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. The resulting part matches the shape of the forming tool. However, manual layup of the fiber plies is time consuming and laborious.

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

Document <CIT>, in accordance with its abstract, states an integrated, automated composite material manufacturing system for pre-cure processing of preimpregnated composite materials, and particularly, for one-sided preimpregnated composite materials. The manufacturing system includes a computer control subsystem for controlling and synchronizing the pre-cure processing operations, a material cutting station for controlled cutting of preimpregnated composite materials into individual composite plies of predetermined size and shape based upon composite ply configurations stored in the computer control subsystem, a ply unloading station for providing automatic pickup, transfer and placement operations to unload the individual composite plies utilizing a multiplicity of bi-functional transfer feet that are automatically, selectively activated to form a predetermined combination operative to engage and retain and disengage and release the tacky surface of individual composite plies, a ply transfer subsystem automatically operative to transfer composite plies between the unloading subsystem and a ply inverting subsystem for rotating individual composite plies to place the non-tacky surface up, a ply transfer/layup subsystem to transfer composite plies to a composite article mold having a mold surface and to layup the transferred composite plies on the mold surface, and a ply conforming subsystem for conforming said layed up composite plies with the mold surface.

Document <CIT>, in accordance with its abstract, states an apparatus for laying filament reinforced tape in a form, cutting same to a predetermined pattern and molding same in a preferred form.

Document <CIT>, in accordance with its abstract, states an apparatus for forming a composite laminate. The apparatus comprises a mandrel having a surface on which the composite laminate can be formed. The apparatus further comprises an application surface and a conveyor configured to move a composite material piece that has been cut to a desired shape to the application surface. The apparatus also comprises an actuating mechanism for, when actuated, lifting the application surface upward towards the mandrel to apply the composite material piece to the surface of the mandrel to form at least a portion of the composite laminate on the surface of the mandrel.

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.

Disclosed are examples of a system for fabricating a composite structure and a method of fabricating a composite structure.

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

The following 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, as long as they are covered by the appended claims. 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 the present disclosure are provided below. 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.

The present disclosure recognizes that conventional automated processes that lay charges (e.g., all layers of CFRP, i.e., Carbon Fiber Reinforced Polymer ) flat with automated equipment, followed by automated forming may suffer from tow-related issues. As an example, during the forming operation, the fibers may distort causing structural wrinkles and knockdowns in strength. Such knockdowns may result in adding more material to account for structural knockdown. As a result, additional inspection may be required, heavier and less structurally efficient structure may be produced, and additional cost may be incurred. As another example, lamination and forming cycle times in conventional approaches are commonly different, resulting in lamination and forming be performed in series. Such non-synchronist cycle times and serial processing may result in queueing areas between processes and less parallel processing.

Referring generally to <FIG>, by way of examples, the present disclosure is directed to a system for fabricating a composite structure (referred to herein as "system" <NUM>), a method of fabricating a composite structure (referred to herein as "method" <NUM>) and a composite structure <NUM> fabricated using the system <NUM> or according to the method <NUM>.

Examples of the system <NUM> and method <NUM> enable automated fabrication of the composite structure <NUM> and, more particularly, automated fabrication of at least one composite ply <NUM> and formation of at least one composite ply <NUM> over a forming tool <NUM> for manufacture of the composite structure <NUM>. Automation of the fabrication 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 in the finished composite structure as compared to conventional composite fabrication. The system <NUM> and method <NUM> also enable ply-by-ply application and formation of the composite material to fabricate the composite structure <NUM>. Ply-by-ply formation facilitates fabrication of large composite structures, thick composite structures and/or composite structures with complex shapes. Ply-by-ply formation can also provide a reduction in buckling or wrinkling of plies within the composite structure as compared to conventional composite fabrication. Ply-by-ply formation, as disclosed herein, can also provide more structurally efficient (e.g., reduction or elimination of wrinkles) composite structure. Ply-by-ply formation, as disclosed herein, can also provide increased efficiency, as production is scaled for higher rates, by utilizing synchronized parallel processing, which is more efficient in terms of weight, recurring costs and non-recurring costs.

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

The system <NUM> includes a plurality of sub-systems that facilitate and correspond to different fabrication operations associated with the manufacture of the composite structure <NUM>. The sub-systems of the system <NUM> are interlinked and cooperate to automate at least a portion of the fabrication process. Throughout the present disclosure, the sub-systems of the disclosed system <NUM> may be referred to as "systems" themselves or stations in which one or more fabrication operations occur.

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

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

The system <NUM> includes a ply carrier <NUM>. The ply carrier <NUM> receives the composite ply <NUM> thereon. For example, the ply carrier <NUM> includes a ply support surface <NUM>. The ply support surface <NUM> is configured to support the composite ply <NUM>. Generally, the ply carrier <NUM> is movable relative to an individual sub-system or station of the system <NUM>. Once at least one composite ply <NUM> is formed on the ply carrier <NUM>, the ply carrier <NUM> facilitates sequential conveyance of the composite ply <NUM> to the individual sub-systems or stations of the system <NUM>.

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

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

Referring now to <FIG>, which schematically illustrates an example of the ply carrier <NUM> and the carrier transfer device <NUM>. In one or more examples, the ply carrier <NUM> includes a base plate <NUM> and a film <NUM> that is positioned on the base plate <NUM>. In these examples, the film <NUM> forms the ply support surface <NUM>. In other examples, the ply carrier <NUM> may not include the film <NUM>. In these examples, the base plate <NUM> forms the ply support surface <NUM>.

The base plate <NUM> provides a support structure for fabrication of the composite ply <NUM>. Generally, the base plate <NUM> is relatively thin and substantially planar or at least has a substantially planar surface to which the film <NUM> is coupled or that forms the ply support surface <NUM>. In one or more examples, the base plate <NUM> is made of a flexible material. In one or more examples, the base plate <NUM> is made of a resilient material. The base plate <NUM> facilities transfer and application of the composite ply <NUM> to the forming tool <NUM>. The base plate <NUM> is capable of deforming during application (e.g., stamping) of the composite ply <NUM> to the forming tool <NUM> and then returning to its original (e.g., substantially planar) shape. Thus, in production, the base plate <NUM> is reusable for fabrication and application of a number of composite plies <NUM>, thereby reducing equipment and material costs.

In one or more examples, the base plate <NUM> is made of a metallic material. As an example, the base plate <NUM> includes, or takes the form of, a metal sheet, such as a sheet of spring steel. In other examples, the base plate <NUM> may be made of any other suitable material. In one or more examples, the base plate <NUM> is made of a material that is sufficiently flexible and resilient to enable contouring of the base plate <NUM> during application of the composite ply <NUM> to the forming tool <NUM>.

The film <NUM> provides a contact surface onto which the composite ply <NUM> is fabricated. Generally, the film <NUM> is a relatively thin and flexible sheet of material that covers the base plate <NUM>. The film <NUM> facilities fabrication of the composite ply <NUM> and application and formation of the composite ply <NUM> over the forming tool <NUM>. The film <NUM> provides a work surface to which the composite ply <NUM> is formed and temporarily held. The film <NUM> is capable of deforming during application and formation of the composite ply <NUM> over the forming tool <NUM>. The film <NUM> is also capable of being removed from the composite ply <NUM>, after formation of the composite ply <NUM> over the forming tool <NUM>.

Generally, the film <NUM> has surface properties that enable the composite ply <NUM> to temporarily adhere to the film <NUM> via the resin matrix, thereby retaining the composite ply <NUM> on the ply support surface <NUM> but enabling the film <NUM> to be removed from the composite ply <NUM> after formation. The film <NUM> provides protection to the composite ply <NUM> during application of the composite ply <NUM> to the forming tool <NUM> and formation of the composite ply <NUM> over the forming tool <NUM>. The film <NUM> also provides stability to the composite ply <NUM>.

In one or more examples, the film <NUM> is made of a plastic material, such as a thermoplastic material. As an example, the film <NUM> includes, or takes the form of, a sheet of polyethylene, such as a sheet of yellow poly. In one or more examples, the film <NUM> is made of fluorinated ethylene propylene (FEP) or ethylene tetrafluoroethylene (ETFE). In one or more examples, the film <NUM> is a release film, such as a polyester release film, with high modulus and low elongation that provide a substantially flat contact surface that is compatible with most resin systems and adhesives. In one or more examples, the film <NUM> is made of a metallic foil. In other examples, the film <NUM> may be made of any other suitable material.

The film <NUM> is releasably coupled to the base plate <NUM> prior to fabrication of the composite ply <NUM>. The film <NUM> remains coupled to the base plate <NUM> during fabrication of the composite ply <NUM>, during transfer of the composite ply <NUM> and during application of the composite ply <NUM> to the forming tool <NUM>. The film <NUM> is released from the base plate <NUM> after application of the composite ply <NUM> to the forming tool <NUM>. The film <NUM> may be releasably coupled to the base plate <NUM> via any one of various suitable techniques.

Referring to <FIG>, which schematically illustrate examples of the carrier transfer device <NUM> and the ply carrier <NUM>. In one or more examples, the film <NUM> is releasably coupled to the base plate <NUM> via vacuum retention. In these examples, the base plate <NUM> facilitates vacuum to move through the ply carrier <NUM> and engage the film <NUM>. For example, the carrier transfer device <NUM> includes a vacuum table <NUM> (e.g., <FIG>) and the base plate <NUM> includes a plurality of vacuum apertures <NUM> (e.g., <FIG>). The plurality of vacuum apertures <NUM> allow for vacuum to move through the base plate <NUM>. With the ply carrier <NUM> positioned on the carrier transfer device <NUM>, the vacuum table <NUM> is in fluid communication with the plurality of vacuum apertures <NUM>. The vacuum table <NUM> includes a perforated top and a vacuum chamber that is in fluid communication with a vacuum source. The vacuum table <NUM> is configured to apply a retention vacuum to the plurality of vacuum apertures <NUM> of the base plate <NUM> to temporarily hold and retain the film <NUM> on the base plate <NUM>.

