The end effector selectively moves the forming feature relative to a forming surface of a forming tool to apply a compaction force to a composite ply. The movement mechanism selectively moves the end effector relative to the forming surface of the forming tool to deform a portion of the composite ply over a portion of the forming surface using the forming feature, wherein the forming feature is swept across the composite ply. The positioning member selectively positions the forming feature into engagement with a portion of the composite ply over a portion of the forming surface, wherein the positioning member controls a position and an orientation of the forming feature.

According to an aspect of the present disclosure, a composite forming apparatus comprising:.

Advantageously, the composite forming apparatus is one wherein the positioning member controls at least one of a position and an orientation of the forming feature.

Preferably, the clutch assembly is one, wherein the composite forming apparatus is one wherein the positioning member is a shim.

Preferably, the clutch assembly is one, wherein the forming feature comprises a bladder.

Preferably, the clutch assembly is one, wherein the positioning member is a positioning actuator.

Preferably, the clutch assembly is one, wherein the positioning actuator is a pneumatic actuator.

Preferably, the clutch assembly is one, wherein the positioning actuator is a hydraulic actuator.

Preferably, the clutch assembly is one, wherein the positioning actuator is operatively associated with a servo motor.

Preferably, the clutch assembly is one, wherein the positioning member is movable between at least a first position and a second position.

Preferably, the clutch assembly is one, wherein:.

Preferably, the clutch assembly is one, wherein each positioning member of the plurality of positioning members is independently movable between at least a first position and a second position.

According to another aspect of the present disclosure, a method for manipulating a composite material on a forming tool, the method comprising:.

Advantageously, the method is one wherein the positioning comprises actuating the positioning member into engagement with the forming feature.

Preferably, the method further comprises uniformly applying compaction force to the composite material.

Preferably, the method is one wherein the positioning is performed simultaneously with the moving.

Preferably, the method further comprises moving the positioning member from a first position to a second position to manipulate the forming feature from a first cross-sectional shape to a second cross-sectional shape.

Preferably, the method further comprises moving the positioning member from a first orientation to a second orientation to manipulate the forming feature from a first cross-sectional shape to a second cross-sectional shape.

Preferably, the method is one wherein the positioning member comprises a positioning actuator and wherein the positioning actuator is operatively associated with a control unit.

Preferably, the method is one wherein the control unit automates movement of the positioning actuator based upon geometry of the forming tool.

Preferably, the method is one wherein the positioning includes positioning a plurality of positioning members into engagement with an associated forming feature.

Preferably, the method is one wherein each positioning member of the plurality of positioning members is located behind its associated forming feature and wherein each positioning member of the plurality of positioning members is independently positionable into engagement with its associated forming feature.

Preferably, the method is one wherein the plurality of positioning members are operatively associated with a control unit, and wherein the control unit automates movement of each positioning member of the plurality of positioning members based upon geometry of the forming tool.

Preferably, the method is one wherein at least one positioning member of the plurality of positioning members comprises a positioning actuator and wherein the positioning actuator is automated by a control unit.

According to yet another aspect of the present disclosure a method for forming a composite part, the method comprising:
applying at least one ply of composite material over a forming surface of a forming tool or over previously applied composite material on the forming tool;.

Advantageously, the method is one wherein the forming tool is a spar forming tool.

Preferably, the method is one wherein the forming tool is a stringer forming tool.

Preferably, the method is one wherein the forming tool is a hat stringer forming tool.

Preferably, the method is one wherein the forming surface comprises one or more curve, ramp, ply drop, ridge, contour, and joggle.

Preferably, the method is one wherein the positioning comprises actuating the positioning member into engagement with the forming feature.

Preferably, the method is one wherein the forming surface comprises at least one previously formed ply prior to the applying.

Preferably, the method is one wherein the at least one previously formed ply comprises one or more curve, ramp, ply drop, ridge, contour, and joggle.

According to still another aspect of the present disclosure, a composite forming system comprising:.

Preferably, the composite forming system further comprises a ply support member that is movable relative to the forming tool to support the portion of the composite ply, which extends beyond an edge of the forming tool.

Preferably, the composite forming system is one wherein the positioning member comprises a positioning actuator and wherein the positioning actuator is operatively associated with a control unit.

Preferably, the composite forming system is one wherein the control unit automates movement of the positioning actuator based upon geometry of the forming tool.

Preferably, the composite forming system is one wherein the positioning member is one of a plurality of positioning members, and wherein each positioning member of the plurality of positioning members selectively positions an associated forming feature into engagement with a portion of the composite ply over a portion of the forming surface.

Preferably, the composite forming system is one wherein each positioning member of the plurality of positioning members is operatively associated with a control unit and wherein the control unit automates movement of each positioning member of the plurality of positioning members based upon geometry of the forming tool.

Preferably, the composite forming system further comprises:.

Preferably, the composite forming system further comprises a second ply support member that is movable relative to the forming tool to support the second portion of the composite ply, which extends beyond a second edge of the forming tool.

Preferably, the composite forming system further comprises a stomp foot that is coupled to the movement mechanism.

Preferably, the composite forming system is one wherein the stomp foot is movable relative to the movement mechanism to press the composite ply against the forming surface of the forming tool.

Other examples of the disclosed apparatus, methods and systems will become apparent from the following detailed description, the accompanying drawings and the appended claims.

Referring generally to <FIG>, by way of examples, the present disclosure is directed to a composite forming apparatus <NUM> and a composite forming system <NUM> for forming a composite on a forming tool during a composite manufacturing operation. Referring generally to <FIG>, the present disclosure is also directed to methods <NUM> and <NUM> for forming a composite on a forming tool during a composite manufacturing operation. In one or more examples, implementations of the composite forming apparatus <NUM>, the composite forming system <NUM> and the methods <NUM> and <NUM> are utilized to individually lay down a number of composite plies on a forming tool to form a composite laminate on the forming tool <NUM>, which is subsequently cured on the forming tool <NUM> to form a composite structure <NUM>.

Referring to <FIG>, examples of the composite forming apparatus <NUM> and the composite forming system <NUM> enable automated, or at least partially automated, fabrication of a composite laminate <NUM> on a forming tool <NUM>. The composite laminate <NUM> is then cured through the application of heat and/or pressure (e.g., using an oven or autoclave) to manufacture a composite structure <NUM>. More particularly, examples of the composite forming apparatus <NUM> and the composite forming system <NUM> enable automated, or at least partially automated, compaction and formation of at least one composite ply <NUM> over a forming surface <NUM> of the forming tool <NUM> for manufacture of the composite laminate <NUM>. In other words, as used herein, composite ply <NUM> may be one ply or a ply of a stack of plies.

