Patent Description:
The mechanical structure of an aircraft is referred to as an airframe. The airframe itself is made from discrete components such as stringers, spars, skins, and frames which, when assembled together, define the structure of the aircraft. An individual aircraft may be fabricated from many components. Presently, airframe components are fabricated via methods that include labor intensive hand-layup processes, or by moving an Automated Fiber Placement (AFP) machine which utilizes a single head to perform layup while traversing the contour of the airframe component to be fabricated. The airframe components remain in a stationary cell while this work is performed.

The abstract of <CIT> states: "a pre-preg sheet lamination device for producing a pre-preg sheet laminate in which a plurality of pre-preg sheets are laminated and the pre-preg sheet in one layer is laminated such that the fiber direction is different from a pre-preg sheet in another layer. The device is provided with: a main transport path on which a pre-preg base fabric is made to travel; pre-preg cut sheet formation units that form pre-preg cut sheets by cutting the pre-preg base fabric in the width direction at a set angle; transfer hands that transfer the formed pre-preg cut sheets onto the pre-preg base fabric that travels atop the main transport path, and set said pre-preg cut sheets onto the pre-preg base fabric, configuring the fiber direction of said pre-preg cut sheets to a set direction; and welding units that weld the pre-preg base fabric and the pre-preg cut sheets that have been set thereon".

The abstract of <CIT> states: "that systems and methods are provided for laying up laminates. One embodiment is a method that includes laying up a multi-layer laminate of fiber reinforced material onto a surface, by: feeding a tape of fiber reinforced material to tape cutters which cut the tape into pieces, picking up pieces of the fiber reinforced material via pick-and-place devices at each of multiple lamination units that are in sequence in a direction of travel, and placing the pieces of fiber reinforced material via the pick-and-place devices to form a laminate as the surface and the lamination units change position with respect to each other and multiple pieces are laid-up concurrently".

The abstract of <CIT> states: "that a large scale composite structure is fabricated by forming a plurality of composite laminate modules and joining the modules together along their edges using scarf joints".

The abstract of <NPL>, states: "the work completed under a three year European Commission research and development contract, entitled 'Integrating automatic handling of flexible materials, composite component design and quality assurance procedures'. The paper describes the reasons for conducting the work, the main drivers that shaped the final outcome, the key areas of study and the technical solution adopted, with a description of the systems, tests conducted and a discussion of the achievements and future options. A machine was built that took prepreg material from a standard roll, through removal of the backing sheets, visual inspection, cutting, handling, lay-up and consolidation to form a multi-layer doubly curved component. The system demonstrated that the engineering problems are not insurmountable, and with the right products in mind, a semi-automated system could provide the necessary quality and productivity for an acceptable price". The abstract of <CIT> states: "composite structure fabrication systems and methods. The systems include a plurality of ply carriers, each of which is configured to support at least one ply segment, and an elongate forming mandrel, which defines an elongate ply forming surface that is shaped to define a surface contour of the composite structure. The systems further include a carrier transfer device, which is configured to selectively convey a selected ply carrier from a ply kitting area to an intermediate location, and a forming machine, which is configured to deform the selected ply carrier and a respective ply segment over a selected portion of the elongate ply forming surface. The forming machine further is configured to separate the selected ply carrier from the respective ply segment and return the selected ply carrier to the carrier transfer device. The methods include methods of operating the systems".

The abstract of <CIT> states: "that the invention is directed to a method for producing a Fiber Metal Laminate component of an airplane, using a manipulator system with an end effector and a control assigned to the manipulator system, wherein at least one metal layer and at least one unhardened fiber layer are being stacked onto each other in a mould by the manipulator system in a stacking sequence, wherein each stacking cycle comprises picking up a metal layer or a fiber layer from a respective supply stack according to the stacking sequence, transporting the layer to the mould, placement of the layer at a deposition surface in the mould according to the stacking sequence and depositing the so placed layer onto the deposition surface. It is proposed that after being picked up from the supply stack and before being deposited onto the deposition surface the layer to be stacked is being deformed by the end effector as to adapt the form of the layer to the form of the deposition surface".

The abstract of <CIT> states: "flexible material transfer devices, flexible vacuum compaction devices that include the flexible material transfer devices, flexible vacuum chucks that include the flexible vacuum compaction devices, and systems and methods including the same. The flexible material transfer devices include a flexible substrate that is configured to selectively and repeatedly transition between a stowed conformation and a deployed conformation. The flexible substrate defines a material contacting surface that is configured to contact a charge of composite material and to selectively and operatively attach to the charge of composite material. The flexible substrate further defines a plurality of retention conduits that are at least partially defined by the material contacting surface and are configured to have a retention vacuum applied thereto. The flexible material transfer device further includes a retention manifold that provides fluid communication between the plurality of retention conduits and a vacuum source".

The abstract of <CIT> states: "systems and methods are provided for carrying plies of material. One embodiment is an apparatus that includes an end effector of a robot. The apparatus includes a frame, and a fixed cup assembly that is attached to the frame. The fixed cup assembly includes a suction cup for holding a ply, a pneumatic line, and a shaft that is coupled with the suction cup and that houses the pneumatic line, the shaft enabling the suction cup to translate vertically. The apparatus also includes floating cup assemblies. Each floating cup assembly includes a Bernoulli cup, a pneumatic line applying positively pressurized gas to the Bernoulli cup, a shaft that is coupled with the Bernoulli cup and that houses the pneumatic line, the shaft enabling the Bernoulli cup to translate vertically, and a bearing that enables the Bernoulli cup to pivot about an end of the shaft to conform with a surface".

Embodiments described herein provide for assembly line fabrication of airframe components using fiber reinforced broad goods. The broad goods are cut, rotated, and delivered via multiple stations synchronously in order to rapidly prepare a layup pattern (comprising one or more plies) corresponding with a wing skin, fuselage skin, etc. The layup pattern is then picked up, placed, and compacted onto a layup mandrel. After a sufficient number of layup patterns have been applied, the resulting preform is hardened into a composite part.

Disclosed is a method for fabricating a preform for a portion of an aircraft. The method includes acquiring a sheet of broad good fiber reinforced material, trimming the sheet to form layup pieces having boundaries, placing the boundaries into alignment, arranging the layup pieces in a layup pattern to form a ply, performing a placement operation that transports the layup pattern onto a layup mandrel, and shaping the layup pattern into conformance with a contour of the layup mandrel. Additionally or alternatively, the method comprises dividing a composite structure into zones, fabricating a layup piece for each of the zones, arranging the layup pieces into a layup pattern, transporting the layup pattern to a layup mandrel via a carrier, and compacting the layup pattern onto the layup mandrel. It will be understood by the skilled person that this method can also be performed independent from the preceding method in this paragraph. Optionally, each layup piece occupies a zone of the layup pattern. Optionally, the method comprises disposing edges of the layup pattern onto the layup mandrel such that the edges are staggered with respect to other layup patterns for the layup mandrel. Optionally, transporting the layup pattern comprises operating a Pick and Place (PNP) station. Optionally, arranging the layup pieces into the layup pattern comprises arranging the layup pieces into a shape of a wing skin. Optionally, arranging the layup pieces into the layup pattern comprises arranging the layup pieces into a shape of a fuselage skin. Optionally, the fabricating, arranging, transporting, and compacting are performed according to a takt time. Optionally, the takt time is synchronized with one or more feeder lines. Optionally, the takt time is distinct from one or more feeder lines. Optionally, the method further comprises compacting an additional layup pattern onto the layup pattern. Optionally, the additional layup pattern forms staggered splices with the layup pattern. Optionally, the method further comprises iteratively performing dividing, fabricating, arranging, transporting, and compacting until a preform is completed at the layup mandrel.