In one or more examples, the carrier transfer device <NUM> includes parts and components (e.g., vacuum source, vacuum ports, plumbing, actuators, valves and the like) that enable production, application and selective control of the retention vacuum. The vacuum source (e.g., a vacuum pump) may be component of the system <NUM> or a part of a sub-system (e.g., the positioning system <NUM>) of the system <NUM>. Alternatively, the vacuum source may be an integral component of the carrier transfer device <NUM>. In production, the retention vacuum is provided by the vacuum table <NUM>, which is then applied to the film <NUM> through the plurality of vacuum apertures <NUM> formed in the base plate <NUM>.

In one or more examples, the vacuum table <NUM> includes a plurality of vacuum zones <NUM>. Each one of the plurality of vacuum zones <NUM> is controllable to selectively apply and remove vacuum to a corresponding set of vacuum apertures <NUM> (<FIG>) positioned over the respective vacuum zone <NUM>. For example, each one of the plurality of vacuum zones <NUM> includes a valve <NUM> that is selectively open or closed to control application of vacuum to the respective vacuum zone <NUM>. The vacuum zones <NUM> enable the vacuum table <NUM> to apply vacuum where needed to retain the film <NUM> on the base plate <NUM>. The vacuum zones <NUM> also enable the vacuum table <NUM> to cease application of vacuum to select areas of the base plate <NUM>, such as during removal of scrap remnants of the composite ply <NUM> after a trimming operation. The vacuum table <NUM> and the plurality of vacuum apertures <NUM> formed in the base plate <NUM> are arranged to adequately distribute a sufficient retention vacuum to retain the film <NUM> on the surface of the base plate <NUM> during movement of the ply carrier <NUM> through the system <NUM>.

In one or more examples, the vacuum table <NUM> includes a plurality of lip seals <NUM>. Each lip seal <NUM> is located between adjacent ones of the plurality of vacuum zones <NUM>. For example, the lip seals <NUM> form the peripheral boundaries of the vacuum zones <NUM> and isolate each one of the vacuum zones <NUM> from an adjacent one of the vacuum zones <NUM>. The plurality of lip seals <NUM> provide a sealing interface with the base plate <NUM> without affecting the surface flatness of the vacuum table <NUM>.

As illustrated in <FIG> and <FIG>, in one or more examples, the ply carrier <NUM> also includes a liner <NUM>. The liner <NUM> is coupled to the base plate <NUM>. Generally, the liner <NUM> is a relatively thin sheet of material that covers the base plate <NUM>. For example, the liner <NUM> is coupled to and covers the surface of the base plate <NUM> and is located between the base plate <NUM> and the film <NUM>. The liner <NUM> may be coupled to the base plate <NUM> in any one of various techniques, such as via adhesive bonding, mechanical fasteners and the like. In these examples, the film <NUM> is positioned on the liner <NUM> and the liner <NUM> provides a contact surface onto which the film <NUM> is applied.

In one or more examples, the liner <NUM> is permeable by the retention vacuum. The liner <NUM> facilitates distribution of the retention vacuum from the plurality of vacuum apertures <NUM> to the film <NUM>. The liner <NUM> also prevents the film <NUM> from dimpling or wrinkling at the plurality of vacuum apertures <NUM> in response to application of the retention vacuum.

In one or more examples, the liner <NUM> is made of a porous plastic material, such as a porous thermoplastic material. As an example, the liner <NUM> includes, or takes the form of, a sheet of polypropylene. As another example, the liner <NUM> includes, or takes the form of, a sheet of high-density polyethylene. As another example, the liner <NUM> is a sheet of VYON® porous polymer fluidizing media, commercially available from Porvair Filtration Group Inc. In other examples, the liner <NUM> may be made of any other suitable material, such as a material that is flexible, that permits vacuum to pass though itself and that can serve as a cutting surface.

Referring to <FIG>, <FIG>, in one or more examples, the system <NUM> includes an indexing structure <NUM>. The indexing structure <NUM> is configured to operatively locate the ply carrier <NUM> at a specified location on the carrier transfer device <NUM>. In one or more examples, the indexing structure <NUM> includes mating components located on the carrier transfer device <NUM> and the base plate <NUM> of the ply carrier <NUM>. For example, the carrier transfer device <NUM> includes at least one indexing pin <NUM> (e.g., at least two indexing pins <NUM>) and the base plate <NUM> includes at least one indexing aperture <NUM> (e.g., at least two indexing apertures <NUM>) that corresponds to the indexing pin <NUM>. The indexing pin <NUM> and the indexing aperture <NUM> cooperate to position the ply carrier <NUM> on the carrier transfer device <NUM>.

Referring now to <FIG>, the sub-systems of the system <NUM> are generally arranged in operational sequence with each other within a manufacturing environment. In one or more examples, the lamination system <NUM> is in sequential relation to the carrier preparation system <NUM>. In one or more examples, the trim system <NUM> is in sequential relation to the lamination system <NUM>. In one or more examples, the scrap removal system <NUM> is in sequential relation to the trim system <NUM>. In one or more examples, the transfer system <NUM> is in sequential relation to the scrap removal system <NUM>. In one or more examples, the forming system <NUM> is in sequential relation to the transfer system <NUM>. In one or more examples, the film removal system <NUM> is in sequential relation to the forming system <NUM>.

It should be recognized that not every sub-system is required, or certain sub-systems may not be utilized in every implementation of the disclosed system <NUM>. For example, in certain implementations, the carrier preparation system <NUM>, the trim system <NUM> and/or the scrap removal system <NUM> may not be utilized in fabrication of the composite structure <NUM> and, thus, may not be included as a sub-system within the system <NUM>. As such, in one or more examples, the transfer system <NUM> is in sequential relation to the lamination system <NUM>.

It should also be recognized that one or more of the sub-systems may be co-located or otherwise share an operational station of the system <NUM>. As an example, the trim system <NUM> and the scrap removal system <NUM> may share a location in the manufacturing environment or be part of the same operational station of the system <NUM>. As such, movement of the ply carrier <NUM> from the trim system <NUM> to the scrap removal system <NUM> (e.g., between a trimming operation and a scrap removing operation) may not be required, thereby reducing cycle time. As another example, the forming system <NUM> and the film removal system <NUM> may share a location in the manufacturing environment or be part of the same operation station of the system <NUM>. As such, movement of the forming tool <NUM> from the forming system <NUM> to the film removal system <NUM> (e.g., between a forming operation and a film removing operation) may not be required, thereby reducing cycle time.

In one or more examples, the carrier transfer device <NUM> conveys the ply carrier <NUM> to the carrier preparation system <NUM> for preparation of the ply carrier <NUM>. In one or more examples, the carrier transfer device <NUM> coveys the ply carrier <NUM> from the carrier preparation system <NUM> to the lamination system <NUM> for application of the composite ply <NUM> to the ply carrier <NUM>. In one or more examples, the carrier transfer device <NUM> conveys the ply carrier <NUM>, and the composite ply <NUM> supported on the ply carrier <NUM>, from the lamination system <NUM> to the trim system <NUM> for cutting the composite ply <NUM>. In one or more examples, the carrier transfer device <NUM> conveys the ply carrier <NUM>, and the composite ply <NUM> supported on the ply carrier <NUM>, from the trim system <NUM> to the scrap removal system <NUM> for removal of remnants (e.g., scrap composite material) from the ply carrier <NUM> after cutting. In one or more examples, the carrier transfer device <NUM> conveys the ply carrier <NUM>, and the composite ply <NUM> supported on the ply carrier <NUM>, from the trim system <NUM> to the transfer system <NUM> for application of the composite ply <NUM> to the forming tool <NUM>.

Alternatively, in one or more examples, such as when the trimming operation is not performed, the carrier transfer device <NUM> conveys the ply carrier <NUM>, and the composite ply <NUM> supported on the ply carrier <NUM>, from the lamination system <NUM> directly to the transfer system <NUM>.

In one or more examples, the tool transfer device <NUM> conveys the forming tool <NUM> to the transfer system <NUM> for application of the composite ply <NUM> to the forming tool <NUM>. In one or more examples, the tool transfer device <NUM> conveys the forming tool <NUM>, and the composite ply <NUM> applied to the forming tool <NUM>, from the transfer system <NUM> to the forming system <NUM> for formation and compaction of the composite ply <NUM> over the forming tool <NUM>. In one or more examples, the tool transfer device <NUM> conveys the forming tool <NUM>, and the composite ply <NUM> formed over the forming tool <NUM>, from the forming system <NUM> to the film removal system <NUM> for removal of the film <NUM> from the composite ply <NUM>.

The positioning system <NUM> may be any suitable system that guides the carrier transfer device <NUM> and the tool transfer device <NUM> along a predetermined workflow or path. In one or more examples, the positioning system <NUM> is configured to selectively position the carrier transfer device <NUM> relative to individual sub-systems or workstations of the system <NUM> (e.g., the carrier preparation system <NUM>, the lamination system <NUM>, the trim system <NUM>, the scrap removal system <NUM> and the transfer system <NUM>). In one or more examples, the positioning system <NUM> is configured to selectively position the tool transfer device <NUM> relative to individual sub-systems or workstations of the system <NUM> (e.g., the transfer system <NUM>, the forming system <NUM> and the film removal system <NUM>).