Automation of the ply formation process can provide a reduction in processing time, a reduction in labor and costs, and/or a reduction of process variations (e.g., human error) that may lead to undesired inconsistencies (particularly out of tolerance inconsistencies) in the finished composite structure as compared to conventional composite fabrication. In particular, the composite forming apparatus <NUM> and the composite forming system <NUM> enable, for example, ply-by-ply application (e.g., layup) of composite material to fabricate the composite laminate <NUM> on the forming tool <NUM>. Following layup, the composite laminate <NUM> is cured, for example, on the forming tool <NUM>, to form the composite structure <NUM>. While the present disclosure is not limited to ply-by-ply forming, ply-by-ply forming facilitates fabrication of large composite structures, thick composite structures and/or composite structures with complex shapes. Ply-by-ply formation can also provide a reduction in buckling or wrinkling of plies within the composite structure as compared to conventional composite fabrication. Specifically, ply-by-ply reduces the disadvantages of the forming flat laid multiple ply laminates at one time. Challenges arise in having various plies shear or slip relative to the other plies enough to sufficiently mate up to the desired contour of the mandrel, forming tool, or previously formed plies of composite material. The outer plies have a different length and contour than the previously formed ply <NUM>' closer to the mandrel.

Referring to <FIG>, the composite forming apparatus <NUM> and composite forming system <NUM> operate to compact (e.g., apply pressure of force to) and deform (e.g., manipulate) the composite ply <NUM> on or over the forming surface <NUM> of the forming tool <NUM>. The composite forming apparatus <NUM> and composite forming system <NUM> operate to compact uniformly across non-uniform tool geometries by use of one or more positioning member <NUM>. Additionally, the composite forming apparatus <NUM> and composite forming system <NUM> may operate to transfer heat to a localized region of the composite ply <NUM> that is being compacted and deformed.

In one or more examples, the composite ply <NUM> includes a single ply (e.g., one layer of thickness) of a composite material. In other examples, the composite ply <NUM> includes a plurality of plies (e.g., a plurality of layers of thickness) of the composite material. Throughout the present disclosure, the phrase "composite ply" refers to a number of plies or layers of the composite material, unless explicitly stated otherwise. The composite ply <NUM> may also be referred to as a composite patch, a composite preform, or a composite charge. Further, a composite ply <NUM> may be placed on top of a previously formed ply <NUM>', for example, plies making up the first and subsequent layers on the mandrel. The forming of the new composite ply <NUM> is over the previously formed ply <NUM>', which has a different contour than any other previously formed ply <NUM>'.

The composite material may take the form of any one of various suitable types of composite material having any one of various ply angles or fiber orientations. In one or more examples, the composite material includes a fiber reinforcement, also referred to as a dry fabric. In these examples, the composite laminate <NUM> is formed of a number of composite plies <NUM> of the dry fiber reinforcement, which is infused with a matrix material (e.g., resin) following layup on the forming tool <NUM>. In one or more examples, the composite material includes a fiber reinforcement that is impregnated with the matrix material, also referred to as a pre-preg. In these examples, the composite laminate <NUM> is formed by laminating a number of composite plies <NUM> of the pre-preg, such as multiple courses of unidirectional composite tape, which are pre-impregnated with a resin matrix.

In a particular example, the composite ply <NUM> is a multi-axial non-crimp fabric that includes a thermoplastic veil and a knit stitch. Application of heat to the composite ply <NUM> immediately before and/or during compaction and formation of the composite ply <NUM> softens the thermoplastic veil to improve deformability of the composite ply <NUM>. It also improves tack of the various layers to each other when compressed and cooled during the forming process. Application of heat to the composite ply <NUM> immediately before and/or during compaction and formation of the composite ply <NUM> also melts the knit stitch and increases the tackiness of the thermoplastic veil to improve adhesion of the composite ply <NUM> (to each other as part of a preform <NUM>.

As such, the composite laminate <NUM> is formed on the forming tool <NUM> from a number of composite plies <NUM>. Additionally, in one or more examples, the composite laminate <NUM> is cured on the forming tool <NUM> to form the composite structure <NUM>. Accordingly, in one or more examples, the forming tool <NUM> is a dual-purpose tool, which serves as a layup tool (e.g., mandrel) and a cure tool.

The forming tool <NUM> defines a shape of the composite laminate <NUM> formed on the forming tool <NUM> and, thus, a shape of the composite structure <NUM> cured on the forming tool <NUM>. In an example, the forming surface <NUM> corresponds to and defines a shape of an inner mold line (IML) surface the composite laminate <NUM> and, thus, the composite structure <NUM>. In these examples, the composite forming apparatus <NUM> shapes an outer mold line (OML) surface of the composite laminate <NUM> and, thus, the composite structure <NUM> forms the OML of each of the plies and pushes the composite ply <NUM> against the <NUM> forming tool <NUM> or layers of a previously formed ply <NUM>' such that voids are not created or are within tolerance. Eventually, when the final ply is formed, the final OML of the composite structure <NUM> is reached. In another example, the forming surface <NUM> corresponds to and defines a shape of the outer mold line (OML) surface of the composite laminate <NUM> and, thus, the composite structure <NUM>. In these examples, the composite forming apparatus <NUM> shapes the inner mold line (IML) surface of the composite laminate <NUM> and, thus, the composite structure <NUM>.

In one or more examples, the forming tool <NUM> has any one of various shapes depending on the composite structure <NUM> being manufactured. As an example, the forming tool <NUM> is a stringer forming tool and the composite structure <NUM> is a composite stringer. As another example, the forming tool <NUM> is a spar forming tool and the composite structure <NUM> is a composite spar. As another example, the forming tool <NUM> is a panel, such as wing skin panel and/or fuselage skin panel forming tool and the composite structure <NUM> is a composite panel. The forming tool <NUM> may include various non-uniform geometric shapes including curves, joggles, cervices, and more.

Referring to <FIG>, the composite forming system <NUM> includes a composite forming apparatus <NUM>. The composite forming apparatus <NUM> may be located within a frame <NUM>, see <FIG>. In an example, the frame <NUM> is generally rectangular in shape. The frame <NUM> defines vertical axis <NUM>, horizontal axis <NUM>, and 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 composite forming apparatus <NUM> includes an end effector <NUM>. The end effector <NUM> is movably connected to the carriage <NUM>. In an example, the end effector <NUM> is movable via an actuator <NUM>. The 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>, horizonal 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 control unit <NUM>. The control unit <NUM> is configured to receive data from the one or more sensor <NUM> and analyze that data to control movement of the end effector <NUM>. The control unit <NUM> may utilize one or more numerical control program in conjunction with the data collected from the one or more sensor <NUM> to determine proper movement and placement of the end effector <NUM>.

The end effector <NUM> includes a forming feature <NUM>. In an example, the forming feature <NUM> is a forming finger. In an example, forming feature <NUM> is a bladder <NUM>. The bladder <NUM> is configured, such as in a "fire hose" configuration, 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 bladder <NUM> position, profile, or orientation may be manipulated with one or more positioning member <NUM>.