Also disclosed is a system for fabricating a preform for a portion of an aircraft. The system includes a broad goods station that acquires a sheet of broad good fiber reinforced material, and that trims the sheet to form a plurality of layup pieces having boundaries, a rotary table that places the boundaries into alignment, a shuttle that holds layup pieces from the rotary table in a layup pattern, and a shuttle that transports the layup pattern onto a layup mandrel, and that shapes the layup pattern into conformance with a contour of the layup mandrel.

The term mandrel is interchangeably used with the word `tool' in this application and is considered direct to a single subject.

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

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

Composite parts, such as Carbon Fiber Reinforced Polymer (CFRP) parts, are initially laid-up in multiple layers that together are referred to as a preform. Individual fibers within each layer of the preform are aligned parallel with each other, but different layers exhibit different fiber orientations in order to increase the strength of the resulting composite part along different dimensions. The preform includes a viscous resin that solidifies in order to harden the preform into a composite part (e.g., for use in an aircraft). Carbon fiber that has been impregnated with an uncured thermoset resin or a thermoplastic resin is referred to as "prepreg. " Other types of carbon fiber include "dry fiber" which has not been impregnated with thermoset resin but may include a tackifier or binder. Dry fiber is infused with resin prior to hardening. For thermoset resins, the hardening is a one-way process referred to as curing, while for thermoplastic resins, the resin reaches a viscous form if it is re-heated, after which it can be consolidated to a desired shape and solidified. As used herein, the umbrella term for the process of transitioning a preform to a final hardened shape (i.e., transitioning a preform into a composite part) is referred to as "hardening," and this term encompasses both the curing of thermoset preforms and the forming/solidifying of thermoplastic preforms into a final desired shape.

<FIG> illustrate an assembly line <NUM> for fabricating an airframe component from broad goods in an illustrative embodiment. In <FIG>, the assembly line <NUM> is depicted as including a broad goods station <NUM>, which trims/cuts out layup pieces <NUM>-<NUM> through <NUM>-<NUM> (collectively referred to as "layup pieces <NUM>") from a roll <NUM> of fiber reinforced broad goods material having a common width W. That is, the broad goods station <NUM> acquires a sheet <NUM> of broad good fiber reinforced material <NUM>-<NUM>, and trims the sheet <NUM> (e.g., applies cuts to the sheet <NUM>) to form a plurality of layup pieces <NUM>-<NUM> through <NUM>-<NUM> (also referred to collectively as "layup pieces <NUM>").

The sheet <NUM> of broad goods material from which the layup pieces <NUM> are trimmed may comprise a series of continuous fibers that proceed along the length of the roll <NUM>. By trimming pieces from the sheet <NUM> and rotating the pieces to desired angles (e.g., leading edge and trailing edge angles of a wing), layup pieces <NUM> for a variety of fiber angles are created.

In this embodiment, a first straight cut <NUM> for a layup piece <NUM>-<NUM> through <NUM>-<NUM> is made by a first cutting station <NUM> from a sheet <NUM> of broad good fiber reinforced material <NUM>-<NUM>. While six layup pieces <NUM>-<NUM> through <NUM>-<NUM> are shown, embodiments may have more or fewer layup pieces (<NUM>). The number of layup pieces <NUM> may vary from ply <NUM> to ply <NUM>. A second cutting station <NUM> makes a second straight cut <NUM> for the layup piece <NUM>, without the need to rotate the layup piece <NUM>. Layup pieces <NUM> are advanced to a rotary table <NUM>, or other orienting station, where they are rotated into an alignment <NUM> with placement locations <NUM> at a shuttle <NUM>. The rotary table <NUM> rotates the plurality of layup pieces <NUM>.

Boundaries <NUM> shared between adjoined layup pieces <NUM> are oriented by the rotary table <NUM> to the same angle (i.e., resulting in a butt with no gaps or overlaps). In one embodiment, the broad goods station <NUM> trims the sheet <NUM> to cause the layup pieces <NUM> to exhibit a shared leading edge <NUM> angle and shared trailing edge <NUM> angle, and the rotary table <NUM> rotates the layup pieces <NUM> by orienting leading edges <NUM> of the layup pieces (<NUM>) to a common angle. Similarly, in another embodiment, the broad goods station <NUM> trims the sheet <NUM> to cause the layup pieces <NUM> to exhibit a shared leading edge <NUM> angle and shared trailing edge <NUM> angle, and the rotary table <NUM> rotates the layup pieces <NUM> by orienting trailing edge <NUM> of the layup pieces (<NUM>) to a common angle.

The layup pieces <NUM> are arranged by assembly line <NUM> into a layup pattern <NUM> for a preform <NUM>. For example, the layup pieces <NUM>-<NUM> through <NUM>-<NUM> are capable of being arranged into a layup pattern <NUM> wherein boundaries <NUM> of the layup pieces <NUM> are complementary to each other (i.e., align with each other without gaps or overlaps). A layup pattern <NUM> may comprise one or more plies <NUM> formed from the layup pieces <NUM>. Phrased another way, disparate layup pieces <NUM> are arranged into one or more plies <NUM> such that when subsequent plies <NUM> are added, the layup pieces <NUM> form a preform <NUM>.

Layup patterns <NUM> are placed together to form a preform <NUM>. When fully fabricated, the preform <NUM> includes multiple layup patterns <NUM> and/or individually shaped layup pieces <NUM>. Between adjacent plies <NUM>, and/or between adjoined layup patterns <NUM>, staggered splices <NUM> are formed. These staggered splices <NUM> enhance a resilience of the preform <NUM> after it has been hardened. The splices <NUM> may comprise butt, lap and/or scarf splices.

Stated another way, the layup pieces <NUM> and layup patterns <NUM> are formed at disparate locations and carried to a preform <NUM> and/or layup mandrel <NUM>, where these elements are butted/spliced to adjoined elements to contribute to the preform <NUM>. Multiple plies <NUM> are formed iteratively in this manner with staggered splices <NUM> until the preform <NUM> is fully formed, resulting in a form of zonal lamination. Thus, in one embodiment placement operations at the assembly line <NUM> form staggered splices <NUM> between layup pieces <NUM> of the layup pattern <NUM> and layup pieces <NUM> of another layup pattern <NUM> disposed at the layup mandrel <NUM>.

As discussed above, in this embodiment, the layup pieces <NUM> extend from a leading edge <NUM> to a trailing edge <NUM> of the preform <NUM>. However, such an arrangement is not universally required. In one embodiment, the layup pieces <NUM>-<NUM> through <NUM>-<NUM> do not coincide with the leading edge <NUM> or trailing edge <NUM>, and butt against adjoined layup pieces <NUM>-<NUM> through <NUM>-<NUM>. In such an arrangement, the layup pieces <NUM>-<NUM> through <NUM>-<NUM> for a layup pattern <NUM> are not just placed side by side, but are also placed such that they form a pattern that extends forward and backward, such as leading edge <NUM> or trailing edge <NUM> or vice versa, as well as spanwise from a root at inboard end to a tip at outboard end.

The operations discussed above provide input for a feeder line <NUM> for fabricating a wing skin (e.g., wing skin <NUM> of <FIG>) at a mandrel <NUM>. In one embodiment, placement of the layup pieces <NUM> and the layup patterns <NUM> is provided in a Just In Time (JIT) manner to the feeder line <NUM>, such that layup patterns <NUM> are received in a short period of time such as within seconds or less than a minute of feeder line <NUM> being ready to receive a next layup pattern.