In one or more examples, as illustrated in <FIG>, the positioning system <NUM> includes a rail assembly <NUM> or similar conveyor assembly that physically guides the carrier transfer device <NUM> and the tool transfer device <NUM> through the system <NUM>. In these examples, the carrier transfer device <NUM> and the tool transfer device <NUM> may include a cart, a pallet, a carriage, or similar platform that is configured to travel along the rail assembly <NUM>. As such, in these examples, the positioning system <NUM>, the carrier transfer device <NUM> and the tool transfer device <NUM> include cooperating parts and components (e.g., drive motors, tracks, actuators, gears, wheels, sensors and the like) that enable selectively controlled transportation of the carrier transfer device <NUM> and the tool transfer device <NUM> along the positioning system <NUM>.

In one or more examples, the rail assembly <NUM> includes parts and components (e.g., rack and pinion assembly, roller tables, gauges and the like) that precisely control movement of the carrier transfer device <NUM> and the tool transfer device <NUM> through the system <NUM>. As such, the positioning system <NUM> may be configured to index the carrier transfer device <NUM> and the tool transfer device <NUM> at a plurality of predetermined locations relative to respective sub-systems or workstations of the system <NUM>.

Referring to <FIG>, in one or more examples, the system <NUM> includes an indexing device <NUM>. For example, the system <NUM> may include a plurality of indexing devices <NUM> located along the positioning system <NUM>. As an example, at least one indexing device <NUM> is located along the rail assembly <NUM> at each one of the sub-systems or workstations of the system <NUM>. In one or more examples, the indexing device <NUM> is configured to operatively locate the carrier transfer device <NUM> at a plurality of specified locations, for example, relative to at least one of the carrier preparation system <NUM>, the lamination system <NUM>, the trim system <NUM>, the scrap removal system <NUM> and the transfer system <NUM>. In one or more examples, the indexing device <NUM> is configured to operatively locate the tool transfer device <NUM> at a plurality of specified locations, for example, relative to at least one of the transfer system <NUM>, the forming system <NUM> and the film removal system <NUM>.

In an example, the indexing device <NUM> includes parts and components (e.g., actuators, indexing pins, sensors and the like) that enable the indexing device <NUM> to automatically detect and index the carrier transfer device <NUM> and the tool transfer device <NUM>.

Referring to <FIG>, in one or more examples, the positioning system <NUM> includes a linear carrier guide <NUM>. The linear carrier guide <NUM> is configured to operatively translate the carrier transfer device <NUM> through the sub-systems or workstations of the system <NUM>, for example, along a linear workflow path. For example, a portion of rail assembly <NUM> dedicated to conveying the carrier transfer device <NUM> is a linear segment with discrete terminal ends. In these examples, the positioning system <NUM> is configured to selectively move the carrier transfer device <NUM> along an X-axis.

In one or more examples, in operation, the carrier transfer device <NUM> moves in a first direction along the linear carrier guide <NUM> from the carrier preparation system <NUM> to the lamination system <NUM>. The carrier transfer device <NUM> then moves in the first direction along the linear carrier guide <NUM> from the lamination system <NUM> to the trim system <NUM> and the scrap removal system <NUM>. The carrier transfer device <NUM> then moves in the first direction along the linear carrier guide <NUM> from the scrap removal system <NUM> to the transfer system <NUM>. Alternatively, as described above, the carrier transfer device <NUM> moves in the first direction along the linear carrier guide <NUM> from the lamination system <NUM> directly to the transfer system <NUM>, for example, when trim system <NUM> and the scrap removal system <NUM> are not utilized or included in the system <NUM>. After application of the composite ply <NUM> to the forming tool <NUM> and following return of the ply carrier <NUM> to the carrier transfer device <NUM>, the carrier transfer device <NUM> then moves in a second direction, opposite the first direction, along the linear carrier guide <NUM> from the transfer system <NUM> back to the carrier preparation system <NUM> through the scrap removal system <NUM>, the trim system <NUM> and the lamination system <NUM>, where the process repeats for fabrication and transfer of a subsequent composite ply <NUM>.

In one or more examples, the positioning system <NUM> includes a linear tool guide <NUM>. The linear tool guide <NUM> is configured to operatively translate the tool transfer device <NUM> through the sub-systems or workstations of the system <NUM>, for example, along a linear workflow path. For example, a portion of rail assembly <NUM> dedicated to conveying the tool transfer device <NUM> is a linear segment with discrete terminal ends. In these examples, the positioning system <NUM> is configured to selectively move the tool transfer device <NUM> along an X-axis.

In one or more examples, in operation, the tool transfer device <NUM> moves in a first direction along the linear tool guide <NUM> to the transfer system <NUM>. The tool transfer device <NUM> then moves in the first direction along the linear tool guide <NUM> from the transfer system <NUM> to the forming system <NUM>. The tool transfer device <NUM> then moves in the first direction along the linear tool guide <NUM> from the forming system <NUM> to the film removal system <NUM>. The tool transfer device <NUM> then moves in a second direction, opposite the first direction, along the linear tool guide <NUM> from film removal system <NUM> back to the transfer system <NUM> through the forming system <NUM>, where the process repeats for application and formation of a subsequent composite ply <NUM>.

Referring to <FIG>, in one or more examples, the positioning system <NUM> includes a closed-loop carrier guide <NUM>. The closed-loop carrier guide <NUM> is configured to operatively circulate the carrier transfer device <NUM> through the sub-systems or workstations of the system <NUM>, for example, along a continuous workflow path. For example, a portion of rail assembly <NUM> dedicated to conveying the carrier transfer device <NUM> is a continuous loop. In these examples, the positioning system <NUM> is configured to selectively move the carrier transfer device <NUM> along an X-axis and a Y-axis.

In one or more examples, in operation, the carrier transfer device <NUM> moves in a first direction along the closed-loop carrier guide <NUM> from the carrier preparation system <NUM> to the lamination system <NUM>. The carrier transfer device <NUM> then moves in the first direction along the closed-loop carrier guide <NUM> from the lamination system <NUM> to the trim system <NUM> and the scrap removal system <NUM>. The carrier transfer device <NUM> then moves in the first direction along the closed-loop carrier guide <NUM> from the scrap removal system <NUM> to the transfer system <NUM>. Alternatively, as described above, the carrier transfer device <NUM> moves in the first direction along the closed-loop carrier guide <NUM> from the lamination system <NUM> directly to the transfer system <NUM>, for example, when trim system <NUM> and the scrap removal system <NUM> are not utilized or included in the system <NUM>. After application of the composite ply <NUM> to the forming tool <NUM> and following return of the ply carrier <NUM> to the carrier transfer device <NUM>, the carrier transfer device <NUM> then moves in the first direction along the closed-loop carrier guide <NUM> from the transfer system <NUM> back to the carrier preparation system <NUM>, where the process repeats for fabrication and transfer of a subsequent composite ply <NUM>.

In one or more examples, the positioning system <NUM> includes a closed-loop tool guide <NUM>. The closed-loop tool guide <NUM> is configured to operatively circulate the tool transfer device <NUM> through the sub-systems or workstations of the system <NUM>, for example, along a continuous workflow path. For example, a portion of rail assembly <NUM> dedicated to conveying the tool transfer device <NUM> is a continuous loop. In these examples, the positioning system <NUM> is configured to selectively move the tool transfer device <NUM> along an X-axis and a Y-axis.

In one or more examples, in operation, the tool transfer device <NUM> moves in a first direction along the closed-loop tool guide <NUM> to the transfer system <NUM>. The tool transfer device <NUM> then moves in the first direction along the closed-loop tool guide <NUM> from the transfer system <NUM> to the forming system <NUM>. The tool transfer device <NUM> then moves in the first direction along the closed-loop tool guide <NUM> from the forming system <NUM> to the film removal system <NUM>. The tool transfer device <NUM> then moves in the first direction along the closed-loop tool guide <NUM> from film removal system <NUM> back to the transfer system <NUM>, where the process repeats for application and formation of a subsequent composite ply <NUM>.

In either of the example configurations of the positioning system <NUM> described above (e.g., utilizing a translating workflow or a continuous workflow), the positioning system <NUM> includes access areas that enable on-loading and off-loading of the carrier transfer device <NUM> and the tool transfer device <NUM>.

In one or more examples, the system <NUM> utilizes a plurality of carrier transfer devices <NUM>. Each one of the plurality of carrier transfer devices <NUM> conveys a respective one of a plurality of ply carriers <NUM> through the system <NUM>. Thus, in production, multiple operations can be performed simultaneously on different ones of the plurality of ply carriers <NUM>, thereby reducing cycle time. Similarly, in one or more examples, the system <NUM> utilizes a plurality of tool transfer devices <NUM>. Each one of the plurality of tool transfer devices <NUM> conveys a respective one of a plurality of forming tool <NUM> through the system <NUM>. Thus, in production, multiple operations can be performed simultaneously on different ones of the plurality of forming tools <NUM>, thereby reducing cycle time.

Referring again to <FIG>, in one or more examples, the carrier preparation system <NUM> is configured to prepare the ply carrier <NUM> and, more particularly, the ply support surface <NUM>, to receive the composite ply <NUM>. For example, in production, the carrier transfer device <NUM> positions the ply carrier <NUM> relative to the carrier preparation system <NUM>, which automatically applies the film <NUM> to the base plate <NUM>, or to the liner <NUM> covering the base plate <NUM>, to prepare the ply support surface <NUM>.

In one or more examples, the carrier preparation system <NUM> includes at least one preparing device <NUM>. The preparing device <NUM> is configured to interact with ply carrier <NUM>. The preparing device <NUM> may be any suitable machine or device capable of manipulating the film <NUM> and properly positioning the film <NUM> on the base plate <NUM>, or on the liner <NUM>. In one or more examples, the preparing device <NUM> includes, or takes the form of, a robotic end effector. The preparing device <NUM> includes parts and components (e.g., drive motors, actuators, grippers, cutters, rollers, sensors and the like) that enable the preparing device <NUM> to automatically apply the film <NUM> to the base plate <NUM>, or the liner <NUM>. As an example, the preparing device <NUM> is configured to remove the film <NUM> from a supply roll, cut the film <NUM> to a predetermined size and shape and apply the film <NUM>.