In one or more examples, the forming feature <NUM> includes, or takes the form of, a wiper. The wiper includes a wiper body and a wiper edge that extends from the wiper body. The wiper has any suitable geometry and/or stiffness depending on the application of the forming feature <NUM>.

In one or more examples, the forming feature <NUM> includes, or takes the form of, a finger. The finger includes a finger body and a finger end that extends from the finger body. The finger has any suitable geometry and/or stiffness depending on the application of the forming feature <NUM>.

In other examples, the forming feature <NUM> includes, or takes the form of, any one of various other forming members having various shapes, geometries, and/or configurations. For example, the body <NUM> of the forming feature <NUM> may be a bead of material, such as a bead of silicone, rubber, and the like.

Referring to <FIG>, in one or more examples, the forming feature <NUM> is made of any material that is suitable for contact with the composite ply <NUM> in order to deform the composite ply <NUM> over the forming surface <NUM> and compact the composite ply <NUM> against the forming surface <NUM>. The forming surface <NUM> may be the actual surface of the forming tool <NUM>, or mandrel. In another example, the forming surface <NUM> may be previously applied composite material <NUM> on the forming tool <NUM>.

In one or more examples, the forming feature <NUM> is made of a material that is capable of withstanding generated by heat and transferring to the composite ply <NUM> when the forming feature <NUM> is in contact with the composite ply <NUM>. In one or more examples, the forming feature <NUM> is made of a material that is flexible.

In one or more examples, the forming feature <NUM>, <FIG>, is made of natural or synthetic rubber. In one or more examples, the forming feature <NUM> is made of a fluoroelastomer (e.g., fluorocarbon-based synthetic rubber). In one or more examples, the forming feature <NUM> is made of silicone. Other materials for the forming feature <NUM> are also contemplated. In one or more examples, the forming feature <NUM> is made of a combination of various materials.

Referring to <FIG>, the forming feature <NUM> is coupled to the end effector <NUM>. The end effector <NUM> moves the forming feature <NUM> relative to a forming tool <NUM> to deform a composite ply <NUM> over a forming surface <NUM> of the forming tool <NUM>. The positioning member <NUM> is engageable with the forming feature <NUM> such that the engagement <NUM> between the positioning member <NUM> and the forming feature <NUM> facilitates a position between the forming feature <NUM> and the composite ply <NUM>. The positioning member <NUM> facilitates uniform positioning of the forming feature <NUM> against the composite ply <NUM> across non-uniform, curved, joggled, or other irregular shapes of forming surface <NUM> of forming tool <NUM>. Further, the positioning member facilitates forming the composite ply <NUM> into any valleys and sweeping the composite ply <NUM> into the desired contour, thus reducing "bridging" of the composite material <NUM> over the valleys.

The positioning member <NUM> is engageable with the forming feature <NUM> such that engagement <NUM> between the positioning member <NUM> and the forming feature <NUM> facilitates a position <NUM> between the forming feature <NUM> and the composite ply <NUM> to promote uniform application of compaction force <NUM> over the forming surface <NUM> of the forming tool <NUM>. The position <NUM> generally refers to the relationship between the forming feature <NUM> and positioning member <NUM>. In one example, the positioning member <NUM> is movable between at least a first position <NUM> and a second position <NUM>. The positioning member <NUM> may be segmented and segments may be placed in the first position <NUM> while other segments may be in the second position <NUM>. Positioning <NUM>, <FIG>, of the positioning member <NUM> may be automated or manual. The first position <NUM> may be when the positioning member <NUM> is not engaged <NUM>, <FIG>, with the forming feature <NUM>, or, alternatively, the first position <NUM> may be when there is no positioning member <NUM> present in forming apparatus <NUM>. The second position <NUM> may be when the positioning member <NUM> is in engagement <NUM> with the forming feature <NUM>. The control unit <NUM> selectively controls positioning <NUM> of the positioning member <NUM>.

The positioning member <NUM> may be located behind forming feature <NUM>. For example, each positioning member <NUM> of the plurality of positioning members <NUM> may be located behind its associated forming feature <NUM>, and wherein each positioning member <NUM> of the plurality of positioning members <NUM> may be independently positionable into engagement <NUM> with its associated forming feature <NUM>.

In one example, the forming feature <NUM> assumes a first particular cross-sectional shape <NUM> when the positioning member <NUM> is in the first position <NUM>, and the forming feature <NUM> assumes a different, second cross-sectional shape <NUM> when the positioning member <NUM> is in the second position <NUM>. In another example, the cross-sectional shapes <NUM>, <NUM> of the forming feature <NUM> are generally dictated by the shape of the forming surface <NUM> of forming tool <NUM>. For example, if the forming feature <NUM> is engaged with a portion of a forming surface <NUM> that is generally the shape of a right angle <NUM>, the forming feature <NUM> will substantially assume a mating shape <NUM>' to that right angle <NUM>, see <FIG>.

Referring to <FIG>, the end effector <NUM> is one of a plurality of end effectors <NUM> extending along the longitudinal axis <NUM>. Each end effector <NUM> of the plurality of end effectors <NUM> is coupled with an associated forming feature <NUM>. In one example, the positioning member <NUM> is one of a plurality of positioning members <NUM> located along the longitudinal axis <NUM>, each positioning member <NUM> of the plurality of positioning members <NUM> being engageable with an associated forming feature <NUM> of the plurality of end effectors <NUM>. In one example, each positioning member <NUM> of the plurality of positioning members <NUM>, <FIG>, is independently movable between at least a first position <NUM> and a second position <NUM>. In another example, the plurality of positioning members <NUM> may extend across each associated forming feature <NUM> or, alternatively, may extend across portions of each associated forming feature <NUM>. For example, while applying compaction force <NUM>, some but not every positioning member <NUM> of the plurality of positioning members <NUM> is engaged with its associated forming feature <NUM>.

In one or more examples, each positioning member <NUM> of the plurality of positioning members <NUM> is operatively associated with a control unit <NUM>. The control unit <NUM> automates positioning of each positioning member <NUM> of the plurality of positioning members <NUM> based upon geometry of the forming tool <NUM> or of prior formed composite material <NUM> on the forming surface <NUM> of the forming tool. In one example, each positioning member <NUM> of the plurality of positioning members <NUM> is independently moveable such that each positioning member <NUM> may have a different position <NUM> along the longitudinal axis <NUM> to achieve uniform application of compaction force <NUM> across the forming surface <NUM> or prior formed composite material <NUM> on the forming surface <NUM> of the forming tool <NUM>.

