Patent ID: 12194693

DETAILED DESCRIPTION

The present application is directed to an apparatus, method, and system of ply by ply forming of composite parts. It is to be understood that the disclosure below provides a number of embodiments or examples for implementing different features of various embodiments. Specific examples of components and arrangements are described to simplify the present disclosure. 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.

Examples of the forming apparatus100(FIG.1), method200(FIG.10), and system300(FIG.11) enable automated forming of a composite part375and, more particularly, formation of at least one ply320of composite material325over a forming tool310for manufacture of the composite part375. Automation of the fabrication process provides a reduction in processing time, a reduction in labor and costs and a reduction of process variations (e.g., human error) that may lead to undesired inconsistencies in the finished composite structure as compared to conventional composite fabrication. The forming apparatus100, method200, and system300also enable ply-by-ply formation of the composite material325to fabricate the composite part375. Ply-by-ply formation facilitates fabrication of large composite structures, thick composite structures and/or composite structures with complex shapes. Ply-by-ply formation also provides a reduction in buckling or wrinkling of plies within the composite structure as compared to conventional composite fabrication.

Generally, a composite ply includes a single ply (e.g., one layer of thickness) of composite material325. The composite material325may take the form of any one of various suitable types of composite material325. In one or more examples, the ply320of composite material325is formed by laminating multiple courses of unidirectional composite tape, which is pre-impregnated with a resin matrix. Throughout the present disclosure, the phrase “the ply” refers to at least one ply320of composite material325, unless explicitly stated otherwise. The ply320may also be referred to as a composite patch or a composite charge.

Illustrated inFIG.1, composite manufacturing system600includes a plurality of sub-systems, including a forming system300(FIG.11), that facilitate and correspond to different fabrication operations associated with the manufacture of the composite part375. The sub-systems of the composite manufacturing system600are interlinked and cooperate to automate at least a portion of the fabrication process. Throughout the present disclosure, the sub-systems of the disclosed system600may be referred to as “systems” themselves or stations in which one or more fabrication operations occur. Among those sub-systems or stations is a system300for forming, which is shown and described in detail below.

The examples of the forming apparatus100, method200, and system300described herein utilize a plurality of semi-automated or automated sub-systems to perform ply-by-ply formation and compaction of individual one or more ply320of composite material325on the forming tool310. Ply-by-ply formation refers to the laydown of one or more ply320of composite material325on the forming tool310in a predetermined sequence, and the one or more ply320of composite material325is compacted onto the forming tool310individually after each ply320of composite material325is laid down, or after more than one ply320of composite material325had been laid down.

Disclosed is a forming apparatus100, a method200, and a system300directed to ply by ply forming of a composite part375to apply pressure and manipulate plies on a forming tool310. The forming apparatus100, method200, and system300utilize a forming tool310to define the shape of the composite part375. The forming tool310may be any desired shape including a hat stringer forming tool312, a spar forming tool314, and a stringer forming tool316. The forming tool310may accommodate any forming tool310shape variations including an “L” shape, a “Y” shape, and any combination thereof. The forming apparatus100is configured to apply pressure or compaction force350evenly across at least one ply320of composite material325over a forming surface308of a forming tool310. The forming apparatus100is further configured to deform220the at least one ply320of composite material325over the forming surface308of the forming tool310while eliminating any bubbles. The forming apparatus100is configured to move along the forming tool310at varying speeds, pressures, and angles to accommodate various geometries.

FIG.1andFIG.13illustrate an example composite manufacturing composite manufacturing system600. In an example, the composite manufacturing composite manufacturing system600includes a lamination system612(e.g., laminating sub-system or station), a transfer system616(e.g., transfer sub-system or station) and a forming system622(e.g., forming sub-system or station). In one or more examples, the composite manufacturing composite manufacturing system600also includes a trim system614(e.g., trim sub-system or station) and a scrap removal system642(e.g., a scrap removal sub-system of station). In one or more examples, the composite manufacturing composite manufacturing system600further includes a film removal system660(e.g., film removal sub-system or station). In one or more examples, the composite manufacturing composite manufacturing system600additionally includes a carrier preparation system662(e.g., carrier preparation sub-system or station). In one or more examples, the composite manufacturing composite manufacturing system600also includes a positioning system644(e.g., positioning sub-system).

In one or more examples, the composite manufacturing system600includes a tool transfer device646. The tool transfer device646is configured to convey the forming tool310. For example, the tool transfer device646includes, or takes the form of, a mobile platform that supports the forming tool310and moves the forming tool310between the sub-systems of the composite manufacturing system600that implement composite structure fabrication operations of the composite manufacturing process.