The preparing device <NUM> is movable relative to the ply carrier <NUM>. For example, the preparing device <NUM> operates in a three-dimensional X, Y, Z coordinate system. In one or more examples, the carrier preparation system <NUM> includes a support platform <NUM> that is configured to selectively move and position the preparing device <NUM> relative to the carrier transfer device <NUM> and, thus, the ply carrier <NUM>. The support platform <NUM> may be any suitable machine capable of automatically driving and controlling movement of the preparing device <NUM>, such as a robot, a robotic arm, and overhead gantry and the like.

Additionally, the carrier preparation system <NUM> is configured to automatically position the base plate <NUM> on the carrier transfer device <NUM>. For example, the preparing device <NUM> is configured to manipulate the base plate <NUM> and position the base plate <NUM> on the carrier transfer device <NUM> at the proper location using the indexing structure <NUM>.

Alternatively, preparation of the ply carrier <NUM> may be performed manually or semi-autonomously with manual assistance.

In one or more examples, the lamination system <NUM> is configured to selectively apply the composite ply <NUM> to the ply support surface <NUM> of the ply carrier <NUM>. For example, in production, the carrier transfer device <NUM> positions the ply carrier <NUM> relative to the lamination system <NUM>, which automatically fabricates the composite ply <NUM> on the ply support surface <NUM> of the ply carrier <NUM>.

In one or more examples, the lamination system <NUM> include at least one laminating device <NUM>. The laminating device <NUM> is configured to lay up and laminate the composite ply <NUM>. The laminating device <NUM> may be any suitable machine or device capable of manipulating a composite material to lay the composite ply <NUM> on the ply support surface <NUM>. As an example, the laminating device <NUM> is configured to lay down and laminate multiple courses (e.g., continuous or discontinuous courses) of unidirectional composite tape in an edge-to-edge relationship. The laminating device <NUM> includes parts and components (e.g., drive motors, actuators, cutters, rollers, tape control modules, sensors and the like) that enable the laminating device <NUM> to automatically fabricate the composite ply <NUM>. In one example, when the lamination system <NUM> includes multiple laminating devices <NUM>, each laminating device <NUM> operates to lay material in one or more particular orientations. As an example, the laminating device <NUM> is configured to lay, cut, add and compact the composite material (e.g., composite tape) onto the ply support surface <NUM> or a previously laid composite ply <NUM>.

The laminating device <NUM> is movable relative to the ply carrier <NUM>. For example, the laminating device <NUM> operates in the three-dimensional X, Y, Z coordinate system. In these examples, the X-axis may correspond to the length of the composite ply <NUM>, the Y-axis may correspond to the width of the composite ply <NUM>, and the Z-axis extends substantially normal to the X-Y plane. In one or more examples, the lamination system <NUM> includes a support platform <NUM> that is configured to selectively move and position the laminating device <NUM> relative to the carrier transfer device <NUM> and, thus, the ply carrier <NUM>. The support platform <NUM> may be any suitable machine capable of automatically driving and controlling movement of the laminating device <NUM>, such as a robot, a robotic arm, and overhead gantry and the like.

In one or more examples, the composite ply <NUM> includes one layer of thickness (e.g., one ply of composite material). For example, courses of composite tape are laminated on the ply support surface <NUM> to form one composite ply <NUM>. In one or more examples, the composite ply <NUM> includes a plurality of layers of thickness (e.g., a plurality of plies of composite material). For example, courses of composite tape are laminated on a previously laid ply to form additional composite plies <NUM>.

The lamination system <NUM> is configured to lay down the composite ply <NUM> having any desired fiber orientation, for example, based on the predetermined ply schedule or laydown sequence. The lamination system <NUM> may be particularly well suited for lay up of a relatively long and narrow composite ply <NUM> (e.g., relatively long in relation to width), such as used in ply-by-ply fabrication of composite spars and stringers used in the aerospace industry.

In one or more examples, the lamination system <NUM> fabricates and provides the composite plies <NUM> as-needed and on-demand, for example, in accordance with a predetermined ply laydown sequence. As such, the need for ply sequencing, sorting and storage of prefabricated plies is eliminated, thereby reducing manual labor and the opportunity for error in performing the ply laydown process. In one or more examples, each composite ply <NUM> in the ply laydown sequence may be different from each other by at least one parameter, such as, but not limited to, fiber orientation, weave pattern, ply laydown orientation, ply laydown location and overall ply shape.

In one or more examples, the lamination system <NUM> may include more than one laminating device <NUM>. In these examples, a plurality of laminating devices <NUM> is configured to concurrently fabricate a plurality of composite plies <NUM> that can be provided to a plurality of forming tools <NUM>, thereby reducing cycle time.

In one or more examples, the trim system <NUM> is configured to selectively cut the composite ply <NUM> into a predetermined shape. For example, in production, the carrier transfer device <NUM> positions the ply carrier <NUM> relative to the trim system <NUM>, which automatically cuts the composite ply <NUM> to the predetermined shape on the ply support surface <NUM> of the ply carrier <NUM>. The predetermined shape may be based on the type of composite structure <NUM> being fabricated, the shape or contour of the forming surface <NUM>, the ply laydown sequence, the ply laydown location and the overall ply shape as well as to compensate for transformation from a flat state to a contoured shape upon application to and formation over the forming tool <NUM>.

In one or more examples, the trim system <NUM> includes at least one cutting device <NUM>. The cutting device <NUM> is configured to cut the composite ply <NUM>. The cutting device <NUM> may be any suitable cutter capable of cutting through the composite material of the composite ply <NUM>. As an example, the cutting device <NUM> includes, or takes the form of, an ultrasonic cutter. In other examples, the cutting device <NUM> includes, or takes the form of, a blade, a laser cutter or the like. When the ply carrier <NUM> includes the liner <NUM>, the liner <NUM> protects the surface of the base plate <NUM> from damage when the composite ply <NUM> is cut to shape.

The cutting device <NUM> is movable relative to the ply carrier <NUM>. For example, the cutting device <NUM> operates in the three-dimensional X, Y, Z coordinate system. In one or more examples, the trim system <NUM> includes a support platform <NUM> that is configured to selectively move and position the cutting device <NUM> relative to the carrier transfer device <NUM> and, thus, the ply carrier <NUM>. The support platform <NUM> may be any suitable machine capable of automatically driving and controlling movement of the cutting device <NUM>, such as a robot, a robotic arm, and overhead gantry and the like.

It should be recognized that in some implementations of the system <NUM>, such as depending on the overall ply shape of the composite ply <NUM> after lamination and the type of composite structure <NUM> being fabricated, that the trimming and scrap removing operations may not be required. In such examples, the composite ply <NUM> is provided directly to the transfer system <NUM> from the lamination system <NUM>.

In one or more examples, the scrap removal system <NUM> is configured to remove a remnant of (e.g., scrap cut from) the composite ply <NUM> from the ply support surface <NUM>, after the composite ply <NUM> is cut into the predetermined shape by the trim system <NUM>. For example, in production, the carrier transfer device <NUM> positions the ply carrier <NUM> relative to the scrap removal system <NUM>, which automatically separates and takes away the remnant of the composite ply <NUM> from the ply support surface <NUM> of the ply carrier <NUM>.

As described above, in one or more examples, the retention vacuum may be selectively removed from designated portions of the film <NUM> to enable removal of the remnant from the ply support surface <NUM>. For example, the retention vacuum provided by select ones of the vacuum zones <NUM> (e.g., as shown in <FIG>), corresponding to portions of the film <NUM> on which the remnant is located, may be selectively turned off during removal of the remnant.

In one or more examples, the scrap removal system <NUM> includes at least one scrap-removing device <NUM>. The scrap-removing device <NUM> is configured to locate, engage and remove the remnant of the composite ply <NUM>. The scrap-removing device <NUM> may be any machine or device capable of manipulating the remnant and removing the remnant from the ply carrier <NUM>. In one or more examples, the scrap-removing device <NUM> includes, or takes the form of, a robotic end effector. The scrap-removing device <NUM> includes parts and components (e.g., drive motors, actuators, grippers, sensors and the like) that enable the scrap-removing device <NUM> to automatically remove the remnant. As an example, the scrap-removing device <NUM> may be a pick-and-place gripper. As another example, the scrap-removing device <NUM> may be a vacuum gripper or vacuum roller.

The scrap-removing device <NUM> is movable relative to the ply carrier <NUM>. For example, the scrap-removing device <NUM> operates in a three-dimensional X, Y, Z coordinate system. In one or more examples, the scrap removal system <NUM> includes a support platform <NUM> that is configured to selectively move and position the scrap-removing device <NUM> relative to the carrier transfer device <NUM> and, thus, the ply carrier <NUM>. The support platform <NUM> may be any suitable machine capable of automatically driving and controlling movement of the scrap-removing device <NUM>, such as a robot, a robotic arm, and overhead gantry and the like. In one or more examples, the scrap-removing device <NUM> may be configured to automatically place scrap remnants in a scrap container for subsequent removal.

In one or more examples, the trim system <NUM> and the scrap removal system <NUM> may be integrated within a single workstation. In these examples, the cutting device <NUM> and the scrap-removing device <NUM> may share the same support platform.