In one example, the positioning member <NUM> is a shim <NUM>. The shim <NUM> may be manually placed into engagement <NUM> with the forming feature <NUM>. In another example, placement of the shim <NUM> may be automated by the control until <NUM>. In another example, the positioning member <NUM> includes a positioning actuator <NUM>. The positioning actuator <NUM> may control at least one of a position and an orientation <NUM> of the forming feature <NUM>. The positioning actuator <NUM> may be operatively associated with a control unit <NUM>. The control unit <NUM> facilitates positioning of the positioning member <NUM> to a desired location and extension, either automated or manually.

The control unit <NUM> may automate positioning of the positioning actuator <NUM> based upon sensed data collected, a numerical control program, or a combination thereof. The sensed data may include information about geometry of the forming surface <NUM> or of prior formed composite material <NUM> on the forming surface <NUM> of the forming tool <NUM> to facilitate uniform application of compaction force <NUM> is applied across all geometries. For a plurality of positioning members <NUM>, the control unit <NUM> individually determines and controls positioning of each positioning member <NUM> of the plurality of positioning members <NUM> based upon its current location on the forming tool <NUM>. For example, one positioning member <NUM> of the plurality of positioning members <NUM> may be fully extended while an adjacent positioning member <NUM> may be partially extended or may be completely retracted.

In yet another example, the positioning member <NUM> includes both a shim <NUM> and a positioning actuator <NUM> that is configured to actuate the shim <NUM> into engagement <NUM> with the forming feature <NUM>. The positioning actuator <NUM> may be a pneumatic actuator <NUM> or a hydraulic actuator <NUM>. The positioning actuator <NUM> may be operatively associated with a servo motor <NUM>. The servo motor <NUM> may be operatively associated with control unit <NUM> such that the control unit <NUM> provides feedback to the servo motor <NUM> based upon sensed data, a numerical control program, or a combination thereof. The positioning actuator <NUM> is configured to automatically move the forming feature <NUM> from a first position <NUM> to a second position <NUM> based upon the control unit <NUM>.

Referring to <FIG>, disclosed is a method <NUM> for manipulating a composite material <NUM> on a forming tool <NUM>. The method <NUM> includes positioning <NUM> a positioning member <NUM> into engagement <NUM> with a forming feature <NUM> to manipulate a position of the forming feature <NUM>, such as pushing a bladder <NUM> out and away from the end effector <NUM>. The positioning <NUM> may be manual or automated via a control unit <NUM>. In one example, the positioning <NUM> includes actuating the positioning member <NUM> with a positioning actuator <NUM> into engagement <NUM> with the forming feature <NUM>.

The method <NUM> further includes moving <NUM> the forming feature <NUM> into engagement with the composite material <NUM>. In one example, the moving <NUM> is automated. In another example, the positioning <NUM> is performed simultaneously with the moving <NUM>. In one example, the moving <NUM> includes sweeping the forming feature <NUM> across the composite material <NUM> to conform the composite material <NUM> to the geometry of the forming tool <NUM> or, alternatively, over one or more previously formed ply <NUM>'. The moving <NUM> may include movement along both the horizontal axis <NUM> and vertical axis <NUM>, see <FIG>.

The positioning <NUM> may constantly adjust based upon the geometry of the forming tool <NUM>. The method <NUM> may further include uniformly applying <NUM> compaction force <NUM> to the composite material <NUM>, i.e. the force applied during forming. The positing member <NUM> facilitates uniform application of compaction force <NUM> by positioning the forming feature <NUM> into uniform engagement with the composite material <NUM> across non-uniform geometries and complex contours of the forming tool <NUM>.

In one example, the method <NUM> includes moving <NUM> the positioning member <NUM> from a first position <NUM> to a second position <NUM> to manipulate the forming feature <NUM> from a first cross-sectional shape <NUM> to a second cross-sectional shape <NUM>. In another example, the method <NUM> incudes moving <NUM> the positioning member <NUM> from a first orientation <NUM> to a second orientation <NUM> to manipulate the forming feature <NUM> from a first cross-sectional shape <NUM> to a second cross-sectional shape <NUM>.

In one example, the positioning member <NUM> is a shim <NUM>. The shim <NUM> may be manually placed into engagement <NUM> with the forming feature <NUM>. In another example, placement of the shim <NUM> may be automated. In another example, the positioning member <NUM> includes an actuator <NUM>. The actuator <NUM> may control at least one of a position and an orientation <NUM> of the forming feature <NUM>. In yet another example, the positioning member <NUM> includes both a shim <NUM> and an actuator <NUM> that is configured to actuate the shim <NUM> into engagement <NUM> with the forming feature <NUM>. The actuator <NUM> may be a pneumatic actuator <NUM> or a hydraulic actuator <NUM>. The actuator <NUM> may be operatively associated with a servo motor <NUM>. The actuator <NUM> is configured to automatically move the forming feature <NUM> from a first position <NUM> to a second position <NUM>, see <FIG> and <FIG>.

Referring to <FIG>, disclosed is a method <NUM> for forming a composite part <NUM>. The method <NUM> includes applying <NUM> at least one ply <NUM> of composite material <NUM> over a forming surface <NUM> of a forming tool <NUM> or over a previously formed ply <NUM>' of composite material <NUM>. Each ply <NUM> of composite material <NUM> applied <NUM> assumes the shape of the forming tool <NUM>, or previously formed ply <NUM>' of composite material <NUM> over the forming tool <NUM>.

Referring to <FIG>, the method <NUM> includes positioning <NUM> a positioning member <NUM> into engagement <NUM> with a forming feature <NUM>. In one example, the positioning <NUM> includes actuating 220a the positioning member <NUM> into engagement <NUM> with the forming feature <NUM>. The positioning <NUM> may include moving the positing member <NUM> from a first position <NUM> to a second position <NUM>. The shape and size of the positioning member <NUM> may change based upon the forming feature <NUM>, forming tool <NUM>, amount of composite material <NUM> applied, etc..

After the positioning <NUM>, the method <NUM> includes forming <NUM> the at least one ply <NUM> of composite material <NUM> over the forming surface <NUM> of the forming tool <NUM> with the forming feature <NUM>. The forming <NUM> includes forming the least one ply <NUM> of composite material <NUM> to the contours of the forming surface <NUM> or of previously formed ply <NUM>' of composite material <NUM> over the forming surface <NUM>. The forming <NUM> may include moving the forming feature <NUM> across the forming surface <NUM> of the forming tool <NUM>. During the forming <NUM>, each positioning member <NUM> of a plurality of positioning member <NUM> may move independently between at least a first position <NUM> and a second position <NUM> to conform to the geometry of the forming tool <NUM>.

In one example, the forming tool <NUM> is a spar forming tool. In another example, the forming tool <NUM> is a stringer forming tool. In yet another example, the forming tool <NUM> is a hat stringer forming tool. The forming surface <NUM> of the forming tool <NUM> may include one or more curve, ramp, ply drop, ridge, contour, and joggle.