In an example, the composite manufacturing composite manufacturing system600for fabricating a composite part375includes a ply carrier604comprising a ply support surface608configured to support at least one ply320of composite material325. The composite manufacturing composite manufacturing system600further includes a carrier transfer device610configured to convey the ply carrier604, a lamination system612configured to selectively apply the at least one ply320of composite material325to the ply support surface608of the ply carrier604, a transfer system616configured to remove the ply carrier604from the carrier transfer device610and to apply the at least one ply320of composite material325to at least a portion of a forming surface308of a forming tool310, and a forming system622configured to form the at least one ply320of composite material325over the at least a portion of the forming surface308of the forming tool310. The forming system622comprises a forming apparatus100.

Referring toFIG.1, disclosed is an example of forming apparatus100. The forming apparatus100is located in the forming system622. In an example, the forming apparatus100includes a frame110. In an example, the frame110is generally rectangular in shape. The frame110defines a vertical axis112, a horizontal axis114, and a longitudinal axis116. The frame110surrounds a carriage120having a shape that is generally the same as the frame110but is smaller such that the carriage120nests within the frame110. In an example, the carriage120is movably connected to the frame110such that it may pivot or rotate along the vertical axis112and horizontal axis114to accommodate any specific geometry or configuration and achieve a best fit position.

FIG.2andFIG.3illustrate an example of a forming apparatus100. In an example, the forming apparatus100comprises a first stomp foot130. First stomp foot130is movably connected to the carriage120. The first stomp foot130is movable along the vertical axis112. The first stomp foot130may have a flat or a curved design based upon the geometry of the forming tool310. The first stomp foot130is controlled by any suitable means and is further configured to press one or more ply320of composite material325onto a forming surface308of a forming tool310and hold the one or more ply320of composite material325in place. In an example, the first stomp foot130movement is controlled by an actuator147. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, the first stomp foot130movement is controlled by at least one magnetic switch configured to detect travel and location of the first stomp foot130with respect to a forming tool310. The first stomp foot130is configured to apply compaction force350,FIG.11, to a forming tool310. The applied compaction force350may be variable or may be consistent based upon the geometry of the forming tool310.

Still referring toFIG.2, in an example, the forming apparatus100comprises a second stomp foot135. The second stomp foot135is movably connected to the carriage120. The second stomp foot135is movable along the vertical axis112. The second stomp foot135may have a flat or a curved design based upon the geometry of the forming tool310. The second stomp foot135is controlled by any suitable means and is further configured to press one or more ply320of composite material325onto a forming surface308of a forming tool310and hold the one or more ply320of composite material325in place. In an example, the second stomp foot135movement is controlled by an actuator147. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, the second stomp foot135movement is controlled by at least one magnetic switch configured to detect travel and location of the second stomp foot135with respect to a forming tool310. The second stomp foot135is configured to apply compaction force350to a forming tool310. The applied compaction force350may be variable or may be consistent based upon the geometry of the forming tool310.

In an example, the forming apparatus100comprises a ply support feature185. Ply support feature185may be located below the first stomp foot130and the second stomp foot135. Ply support feature185may be configured to support one or more ply320of composite material325prior to initiation of forming. Ply support feature185may further be configured to prevent the one or more ply320of composite material325from wrinkling prior to or during forming. The ply support feature185may be mechanical or may be air driven. In an example, the ply support feature185is an air knife.

Still referring toFIG.2, in an example, the forming apparatus100comprises a first swing arm140. The first swing arm140is movably connected to the carriage120. In an example, the forming apparatus100comprises an actuator147. Actuator147is configured to move the first swing arm140along the vertical axis112. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, a first end effector145is movably connected to the first swing arm140. In an example, the first end effector145comprises a first forming feature142. In an example, the first forming feature142is an inflatable bladder146. In an example, the first forming feature142is a forming finger148,FIG.11.

In an example, the first swing arm140is configured to pivot along the horizontal axis114and the longitudinal axis116and apply forming force330to a forming surface308of a forming tool310. The pivoting capabilities of the first swing arm140are advantageous for uniformly applying forming force330to a forming surface308of the inside of a stringer forming tool316. In an example, the forming force330averages about 20 lbs per linear inch. In an example, the forming force330ranges from about 5 lbs per linear inch to about 50 lbs per linear inch based upon material properties and forming tool310geometry. The forming force330applied to the forming surface308of the forming tool310is dependent upon various factors including geometry of the forming tool310, the amount of composite material325on the forming surface308of the forming tool310, and one or more numerical control program420. The first swing arm140includes one or more sensor410configured to detect the location and configuration of a forming tool310. The one or more sensor410may be in communication with a controller400. The controller400is configured to receive data from the one or more sensor410and analyze that data to control movement of the second end effector155. The controller may utilize one or more numerical control program420in conjunction with the data collected from the one or more sensor410to determine proper movement and placement of the second end effector155.