In one or more examples, the transfer system <NUM> is configured to remove the ply carrier <NUM> from the carrier transfer device <NUM>. The transfer system <NUM> is configured to apply the composite ply <NUM> to at least a portion of a forming surface <NUM> of the forming tool <NUM>. The transfer system <NUM> is further configured to release the film <NUM> from the base plate <NUM> while retaining the base plate <NUM>, after application of the composite ply <NUM> to at least a portion of the forming surface <NUM> of the forming tool <NUM>. The transfer system <NUM> is configured to return the base plate <NUM> to the carrier transfer device <NUM>, after application of the composite ply <NUM> to at least a portion of the forming surface <NUM> of the forming tool <NUM>. For example, in production, the carrier transfer device <NUM> positions the ply carrier <NUM> and the tool transfer device <NUM> positions the forming tool <NUM> relative to the transfer system <NUM>, which automatically removes the ply carrier <NUM> from the carrier transfer device <NUM>, applies the composite ply <NUM> to the forming tool <NUM> and returns the ply carrier <NUM> to the carrier transfer device <NUM>.

In one or more examples, the transfer system <NUM> applies a plurality of composite plies <NUM> to the forming tool <NUM> one at a time according to the ply laydown sequence. The transfer system <NUM> is capable of providing the composite ply <NUM> at different locations on the forming tool <NUM>. As such, a technician is not required to retrieve individual plies from a workstation and then manually position each ply to a laydown location on the forming tool in accordance with the ply laydown sequence.

In one or more examples, the transfer system <NUM> includes at least one transferring device <NUM>. The transferring device <NUM> is configured to manipulate the ply carrier <NUM>. The transferring device <NUM> may be any suitable machine or device capable of removing the ply carrier <NUM> from the carrier transfer device <NUM> and applying (e.g., stamping) the composite ply <NUM> to the forming tool <NUM>. In one or more examples, the transferring device <NUM> includes, or takes the form of, a robotic end effector. The transferring device <NUM> includes parts and components (e.g., drive motors, actuators, grippers, bearings, sensors and the like) that enable the transferring device <NUM> to automatically apply the composite ply <NUM> to the forming tool <NUM>.

In one or more examples, the transferring device <NUM> is configured to remove the ply carrier <NUM> from the carrier transfer device <NUM>. In one or more examples, the transferring device <NUM> is configured to orient the ply carrier <NUM> relative to the forming tool <NUM>. In one or more examples, the transferring device <NUM> is configured to press the ply carrier <NUM> against the forming surface <NUM> to apply the composite ply <NUM> to the forming tool <NUM>. In one or more examples, the transferring device <NUM> is configured to remove the ply carrier <NUM> from the forming surface <NUM>, thereby leaving the composite ply <NUM> on (e.g., tacked to) the forming tool <NUM>.

In one or more examples, the transfer system <NUM> is configured to reorient the ply carrier (e.g., flip the ply carrier or rotate the ply carrier <NUM> one hundred eighty degrees about a horizontal axis), before application of the composite ply <NUM> to at least a portion of the forming surface <NUM> of the forming tool <NUM>. For example, in production, the ply carrier <NUM> is introduced to the transfer system <NUM> by the carrier transfer device <NUM> with the composite ply <NUM> facing substantially upward. The transfer system <NUM> reorients (e.g., flips) the ply carrier <NUM> such that the composite ply <NUM> is facing toward the forming surface <NUM> of the forming tool <NUM> (e.g., facing substantially downward).

As illustrated in <FIG>, in one or more examples, the transfer system <NUM> includes a plurality transferring devices <NUM>. For example, the transfer system <NUM> includes a first one of the transferring devices <NUM> associated with a first stage of the transferring operation and a second one of the transferring devices <NUM> associated with a second stage of the transferring operation.

In one or more examples, the first one of the transferring devices <NUM> is configured to engage the ply carrier <NUM> and to remove the ply carrier <NUM> from the carrier transfer device <NUM>. For example, the ply carrier <NUM> is located at a first stage of the transfer system <NUM> and the first one of the transferring devices <NUM> in position to remove the ply carrier <NUM> from the carrier transfer device <NUM>. The first one of the transferring devices <NUM> is configured to support and maintain the composite ply <NUM> on the ply support surface <NUM> of the ply carrier <NUM> after removal of the ply carrier <NUM> from the carrier transfer device <NUM>.

In one or more examples, as illustrated in <FIG>, the first one of the transferring devices <NUM> is configured to then reorient (e.g., flip) the ply carrier <NUM> for hand-off to the second one of the transferring devices <NUM>. The first one of the transferring devices <NUM> may also be configured to position (e.g., move) the ply carrier <NUM> for hand-off to the second one of the transferring devices <NUM>. For example, the ply carrier <NUM> is removed from the carrier transfer device <NUM> and reoriented and repositioned for hand-off to the second one of the transferring devices <NUM>. The first one of the transferring devices <NUM> is configured to support and maintain the composite ply <NUM> on the ply support surface <NUM> of the ply carrier <NUM>, during and after reorientation of the ply carrier <NUM>. For example, the first one of the transferring devices <NUM> may physically contact the composite ply <NUM> or otherwise clamp the composite ply <NUM> between the first one of the transferring devices <NUM> and the ply carrier <NUM>.

The second one of the transferring devices <NUM> is configured to remove the ply carrier <NUM> from the first one of the transferring devices <NUM>. The second one of the transferring devices <NUM> is configured to support and maintain the composite ply <NUM> on the ply support surface <NUM> of the ply carrier <NUM>, after removal from the first one of the transferring devices <NUM>. For example, as described herein above, the film <NUM> and, thus, the composite ply <NUM>, is retained on the base plate <NUM> via the vacuum retention. The second one of the transferring devices <NUM> is configured to maintain the retention vacuum to the plurality of vacuum apertures <NUM> of the base plate <NUM> to retain the film <NUM> on the base plate <NUM>, after removal of the ply carrier <NUM> from the carrier transfer device <NUM>. In one or more examples, the second one of the transferring devices <NUM> includes a vacuum table <NUM> (<FIG>). With the ply carrier <NUM> positioned on the second one of the transferring devices <NUM>, the vacuum table <NUM> is in fluid communication with the plurality of vacuum apertures <NUM> of the base plate <NUM>. The vacuum table <NUM> is configured to apply the retention vacuum to the plurality of vacuum apertures <NUM> to retain the film <NUM> on the base plate <NUM>.

The second one of the transferring devices <NUM> is configured to press (e.g., stamp) the ply carrier <NUM> against the forming tool <NUM>, thereby applying the composite ply <NUM> to the forming surface <NUM> of the forming tool <NUM>. The second one of the transferring devices <NUM> is configured to release the film <NUM> from the base plate <NUM> and remove the base plate <NUM> from the forming tool <NUM>, thereby leaving the composite ply <NUM>, and the film <NUM> coupled to the composite ply <NUM>, on the forming tool <NUM>. For example, the second one of the transferring devices <NUM> is configured to selectively remove the retention vacuum to release the film <NUM> from the base plate <NUM>.

The second one of the transferring devices <NUM> is configured to then position (e.g., move) the ply carrier <NUM> for hand-off back to the first one of the transferring devices <NUM>. The first one of the transferring devices <NUM> is configured to remove the base plate <NUM> from the second one of the transferring devices <NUM>. For example, as illustrated in <FIG> illustrates the ply carrier <NUM> (e.g., the base plate <NUM> without the film <NUM>) passed back to the first one of the transferring devices <NUM>. The first one of the transferring devices <NUM> is configured to then return the base plate <NUM> to the carrier transfer device <NUM>.

The transferring device <NUM> is movable relative to the carrier transfer device <NUM> and the forming tool <NUM>. For example, the transferring device <NUM> operates in the three-dimensional X, Y, Z coordinate system. As an example, the first one of the transferring devices <NUM> is movable relative to ply carrier <NUM>, before removing the ply carrier <NUM> from the carrier transfer device <NUM>, and is movable relative to the carrier transfer device <NUM>, after removal of the ply carrier <NUM>. The second one of the transferring devices <NUM> is movable relative to the forming tool <NUM>. Additionally, or alternatively, the forming tool <NUM> is movable relative to the transferring device <NUM>. In either example, the transferring device <NUM> is positionable at different locations along the forming tool <NUM> to facilitate streamlining the ply laydown workflow process.

In one or more examples, the transfer system <NUM> includes a support platform <NUM> that is configured to selectively move and position the transferring device <NUM> relative to the carrier transfer device <NUM> and the forming tool <NUM>. The support platform <NUM> may be any suitable machine capable of automatically driving and controlling movement of the transferring device <NUM>, such as a robot, a robotic arm, and overhead gantry and the like. In one or more examples, the first one and the second one of the transferring devices <NUM> share the same support platform <NUM>.

In one or more examples, the forming system <NUM> is configured to form the composite ply <NUM> over at least a portion of the forming surface <NUM> of the forming tool <NUM>. For example, in production, the tool transfer device <NUM> positions the forming tool <NUM> relative to the forming system <NUM>, which automatically forms the composite ply <NUM> over the forming surface <NUM> of the forming tool <NUM>.

In one or more examples, the forming system <NUM> includes at least one forming device <NUM>. The forming device <NUM> is configured to compress the composite ply <NUM> and form the composite ply <NUM> over the forming surface <NUM> of the forming tool <NUM>. The forming device <NUM> may be any suitable machine or device capable of forming the composite ply <NUM> to the shape of the forming surface <NUM> of the forming tool <NUM>. In one or more examples, the forming device <NUM> includes, or takes the form of, a robotic end effector. The forming device <NUM> includes parts and components (e.g., drive motors, actuators, bearing, rollers, sensors and the like) that enable automatic formation of the composite ply <NUM> over the forming tool <NUM>.

In one or more examples, the forming tool <NUM>, or at least a portion of the forming surface <NUM>, has a complex geometry and is contoured along one or more planes. In operation, the forming device <NUM> moves across the forming surface <NUM> of the forming tool <NUM> to form and compact the composite ply <NUM> on the forming tool <NUM>. Thus, the forming system <NUM> is provided with the dynamic ability to adjust to variations in the shape, taper and/or contour of the forming tool <NUM>, and to facilitate maintaining parallelism with the contoured forming surface <NUM> of the forming tool <NUM>. As such, the composite structure <NUM> formed using the forming system <NUM> may be provided with reduced ply wrinkling, thereby reducing disruptions in manufacturing flow and production of defective parts.