Referring generally to <FIG>, in one or more examples, composite forming system <NUM> includes movement mechanism <NUM>, the end effector <NUM>, the forming feature <NUM>, and the positioning member <NUM>. <FIG> illustrates an exemplary overview of composite forming system <NUM>.

Referring to <FIG>, the end effector <NUM> is coupled to the movement mechanism <NUM>. The forming feature <NUM> is coupled to the end effector <NUM>. Referring to <FIG>, the positioning member <NUM> is coupled to the forming feature <NUM>. The end effector <NUM> selectively positions and moves the forming feature <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to apply the compaction force <NUM> to the composite ply <NUM>, see <FIG>. The movement mechanism <NUM> selectively positions and moves the end effector <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to form a portion of the composite ply <NUM> over a portion of the forming surface <NUM> using the forming feature <NUM>. The positioning member <NUM> selectively positions and moves the forming feature <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to apply uniform compaction force <NUM> to the composite ply <NUM> across non-uniform tool geometries.

Referring to <FIG>, in one or more examples, the movement mechanism <NUM> moves and selectively positions the end effector <NUM> along a plurality of movement axes, including a first axis <NUM>, a second axis <NUM> that is perpendicular to the first axis <NUM>, and a third axis <NUM> that is perpendicular to the first axis <NUM> and the second axis <NUM>. In the illustrative examples, the first axis <NUM> (e.g., a vertical axis) is approximately vertical and the second axis <NUM> (e.g., a horizontal axis) and the third axis <NUM> (e.g., a longitudinal axis) are approximately horizontal.

Still referring to <FIG>, in one or more example, the movement mechanism <NUM> includes a frame <NUM>. In one or more examples, the frame <NUM> is generally rectangular in shape. In one or more examples, the frame <NUM> is an overhead frame and the forming tool <NUM> is positioned under the frame <NUM> during the layup operation. Generally, the frame <NUM> defines the first axis <NUM>, the second axis <NUM>, and the third axis <NUM>. In one or more examples, the movement mechanism <NUM> includes a carriage <NUM>. The carriage <NUM> is coupled to the frame <NUM>. The frame <NUM> surrounds the carriage <NUM>. In one or more examples, the carriage <NUM> has 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 one or more examples, the carriage <NUM> is movable relative to the frame <NUM>. In one or more examples, the carriage <NUM> is pivotably movable and/or rotationally movable about the first axis <NUM>, the second axis <NUM>, and/or the third axis <NUM>. In one or more examples, the carriage <NUM> is linearly movable along the first axis <NUM>, the second axis <NUM>, and/or the third axis <NUM>. In one or more examples, the end effector <NUM> is coupled to the carriage <NUM>. Movement of the carriage <NUM> moves and selectively positions the end effector <NUM> relative to the forming tool <NUM> to accommodate the geometry or configuration of the forming tool <NUM> and achieve a best fit position for the end effector <NUM>.

Referring to <FIG>, in one or more examples, the end effector <NUM> is movable relative to the movement mechanism <NUM>, such as relative to the carriage <NUM>. In one or more examples, the end effector <NUM> is linearly movable relative to the movement mechanism <NUM>. In one or more examples, the end effector <NUM> is rotationally movable relative to the movement mechanism <NUM>.

Referring to <FIG>, in one or more examples, the composite forming apparatus <NUM> includes an actuator <NUM>. The actuator <NUM> is coupled to, or forms a portion of, the end effector <NUM>. In one or more examples, the actuator <NUM> is, or includes, a linear actuator and the actuator <NUM> linearly moves the end effector <NUM> or the forming feature <NUM> relative to the carriage <NUM> to position the forming feature <NUM> into contact with the composite ply <NUM>. In one or more examples, the actuator <NUM> is, or includes, a rotary actuator and the actuator <NUM> rotationally moves the end effector <NUM> or the forming feature <NUM> relative to the carriage <NUM> to angularly orient the forming feature <NUM> relative to the forming tool <NUM> and position the forming feature <NUM> into contact with the composite ply <NUM>. In one or more examples, the actuator <NUM> is selectively controlled, for example, by the control unit <NUM>, to control the position of the forming feature <NUM> and, thus, the compaction force <NUM> applied to the composite ply <NUM> by the forming feature <NUM>.

Still referring to <FIG>, in one or more examples, the actuator <NUM> is any one of various suitable types of controllable actuators. In an example, the actuator <NUM> is a pneumatic actuator. In an example, the actuator <NUM> is a hydraulic actuator. In an example, the actuator <NUM> is a mechanical actuator.

In one or more examples, the sensor <NUM> is coupled to, or is in communication with, the actuator <NUM>. In one or more examples, the sensor <NUM> detects at least one of a stroke position of the actuator <NUM> and a force acting on the actuator <NUM>, which is used to determine the position of the forming feature <NUM> and to control the compaction force <NUM> for precise forming on the forming tool <NUM> having a complex geometry or surface contour.

In one or more examples, the control unit <NUM> is, or includes, a numerical control (NC) unit. In these examples, the control unit <NUM> operates in accordance with a numerical control program and in conjunction with data (e.g., collected, received, and analyzed) from the sensor <NUM> to determine proper movement and position of the end effector <NUM> relative to the forming tool <NUM>.

Referring to <FIG>, in one or more examples, the composite forming system <NUM> includes the ply support member <NUM> that is movable relative to the forming tool <NUM> and relative to the composite forming composite forming apparatus <NUM> to support the portion of the composite ply <NUM>, which extends beyond an edge <NUM> of the forming tool <NUM>.

In one or more examples, the ply support member <NUM> is coupled to the end effector <NUM>. In these examples, the ply support member <NUM> is movable with the end effector <NUM>, such as by the carriage <NUM>, relative to the forming tool <NUM>. In these examples, the ply support member <NUM> may also be movable relative to the end effector <NUM>. In one or more examples, the ply support member <NUM> is coupled to the movement mechanism <NUM>, such as to the carriage <NUM>. In these examples, the ply support member <NUM> is movable relative to the carriage <NUM>, relative to the end effector <NUM>, and relative to the forming tool <NUM>. In one or more examples, movement mechanism <NUM> includes a drive mechanism dedicated to the ply support member <NUM> such that the ply support member <NUM> moves and is selectively positioned relative to the forming tool <NUM> independent of the carriage <NUM> and/or the end effector <NUM>.

Referring to <FIG>, in one or more examples, the composite forming system <NUM> includes a second composite forming apparatus <NUM>. The second composite forming apparatus <NUM> is coupled to the movement mechanism <NUM>. The second composite forming apparatus <NUM> is spaced away from the composite forming composite forming apparatus <NUM>. The movement mechanism <NUM> selectively positions and moves the second composite forming apparatus <NUM> to form and compact the composite ply <NUM> over the forming surface <NUM>.