FIG.8illustrates an example of a portion of forming apparatus100. In an example, the forming apparatus100comprises a second swing arm150. The second swing arm150is movably connected to the carriage120. The second swing arm150is laterally opposed from said first swing arm140relative to the longitudinal axis116such that it mirrors the first swing arm140. In an example, the second swing arm150comprises a second end effector155movably connected to the second swing arm150. In an example, the second end effector155comprises a second forming feature152. In an example, the second forming feature152is an inflatable bladder146. In an example, the second forming feature152is a forming finger148.

In an example, the second swing arm150is configured to pivot along the horizontal axis114and the longitudinal axis116and apply forming force330to a forming surface308of a forming tool310as illustrated inFIG.9. The pivoting capabilities of the second swing arm150are advantageous for uniformly applying forming force330to a forming surface308of the inside of a stringer forming tool316. The first swing arm140and the second swing arm150are independently pivotable. In an example, the forming force330averages about 20 lbs per linear inch. In an example, the forming force330ranges from about 5 lbs per linear inch to about 50 lbs per linear inch based upon material properties and forming tool310geometry. The forming force330applied to the forming surface308of the forming tool310is dependent upon various factors including geometry of the forming tool310, the amount of composite material325on the forming surface308of the forming tool310, and one or more numerical control program420. The second swing arm150includes one or more sensor410configured to detect the location and configuration of a forming tool310. The one or more sensor410may be in communication with a controller400. The controller400is configured to receive data from the one or more sensor410and analyze that data to control movement of the second end effector155. The controller may utilize one or more numerical control program420in conjunction with the data collected from the one or more sensor410to determine proper movement and placement of the second end effector155.

In an example, as illustrated inFIG.1andFIG.3, the forming apparatus100comprises a first plurality144of the first end effector145. The first plurality144of the first end effector145extends along the longitudinal axis116. In an example, each individual first end effector145of the first plurality144of the first end effector145is independently movable. This arrangement allows for the first plurality144of the first end effector145to form a convex, concave, or linear configuration. In an example, the first plurality144of the first end effector145includes five of the first end effector145that are movably connected to a mounting beam180. The mounting beam180is movably connected to the carriage120such that it may move along the vertical axis112and horizontal axis114in accordance with the shape and geometry of a forming tool310.

In an example, the forming apparatus100comprises a second plurality154of the second end effector155. The second plurality154of the second end effector155extends along the longitudinal axis116and is laterally opposed from the second plurality154of the second end effector155. In an example, each individual second end effector155of the second plurality154of the second end effector155is independently movable. This arrangement allows for the second plurality154of the second end effector155to form a convex, concave, or linear configuration. In an example, the second plurality154of the second end effector155includes five of the second end effector155that are movably connected to a mounting beam180. The mounting beam180is movably connected to the carriage120such that it may move along the vertical axis112and horizontal axis114in accordance with the shape and geometry of a forming tool310.

In an example, the forming apparatus100comprises a protective slip film160as illustrated inFIG.8. The protective slip film160may be of any suitable material including a polymer material such as PTFE or FEP. The protective slip film160is connected to at least one retractable spool165. The retractable spool165is configured to provide constant tension to the protective slip film160. The protective slip film160is advantageous in prevention of bunching, distorting, or wrinkling of composite material325material during the forming process.

In an example, the forming apparatus100includes a pivoting bearing assembly170,FIG.2. The forming apparatus100may include more than one pivoting bearing assembly170that is movably connected to the carriage120and a mounting beam180via a bearing mount180a. The pivoting bearing assembly170is configured to have linear and radial configurations. The pivoting bearing assembly170allows for adjustments in yaw angle with respect to the first plurality144of first end effector145and second plurality154of the second end effector155. Adjustments in yaw angle allow for uniform application of compaction force350across a forming tool310, and particularly to a spar forming tool314.

FIG.5,FIG.6, andFIG.7illustrate an exemplary series of deforming220the at least one ply320of composite material325over the forming surface308of the forming tool310with a forming apparatus100.FIG.5illustrates initiation of the deforming220at least one ply320of composite material325over the forming surface308of a stringer forming tool316. In an example, the first stomp foot130abuts the forming surface308. The first stomp foot130is applying compaction force350to the forming surface308. First swing arm140is generally parallel to the vertical axis112.

FIG.6illustrates progression of the deforming220at least one ply320of composite material325over the forming surface308of a stringer forming tool316. The first swing arm140has pivoted across the horizontal axis114while uniformly applying compaction force350across the forming surface308. The first end effector145has also moved to conform to the geometry of the stringer forming tool316. Movement of the first swing arm140and first end effector145along the horizontal axis114and/or vertical axis112may be simultaneous or may occur independently based upon forming tool310geometry. A controller400may utilize one or more numerical control program420in conjunction with data collected from one or more sensor410to determine proper movement and placement of the first end effector145forming feature142.