The forming device <NUM> is movable relative to the forming tool <NUM>. For example, the forming device <NUM> operates in the three-dimensional X, Y, Z coordinate system. In one or more examples, the forming system <NUM> includes a support platform <NUM> that is configured to selectively move and position the forming device <NUM> relative to the forming tool <NUM>. The support platform <NUM> may be any suitable machine capable of automatically driving and controlling movement of the forming device <NUM>, such as a robot, a robotic arm, and overhead gantry and the like.

Additionally, or alternatively, the forming tool <NUM> is movable relative to the forming device <NUM>. In either example, the forming device <NUM> is positionable at different locations along the forming tool <NUM> to facilitate streamlining the ply compaction workflow process.

In one or more examples, the film removal system <NUM> is configured to remove the film <NUM> from the composite ply <NUM>, after the composite ply <NUM> is formed over at least a portion of the forming surface <NUM> of the forming tool <NUM>. For example, in production, the tool transfer device <NUM> positions the forming tool <NUM> relative to the film removal system <NUM>, which automatically pulls the film <NUM> from the composite ply <NUM>.

In one or more examples, the film removal system <NUM> includes at least one film-removing device <NUM>. The film-removing device <NUM> is configured to engage and remove the film <NUM> from the composite ply <NUM>. The film-removing device <NUM> may be any machine or device capable of manipulating the film <NUM> and removing the film <NUM> from the composite ply <NUM>. In one or more examples, the film-removing device <NUM> includes, or takes the form of, a robotic end effector. The film-removing device <NUM> includes parts and components (e.g., drive motors, actuators, grippers, sensors and the like) that enable the film-removing device <NUM> to automatically remove the film <NUM>. As example, the film-removing device <NUM> is a vacuum gripper or vacuum roller.

In one or more examples, the film-removing device <NUM> is configured to peel the film <NUM> away from the composite ply <NUM> according to one or more predefined peeling parameters. As an example, the film-removing device <NUM> is configured to peel the film <NUM> away from the composite ply <NUM> in a predetermined peel direction relative to the fiber orientation of the composite ply, such as parallel to the direction of the fibers of the composite ply <NUM>. As another example, the film-removing device <NUM> is configured to peel the film <NUM> away from the composite ply <NUM> at a predetermined peel angle. As an example, the film-removing device <NUM> is configured to initiate peeling of the film <NUM> at a predetermined peel initiation zone.

The film-removing device <NUM> is movable relative to the forming tool <NUM>. For example, the film-removing device <NUM> operates in a three-dimensional X, Y, Z coordinate system. In one or more examples, the film removal system <NUM> includes a support platform <NUM> that is configured to selectively move and position the film-removing device <NUM> relative to the forming tool <NUM> and, thus, the composite ply <NUM>. The support platform <NUM> may be any suitable machine capable of automatically driving and controlling movement of the film-removing device <NUM>, such as a robot, a robotic arm, and overhead gantry and the like.

In one or more examples, the forming system <NUM> and the film removal system <NUM> may be integrated within a single workstation. In these examples, the forming device <NUM> and the film-removing device <NUM> may share the same support platform.

Referring now to <FIG>, which illustrates an example of the method <NUM> that utilizes the system <NUM> (e.g., shown in <FIG>) to fabricate the composite structure <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) preparing the ply carrier <NUM>. In one or more examples, the carrier transfer device <NUM> is provided to the carrier preparation system <NUM> for preparation of the ply carrier <NUM>. For example, the carrier transfer device <NUM> is conveyed to the carrier preparation system <NUM> using the positioning system <NUM>. In one or more examples, the base plate <NUM> is coupled to the carrier transfer device <NUM> and is indexed relative to the carrier transfer device <NUM> using the indexing structure <NUM>. In one or more examples, the film <NUM> is applied to the base plate <NUM> to form the ply support surface <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) selectively applying the retention vacuum to retain the film <NUM> on the base plate <NUM> using the carrier transfer device <NUM>. For example, the retention vacuum is applied to the ply carrier <NUM> via the vacuum table <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) conveying the ply carrier <NUM> to the lamination system <NUM> using the carrier transfer device <NUM>. For example, the carrier transfer device <NUM> moves along the positioning system <NUM> to a predefined location relative to the lamination system <NUM>. In one or more examples, the carrier transfer device <NUM> and, thus, the ply carrier <NUM>, is indexed relative to the lamination system <NUM> using the indexing device <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) selectively applying the composite ply <NUM> to the ply support surface <NUM> of the ply carrier <NUM> using the lamination system <NUM>. The lamination system <NUM> may operate according to programmed instructions to lay down and laminate composite material on the ply support surface <NUM>. For example, the lamination system <NUM> may operate according to the predetermined ply laydown sequence such that the fabricated composite ply <NUM> corresponds to the next composite ply <NUM> to be applied to the forming tool <NUM>. Following fabrication of the composite ply <NUM>, the composite ply <NUM> is adhered (e.g., tacked) to the film <NUM> by the resin matrix of the composite ply <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) conveying the ply carrier <NUM> from the lamination system <NUM> to the trim system <NUM> using the carrier transfer device <NUM>. For example, the carrier transfer device <NUM> moves along the positioning system <NUM> to a predefined location relative to the trim system <NUM>. In one or more examples, the carrier transfer device <NUM> and, thus, the ply carrier <NUM> and the composite ply <NUM>, is indexed relative to the trim system <NUM> using the indexing device <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) selectively cutting the composite ply <NUM> into the predetermined shape using the trim system <NUM>. The trim system <NUM> may operate in accordance to programmed instructions that define the predetermined shape to be cut in the composite ply <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) removing a remnant of the at least one composite ply <NUM> from the ply support surface <NUM> using the scrap removal system <NUM>, after the step of (block <NUM>) selectively cutting the at least one composite ply <NUM>. For example, the carrier transfer device <NUM> is conveyed along the positioning system <NUM> to a predefined location relative to the scrap removal system <NUM>. In one or more examples, the carrier transfer device <NUM> and, thus, the ply carrier <NUM> and the composite ply <NUM>, is indexed relative to the scrap removal system <NUM> using the indexing device <NUM>.

In one or more examples, the method <NUM> includes a step of selectively removing the retention vacuum from select areas of the film <NUM> using the carrier transfer device <NUM>. For example, the retention vacuum is removed from areas of the film <NUM> corresponding to the remnant to be removed from the ply carrier <NUM>.

In one or more examples, the method <NUM> also includes a step of (block <NUM>) conveying the ply carrier <NUM> from the trim system <NUM> to the transfer system <NUM> using the carrier transfer device <NUM>. For example, the carrier transfer device <NUM> moves along the positioning system <NUM> to a predefined location relative to the transfer system <NUM>. In one or more examples, the carrier transfer device <NUM> and, thus, the ply carrier <NUM> and the composite ply <NUM>, is indexed relative to the transfer system <NUM> using the indexing device <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) removing the ply carrier <NUM> from the carrier transfer device <NUM> and a step of (block <NUM>) reorienting (e.g., rotating) the ply carrier <NUM> using the transfer system <NUM>. In one or more examples, the method <NUM> includes a step of (block <NUM>) maintaining the retention vacuum to retain the film <NUM> on the base plate <NUM> using the transfer system <NUM>. The step of (block <NUM>) maintaining the retention vacuum is performed during and after the step of (block <NUM>) removing of the ply carrier <NUM> and the step of (block <NUM>) reorienting the ply carrier <NUM>. For example, the retention vacuum is applied to the ply carrier <NUM> via the vacuum table <NUM> (<FIG>) of the transferring device <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) conveying the forming tool <NUM> to the transfer system <NUM> using the tool transfer device <NUM>. For example, the tool transfer device <NUM> moves along the positioning system <NUM> to a predefined location relative to the transfer system <NUM>. In one or more examples, the tool transfer device <NUM> is indexed relative to the transfer system <NUM> using the indexing device <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) applying the composite ply <NUM> to at least a portion of the forming surface <NUM> of the forming tool <NUM> using the transfer system <NUM>. For example, the ply carrier <NUM> is positioned at a predefined location along the forming tool <NUM> according to the predetermined ply laydown sequence. The ply carrier <NUM> is oriented such that the composite ply <NUM> is parallel to at least a portion of the forming surface <NUM> of the forming tool <NUM>. The ply carrier <NUM> is pressed on the forming tool <NUM> to compress the composite ply <NUM> against a portion of the forming surface <NUM> of the forming tool <NUM>. In one or more examples, the ply carrier <NUM> may deform when pressed against the forming tool <NUM>, thereby enabling the composite ply <NUM> to be applied to a greater portion of the contoured forming surface <NUM>.

In one or more examples, the method <NUM> includes a step of releasing the film <NUM> from the base plate <NUM> and a step of removing the ply carrier <NUM> (e.g., the base plate <NUM>) from the forming tool <NUM> using the transfer system <NUM>, after the step of (block <NUM>) applying the composite ply <NUM> to at least a portion of the forming surface <NUM> of the forming tool <NUM>. For example, the method <NUM> includes a step of (block <NUM>) selectively removing the retention vacuum to release the film <NUM> from the base plate <NUM> while retaining the base plate <NUM> using the transfer system <NUM>. Following application of the composite ply <NUM> to the forming tool <NUM>, the composite ply <NUM> is coupled (e.g., adhered or tacked) to the forming surface <NUM> and the film <NUM> remains coupled (e.g., adhered or tacked) to the composite ply <NUM> by the resin matrix of the composite ply <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) conveying the forming tool <NUM> from the transfer system <NUM> to the forming system <NUM> using the tool transfer device <NUM>. For example, the tool transfer device <NUM> moves along the positioning system <NUM> to a predefined location relative to the forming system <NUM>. In one or more examples, the tool transfer device <NUM> and the composite ply <NUM> are indexed relative to the forming system <NUM> using the indexing device <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) forming the composite ply <NUM> over the at least a portion of the forming surface <NUM> of the forming tool <NUM> using the forming system <NUM>. In one or more examples, the film <NUM> provides a protective barrier between the forming system <NUM> and the composite ply <NUM> during formation of the composite ply <NUM> over the forming tool <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) removing the film <NUM> from the composite ply <NUM> using the film removal system <NUM>. The step of (block <NUM>) removing the film <NUM> is preformed after the step of (block <NUM>) forming the composite ply <NUM>.