In this embodiment, in addition to broad goods station <NUM>, the assembly line <NUM> includes a small-piece station <NUM> and a tow-piece station <NUM>. Depending on embodiment and design, small-piece station <NUM> or tow-piece station <NUM> are capable of providing different amounts of material for a wing, and either can provide a majority of material for a wing, fuselage section, or other composite structure. The small-piece station <NUM> operates a dynamic cutter station <NUM> (e.g., utilizing a laser cutter, or mobile blade that operates in accordance with a Numerical Control (NC) program, a technician with hand tools, etc.) to trim and/or cut out a layup piece <NUM> from a roll <NUM> of broad goods material for placement onto table <NUM>. No dimension of the layup piece <NUM> equals the width of the roll <NUM>, and thus, the layup piece <NUM> cannot be fabricated from two straight cuts across the width of the roll <NUM>. Dynamic cutter station <NUM> accommodates layup pieces of this geometry via automated or hand layup techniques. Tow-piece station <NUM> fabricates layup pieces <NUM> from multiple tows <NUM> of fiber reinforced material stored on rolls <NUM>, by dispensing the tows <NUM> onto table <NUM>. Rolls <NUM> are cut to length and then kitted onto table <NUM>, and then may be transferred (e.g., manually or automatically) to small-piece station <NUM>.

Layup pieces <NUM>-<NUM> through <NUM>-<NUM>, <NUM>, and/or <NUM> are transported from the rotary table <NUM> to a shuttle <NUM> via a carrier <NUM> that slidably moves along a frame <NUM>. The carrier <NUM> operates as a placement station <NUM>, such as an automatic Pick and Place (PNP) station, assisted station, or manual station, and may comprise, for example, a polycarbonate resin thermoplastic film (e.g., a LEXAN™ brand polycarbonate film), or other flexible material <NUM>-<NUM> that conforms to the layup piece <NUM> while applying vacuum to controllably hold the layup piece <NUM> against it. The use of vacuum/suction for picking and placement may be performed in any suitable manner already known to those of ordinary skill in the art.

The shuttle <NUM> holds layup pieces from the rotary table <NUM> in a layup pattern <NUM>. When all layup pieces <NUM> for a layup pattern <NUM> have been laid-up, the shuttle <NUM> is driven along a track <NUM>. The layup pattern <NUM> forms a shape of a portion of a composite part (such as wing skin <NUM> of <FIG>) being fabricated. For example, a layup pattern <NUM> can form a shape of a wing skin (such as wing skin <NUM> of <FIG>) or a shape of a fuselage skin (e.g., fuselage skin <NUM> of <FIG>). In one embodiment, the layup pattern <NUM> comprises multiple plies of the fiber reinforced material.

A layup pattern <NUM> can be implemented as a single layer or single ply sequence for a preform that will be hardened into a composite part, or any number of non-overlapping ply sequences defined for the preform. In one embodiment, a technician or automated system then removes a backing from the layup pattern <NUM>. In further embodiments, subsequent layers are added in the fashion described above before proceeding to additional operations.

Any of the operations discussed herein may be implemented in a micro pulsed fashion wherein components are advanced by less than their length and then paused, in a full pulsed fashion wherein components are advanced by at least their length and then paused, or in a continuously moving fashion. In one embodiment, multiple sheets <NUM> of broad goods are used to form a layup piece <NUM>-<NUM> through <NUM>-<NUM> that spans from a leading edge to the trailing edge. Thus, in some embodiments each layup pattern <NUM> includes multiple rows of layup pieces <NUM>-<NUM> through <NUM>-<NUM>. The layup pattern <NUM> is transferred from the shuttle <NUM> to a layup mandrel <NUM> via a carrier <NUM> mounted to a frame <NUM>, and the layup pattern <NUM> is compacted into place. The carrier <NUM> may be operated in a similar fashion to carrier <NUM>. In one embodiment, the carrier <NUM> therefore operates as a Pick and Place (PNP) machine that transports the layup pattern <NUM> onto a layup mandrel <NUM> (<FIG>), and that shapes the layup pattern <NUM> into conformance with a contour <NUM> of the layup mandrel <NUM>. In one embodiment, shaping the layup pattern comprises applying vacuum to (e.g., a load needed to form) the layup pattern <NUM> via a placement station <NUM>-<NUM> (e.g., a PNP station <NUM>) comprising the carrier <NUM> and frame <NUM>.

In a further embodiment, the sheet <NUM> is pulsed and paused to periodically advance through the assembly line <NUM>. The stations of assembly line <NUM> perform work synchronously during pauses wherein the layup pieces <NUM> remain stationary, and refrain from performing work synchronously during pulses wherein the layup pieces <NUM> are moved.

In further embodiments, additional carriers <NUM> and <NUM> are utilized to place ply stacks for components such as a spar land area or a rib land area for wing skins, door and window surrounds, aft pad-ups, and other separately onto the layup mandrel <NUM> and to compact those components into place.

After a sufficient number of layup patterns <NUM> (e.g., multiple layup patterns for each of multiple fiber orientations) have been placed and compacted onto the contour <NUM> of the layup mandrel <NUM>, a preform <NUM> has been completed. The layup mandrel <NUM> then exits the assembly line <NUM> to receive additional processing. A new layup mandrel <NUM> then takes the place of the previous layup mandrel <NUM>. In one embodiment, each layup mandrel <NUM> includes an identifier (e.g., a Radio Frequency Identifier (RFID) chip, a barcode, etc. <NUM>-<NUM> in <FIG>) indicating the type of composite part that the layup mandrel <NUM> is intended for. By reading this identifier, a controller of the assembly line <NUM> can confirm that the layup mandrel <NUM> matches an expected design.

A controller <NUM> operates the various components described above, often synchronously, to fabricate preforms <NUM> for composite parts in a rapid and effective manner. In one embodiment, controller <NUM> is implemented as custom circuitry, as a hardware processor executing programmed instructions stored in memory, or some combination thereof.

In still further embodiments, assembly line <NUM> utilizes broad goods of the same or similar size to fabricate preforms for a variety of parts, and a variety of models of aircraft. For example, assembly line <NUM> can be adapted to form preforms for wing skins, spars, stringers, fuselage skins, etc. In such embodiments, the specific carriers used may be swapped out for carriers that are adapted to the specific product being fabricated.

In <FIG>, a layup piece <NUM> that has been rotated into alignment at a rotary table <NUM> is transported via carrier <NUM> to a placement location <NUM> at the shuttle <NUM>. Meanwhile, a next layup piece <NUM> is placed onto the rotary table <NUM> and a cut <NUM> is made at another layup piece <NUM>. In <FIG>, the next layup piece <NUM> has been rotated and the carrier <NUM> has been moved over the rotary table <NUM> to acquire and transport the next layup piece <NUM> to the shuttle <NUM>. While only one preform <NUM> for a wing skin is shown, the rotary table <NUM> enables rotations of the layup pieces <NUM> into suitable orientations for left and right wing skins, upper and lower wing skins, etc. Thus, one assembly line <NUM> can be utilized to fabricate four separate types of wing panels, and/or wing panels for other models.