FIG.7illustrates further progression of the deforming220at least one ply320of composite material325over the forming surface308of a stringer forming tool316. The first swing arm140and first end effector145have moved across the horizontal axis114and down the vertical axis112while uniformly applying compaction force350across the forming surface308. Further, the first stomp foot130has remained stationary to hold the at least one ply320of composite material325in place while the deforming220occurs.

FIG.10illustrates an example of method200herein. Disclosed is a method200for forming a composite part375. The method200comprises applying210at least one ply320of composite material325over a forming surface308of a forming tool310. The method200further comprises deforming220the at least one ply320of composite material325over the forming surface308of the forming tool310with a forming apparatus100. The method200further comprises advancing230the composite part375to a subsequent process. In an example, the forming apparatus100of the method200includes a frame110. In an example, the frame110is generally rectangular in shape. The frame110defines a vertical axis112, a horizontal axis114, and a longitudinal axis116. The frame110surrounds a carriage120having a shape that is generally the same as the frame110but is smaller such that the carriage120nests within the frame110. In an example, the carriage120is movably connected to the frame110such that it may pivot or rotate along the vertical axis112and horizontal axis114to accommodate any specific geometry or configuration and achieve a best fit position.

In an example, the forming apparatus100comprises a first stomp foot130. First stomp foot130is movably connected to the carriage120. The first stomp foot130is movable along the vertical axis112. The first stomp foot130may have a flat or a curved design based upon the geometry of the forming tool310. The first stomp foot130is controlled by any suitable means and is further configured to press one or more ply320of composite material325onto a forming surface308of a forming tool310and hold the one or more ply320of composite material325in place. In an example, the first stomp foot130movement is controlled by an actuator147. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, the first stomp foot130movement is controlled by at least one magnetic switch configured to detect travel and location of the first stomp foot130with respect to a forming tool310. The first stomp foot130is configured to apply compaction force350to a forming tool310. The applied compaction force350may be variable or may be consistent based upon the geometry of the forming tool310.

In an example, the forming apparatus100comprises a second stomp foot135. The second stomp foot135is movably connected to the carriage120. The second stomp foot135is movable along the vertical axis112. The second stomp foot135may have a flat or a curved design based upon the geometry of the forming tool310. The second stomp foot135is controlled by any suitable means and is further configured to press one or more ply320of composite material325onto a forming surface308of a forming tool310and hold the one or more ply320of composite material325in place. In an example, the second stomp foot135movement is controlled by an actuator147. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, the second stomp foot135movement is controlled by at least one magnetic switch configured to detect travel and location of the second stomp foot135with respect to a forming tool310. The second stomp foot135is configured to apply compaction force350to a forming tool310. The applied compaction force350may be variable or may be consistent based upon the geometry of the forming tool310.

In an example, the forming apparatus100comprises a ply support feature185. Ply support feature185may be located below the first stomp foot130and the second stomp foot135. Ply support feature185may be configured to support one or more ply320of composite material325prior to initiation of forming. Ply support feature185may further be configured to prevent the one or more ply320of composite material325from wrinkling prior to or during forming. The ply support feature185may be mechanical or may be air driven. In an example, the ply support feature185is an air knife.

In an example, the forming apparatus100comprises a first swing arm140. The first swing arm140is movably connected to the carriage120. In an example, the forming apparatus100comprises an actuator147. Actuator147is configured to move the first swing arm140along the vertical axis112. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, a first end effector145is movably connected to the first swing arm140. In an example, the first end effector145comprises a first forming feature142. In an example, the first forming feature142is an inflatable bladder146. In an example, the first forming feature142is a forming finger148.

In an example, the first swing arm140is configured to pivot along the horizontal axis114and the longitudinal axis116and apply forming force330to a forming surface308of a forming tool310. The pivoting capabilities of the first swing arm140are advantageous for uniformly applying forming force330to a forming surface308of the inside of a stringer forming tool316. In an example, the forming force330averages about 20 lbs per linear inch. In an example, the forming force330ranges from about 5 lbs per linear inch to about 50 lbs per linear inch based upon material properties and forming tool310geometry. The forming force330applied to the forming surface308of the forming tool310is dependent upon various factors including geometry of the forming tool310, the amount of composite material325on the forming surface308of the forming tool310, and one or more numerical control program420. The first swing arm140includes one or more sensor410configured to detect the location and configuration of a forming tool310. The one or more sensor410may be in communication with a controller400. The controller400is configured to receive data from the one or more sensor410and analyze that data to control movement of the second end effector155. The controller may utilize one or more numerical control program420in conjunction with the data collected from the one or more sensor410to determine proper movement and placement of the second end effector155.