Examples of the second composite forming apparatus <NUM> are substantially the same as the examples of the composite forming apparatus <NUM> described herein above and illustrated in <FIG>. In one or more examples, the second composite forming apparatus <NUM> includes a second end effector <NUM>, a second forming feature <NUM>, and a second positioning member <NUM>, which may include a second shim <NUM>, and/or may further include a second positioning actuator <NUM>.

Examples of the second end effector <NUM>, the second forming feature <NUM>, and the second positioning member <NUM> are substantially the same as the examples of the end effector <NUM>, the forming feature <NUM>, and the positioning member <NUM> described herein above. The second forming feature <NUM> is coupled to the second end effector <NUM>. The second positioning member <NUM> is coupled to the second forming feature <NUM>. The second positioning member <NUM> abuts the second forming feature <NUM>. The second end effector <NUM> moves the second forming feature <NUM> relative to the forming tool <NUM> to form the composite ply <NUM> over the forming surface <NUM> of the forming tool <NUM>. The second positioning member <NUM> uniformly positions the second forming feature <NUM> against the composite ply <NUM> before and/or while the composite ply <NUM> is formed over the forming surface <NUM> of the forming tool <NUM>.

Referring still to <FIG> and <FIG>, in one or more examples, the composite forming system <NUM> includes the second end effector <NUM>, the second forming feature <NUM>, and the second positioning member <NUM>. The second end effector <NUM> is coupled to the movement mechanism <NUM>, such as to the carriage <NUM>. The second forming feature <NUM> is coupled to the second end effector <NUM>. The second positioning member <NUM> is coupled to the second forming feature <NUM>. The second end effector <NUM> selectively moves the second forming feature <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to apply a second compaction force <NUM> to the composite ply <NUM>. The movement mechanism <NUM> selectively moves the second end effector <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to form a second portion of the composite ply <NUM> over a second portion of the forming surface <NUM> using the second forming feature <NUM>. The second positioning member <NUM> selectively moves the second forming feature <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to apply uniform second compaction force <NUM> to the composite ply <NUM> across non-uniform tool geometries.

Referring to <FIG> and <FIG>, in one or more examples, the composite forming system <NUM> includes a second ply support member <NUM>. Examples of the second ply support member <NUM> are substantially the same as the examples of the ply support member <NUM> described herein above and illustrated in <FIG>. In one or more examples, the second ply support member <NUM> is movable relative to the forming tool <NUM>. In one or more examples, the second ply support member <NUM> is movable relative to the second end effector <NUM> and/or the second forming feature <NUM>. The second ply support member <NUM> supports the second portion of the composite ply <NUM>, which extends beyond a second edge <NUM> of the forming tool <NUM>.

Referring to <FIG>, <FIG>, and <FIG>, in one or more examples, the composite forming system <NUM> includes the stomp foot <NUM>. In one or more examples, the stomp foot <NUM> is coupled to the movement mechanism <NUM>, such as to the carriage <NUM>. The stomp foot <NUM> is movable relative to the movement mechanism <NUM> to press the composite ply <NUM> against the forming surface <NUM> of the forming tool <NUM> before and/or while the composite ply <NUM> is formed over the forming surface <NUM> of the forming tool <NUM> using the forming feature <NUM> and/or the second forming feature <NUM>, see <FIG>.

Referring to <FIG> and <FIG>, in one or more examples, the stomp foot <NUM> is located between the composite forming apparatus <NUM> (e.g., the end effector <NUM>) and the second composite forming apparatus <NUM> (e.g., the second end effector <NUM>). In one example, the stomp foot <NUM> is actuated into engagement with the composite material <NUM>.

Referring to <FIG> and <FIG>, in one or more examples, the second forming feature <NUM> (e.g., the body <NUM>) includes or takes the form of any forming member that is suitable for or that is capable of forming the composite ply <NUM> over the forming surface <NUM> and compacting the composite ply <NUM> against the forming surface <NUM>.

Referring to <FIG>, in one or more examples, the second forming feature <NUM> includes, or takes the form of, the bladder <NUM>. The bladder <NUM> is inflatable. The bladder <NUM> is configured to move between at least two positions based upon location of the positioning member <NUM>. Inflation pressure of the bladder <NUM> facilitates engagement <NUM> and conforming of the forming feature <NUM> with the forming surface <NUM> of the forming tool <NUM> or previously formed ply <NUM>' over the forming surface <NUM> of the forming tool <NUM>. For example, reducing inflation pressure of the bladder <NUM> facilitates the forming feature <NUM> ability to conform to complex geometries. Further, adjustment of inflation pressure may be automated such that it is optimized for the particular geometry of the forming surface <NUM>. Inflation pressure may automatically be reduced for complex forming surface <NUM> shapes to apply uniform compaction force <NUM> and to prevent bridging over valleys of the forming surface <NUM>. Similarly, inflation pressure may automatically increase across a portion of the forming surface <NUM> that is more uniform and planar.

Referring still to <FIG>, in one or more examples, the second forming feature <NUM> includes, or takes the form of, a wiper. In one or more examples, the second forming feature <NUM> includes, or takes the form of, a finger. In other examples, the second forming feature <NUM> includes, or takes the form of, any one of various other forming members having various shapes, geometries, and/or configurations. For example, the body <NUM> of the second forming feature <NUM> may be a bead of material, such as a bead of silicone, rubber, and the like.

Referring to <FIG>, in one or more examples, the second forming feature <NUM> is made of any material that is suitable for contact with the composite ply <NUM> in order to form the composite ply <NUM> over the forming surface <NUM> and compact the composite ply <NUM> against the forming surface <NUM>. In one or more examples, the second forming feature <NUM> is made of a material that is capable of withstanding heat and transferring heat when the second forming feature <NUM> is in contact with the composite ply <NUM>. In one or more examples, the second forming feature <NUM> is made of a material that is flexible. In one or more examples, the second forming feature <NUM> is made of a fluoroelastomer. In one or more examples, the second forming feature <NUM> is made of silicone.

Referring to <FIG> and <FIG>, in one or more examples, the second end effector <NUM> is movable relative to the movement mechanism <NUM>, such as relative to the carriage <NUM>. In one or more examples, the second end effector <NUM> is linearly movable relative to the movement mechanism <NUM>. In one or more examples, the second end effector <NUM> is rotationally movable relative to the movement mechanism <NUM>.

In one or more examples, the second composite forming apparatus <NUM> includes a second actuator <NUM>. The second actuator <NUM> is coupled to, or forms a portion of, the second end effector <NUM>. In one or more examples, the second actuator <NUM> is, or includes, a linear actuator and the second actuator <NUM> linearly moves the second end effector <NUM> or the second forming feature <NUM> relative to the carriage <NUM> to position the second forming feature <NUM> into contact with the composite ply <NUM>. In one or more examples, the second actuator <NUM> is, or includes, a rotary actuator and the second actuator <NUM> rotationally moves the second end effector <NUM> or the second forming feature <NUM> relative to the carriage <NUM> to angularly orient the second forming feature <NUM> relative to the forming tool <NUM> and position the second forming feature <NUM> into contact with the composite ply <NUM>. In one or more examples, the second actuator <NUM> is selectively controlled, for example, by the control unit <NUM>, to control the position of the second forming feature <NUM> and, thus, the second compaction force <NUM> applied to the composite ply <NUM> by the second forming feature <NUM>.