In <FIG>, a layup pattern <NUM> comprising one or more layers, such as one or two to four plies <NUM> of fiber reinforced material has been placed onto the shuttle <NUM>. Each ply has the fiber reinforcement at an orientation throughout the ply and at a different orientation or the same orientation as an adjacent ply. Each of the two to four layers has to be spliced to adjoined two to four layers. In one embodiment, boundaries <NUM> of layup pieces <NUM> in different layers of the layup pattern <NUM> are staggered, crossed, or otherwise arranged relative to adjacent layers such that they do no result in a stacking of the boundaries <NUM> through a plurality of adjacent layers. The shuttle <NUM> carries the layup pattern <NUM> along track <NUM> until the shuttle <NUM> is positioned to receive carrier <NUM>. In <FIG>, the carrier <NUM> is moved over the layup pattern <NUM>, and picks up the layup pattern <NUM> via vacuum coupling. In <FIG>, the carrier <NUM> moves along frame <NUM> until the layup pattern <NUM> is disposed over a layup mandrel <NUM>. The carrier <NUM> then releases the vacuum coupling to the layup pattern <NUM>, and applies a separate vacuum that compresses the layup pattern <NUM> into place onto the layup mandrel <NUM>. In a further embodiment, positive airflow is provided from the carrier <NUM> in order to push the layup pattern <NUM> away from carrier <NUM> and onto the layup mandrel <NUM>. In <FIG>, the shuttle <NUM> returns to an initiation position <NUM>, and the layup mandrel <NUM>, which has received one or more layup patterns <NUM> that form a preform <NUM>, is advanced to a next process prior to an autoclave (not shown) or similar device for hardening. After hardening, manufacturing excess can be partially trimmed off, leaving indexing features on a remaining manufacturing excess, or fully trimmed off from the resulting composite part. The trimming is performed prior to assembly, with a precision that does not require a final trimming after assembly to finalize the leading and trailing edges. That is, the layup pieces <NUM>-<NUM> through <NUM>-<NUM> are trimmed and placed with sufficient precision that the resulting ply <NUM> does not need a perimeter trim to achieve desired final panel dimensions.

<FIG> depict flow arrangements for an assembly line in illustrative embodiments. Each of these arrangements show alternative configurations of multiple assembly lines (e.g. assembly line <NUM> or broad goods lamination stations <NUM>) for fabricating an airframe component from broad goods. Broad goods lamination station <NUM> (as shown in <FIG>) includes broad goods station <NUM>, rotary table <NUM> or other orienting station, and placement stations <NUM> and <NUM>-<NUM> for fabricating a preform from broad goods. At each of the plurality of broad goods lamination stations in <FIG>, work is performed at a layup mandrel.

Referring to <FIG>, in an example, an assembly line <NUM> is depicted which includes broad goods lamination stations <NUM>-<NUM> through <NUM>-<NUM>, collectively referred to as "stations <NUM>," that are disposed along loop <NUM>. The stations <NUM> perform work on a layup mandrel <NUM> which enters via direction <NUM>, and proceeds in a micro pulsed, full pulsed, or continuous fashion along the stations <NUM> disposed at loop <NUM>. In this example, a plurality of mandrels <NUM>, such as upper and lower wing skin panels, are being processed in assembly line <NUM> along loop <NUM>. In this example, layup mandrel <NUM> progresses through horizontal segment <NUM> left to right through stations <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM> and then right to left in the adjacent horizontal segment <NUM> through stations <NUM>-<NUM>, <NUM>-<NUM>, <NUM>-<NUM>, and <NUM>-<NUM>. With this left to right and then right to left arrangement processing through the stations <NUM>-<NUM> through <NUM>-<NUM>, the layup mandrel <NUM> never turns orientation relative to the stations <NUM>-<NUM> through <NUM>-<NUM> and merely laterally shifts between horizontal segment <NUM> and adjacent horizontal segment <NUM>. The preform <NUM> on the mandrel progresses through the stations <NUM>-<NUM> through <NUM>-<NUM> until completed and then layup mandrel <NUM> and preform <NUM> exits via direction <NUM>. As needed, the mandrel <NUM> may require multiple passes through loop <NUM> and stations <NUM>-<NUM> through <NUM>-<NUM> to complete preform <NUM>. In some examples, one or more stations <NUM>-n may be located along the vertical segment <NUM>, while in other examples, there may not be any stations <NUM>-n located along the vertical segment <NUM>, in which case the layup mandrels <NUM> are laterally shifted directly from one horizontal segment <NUM> to an adjacent horizontal segment <NUM>.

In this example, the layup mandrel <NUM> reaches an end <NUM> of a horizontal segment <NUM> and is laterally shifted, rather than pivoted, and proceeds along the vertical segment <NUM>, resulting in no change of orientation of the layup mandrel <NUM> relative to the process direction P. The layup mandrel <NUM> reaches the end <NUM>-<NUM> of horizontal segment <NUM> to complete movement through loop <NUM>. Layup mandrel <NUM> and preform <NUM> exit laterally via direction <NUM> and is replaced by another layup mandrel <NUM> in loop <NUM>.

In the configuration of <FIG>, the lateral movement of mandrel <NUM> within loop <NUM> allows for a compact assembly line <NUM> without the need for additional floor space due to the fact that the mandrel <NUM> never needs to pivot. A further benefit of this compact configuration is that manpower required to operate stations <NUM> may be shared between the horizontal segment <NUM> and adjacent horizontal segment <NUM>.

In <FIG>, an assembly line <NUM> is depicted which includes broad goods lamination stations <NUM>-<NUM> through <NUM>-<NUM>, collectively referred to as "stations <NUM>," that are disposed along loop <NUM>. The stations <NUM> perform work on a layup mandrel <NUM> which enters loop <NUM> via direction <NUM>, and proceeds in a micro pulsed, full pulsed, or continuous fashion along the stations <NUM> disposed at loop <NUM> across directions <NUM>, <NUM>, <NUM>, and <NUM>. After one or more laps through loop <NUM>, layup mandrel <NUM> exits via direction <NUM>. The orientation of layup mandrel <NUM> is turned to conform to the orientation of loop <NUM>. Any of stations <NUM> depicted herein may be implemented as one or more of the broad goods lamination stations <NUM> discussed above with regard to <FIG>. Stations <NUM>-<NUM> through <NUM>-<NUM> may be implemented on either side <NUM>-<NUM> and <NUM>-<NUM> of loop <NUM> (e.g., to facilitate a return loop operation), and the layup mandrel <NUM> may receive layup from one or more of the stations <NUM>. The layup (e.g. layup pieces <NUM>) may be spliced together to form a ply <NUM>, and splice locations may be staggered from ply to ply to avoid stacking splices directly upon prior splices. The layup mandrel <NUM> continues to receive layup pieces <NUM> until the preform <NUM> is completed. In one embodiment, the layup pieces <NUM> exhibit varied orientations. After the preform <NUM> has received all plies, the preform <NUM> and the mandrel <NUM> exit for further processing, and one or more other layup mandrels <NUM> are added to loop <NUM>. In one embodiment, multiple mandrels <NUM> progress along loop <NUM> in a synchronized fashion, wherein these components are pulsed and paused at the same time. The orientation of loop <NUM> may be process direction P.