In an example, the forming apparatus100comprises a second swing arm150. The second swing arm150is movably connected to the carriage120. The second swing arm150is laterally opposed from said first swing arm140relative to the longitudinal axis116such that it mirrors the first swing arm140. In an example, the second swing arm150comprises a second end effector155movably connected to the second swing arm150. In an example, the second end effector155comprises a second forming feature152. In an example, the second forming feature152is an inflatable bladder146. In an example, the second forming feature152is a forming finger148.

In an example, the second swing arm150is configured to pivot along the horizontal axis114and the longitudinal axis116and apply forming force330to a forming surface308of a forming tool310. The pivoting capabilities of the second swing arm150are advantageous for uniformly applying forming force330to a forming surface308of the inside of a stringer forming tool316. In an example, the forming force330averages about 20 lbs per linear inch. In an example, the forming force330ranges from about 5 lbs per linear inch to about 50 lbs per linear inch based upon material properties and forming tool310geometry. The forming force330applied to the forming surface308of the forming tool310is dependent upon various factors including geometry of the forming tool310, the amount of composite material325on the forming surface308of the forming tool310, and one or more numerical control program420. The second swing arm150includes one or more sensor410configured to detect the location and configuration of a forming tool310. The one or more sensor410may be in communication with a controller400. The controller400is configured to receive data from the one or more sensor410and analyze that data to control movement of the second end effector155. The controller may utilize one or more numerical control program420in conjunction with the data collected from the one or more sensor410to determine proper movement and placement of the second end effector155.

FIG.11illustrates an example of system300herein. In an example, a system300is disclosed. The system300comprises a forming apparatus100, a forming tool310, and at least one ply320of composite material325. In an example, the forming tool310is a spar forming tool314. In an example, the forming tool310is a stringer forming tool316. In an example, the forming tool310is a hat stringer forming tool312.

The forming apparatus100of system300includes a frame110. In an example, the frame110is generally rectangular in shape. The frame110defines a vertical axis112, a horizontal axis114, and a longitudinal axis116. The frame110surrounds a carriage120having a shape that is generally the same as the frame110but is smaller such that the carriage120nests within the frame110. In an example, the carriage120is movably connected to the frame110such that it may pivot or rotate along the vertical axis112and horizontal axis114to accommodate any specific geometry or configuration and achieve a best fit position.

In an example, the forming apparatus100of the system300includes a first stomp foot130. First stomp foot130is movably connected to the carriage120. The first stomp foot130is movable along the vertical axis112. The first stomp foot130may have a flat or a curved design based upon the geometry of the forming tool310. The first stomp foot130is controlled by any suitable means and is further configured to press one or more ply320of composite material325onto a forming surface308of a forming tool310and hold the one or more ply320of composite material325in place. In an example, the first stomp foot130movement is controlled by an actuator147. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, the first stomp foot130movement is controlled by at least one magnetic switch configured to detect travel and location of the first stomp foot130with respect to a forming tool310. The first stomp foot130is configured to apply compaction force350to a forming tool310. The applied compaction force350may be variable or may be consistent based upon the geometry of the forming tool310.

In an example, the forming apparatus100comprises a second stomp foot135. The second stomp foot135is movably connected to the carriage120. The second stomp foot135is movable along the vertical axis112. The second stomp foot135may have a flat or a curved design based upon the geometry of the forming tool310. The second stomp foot135is controlled by any suitable means and is further configured to press one or more ply320of composite material325onto a forming surface308of a forming tool310and hold the one or more ply320of composite material325in place. In an example, the second stomp foot135movement is controlled by an actuator147. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, the second stomp foot135movement is controlled by at least one magnetic switch configured to detect travel and location of the second stomp foot135with respect to a forming tool310. The second stomp foot135is configured to apply compaction force350to a forming tool310. The applied compaction force350may be variable or may be consistent based upon the geometry of the forming tool310.

In an example, the forming apparatus100comprises a ply support feature185. Ply support feature185may be located below the first stomp foot130and the second stomp foot135. Ply support feature185may be configured to support one or more ply320of composite material325prior to initiation of forming. Ply support feature185may further be configured to prevent the one or more ply320of composite material325from wrinkling prior to or during forming. The ply support feature185may be mechanical or may be air driven. In an example, the ply support feature185is an air knife.

In an example, the forming apparatus100comprises a first swing arm140. The first swing arm140is movably connected to the carriage120. In an example, the forming apparatus100comprises an actuator147. Actuator147is configured to move the first swing arm140along the vertical axis112. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, a first end effector145is movably connected to the first swing arm140. In an example, the first end effector145comprises a first forming feature142. In an example, the first forming feature142is an inflatable bladder146. In an example, the first forming feature142is a forming finger148.