Referring to <FIG>, in one or more examples, the composite forming system <NUM> includes the control unit <NUM>. The control unit <NUM> may be coupled to (e.g., in communication with) the positioning member <NUM>. The control unit <NUM> is configured to analyze data collected from one or more sensor <NUM> to determine movement within the system <NUM>.

Referring still to <FIG>, in one or more examples, the second composite forming apparatus <NUM> includes a second sensor <NUM>. In one or more examples, the second sensor <NUM> is a pressure sensor or a load cell that detects a force or a load applied to the second forming feature <NUM>. In one or more examples, the second sensor <NUM> is a position sensor that detects a relative position of the second forming feature <NUM>.

In one or more examples, the control unit <NUM> is coupled to (e.g., is in communication with) the second end effector <NUM> and the second sensor <NUM>. The control unit <NUM> selectively controls movement of the second end effector <NUM> based on a second sensor signal <NUM> provided by the second sensor <NUM> to appropriately position the second forming feature <NUM> such that the second compaction force <NUM> is applied to the composite ply <NUM> using the second forming feature <NUM> at a constant magnitude.

Referring to <FIG>, <FIG>, and <FIG>, in one or more examples, the composite forming system <NUM> includes a plurality of composite forming apparatus <NUM> (e.g., as illustrated in <FIG>). In one or more examples, the composite forming system <NUM> includes a plurality of second composite forming apparatus <NUM> (e.g., as shown in <FIG>). Each one of the plurality of composite forming apparatus <NUM> is coupled to the movement mechanism <NUM>. Each one of the plurality of second composite forming apparatus <NUM> is coupled to the movement mechanism <NUM>.

Referring to <FIG>, in one or more examples, the composite forming system <NUM> includes a plurality of end effectors <NUM>, a plurality of forming features <NUM>, and a plurality of positioning members <NUM>. Each one of the plurality of end effectors <NUM> is coupled to the movement mechanism <NUM>, such as to the carriage <NUM>. Each one of the plurality of forming features <NUM> is coupled to a corresponding one of the plurality of end effectors <NUM>. Each one of the plurality of positioning members <NUM> is coupled to a corresponding one of the plurality of forming features <NUM>, or associated forming feature <NUM>. Each one of the plurality of end effectors <NUM> selectively positions and moves a corresponding one of the plurality of forming features <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to apply the compaction force <NUM> to the composite ply <NUM>. The movement mechanism <NUM> selectively positions and moves each one of the plurality of end effectors <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to form a portion of the composite ply <NUM> over a portion of the forming surface <NUM> using a corresponding one of the plurality of forming features <NUM>.

In one or more examples, the composite forming system <NUM> includes a plurality of sensors <NUM>. Each one of the plurality of sensors <NUM> detects at least one of a force applied to and a relative position of a corresponding one of the plurality of forming features <NUM>. In one or more examples, the control unit <NUM> is coupled to (e.g., is in communication with) each one of the plurality of end effectors <NUM> and each one of the plurality of sensors <NUM>. The control unit <NUM> selectively controls movement of each one of the plurality of end effectors <NUM> based on the sensor signal <NUM> provided by a corresponding one of the plurality of sensors <NUM> to apply the compaction force <NUM> at a constant magnitude to the composite ply <NUM> using a corresponding one of the plurality of forming features <NUM>.

In one or more examples, the plurality of forming features <NUM> form an interface surface <NUM> that is substantially continuous for contact with the composite ply <NUM>. For example, each one of the plurality of forming features <NUM> abuts a directly adjacent one of the plurality of forming features <NUM> to form the substantially continuous interface surface <NUM> for contact with the composite ply <NUM>.

Referring to <FIG>, in one or more examples, the composite forming system <NUM> includes a plurality of second end effectors <NUM>, a plurality of second forming features <NUM>, and a plurality of second positioning members <NUM>. Each one of the plurality of second end effectors <NUM> is coupled to the movement mechanism <NUM>, such as to the carriage <NUM>. Each one of the plurality of second forming features <NUM> is coupled to a corresponding one of the plurality of second end effectors <NUM>. Each one of the plurality of second positioning members <NUM> is coupled to a corresponding one of the plurality of second forming features <NUM>. Each one of the plurality of second end effectors <NUM> selectively positions and moves a corresponding one of the plurality of second forming features <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to apply the second compaction force <NUM> to the composite ply <NUM>. The movement mechanism <NUM> selectively positions and moves each one of the plurality of second end effectors <NUM> relative to the forming surface <NUM> of the forming tool <NUM> to form a portion of the composite ply <NUM> over a portion of the forming surface <NUM> using a corresponding one of the plurality of second forming features <NUM>.

In one or more examples, the composite forming system <NUM> includes a plurality of second sensors <NUM>. Each one of the plurality of second sensors <NUM> detects at least one of a force applied to and a relative position of a corresponding one of the plurality of second forming features <NUM>. In one or more examples, the control unit <NUM> is coupled to (e.g., is in communication with) each one of the plurality of second end effectors <NUM> and each one of the plurality of second sensors <NUM>. The control unit <NUM> selectively controls movement of each one of the plurality of second end effectors <NUM> based on a second sensor signal <NUM> provided by a corresponding one of the plurality of second sensors <NUM> to apply the second compaction force <NUM> at a constant magnitude to the composite ply <NUM> using a corresponding one of the plurality of second forming features <NUM>.

In one or more examples, the plurality of second forming features <NUM> form a second interface surface <NUM> that is substantially continuous for contact with the composite ply <NUM>. For example, each one of the plurality of second forming feature <NUM> abuts a directly adjacent one of the plurality of second forming features <NUM> to form the substantially continuous second interface surface <NUM> for contact with the composite ply <NUM>.

In one or more examples, the composite forming system <NUM> is one of a plurality of sub-systems of a larger automated composite manufacturing system. Each one of the plurality of sub-systems facilitates and corresponds to a different fabrication operation associated with the manufacture of the composite structure <NUM> (e.g., a composite part). The sub-systems of the automated composite manufacturing system are interlinked and cooperate to automate at least a portion of the fabrication process.