In <FIG>, an assembly line <NUM> is depicted which includes broad goods lamination stations <NUM>-<NUM> through <NUM>-<NUM>, and <NUM>-<NUM> through <NUM>-<NUM> (collectively referred to as "stations <NUM>") that are disposed along loop <NUM> that forms a "U" shape <NUM>-<NUM>. The stations <NUM> perform work on a layup mandrel <NUM> which enters loop <NUM> via direction <NUM>, and proceeds in a micro pulsed, full pulsed, or continuous fashion along the stations <NUM> disposed at loop <NUM> across directions <NUM>, <NUM>, and <NUM>. The orientation of the layup mandrel <NUM> is turned to conform to the orientation of loop <NUM>. After proceeding along loop <NUM>, layup mandrel <NUM> and preform <NUM> exit via direction <NUM>. Any of the stations <NUM> depicted herein may be implemented as one or more of the broad goods lamination stations <NUM> discussed above with regard to <FIG>. Stations <NUM>-<NUM> through <NUM>-<NUM> and stations <NUM>-<NUM> through <NUM>-<NUM> may be implemented on each side <NUM>-<NUM> and <NUM>-<NUM> of loop <NUM>, and the layup mandrel <NUM> may receive layup from one or more of the stations <NUM>. The layup (e.g. layup pieces <NUM>) may be spliced together to form a ply <NUM>, and splice locations may be staggered from ply to ply to avoid stacking splices directly upon prior splices. The layup mandrel <NUM> continues to receive layup pieces <NUM> until the preform <NUM> is completed. In one embodiment, the layup pieces <NUM> exhibit varied orientations. After preform <NUM> has received all plies, preform <NUM> and mandrel <NUM> exit for further processing, and one or more other layup mandrels <NUM> are added to loop <NUM>. In one embodiment, multiple mandrels <NUM> progress along loop <NUM> in a synchronized fashion, wherein these components are pulsed and paused at the same time.

In <FIG>, an assembly line <NUM> is depicted which includes broad goods lamination stations <NUM>-<NUM> through <NUM>-<NUM> (collectively referred to as "stations <NUM>") that are disposed along loop <NUM> that forms an "S" shape <NUM>-<NUM>. The stations <NUM> perform work on a layup mandrel <NUM> which enters loop <NUM> via direction <NUM>, and proceeds in a micro pulsed, full pulsed, or continuous fashion along the stations <NUM> disposed at loop <NUM> across directions <NUM>, <NUM>, <NUM>, and <NUM>. After proceeding through loop <NUM>, the layup mandrel <NUM> exits via direction <NUM>. Any of the stations <NUM> depicted herein may be implemented as one or more of the broad goods lamination stations <NUM> discussed above with regard to <FIG>. Stations <NUM>-<NUM> through <NUM>-<NUM> may be implemented on each side <NUM>-<NUM> and <NUM>-<NUM> of loop <NUM>, and the layup mandrel <NUM> may receive layup from one or more of the stations <NUM>. The layup (e.g. layup pieces <NUM>) may be spliced together to form a ply <NUM>, and splice locations may be staggered from ply to ply to avoid stacking splices directly upon prior splices. The layup mandrel <NUM> continues to receive layup pieces <NUM> until preform <NUM> is completed. In one embodiment, the layup pieces <NUM> exhibit varied orientations. After preform <NUM> has received all plies, preform <NUM> and mandrel <NUM> exit for further processing, and one or more other layup mandrels <NUM> are added to loop <NUM>. In one embodiment, multiple mandrels <NUM> progress along loop <NUM> in a synchronized fashion, wherein these components are pulsed and paused at the same time.

<FIG> depict layup patterns in illustrative embodiments. <FIG> is a top view of a layup pattern <NUM> for a laminate <NUM> in an illustrative embodiment. According to <FIG>, layup pattern <NUM> includes zones A and zones B, as indicated by "A" and "B" on layup pieces <NUM> of laminate <NUM>. Splices <NUM> between the layup pieces <NUM> in zones A and B vary along the length L of the laminate <NUM>, forming a staggered pattern <NUM> and preventing a single seam from being formed along the length of the ply map. That is, zonal lamination is performed such that boundaries <NUM> between the layup pieces <NUM> in zones A and B are staggered across layers in order to avoid boundary <NUM> and/or splice <NUM> stack-up. In further embodiments, zones overlap in angled shapes depending on the fiber orientation of material being laid-up.

Each splice <NUM> may be formed by the placement of different layup pieces <NUM>. While the splices <NUM> are shown as lines, each splice <NUM> occupies a narrow region between neighboring zones where layup pieces <NUM> from the zones are butt spliced, overlap spliced, or otherwise made physically integral with each other. Each ply <NUM> being spliced may have boundaries <NUM> that are unique, and the boundaries <NUM> may vary by a fraction of a centimeter (or inch) between neighboring plies, resulting in splices <NUM> that are staggered through the thickness of the zones. That is, the location of a splice <NUM> changes incrementally between layers, forming a staggered pattern <NUM> (e.g., stairstep pattern, staggered shape, etc.) through multiple plies. Staggering splice prevents overlaps from stacking on top of each other and causing build-up of material. Thus, the locations of cuts for splices <NUM> vary between plies <NUM> in one embodiment. The splices <NUM> extend across a plurality of plies. In this embodiment, the splices <NUM> are selected/placed such that they do not intersect the pad-ups <NUM>, in order to prevent substantial increases in thickness or complexity near pad-ups <NUM>. Thus, the boundaries <NUM> are staggered from ply <NUM> to ply <NUM>. <FIG> illustrates a similar arrangement of layup pieces <NUM> in zones A and B, as well as splices <NUM> of a laminate <NUM> for a wing skin. Pad-ups <NUM> are also included in the laminate <NUM>, and may be utilized to provide reinforcement for access panels, wing flaps, etc. <FIG> illustrate that the zonal lamination techniques discussed herein can be utilized for a variety of laminate designs. Illustrative details of the operation of assembly line <NUM> will be discussed with regard to <FIG>. Assume, for this embodiment, that rolls <NUM> of broad goods comprising continuous fiber reinforced material have been loaded at the assembly line <NUM>.

It is noted that the term 'mandrel' as used in the application refers to a mandrel upon which parts, for example aircraft parts, can be positioned. The term mandrel may interchangeably be used with the term 'layup mandrel. The mandrel is provided with and/or used as a surface upon which parts, layers of material or combinations thereof may be positioned. This may for example be a lay-up mandrel or mandrel upon which wing panels and/or wing skins are transported. It is clear for the skilled person that layup mandrels <NUM>, <NUM> as illustrated in the figures of the present disclosure are schematic illustrations of a layup mandrel <NUM>, <NUM> that may have a certain <NUM>-dimensional form, structure and/or surface as described above.

<FIG> is a flowchart illustrating a method <NUM> for fabricating an airframe in an illustrative embodiment. The steps of method <NUM> are described with reference to assembly line <NUM> of <FIG>, but those skilled in the art will appreciate that method <NUM> may be performed in other systems. The steps of the flowcharts described herein are not all inclusive and may include other steps not shown. The steps described herein may also be performed in an alternative order.

In step <NUM>, a sheet <NUM> of fiber reinforced broad goods is acquired by the assembly line <NUM>. In one embodiment, acquiring the sheet <NUM> comprises threading the sheet <NUM> through first cutting station <NUM> and second cutting station <NUM>.

Step <NUM> comprises trimming the sheet <NUM> (e.g., applying cuts to the sheet <NUM>) to form layup pieces <NUM> having boundaries <NUM> that are complementary. The cuts for each of the layup pieces <NUM> are applied as a first straight cut <NUM> from a first cutting station <NUM>, followed by a second straight cut <NUM> from a second cutting station <NUM>. Each first straight cut <NUM> proceeds across the entire width of the sheet <NUM> of broad goods, at a desired angle (e.g., a leading edge <NUM> angle or a trailing edge <NUM> angle). Meanwhile, second straight cuts <NUM> are applied to pieces created by the first cuts. For example, for each piece, one cut may correspond with a leading edge <NUM> angle for a wing skin, while the other cut may correspond with a trailing edge <NUM> angle for the wing skin.

This enables cutting of a constant width broad good material via two cuts to create pieces with two parallel edges that taper to form shapes desired for placement as a layer of, for example, a wing skin. In short, a composite structure is formed from several layup pieces <NUM> that are each created with two straight cuts of a broad good piece and then placed to adjoin to each other. The arrangement of the cuts and the sizing of the layup pieces <NUM> results in little to no wasted material reduces the "buy to fly" cost of a resulting aircraft. This approach of using straight cuts saves time and eliminates complexity, while also reducing waste.