In an example, the first swing arm140is configured to pivot along the horizontal axis114and the longitudinal axis116and apply forming force330to a forming surface308of a forming tool310. The pivoting capabilities of the first swing arm140are advantageous for uniformly applying forming force330to a forming surface308of the inside of a stringer forming tool316. In an example, the forming force330averages about 20 lbs per linear inch. In an example, the forming force330ranges from about 5 lbs per linear inch to about 50 lbs per linear inch based upon material properties and forming tool310geometry. The forming force330applied to the forming surface308of the forming tool310is dependent upon various factors including geometry of the forming tool310, the amount of composite material325on the forming surface308of the forming tool310, and one or more numerical control program420. The first swing arm140includes one or more sensor410configured to detect the location and configuration of a forming tool310. The one or more sensor410may be in communication with a controller400. The controller400is configured to receive data from the one or more sensor410and analyze that data to control movement of the second end effector155. The controller may utilize one or more numerical control program420in conjunction with the data collected from the one or more sensor410to determine proper movement and placement of the second end effector155.

In an example, the forming apparatus100comprises a second swing arm150. The second swing arm150is movably connected to the carriage120. The second swing arm150is laterally opposed from said first swing arm140relative to the longitudinal axis116such that it mirrors the first swing arm140. In an example, the second swing arm150comprises a second end effector155movably connected to the second swing arm150. In an example, the second end effector155comprises a second forming feature152. In an example, the second forming feature152is an inflatable bladder146. In an example, the second forming feature152is a forming finger148.

In an example, the second swing arm150is configured to pivot along the horizontal axis114and the longitudinal axis116and apply forming force330to a forming surface308of a forming tool310. The pivoting capabilities of the second swing arm150are advantageous for uniformly applying forming force330to a forming surface308of the inside of a stringer forming tool316. In an example, the forming force330averages about 20 lbs per linear inch. In an example, the forming force330ranges from about 5 lbs per linear inch to about 50 lbs per linear inch based upon material properties and forming tool310geometry. The forming force330applied to the forming surface308of the forming tool310is dependent upon various factors including geometry of the forming tool310, the amount of composite material325on the forming surface308of the forming tool310, and one or more numerical control program420. The second swing arm150includes one or more sensor410configured to detect the location and configuration of a forming tool310. The one or more sensor410may be in communication with a controller400. The controller400is configured to receive data from the one or more sensor410and analyze that data to control movement of the second end effector155. The controller may utilize one or more numerical control program420in conjunction with the data collected from the one or more sensor410to determine proper movement and placement of the second end effector155.

FIG.12illustrates a flowchart of a manufacturing method1000. Disclosed is a manufacturing method1000of fabricating a composite part375. In an example, the manufacturing method1000comprises various steps. In an example, the manufacturing method1000includes conveying a ply carrier604to a lamination system612using a carrier transfer device610. The manufacturing method1000includes selectively applying at least one ply320of composite material325to a ply support surface608of the ply carrier604using the lamination system612. The manufacturing method1000includes conveying the ply carrier604from the lamination system612to a transfer system616using the carrier transfer device610. In an example, the manufacturing method1000includes the step of removing the ply carrier604from the carrier transfer device610and applying the at least one ply320of composite material325to at least a portion of a forming surface308of a forming tool310using the transfer system616. The manufacturing method1000includes the step of forming the at least one ply320of composite material325over the at least a portion of the forming surface308of the forming tool310using a forming system622. In an example, the forming system622comprises a forming apparatus100.

Still referring toFIG.12, in one or more examples, the manufacturing method1000includes a step of (block1002) preparing the ply carrier604, seeFIG.1. In one or more examples, the manufacturing method1000includes a step of (block1004) selectively applying the retention vacuum to retain the protective slip film160on the base plate124using the carrier transfer device610. In one or more examples, the manufacturing method1000includes a step of (block1006) conveying the ply carrier604to the lamination system612using the carrier transfer device610. In one or more examples, the manufacturing method1000includes a step of (block1008) selectively applying the ply320to the ply support surface608of the ply carrier604using the lamination system612. In one or more examples, the manufacturing method1000includes a step of (block1010) conveying the ply carrier604from the lamination system612to the trim system614using the carrier transfer device610. In one or more examples, the manufacturing method1000includes a step of (block1012) selectively cutting the ply320into the predetermined shape using the trim system614.

In one or more examples, the manufacturing method1000includes a step of (block1014) removing a remnant of the at least one ply320from the ply support surface608using the scrap removal system642, after the step of (block1012) selectively cutting the at least one ply320. In one or more examples, the manufacturing method1000includes a step of selectively removing the retention vacuum from select areas of the protective slip film160using the carrier transfer device610. In one or more examples, the manufacturing method1000also includes a step of (block1016) conveying the ply carrier604from the trim system614to the transfer system616using the carrier transfer device610.