For example, the automated composite manufacturing system utilizes a plurality of semi-automated or fully automated sub-systems to perform ply-by-ply formation and compaction of individual composite plies <NUM> on the forming tool <NUM>. For the purpose of the present disclosure, ply-by-ply formation refers to sequential layup of a number of composite plies <NUM> on the forming tool <NUM> according to a predetermined sequence. For the purpose of the present disclosure, layup refers to placement of the composite ply <NUM> on at least a portion of the forming tool <NUM>, compaction of the composite ply <NUM> against the forming surface <NUM> of the forming tool <NUM>, and formation of at least a portion of the composite ply <NUM> over at least a portion of the forming surface <NUM>. During or subsequent to layup, the number of composite plies <NUM> is compacted on the forming tool <NUM>, such as individually after each composite ply <NUM> has been laid down or after more than one composite ply <NUM> had been laid down.

Referring now to <FIG> and <FIG>, examples of the composite forming apparatus <NUM>, the composite forming system <NUM>, the methods <NUM> and <NUM>, and the composite structure <NUM> may be related to, or used in the context of, an aircraft manufacturing and service method <NUM>, as shown in the flow diagram of <FIG> and an aircraft <NUM>, as schematically illustrated in <FIG>. For example, the aircraft <NUM> and/or the aircraft production and service method <NUM> may utilize the composite structure <NUM> that is made using the composite forming apparatus <NUM> or the composite forming system <NUM>, described herein and illustrated in <FIG>, and/or according to the methods <NUM> and <NUM>.

The present disclosure recognizes that composite structures can be advantageous in the manufacture of aircraft to decrease the weight of the aircraft and provide longer service life for various components of the aircraft. In manufacturing composite structures, layers of composite material are typically laid up on a tool. Often, each layer of composite material includes a fiber sheet that is infused or pre-impregnated with a matrix material. The different layers of composite material may be laid up in different orientations, and different numbers of layers may be used depending on the performance requirements of the composite structure being manufactured. Due to size, geometry, and/or complexity of composite structure, layup of the layers of composite material may be more difficult or more labor intensive than desired. The examples of the composite forming apparatus <NUM>, the composite forming system <NUM>, and the methods <NUM> and <NUM> improve upon production speed, conformity, and manufacturability of such composite structures.

Referring to <FIG>, examples of the aircraft <NUM> may include an airframe <NUM> having the interior <NUM>. The aircraft <NUM> also includes a plurality of high-level systems <NUM>. Examples of the high-level systems <NUM> include one or more of a propulsion system <NUM>, an electrical system <NUM>, a hydraulic system <NUM>, and an environmental system <NUM>. In other examples, the aircraft <NUM> may include any number of other types of systems, such as a communications system, a flight control system, a guidance system, a weapons system, and the like. In one or more examples, the composite structure <NUM> made using the composite forming apparatus <NUM> or the composite forming system <NUM> and/or according to the methods <NUM> and <NUM> forms a component of the airframe <NUM>, such as a wing, a fuselage, a panel, a stringer, a spar, and the like.

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

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

Examples of the composite forming apparatus <NUM>, the composite forming system <NUM>, and the methods <NUM> and <NUM> shown and described herein may be employed during any one or more of the stages of the manufacturing and service method <NUM> shown in the flow diagram illustrated by <FIG>. In an example, manufacture of the composite structure <NUM> in accordance with the methods <NUM> and <NUM> and/or using the composite forming apparatus <NUM> or the composite forming system <NUM> may form a portion of component and subassembly manufacturing (block <NUM>) and/or system integration (block <NUM>). Further, the composite structure <NUM> manufactured in accordance with the methods <NUM> and <NUM> and/or using the composite forming apparatus <NUM> or the composite forming system <NUM> may be utilized in a manner similar to components or subassemblies prepared while the aircraft <NUM> is in service (block <NUM>). Also, the composite structure <NUM> manufactured in accordance with the methods <NUM> and <NUM> and/or using the composite forming apparatus <NUM> or the composite forming system <NUM> may be utilized during system integration (block <NUM>) and certification and delivery (block <NUM>). Similarly, manufacture of the composite structure <NUM> in accordance with the methods <NUM> and <NUM> and/or using the composite forming apparatus <NUM> or the composite forming system <NUM> may be utilized, for example and without limitation, while the aircraft <NUM> is in service (block <NUM>) and during maintenance and service (block <NUM>).

Although an aerospace example is shown, the examples and principles disclosed herein may be applied to other industries, such as the automotive industry, the space industry, the construction industry, and other design and manufacturing industries. Accordingly, in addition to aircraft, the examples and principles disclosed herein may apply to structural component assemblies and systems and methods of making the same for other types of vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.) and stand-alone structures.

The preceding detailed description refers to the accompanying drawings, which illustrate specific examples described by the present disclosure. Other examples having different structures and operations do not depart from the scope of the present disclosure. Like reference numerals may refer to the same feature, element, or component in the different drawings. Throughout the present disclosure, any one of a plurality of items may be referred to individually as the item and a plurality of items may be referred to collectively as the items and may be referred to with like reference numerals. Moreover, as used herein, a feature, element, component, or step preceded with the word "a" or "an" should be understood as not excluding a plurality of features, elements, components, or steps, unless such exclusion is explicitly recited.

Illustrative, non-exhaustive examples, which may be, but are not necessarily, claimed, of the subject matter according to the present disclosure are provided above. Reference herein to "example" means that one or more feature, structure, element, component, characteristic, and/or operational step described in connection with the example is included in at least one aspect, embodiment, and/or implementation of the subject matter according to the present disclosure. Thus, the phrases "an example," "another example," "one or more examples," and similar language throughout the present disclosure may, but do not necessarily, refer to the same example. Further, the subject matter characterizing any one example may, but does not necessarily, include the subject matter characterizing any other example. Moreover, the subject matter characterizing any one example may be, but is not necessarily, combined with the subject matter characterizing any other example.

Unless otherwise indicated, the terms "first," "second," "third," etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer.

Claim 1:
A composite forming apparatus (<NUM>) comprising:
an end effector (<NUM>);
a forming feature (<NUM>) that is coupled to the end effector (<NUM>), the forming feature (<NUM>) sweeps into engagement with and across a composite ply (<NUM>) relative to a forming tool (<NUM>) to form the composite ply (<NUM>) over one of a forming surface (<NUM>) of the forming tool (<NUM>) when the forming surface (<NUM>) is free from composite material (<NUM>) and at least one previously formed ply (<NUM>') over the forming surface (<NUM>) of the forming tool (<NUM>) when the forming surface (<NUM>) includes at least one previously formed ply (<NUM>'); and
a positioning member (<NUM>) that is engageable with the forming feature (<NUM>), wherein engagement (<NUM>) between the positioning member (<NUM>) and the forming feature (<NUM>) facilitates a position (<NUM>) between the forming feature (<NUM>) and the composite ply (<NUM>) to promote uniform application of compaction force (<NUM>) over the forming surface (<NUM>) of the forming tool (<NUM>), wherein the positioning member (<NUM>) controls a position (<NUM>) and an orientation (<NUM>) of the forming feature (<NUM>).