Step <NUM> includes placing the boundaries <NUM> into alignment (e.g., by rotating and translating the layup pieces <NUM>). In this embodiment, because the edges of the sheet <NUM> of broad goods form sides of the layup pieces (<NUM>), the layup pieces <NUM> can be placed side-by-side without overlap, by placing the boundaries <NUM> together (i.e., by butting together the layup pieces <NUM> as part of a splicing process). In this embodiment, the edges of the sheet <NUM> of broad goods form complementary sides of the layup pieces <NUM>. By aligning the complementary sides such that they are rotated to a common angle, the layup pieces <NUM> can be combined into a single layup pattern <NUM> simply by translating the layup pieces <NUM>. In one embodiment, trimming the sheet/applying cuts to the sheet <NUM> results in the layup pieces <NUM> exhibiting a shared leading edge <NUM> angle and shared trailing edge <NUM> angle, and rotating the layup pieces <NUM> comprises orienting leading edges of the layup pieces <NUM> to a common angle (e.g., a leading edge angle or a trailing edge angle). In further embodiments, several rows of layup pieces <NUM>-<NUM> through <NUM>-<NUM> that span across the chordwise direction are utilized to form a single layup pattern <NUM>.

Step <NUM> includes arranging the layup pieces <NUM> onto a shuttle <NUM> in a layup pattern <NUM> to form one or more plies <NUM>. That is, the layup pattern <NUM> itself comprises one or more plies <NUM>. In this embodiment, this step includes moving the shuttle <NUM> laterally until a new placement location <NUM> is exposed, and then moving carrier <NUM> until a layup piece <NUM> is aligned with the placement location <NUM>. The layup piece <NUM> is then placed into position. These operations continue for multiple layup pieces <NUM> until an entire layup pattern <NUM> is created. Depending on embodiment, arranging the layup pieces <NUM> into the layup pattern <NUM> comprises arranging the layup pieces <NUM> into a shape of a wing skin (e.g., wing skin <NUM> of <FIG>) or a shape of a fuselage skin (e.g., fuselage skin <NUM> of <FIG>). Thus, in one embodiment, the layup pattern <NUM> forms a ply <NUM> for a wing skin (e.g. wing skin <NUM> of <FIG>). In a further embodiment, arranging the layup pieces <NUM> into the layup pattern <NUM> comprises arranging the layup pieces <NUM> into a shape of one or more plies <NUM> for a fuselage skin (e.g., fuselage skin <NUM> of <FIG>).

Step <NUM> includes performing a placing operation that transports the layup pattern <NUM> onto a layup mandrel <NUM>. This operation comprises moving shuttle <NUM> along track <NUM>, then picking up the entire layup pattern <NUM> at once with a carrier <NUM>, and moving the layup pattern <NUM> to a layup mandrel <NUM>. In further embodiments, placement is performed manually instead of via automated Pick and Placement (PNP) processes. Thus, in one embodiment PNP processes are performed automatically via a PNP station <NUM>, while in another embodiment placement is performed manually.

In step <NUM>, the layup pattern <NUM> is shaped into conformance with a contour <NUM> of the layup mandrel <NUM>. This comprises driving the carrier <NUM> into the layup mandrel <NUM> to conform the layup pattern <NUM> against a contour <NUM> of the layup mandrel <NUM>. In one embodiment, shaping the layup pattern <NUM> comprises applying vacuum via the carrier <NUM> to the layup pattern <NUM> for consolidating/conforming/compressing the layup pattern while performing the PNP operation. Thus, in one embodiment, shaping the layup pattern <NUM> is performed by a carrier <NUM> that performs the placement operation.

The steps of method <NUM>, including the trimming, placing, arranging, performing a placement operation, and shaping may be iteratively performed until a preform <NUM> is completed at the layup mandrel <NUM>. Furthermore, in one embodiment, the operations of acquiring, trimming/applying cuts, rotating, arranging, placing (e.g., performing a PNP operation), and shaping are performed via the stations of the assembly line <NUM> synchronously in a pulsed fashion, wherein pulses of work are followed by pauses.

In further embodiments, the operations of acquiring, trimming/applying cuts, rotating, arranging, placing (e.g., performing a PNP operation), and shaping are performed according to a takt time. In such an embodiment, assembly line <NUM> operates as a feeder line, wherein a takt time for assembly line <NUM> is synchronized with a takt time for one or more other feeder lines (e.g., a feeder a line <NUM> for fabricating a wing skin at a mandrel <NUM>), or is distinct from one or more feeder lines. Multiple feeder lines such as assembly line <NUM> may provide multiple layup pieces <NUM> to multiple locations along a looped, "S" shaped or "C" shaped assembly line (e.g. systems of <FIG>) to apply multiple plies <NUM> to a layup mandrel <NUM> and/or preform as it progresses in a process direction. The takt time for the feeder lines do not have to be the same as the takt time used for a looped, "S" shaped or "C" shaped assembly line (e.g. systems of <FIG>). In one embodiment, multiple assembly lines <NUM> feed layup pieces <NUM> to the same wing skin at the same time.

Furthermore, while the assembly line <NUM> is depicted as fabricating wing skins, in further embodiments the assembly line <NUM> is utilized to fabricated sections of fuselage, empennage sections, engine nacelles, doors, flaps, slats, and/or other components.

<FIG> is a flowchart illustrating a method <NUM> for fabricating a composite structure of an airframe in an illustrative embodiment. Step <NUM> includes dividing a composite structure into zones (e.g., zones <NUM>-<NUM> through <NUM>-<NUM>, collectively referred to as zones <NUM> of <FIG>). In one embodiment, the zones (e.g., zones <NUM>-<NUM> through <NUM>-<NUM> of <FIG>) correspond with the shapes and sizes of the placement locations <NUM>.

Step <NUM> includes fabricating a layup piece <NUM> for each of the zones <NUM>. Fabricating the layup pieces <NUM> comprises performing the trimming/cutting operations discussed above by the stations of the assembly line <NUM>. In step <NUM>, the layup pieces <NUM> are arranged into a layup pattern <NUM>. Each layup piece <NUM> occupies a zone (e.g., any of zones <NUM>-<NUM> through <NUM>-<NUM> of <FIG>) of the layup pattern <NUM>. This comprises operating the rotary table <NUM> and the carrier <NUM> to place the layup pieces <NUM> into the layup pattern <NUM>. In one embodiment, arranging the layup pieces <NUM> into the layup pattern <NUM> comprises arranging the layup pieces <NUM> into a shape of a wing skin (e.g., wing skin <NUM> of <FIG>) or a shape of a fuselage skin (e.g., fuselage skin <NUM> of <FIG>). Step <NUM> includes transporting the layup pattern <NUM> to a layup mandrel <NUM> via a carrier. In this embodiment, the operation is performed by advancing a shuttle <NUM> carrying the layup pattern <NUM> underneath a carrier <NUM>. Thus, in one embodiment, transporting the layup pattern <NUM> comprises operating a Pick and Place (PNP) station <NUM>.

Step <NUM> includes compacting the layup pattern <NUM> onto the layup mandrel <NUM> to fabricate the preform <NUM>. In this embodiment, this comprises utilizing the carrier <NUM> to pick up, place, and compact the entire layup pattern <NUM> at once onto the layup mandrel <NUM>. In a further embodiment, the method further comprises disposing edges of the layup pattern <NUM> onto the layup mandrel <NUM> such that the edges are staggered with respect to other layup patterns <NUM> for the layup mandrel <NUM>.