In one or more examples, the manufacturing method1000includes a step of (block1018) removing the ply carrier604from the carrier transfer device610and a step of (block1022) reorienting (e.g., rotating) the ply carrier604using the transfer system616. In one or more examples, the manufacturing method1000includes a step of (block1020) maintaining the retention vacuum to retain the protective slip film160on the base plate124using the transfer system616. In one or more examples, the manufacturing method1000includes a step of (block1024) conveying the forming tool310to the transfer system616using the tool transfer device646. In one or more examples, the manufacturing method1000includes a step of (block1026) applying the ply320to at least a portion of the forming surface308of the forming tool310using the transfer system616. In one or more examples, the manufacturing method1000includes a step of releasing the protective slip film160from the base plate124and a step of removing the ply carrier604(e.g., the base plate124) from the forming tool310using the transfer system616, after the step of (block1026) applying the ply320to at least a portion of the forming surface308of the forming tool310. For example, the manufacturing method1000includes a step of (block1028) selectively removing the retention vacuum to release the protective slip film160from the base plate124while retaining the base plate124using the transfer system616.

In one or more examples, the manufacturing method1000includes a step of (block1030) conveying the forming tool310from the transfer system616to the forming system622using the tool transfer device646. In one or more examples, the manufacturing method1000includes a step of (block1032) forming the ply320over the at least a portion of the forming surface308of the forming tool310using the forming system622. In one or more examples, the manufacturing method1000includes a step of (block1034) removing the protective slip film160from the ply320using the film removal system660. In one or more examples, the manufacturing method1000includes a step of (block1036) returning the ply carrier604(e.g., the base plate124) to the carrier transfer device610using the transfer system616. In one or more examples, the above operations are repeated a number of times to fully form the composite structure (block1038), at which point the process terminates.

In an example, the forming apparatus100of the manufacturing method1000includes a frame110. In an example, the frame110is generally rectangular in shape. The frame110defines a vertical axis112, a horizontal axis114, and a longitudinal axis116. The frame110surrounds a carriage120having a shape that is generally the same as the frame110but is smaller such that the carriage120nests within the frame110. In an example, the carriage120is movably connected to the frame110such that it may pivot or rotate along the vertical axis112and horizontal axis114to accommodate any specific geometry or configuration and achieve a best fit position.

In an example, the forming apparatus100includes a first stomp foot130. First stomp foot130is movably connected to the carriage120. The first stomp foot130is movable along the vertical axis112. The first stomp foot130may have a flat or a curved design based upon the geometry of the forming tool310. The first stomp foot130is controlled by any suitable means and is further configured to press one or more ply320of composite material325onto a forming surface308of a forming tool310and hold the one or more ply320of composite material325in place. In an example, the first stomp foot130movement is controlled by an actuator147. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, the first stomp foot130movement is controlled by at least one magnetic switch configured to detect travel and location of the first stomp foot130with respect to a forming tool310. The first stomp foot130is configured to apply compaction force350to a forming tool310. The applied compaction force350may be variable or may be consistent based upon the geometry of the forming tool310.

In an example, the forming apparatus100comprises a second stomp foot135. The second stomp foot135is movably connected to the carriage120. The second stomp foot135is movable along the vertical axis112. The second stomp foot135may have a flat or a curved design based upon the geometry of the forming tool310. The second stomp foot135is controlled by any suitable means and is further configured to press one or more ply320of composite material325onto a forming surface308of a forming tool310and hold the one or more ply320of composite material325in place. In an example, the second stomp foot135movement is controlled by an actuator147. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, the second stomp foot135movement is controlled by at least one magnetic switch configured to detect travel and location of the second stomp foot135with respect to a forming tool310. The second stomp foot135is configured to apply compaction force350to a forming tool310. The applied compaction force350may be variable or may be consistent based upon the geometry of the forming tool310.

In an example, the forming apparatus100comprises a ply support feature185. Ply support feature185may be located below the first stomp foot130and the second stomp foot135. Ply support feature185may be configured to support one or more ply320of composite material325prior to initiation of forming. Ply support feature185may further be configured to prevent the one or more ply320of composite material325from wrinkling prior to or during forming. The ply support feature185may be mechanical or may be air driven. In an example, the ply support feature185is an air knife.

In an example, the forming apparatus100comprises a first swing arm140. The first swing arm140is movably connected to the carriage120. In an example, the forming apparatus100comprises an actuator147. Actuator147is configured to move the first swing arm140along the vertical axis112. In an example, the actuator147is a pneumatically actuated forming cylinder147a. In an example, a first end effector145is movably connected to the first swing arm140. In an example, the first end effector145comprises a first forming feature142. In an example, the first forming feature142is an inflatable bladder146. In an example, the first forming feature142is a forming finger148.