In one or more examples, the method <NUM> includes a step of (block <NUM>) returning the ply carrier <NUM> (e.g., the base plate <NUM>) to the carrier transfer device <NUM> using the transfer system <NUM>. The step of (block <NUM>) returning the ply carrier <NUM> is performed after the step of (block <NUM>) applying the composite ply <NUM> to the forming tool <NUM>.

In one or more examples, the above operations are repeated a number of times to fully form the composite structure <NUM> (block <NUM>), at which point the process terminates. In one or more examples, a plurality of composite plies <NUM> are sequentially fabricated and applied to and formed over the forming tool <NUM> according the ply-by-ply laydown sequence. For example, a first one of the plurality of composite plies <NUM> is applied to and is formed over a first portion of the forming tool <NUM>. During a second iteration of the above process, a second one of the plurality of composite plies <NUM> is applied to and is formed over a second portion of the forming tool <NUM>. This iterative process is repeated until the composite structure <NUM> is formed.

In one or more examples, the forming tool <NUM> may be simultaneously located at the transfer system <NUM> and the forming system <NUM>. For example, the first portion of the forming tool <NUM> may be conveyed to the transfer system <NUM> for application of the first one of the plurality of composite plies <NUM>. The first portion of the forming tool <NUM> may then be conveyed to forming system <NUM> while a second portion of the forming tool <NUM> is conveyed to the transfer system <NUM>. The second one of the composite plies <NUM> may be applied to the second portion of the forming tool <NUM> while the first one of the composite plies <NUM> is being formed over the forming tool <NUM>. As such, the step of (block <NUM>) applying the second one of the composite plies <NUM> and the step of (block <NUM>) forming the first one of the composite plies <NUM> are performed simultaneously, thereby reducing cycle time.

In one or more examples, the steps of conveying the ply carrier (e.g., blocks <NUM>, <NUM> and <NUM>) include a step of operatively translating the carrier transfer device <NUM> between the carrier preparation system <NUM>, the lamination system <NUM>, the trim system <NUM> (when applicable), the scrap removal system <NUM> (when applicable) and the transfer system <NUM>, for example, as illustrated in <FIG>.

In one or more examples, the steps of conveying the ply carrier (e.g., blocks <NUM>, <NUM> and <NUM>) include a step of operatively circulating the carrier transfer device <NUM> through the carrier preparation system <NUM>, the lamination system <NUM>, the trim system <NUM> (when applicable), the scrap removal system <NUM> (when applicable) and the transfer system <NUM>, for example, as illustrated in <FIG>.

In one or more examples, the steps of conveying the forming tool <NUM> (e.g., blocks <NUM> and <NUM>) include a step of operatively translating the tool transfer device <NUM> between the transfer system <NUM>, the forming system <NUM> and the film removal system <NUM>, for example, as illustrated in <FIG>.

In one or more examples, the steps of conveying the forming tool <NUM> (e.g., blocks <NUM> and <NUM>) include a step of operatively circulating the tool transfer device <NUM> through the transfer system <NUM>, the forming system <NUM> and the film removal system <NUM>, for example, as illustrated in <FIG>.

In one or more examples, the method <NUM> includes a step of selectively positioning the carrier transfer device <NUM> at a plurality of specified locations relative to each one of the carrier preparation system <NUM>, the lamination system <NUM>, the trim system <NUM> (when applicable), the scrap removal system <NUM> (when applicable) and the transfer system <NUM> using the indexing device <NUM>.

In one or more examples, the method <NUM> includes a step of selectively positioning the tool transfer device <NUM> at a plurality of specified locations relative to each one of the transfer system <NUM>, the forming system <NUM> and the film removal system <NUM> using the indexing device <NUM>.

Referring to <FIG>, in one or more examples, the system <NUM> includes a controller <NUM>. In one or more examples, the controller <NUM> is configured to control operation of the system <NUM> and/or implement the operational steps of the method <NUM>.

The controller <NUM> is in communication with and is programmed to control operation of at least one of the carrier transfer device <NUM>, the tool transfer device <NUM>, the positioning system <NUM>, the carrier preparation system <NUM>, the lamination system <NUM>, the trim system <NUM>, the scrap removal system <NUM>, the transfer system <NUM>, the forming system <NUM> and the film removal system <NUM>. In one or more examples, the on-demand fabrication, transfer, application and formation of the composite ply <NUM> is facilitated by the controller <NUM>. The controller <NUM> may be any device capable of facilitating communication between itself and the various sub-systems of the system <NUM>. For example, the controller <NUM> may be a computer workstation, a programmable logic controller (PLC), a mobile device or other electronic controller.

In one or more examples, the controller <NUM> includes a user interface. The user interface may be used by an operator to facilitate semi-autonomous operation of the system <NUM>, such as by triggering movement of the carrier transfer device <NUM> and the tool transfer device <NUM> or by triggering various sub-systems of the system <NUM> to perform the next step in the ply-by-ply formation process. For example, operation of the system <NUM> may be controlled semi-autonomously based on a triggering event, such as a command received from the operator, at various stages in the fabrication process.

Alternatively, one or more triggering events may be provided automatically by the controller <NUM> to facilitate reducing the workload of the operator. For example, one or more of the sub-systems of the system <NUM> may include at least one sensor in communication with the controller <NUM>. The sensor is configured to monitor a condition a respective sub-system or parameter of a respective operational stage and to transmit a signal to the controller <NUM> indicated completion of a respective operation. The signal provides an indication to the controller <NUM> that the next operational step in the fabrication process may be performed and that the next sub-system in the fabrication sequence is ready.

In one or more examples, conveyance of the carrier transfer device <NUM> and/or the tool transfer device <NUM> is controlled under direction from the controller <NUM>. For example, the carrier transfer device <NUM> and/or the tool transfer device <NUM> are moved along the positioning system <NUM> under direction from the controller <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively convey the ply carrier <NUM> to the carrier preparation system <NUM> using the carrier transfer device <NUM> and the positioning system <NUM>. The controller <NUM> is programmed to prepare the ply carrier <NUM> using the carrier preparation system <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively convey the ply carrier <NUM> to the lamination system <NUM> using the carrier transfer device <NUM> and the positioning system <NUM>. The controller <NUM> is programmed to lay down the composite ply <NUM> using the lamination system <NUM>. For example, the controller <NUM> is programmed to selectively apply the composite ply <NUM> to the ply support surface <NUM> of the ply carrier <NUM> using the lamination system <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively convey the ply carrier <NUM> to the trim system <NUM> using the carrier transfer device <NUM> and the positioning system <NUM>. The controller <NUM> is programmed to selectively cut the composite ply <NUM> into the predetermined shape using the trim system <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively convey the ply carrier <NUM> to the scrap removal system <NUM> using the carrier transfer device <NUM> and the positioning system <NUM>. The controller <NUM> is programmed to remove the remnant of the composite ply <NUM> from the ply support surface <NUM> using the scrap removal system <NUM>, after the composite ply <NUM> is cut into the predetermined shape.

In one or more examples, the controller <NUM> is programmed to selectively convey the forming tool <NUM> to the transfer system <NUM> using the tool transfer device <NUM> and the positioning system <NUM>. The controller <NUM> is programmed to selectively convey the ply carrier <NUM> to the transfer system <NUM> using the carrier transfer device <NUM> and the positioning system <NUM>. The controller <NUM> is programmed to transfer the composite ply <NUM> to the forming tool <NUM> using the transfer system <NUM>. For example, the controller <NUM> is programmed to remove the ply carrier <NUM> from the carrier transfer device <NUM>, reorient (e.g., flip) the ply carrier <NUM>, before application of the composite ply <NUM>, and apply the composite ply <NUM> to at least a portion of the forming surface <NUM> of the forming tool <NUM> using the transfer system <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively convey the forming tool <NUM> to the forming system <NUM> using the tool transfer device <NUM> and the positioning system <NUM>. The controller <NUM> is programmed to form the composite ply <NUM> over the forming tool <NUM> using the forming system <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively convey the forming tool <NUM> to the film removal system <NUM> using the tool transfer device <NUM> and the positioning system <NUM>. The controller <NUM> is programmed to remove the film <NUM> from the composite ply <NUM> using the film removal system <NUM>, after the composite ply <NUM> is formed over the forming tool <NUM>.

In one or more examples, the controller <NUM> is programmed to return the ply carrier <NUM> (e.g., the base plate <NUM>) to the carrier transfer device <NUM> using the transfer system <NUM>, after application of the composite ply <NUM> to the forming tool <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively convey the ply carrier <NUM> back to the carrier preparation system <NUM> using the carrier transfer device <NUM> and the positioning system <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively apply the retention vacuum to the plurality of vacuum apertures <NUM> of the base plate <NUM> of the ply carrier <NUM> to retain the film <NUM> on the base plate <NUM> using the carrier transfer device <NUM>.