Methods <NUM> and <NUM> provide a substantial advantage over prior techniques, because it enables rapid fabrication of large composite structures from broad goods, without the need for slow trimming/cutting processes, such as manual processes or automated processes that trace a shape for a composite part with a single cutter head. In further embodiments, it is possible to have more than one broad goods station <NUM> or small-piece station <NUM> feeding materials at the same time and to multiple placement stations around a looped, "S" shaped or "C" shaped assembly line (e.g. systems of <FIG>). This type of parallel processing accelerates the fabrication process. Furthermore, the use of broad goods also increases the rate at which layup is performed, because pick and place operations are substantially faster than utilizing a placement head to layup a piece and then trim it.

<FIG> is a diagram illustrating segmentation of an airframe component into segments of a uniform width in an illustrative embodiment. In this embodiment, the airframe component comprises a wing skin <NUM>. The wing skin <NUM> is subdivided into zones <NUM>-<NUM> through <NUM>-<NUM> cut from broad goods of a uniform width W. A final zone <NUM> for a small layup piece and a first zone <NUM> for another layup piece have been trimmed/cut multiple times from the broad goods to reach desired dimensions. In this instance, W corresponds with a width of a sheet of broad goods material.

<FIG> are diagrams depicting a broad goods station <NUM>. Broad goods station <NUM> is an example broad goods station <NUM> in <FIG>. The broad goods station <NUM> includes cutting stations that trim/cut a sheet <NUM> of broad goods into a desired shape for a layup piece in an illustrative embodiment. In this embodiment, a first cutting station <NUM> includes a rotary element <NUM>, onto which a cutter <NUM> is mounted. The rotary element <NUM> may be implemented with a slick surface that prevents twisting, wrinkling, and/or bunching of the sheet <NUM>. The cutter <NUM> is aligned to make cuts at a single desired angle, and makes a straight cut through a sheet <NUM> of broad goods material. The cutter <NUM> is therefore long enough to accommodate the desired angle of cutting. Second cutting station <NUM> operates a cutter <NUM> to perform a second cut. A second cutting station <NUM> includes a rail <NUM> upon which a cutter <NUM> moves back and forth.

In <FIG>, a sheet <NUM> of broad goods material <NUM> advances through first cutting station <NUM> in a direction <NUM>, and cutter <NUM> makes a first cut <NUM>. In <FIG>, an additional sheet <NUM> is fed to the first cutting station <NUM>, which makes an additional first cut <NUM> (which may or may not be at the same angle as the previous first cut, depending on design considerations). Second cutting station <NUM> slides cutter <NUM> along rail <NUM> in direction <NUM> during motion of the sheet <NUM> in direction <NUM>, which results in an angled cut <NUM> at the layup piece <NUM>. In further embodiments, additional cutting operations are performed to generated polygonal layup pieces having any number of desired sides and angles. This results in a new layup piece <NUM> depicted in <FIG>.

<FIG> depicts layup pieces <NUM>-<NUM> through <NUM>-<NUM> (referred to collectively or individually as "layup pieces <NUM>") that are arranged on a surface <NUM> for cutting out from a sheet <NUM> of broad goods in an illustrative embodiment. In this embodiment, each layup piece <NUM> is cut to exhibit leading edge angle θ1 and a trailing edge angle θ2, and each layup piece <NUM> is cut from the same sheet (or a same-width sheet) of fiber reinforced broad goods. Some of the layup pieces <NUM> receive an additional cut <NUM> in order to achieve a desired size. Furthermore, while not shown, the layup pieces <NUM> are cut in a flat pattern wherein the layup pieces <NUM> butt against and adjoin to layup pieces <NUM>, and flat patterns are stacked onto a mandrel (e.g., having a complex contour) in order to arrive at a complex shape. That is, the layup pieces <NUM> are trimmed in a manner that facilitates the layup piece <NUM> conforming to a complex contour from a flat pattern, while still butting against an adjoined layup piece <NUM> to facilitate splicing. After the layup pieces <NUM> are cut via cut stations <NUM>, they are seamlessly transported and aligned/rotated into a layup pattern <NUM> having a uniform trailing edge <NUM> and leading edge <NUM> (as indicated by arrows <NUM>-<NUM> through <NUM>-<NUM>), and are butted up against neighboring pieces. This butting operation is part of splicing when the butting is staggered from ply <NUM> to ply <NUM> through a stack up (i.e., through the layers of a preform <NUM>).

Scrap <NUM> may be recycled or discarded as desired, or used at other locations as another layup piece <NUM> at another location. In this depiction, the layup pattern <NUM> is depicted in an exploded view for ease of illustration. Layup pieces <NUM> are mirrored horizontally and vertically with respect to adjacent pieces, or arranged at one hundred and eighty degrees relative to each other to enable a common cut angle to be achieved between pieces. That is, a cut according to angle Θ2 for one piece also cuts a neighboring piece at the angle θ2. A sum of leading edge angle θ1 and trailing edge angle θ2 can be equal to <NUM>° or not equal to <NUM>°. In case of the sum of leading edge angle θ1 and trailing edge angle θ2 not being equal to <NUM>°, adjacent pieces are arranged at one hundred and eighty degrees relative to each other. In this way layup pieces <NUM> can effectively be used to form a wing skin with a minimum of scrap <NUM>. In a further embodiment, one layup piece <NUM> fits into a right or upper panel layout and another layup piece <NUM> fits into a left or lower panel layout. These arrangements may provide particular benefits in systems wherein stations are specialized for a specific size and/or orientation of layup piece <NUM>, and deliver roughly similar layup pieces for each wing skin. A system like this may also be implemented for a setup with multiple layup positions around a looped, "S" shaped or "C" shaped assembly line (e.g. systems of <FIG>).

<FIG> depicts a series of layup patterns formed from layup pieces in an illustrative embodiment. Layup pattern <NUM> exhibits a +<NUM>° fiber orientation <NUM>, layup pattern <NUM> exhibits a <NUM>° fiber orientation <NUM>, layup pattern <NUM> exhibits a -<NUM>° fiber orientation <NUM>, and layup pattern <NUM> exhibits a <NUM>° fiber orientation <NUM> for the same wing skin preform <NUM>. In each of <NUM>, <NUM>, <NUM>, and <NUM>, fiber orientations are referenced with respect to orientation of broad good sheet (e.g. <NUM>, <NUM> or <NUM>) of width W. By utilizing different fiber orientations for different layers of the wing skin, a desired level of structural strength is achieved.

<FIG> is a top view that depicts a PNP station <NUM> that places multiple layup patterns onto different circumferential portions of a layup mandrel <NUM> for a half-barrel section of fuselage skin in an illustrative embodiment. While the foregoing figures depict wings, flaps, stabilizers, etc., similar systems may be utilized for a fuselage, nacelle, door, or other structural component of an aircraft. Thus, <FIG> depicts one of many possible broad goods PNP techniques for zonal lamination of arcuate sections of fuselage skin. In this embodiment, a carrier <NUM> moves along a frame <NUM>. The carrier <NUM> utilizes vacuum coupling to hold a layup pattern <NUM> of layup pieces. The carrier <NUM> picks and places, then compacts, a single zone during a single PNP operation. For example, the carrier <NUM> first picks and places a layup pattern <NUM> for a left zone <NUM> of the layup mandrel <NUM>, then picks and places a layup pattern <NUM> for a top zone <NUM> of the layup mandrel <NUM>, then picks and places a layup pattern <NUM> for a right zone <NUM> of the layup mandrel <NUM>. By iteratively performing these operations and staggering the position of layup patterns <NUM> (i.e., the position where the patterns butt up against each other), with respect to layup patterns in other layers of the fuselage skin, the resulting fuselage skin exhibits a desired structural strength. In particular, for layup patterns exhibiting a +/-<NUM>° or <NUM>° fiber orientation, and even for layup patterns of the same orientation that are placed over each other, the layup patterns are designed such that the boundaries of layup pieces in different layers overlap each other or form butt splices. In further embodiments, the PNP station <NUM> places door surrounds or similar pad-ups onto place at a fuselage or wing skin, using the techniques discussed above. For example, a PNP station <NUM> for door surrounds is also depicted in <FIG>. The PNP station <NUM> includes a carrier <NUM>, which moves along a frame <NUM>. A layup pattern <NUM> (or ply pack, or other component) for the door surround is held at the carrier, for placement onto a zone of the layup mandrel <NUM>.