In an example, the first swing arm140is configured to pivot along the horizontal axis114and the longitudinal axis116and apply forming force330to a forming surface308of a forming tool310. The pivoting capabilities of the first swing arm140are advantageous for uniformly applying forming force330to a forming surface308of the inside of a stringer forming tool316. In an example, the forming force330averages about 20 lbs per linear inch. In an example, the forming force330ranges from about 5 lbs per linear inch to about 50 lbs per linear inch based upon material properties and forming tool310geometry. The forming force330applied to the forming surface308of the forming tool310is dependent upon various factors including geometry of the forming tool310, the amount of composite material325on the forming surface308of the forming tool310, and one or more numerical control program420. The first swing arm140includes one or more sensor410configured to detect the location and configuration of a forming tool310. The one or more sensor410may be in communication with a controller400. The controller400is configured to receive data from the one or more sensor410and analyze that data to control movement of the second end effector155. The controller may utilize one or more numerical control program420in conjunction with the data collected from the one or more sensor410to determine proper movement and placement of the second end effector155.

In an example, the forming apparatus100comprises a second swing arm150. The second swing arm150is movably connected to the carriage120. The second swing arm150is laterally opposed from said first swing arm140relative to the longitudinal axis116such that it mirrors the first swing arm140. In an example, the second swing arm150comprises a second end effector155movably connected to the second swing arm150. In an example, the second end effector155comprises a second forming feature152. In an example, the second forming feature152is an inflatable bladder146. In an example, the second forming feature152is a forming finger148.

In an example, the second swing arm150is configured to pivot along the horizontal axis114and the longitudinal axis116and apply forming force330to a forming surface308of a forming tool310. The pivoting capabilities of the second swing arm150are advantageous for uniformly applying forming force330to a forming surface308of the inside of a stringer forming tool316. In an example, the forming force330averages about 20 lbs per linear inch. In an example, the forming force330ranges from about 5 lbs per linear inch to about 50 lbs per linear inch based upon material properties and forming tool310geometry. The forming force330applied to the forming surface308of the forming tool310is dependent upon various factors including geometry of the forming tool310, the amount of composite material325on the forming surface308of the forming tool310, and one or more numerical control program420. The second swing arm150includes one or more sensor410configured to detect the location and configuration of a forming tool310. The one or more sensor410may be in communication with a controller400. The controller400is configured to receive data from the one or more sensor410and analyze that data to control movement of the second end effector155. The controller may utilize one or more numerical control program420in conjunction with the data collected from the one or more sensor410to determine proper movement and placement of the second end effector155.

Examples of the disclosure may be described in the context of an aircraft manufacturing and service method1100, as shown inFIG.14, and an aircraft1102, as shown inFIG.15. During pre-production, the aircraft manufacturing and service method1100may include specification and design1104of the aircraft1102and material procurement1106. During production, component/subassembly manufacturing1108and system integration1110of the aircraft1102takes place. Thereafter, the aircraft1102may go through certification and delivery1112in order to be placed in service1114. While in service by a customer, the aircraft1102is scheduled for routine maintenance and service1116, which may also include modification, reconfiguration, refurbishment and the like.

Each of the steps of the aircraft manufacturing and service method1100may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.

As shown inFIG.15, the aircraft1102produced by the example aircraft manufacturing and service method1100may include an airframe1118with a plurality of systems1120and an interior1122. Examples of the plurality of systems1120may include one or more of a propulsion system1124, an electrical system1126, a hydraulic system1128, and an environmental system1130. Any number of other systems may be included.

The disclosed methods and systems may be employed during any one or more of the stages of the aircraft manufacturing and service method1100. As one example, components or subassemblies corresponding to component/subassembly manufacturing1108, system integration1110and/or maintenance and service1116may be assembled using the disclosed methods and systems. As another example, the airframe1118may be constructed using the disclosed methods and systems. Also, one or more apparatus examples, method examples, or a combination thereof may be utilized during component/subassembly manufacturing1108and/or system integration1110, for example, by substantially expediting assembly of or reducing the cost of an aircraft1102, such as the airframe1118and/or the interior1122. Similarly, one or more of system examples, method examples, or a combination thereof may be utilized while the aircraft1102is in service, for example and without limitation, to maintenance and service1116.

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

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

Also, although the above-description describes methods and systems that may be used to manufacture an aircraft or aircraft component in the aviation industry in accordance with various regulations (e.g., commercial, military, etc.), it is contemplated that the disclosed methods and systems may be implemented to facilitate manufacturing of a part in any industry in accordance with the applicable industry standards. The specific methods and systems can be selected and tailored depending upon the particular application.

The described features, advantages, and characteristics of one example may be combined in any suitable manner in one or more other examples. One skilled in the relevant art will recognize that the examples described herein may be practiced without one or more of the specific features or advantages of a particular example. In other instances, additional features and advantages may be recognized in certain examples that may not be present in all examples. Furthermore, although various examples of the forming apparatus100, method200, and system300have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.