In one or more examples, the controller <NUM> is programmed to maintain the retention vacuum to the plurality of vacuum apertures <NUM> to retain the film <NUM> on the base plate <NUM> using the transfer system <NUM>, after removal of the ply carrier <NUM> from the carrier transfer device <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively remove the retention vacuum from the plurality of vacuum apertures <NUM> to release the film <NUM> from the base plate <NUM> while retaining the base plate <NUM> using the transfer system <NUM>, after application of the at least one composite ply <NUM> to the at least a portion of the forming surface <NUM> of the forming tool <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively position the carrier transfer device <NUM> relative to each one of the carrier preparation system <NUM>, the lamination system <NUM>, the trim system <NUM> (when applicable), the scrap removal system <NUM> (when applicable) and the transfer system <NUM> using the positioning system <NUM>. In one or more examples, the controller <NUM> is programmed to operatively translate the carrier transfer device <NUM>. In one or more examples, the controller <NUM> is further programmed to operatively circulate the carrier transfer device <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively position the tool transfer device <NUM> relative to the transfer system <NUM>, the forming system <NUM> and the film removal system <NUM> using the positioning system <NUM>. In one or more examples, the controller <NUM> is programmed to operatively translate the tool transfer device <NUM>. In one or more examples, the controller <NUM> is programmed to operatively circulate the tool transfer device <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively position the carrier transfer device <NUM> at a plurality of specified locations relative to each one of the carrier preparation system <NUM>, the lamination system <NUM>, the trim system <NUM> (when applicable), the scrap removal system <NUM> (when applicable) and the transfer system <NUM> using the indexing device <NUM>.

In one or more examples, the controller <NUM> is programmed to selectively position the tool transfer device <NUM> at a plurality of specified locations relative to each one of the transfer system <NUM>, the forming system <NUM> and the film removal system <NUM> using the indexing device <NUM>.

In one or more examples, one or more of the components, devices or sub-systems of the system <NUM> may include a dedicated controller that is in communication with and receives instructions from the controller <NUM>.

In one or more examples, the controller <NUM> is programmed to track a plurality of composite plies <NUM> fabricated during manufacture of the composite structure <NUM>. For example, the controller <NUM> tracks which one of the plurality of composite plies <NUM> is fabricated, applied and formed during the composite structure fabrication process according to the ply laydown sequence. In one or more examples, the controller <NUM> is programmed to track a plurality of ply carriers <NUM> and/or carrier transfer devices <NUM> flowing through the system <NUM>. In one or more examples, the controller <NUM> is programmed to track a plurality of forming tools <NUM> and/or tool transfer devices <NUM> flowing through the system <NUM>.

In one or more examples, the system <NUM> is configured to perform multiple operations substantially simultaneously or concurrently. For example, a first composite ply <NUM> may be formed over the forming tool <NUM>, while a second composite ply <NUM> is being transferred and applied to the forming tool <NUM> (e.g., the same forming tool in the translating workflow or a different forming tool in the continuous workflow), while a third composite ply <NUM> is being cut, and while a fourth composite ply <NUM> is being laid down. As such, more than one carrier transfer device <NUM> and, thus, more than one composite ply <NUM> may be moved through the system <NUM> at the same time and more than one forming tool <NUM> and, thus, more than one composite structure <NUM> may be moved through the system <NUM> at the same time.

In one or more examples, the controller <NUM> is programmed to control more than one of the sub-systems and, thus, perform more than one operation simultaneously or in parallel. In one or more examples, the controller <NUM> is programmed to control all the sub-systems and, thus, perform all the operations simultaneously or in parallel.

Referring now to <FIG>, examples of the system <NUM> and the method <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>. The composite structure <NUM> manufactured using the system <NUM> or in accordance with the method <NUM> may be any one of a structure, an assembly, a sub-assembly, a component, a part, or any other portion of the aircraft <NUM>, such as a portion of an airframe, interior, and one or more of the high-level systems. For example, the composite structure <NUM> may be any one of an aircraft spar, a wing section, a fuselage barrel section, an interior panel, an exterior skin panel, and the like.

<FIG> schematically illustrates an example of the aircraft <NUM>. The aircraft <NUM> 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 control ("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.

The aircraft <NUM> includes at least one composite structure <NUM>. The composite structure <NUM> is at least partially fabricated utilizing the system <NUM> and/or the method <NUM>. The aircraft <NUM> may include a plurality of components, including an airframe <NUM>, a fuselage <NUM>, a fuselage barrel <NUM>, an interior <NUM>, a wing <NUM>, and/or a stabilizer <NUM>.

In one or more examples, the composite structure <NUM> includes at least one composite ply <NUM>, such as a plurality of composite plies <NUM>. The composite structure <NUM> may form a composite part or a portion of any suitable component of the aircraft <NUM>. As an example, and as illustrated in <FIG>, the aircraft <NUM> includes skin segments <NUM> that cover and/or form an outer surface of any suitable portion of the aircraft <NUM> and/or a plurality of stringers <NUM> that, together with a plurality of frames, may support an inner surface of the skin segments <NUM>.

<FIG> schematically illustrates an example of the wing <NUM>. In one or more examples, the wing <NUM> includes a plurality of wing stringers <NUM>, which may extend along a length of the wing <NUM>. The wing <NUM> may also include a plurality of spars <NUM>, which also may be referred to herein as ribs. The wing stringers <NUM> and spars <NUM> together may form and/or define at least a portion of an inner support structure <NUM> for the wing <NUM>, which may support an inner surface <NUM> of the skin segments <NUM> that cover the wing <NUM>. The skin segments <NUM> may also be referred to herein as wing skin segments.

It is within the scope of the present disclosure that the skin segments <NUM> (e.g., wing skin or fuselage skin), stringers <NUM> (e.g., fuselage stringers), frames (e.g., multiple piece frames or one piece frames), wing stringers <NUM>, spars <NUM>, the inner support structure <NUM>, floor beams, interior panels or various other components may be at least partially, or even completely, formed from the plies of composite material and/or may be a composite part that may be formed utilizing the system <NUM> and/or method <NUM> disclosed herein.

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>. For example, the composite structure <NUM> manufactured in accordance with the method <NUM> may be produced during material procurement (block <NUM>), component and subassembly manufacturing (block <NUM>), and/or maintenance and service (block <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 aircraft <NUM>, the composite structure <NUM>, the system <NUM> and the method <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, implementations of the system <NUM> and/or method <NUM> may form a portion of component and subassembly manufacturing (block <NUM>) and/or system integration (block <NUM>). For example, composite structures <NUM> made using implementations of the disclosed system <NUM> and method <NUM> may correspond to component and subassembly manufacturing (block <NUM>) and may be utilized in a manner similar to components or subassemblies prepared while the aircraft <NUM> is in service (block <NUM>). Also, implementations of the disclosed system <NUM> and the method <NUM> may be utilized during system integration (block <NUM>) and certification and delivery (block <NUM>). Similarly, implementations of the disclosed system <NUM> and the method <NUM> may be utilized, for example and without limitation, while the aircraft <NUM> is in service (block <NUM>) and during maintenance and service (block <NUM>).

Accordingly, referring to <FIG>, also disclosed is a method of fabricating a portion of the aircraft <NUM> (<FIG>) using the system <NUM>. Also disclosed is a portion of the aircraft <NUM> manufactured in accordance with the method <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.

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.

As used herein, the phrase "at least one of", when used with a list of items, means different combinations of one or more of the listed items may be used and only one of each item in the list may be needed. For example, "at least one of item A, item B, and item C" may include, without limitation, item A or item A and item B. This example also may include item A, item B, and item C, or item B and item C. In other examples, "at least one of" may be, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; and other suitable combinations.

For the purpose of this disclosure, the terms "coupled," "coupling," and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, put in communication, or otherwise associated (e.g., mechanically, electrically, fluidly, optically, electromagnetically) with one another. In various examples, the elements may be associated directly or indirectly. As an example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. It will be understood that not all associations among the various disclosed elements are necessarily represented. Accordingly, couplings other than those depicted in the figures may also exist.

As used herein, the term "approximately" refers to or represent a condition that is close to, but not exactly, the stated condition that still performs the desired function or achieves the desired result. As an example, the term "approximately" refers to a condition that is within an acceptable predetermined tolerance or accuracy, such as to a condition that is within <NUM>% of the stated condition. However, the term "approximately" does not exclude a condition that is exactly the stated condition. As used herein, the term "substantially" refers to a condition that is essentially the stated condition that performs the desired function or achieves the desired result.

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

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

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

Claim 1:
A system (<NUM>) for fabricating a composite structure (<NUM>), the system (<NUM>) comprising:
a ply carrier (<NUM>) comprising a ply support surface (<NUM>) configured to support at least one composite ply (<NUM>);
a carrier transfer device (<NUM>) configured to convey the ply carrier (<NUM>);
a lamination system (<NUM>) configured to selectively apply the at least one composite ply (<NUM>) to the ply support surface (<NUM>) of the ply carrier (<NUM>);
a transfer system (<NUM>) configured to remove the ply carrier (<NUM>) from the carrier transfer device (<NUM>) and to apply the at least one composite ply (<NUM>) to at least a portion of a forming surface (<NUM>) of a forming tool (<NUM>);
a forming system (<NUM>) configured to form the at least one composite ply (<NUM>) over the at least a portion of the forming surface (<NUM>) of the forming tool (<NUM>),
wherein the ply carrier (<NUM>) further comprises:
a base plate (<NUM>); and
a film (<NUM>) positioned on the base plate (<NUM>), wherein the film (<NUM>) forms the ply support surface (<NUM>), and further wherein the base plate (<NUM>) comprises a plurality of vacuum apertures (<NUM>), and the carrier transfer device (<NUM>) comprises a vacuum table (<NUM>) in fluid communication with the plurality of vacuum apertures (<NUM>) and configured to apply a retention vacuum to the plurality of vacuum apertures (<NUM>) to retain the film (<NUM>) on the base plate (<NUM>).