<FIG> is a flow diagram <NUM> illustrating synchronized operations at an assembly line in an illustrative embodiment. <FIG> illustrates that trims/cuts can be synchronized across stations, such that trimming/cutting operations, rotation at a rotary table, and movement of a shuttle is coordinated to a takt time (e.g., a desired production time for a wing skin or fuselage skin), and the stations perform work synchronously. For example, a first cut <NUM> may be applied at a first cutting station <NUM> while a second cutting station <NUM> is applying a second cut <NUM>. Further operations, such as rotation <NUM>, and transportation via a shuttle <NUM>, may also be performed while the first cut <NUM> and second cut <NUM> are being performed. In a similar fashion, a station <NUM> of a layup station <NUM> may perform layup <NUM>, and a station <NUM> may perform layup <NUM> at the same time upon different layup pieces. Further operations, such as applying a layup to a mandrel <NUM>, returning a mandrel <NUM>, and/or transferring a layup piece to a shuttle <NUM>, may also be performed in a synchronized fashion. That is, the trimming/cutting operations, movement of the shuttle, rotation of the rotary table, etc., may occur during a pause between pulses of a sheet of broad goods that is pulsingly advanced from a roll of broad goods. In one embodiment, a pulse and accompanying pause occupy several seconds of time. This insight increases work density and throughput while also ensuring that each station does not interfere with the operations of others.

<FIG> depicts an assembly line <NUM> for fuselage section preforms in an illustrative embodiment. Assembly line <NUM> includes broad goods lines <NUM>-<NUM> through <NUM>-<NUM>, which trim/cut out layup pieces <NUM>-<NUM> through <NUM>-<NUM> for placement into a layup pattern <NUM> for a fuselage skin <NUM>. The broad goods lines <NUM>-<NUM> through <NUM>-<NUM> include rotary tables <NUM>-<NUM> through <NUM>-<NUM>. The rotary tables <NUM>-<NUM> through <NUM>-<NUM> rotate layup pieces <NUM>-<NUM> through <NUM>-<NUM> into a desired alignment, and carriers <NUM> apply layup pieces <NUM>-<NUM> through <NUM>-<NUM> to conveyors <NUM>-<NUM> through <NUM>-<NUM>. The layup pieces form layup patterns which are transferred via carriers <NUM>-<NUM> through <NUM>-<NUM> to zones <NUM>-<NUM> through <NUM>-<NUM> of layup mandrel <NUM> as layup pattern <NUM>. A door surround station <NUM> fabricates preforms <NUM> for door surrounds for application to the layup mandrel <NUM> via the carrier <NUM>-<NUM>. The preforms <NUM> are fabricated from preforms <NUM> of fiber reinforced material that are laid-up at lamination stations <NUM>. System <NUM> may also be suitable for placement onto layup mandrel <NUM> of a length greater than that of the carriers <NUM>-<NUM> through <NUM>-<NUM>. In such a situation, layup mandrel <NUM> may be transferred lateral to allow for multiple placements of layup pieces (<NUM>) <NUM>-<NUM> through <NUM>-<NUM> in each of zones <NUM>-<NUM> through <NUM>-<NUM>.

In the following examples, additional processes, systems, and methods are described in the context of an assembly line for fabricating composite parts from broad goods.

Referring more particularly to the drawings, embodiments of the disclosure may be described in the context of aircraft manufacturing and service in method <NUM> as shown in <FIG> and an aircraft <NUM> as shown in <FIG>. During pre-production, method <NUM> may include specification and design <NUM> of the aircraft <NUM> and material procurement <NUM>. During production, component and subassembly manufacturing <NUM> and system integration <NUM> of the aircraft <NUM> takes place. Thereafter, the aircraft <NUM> may go through certification and delivery <NUM> in order to be placed in service <NUM>. While in service by a customer, the aircraft <NUM> is scheduled for routine work in maintenance and service <NUM> (which may also include modification, reconfiguration, refurbishment, and so on). Apparatus and methods embodied herein may be employed during any one or more suitable stages of the production and service described in method <NUM> (e.g., specification and design <NUM>, material procurement <NUM>, component and subassembly manufacturing <NUM>, system integration <NUM>, certification and delivery <NUM>, in service <NUM>, maintenance and service <NUM>) and/or any suitable component of aircraft <NUM> (e.g., airframe <NUM>, systems <NUM>, interior <NUM>, propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, environmental <NUM>).

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

As already mentioned above, apparatus and methods embodied herein may be employed during any one or more of the stages of the production and service described in method <NUM>. For example, components or subassemblies corresponding to component and subassembly manufacturing <NUM> may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft <NUM> is in service. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during the subassembly manufacturing <NUM> and system integration <NUM>, for example, by substantially expediting assembly of or reducing the cost of an aircraft <NUM>. Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized while the aircraft <NUM> is in service, for example and without limitation during the maintenance and service <NUM>. Thus, the invention may be used in any stages discussed herein, or any combination thereof, such as specification and design <NUM>, material procurement <NUM>, component and subassembly manufacturing <NUM>, system integration <NUM>, certification and delivery <NUM>, in service <NUM>, maintenance and service <NUM> and/or any suitable component of aircraft <NUM> (e.g., airframe <NUM>, systems <NUM>, interior <NUM>, propulsion system <NUM>, electrical system <NUM>, hydraulic system <NUM>, and/or environmental <NUM>).

Claim 1:
A method (<NUM>) for fabricating a preform (<NUM>) for a portion of an aircraft (<NUM>), the method comprising:
acquiring (<NUM>) a sheet (<NUM>) of broad good fiber reinforced material;
trimming (<NUM>) the sheet (<NUM>) to form layup pieces (<NUM>) having boundaries (<NUM>);
placing (<NUM>) the boundaries (<NUM>) into alignment;
arranging (<NUM>) the layup pieces (<NUM>) in a layup pattern (<NUM>) to form a ply (<NUM>);
performing (<NUM>) a placement operation that transports the layup pattern (<NUM>) onto a layup tool (<NUM>); and
shaping (<NUM>) the layup pattern (<NUM>) into conformance with a contour (<NUM>) of the layup tool (<NUM>), wherein the trimming comprises applying a straight cut (<NUM>, <NUM>) across an entire width of the sheet (<NUM>) at an angle corresponding to a leading edge (<NUM>) angle (θ<NUM>) for a wing skin (<NUM>) or a trailing edge (<NUM>) angle (θ<NUM>) for the wing skin (<NUM>), and wherein trimming (<NUM>) the sheet (<NUM>) results in the layup pieces (<NUM>) exhibiting a shared leading edge angle (θ<NUM>) and shared trailing edge angle (θ<NUM>), and wherein at the step of arranging the layup pieces (<NUM>) are butted against each other to form an uniform trailing edge (<NUM>) and leading edge (<NUM>).