Apparatus and method for automated layup of composite structures

A stringer forming apparatus for laying up a course of composite material on a form tool, comprising:

• a tension management system, including:
• a pair of tension arms configured to support opposing lateral sides of a ply carrier having the course mounted thereto;
• one or more actuators configured to sense and control lateral tension in the ply carrier during forming to a form tool contour;
• a stomp system, including:
• an array of stomp foot actuators configured to clamp the ply carrier onto the form tool;
• a forming system, including:
• an array of forming modules each including a nosepiece configured to form the ply carrier to the form tool contour by moving laterally relative to the ply carrier while conforming the ply carrier and course to the form tool contour, each forming module configured to sense and control compaction pressure applied by the nosepiece onto the ply carrier;
• wherein each tension arm is configured to apply tension to the ply carrier within a region limited to between the lateral side supported by the tension arm and the nosepieces located on a side of the array of stomp foot actuators nearest the tension arm;
• and
• the one or more actuators being configured to sense and control lateral tension applied by the tension arms to corresponding regions of the ply carrier during forming of the ply carrier to the form tool contour.

A method of laying up a material layer, comprising the steps of:

• positioning a ply carrier over a form tool, the ply carrier having a material layer mounted to a lower surface of the ply carrier;
• conforming the ply carrier to a form tool contour by laterally sweeping a nosepiece relative to the ply carrier;
• supporting the ply carrier on opposing lateral sides using a pair of tension arms;
• and
• maintaining lateral tension in the ply carrier within a predetermined range in a region of the ply carrier limited to between the nosepiece and one of the lateral sides during the conforming of the ply carrier to the form tool contour.