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US 11,597,167 B2Granted
Continuous-line fabrication for composite parts
AssigneeThe Boeing Company
InventorsMichael Kenneth-Que Louie, Jordan Seth Erickson
Life of this patent
Estimating the term…
Abstract
Systems and methods are provided for forming a laminate. The method includes indexing a layup mandrel to a lamination machine disposed at a first location, transporting the lamination machine and the layup mandrel in a process direction from the first location towards a second location, laying up a laminate comprising layers of fiber-reinforced material onto the layup mandrel via the lamination machine while the lamination machine and the layup mandrel are transported in the process direction, removing the layup mandrel and the laminate at the second location, and returning the lamination machine to the first location for laying up another laminate onto another mandrel.
Claims28
A method for forming a laminate, the method comprising:
- indexing a layup mandrel to a lamination station disposed at a first location;
- transporting the lamination station and the layup mandrel in a process direction from the first location towards a second location;
- laying up the laminate having layers of fiber-reinforced material onto the layup mandrel via a lamination machine while the lamination machine and the layup mandrel are transported in the process direction;
- removing the layup mandrel and the laminate at the second location;
- and
- returning the lamination station to the first location for laying up an additional laminate onto a new layup mandrel.
3 more elements
A non-transitory computer readable medium embodying programmed instructions which, when executed by a processor, are operable for performing a method for forming a laminate, the method comprising:
- indexing a layup mandrel to a lamination station disposed at a first location;
- transporting the lamination station and the layup mandrel in a process direction from the first location towards a second location;
- laying up the laminate having multiple layers of fiber-reinforced material onto the layup mandrel via a lamination machine while the lamination station and the layup mandrel are transported in the process direction;
- removing the layup mandrel and the laminate at the second location;
- and
- returning the lamination station to the first location for laying up an additional laminate onto a new layup mandrel.
3 more elements
A lamination system for forming a laminate having multiple layers of fiber-reinforced material, the lamination system comprising:
- a layup mandrel having mandrel indexing elements;
- a lamination station comprising:
- a shuttle comprising shuttle indexing elements for engaging the mandrel indexing elements of the layup mandrel;
- and
- a lamination machine attached to the shuttle;
- and
- a drive system that transports the shuttle in a process direction while the lamination machine lays up the layers of the laminate onto the layup mandrel.
4 more elements
A method for forming a laminate, the method comprising:
- indexing a layup mandrel to a lamination station disposed at a first location;
- transporting the lamination station and the layup mandrel in a process direction from the first location towards a second location;
- consolidating the laminate while the lamination station and the layup mandrel are transported in the process direction;
- laying up the laminate having layers of fiber-reinforced material onto the layup mandrel via a lamination machine by operating the lamination machine in the process direction to lay up a first layer and operating the lamination machine in a second direction opposed to the process direction to lay up a second layer while the lamination machine and the layup mandrel are transported in the process direction, wherein the lamination machine is disposed on a shuttle that is driven in the process direction, and wherein indexing the layup mandrel to the lamination station comprises indexing the layup mandrel to the shuttle via complementary indexing elements disposed at the layup mandrel and the shuttle;
- powering the lamination machine via a power supply disposed at the shuttle or via a powered rail along which the lamination station travels during the transporting;
- removing the layup mandrel and the laminate at the second location;
- returning the lamination station to the first location for laying up an additional laminate onto a new layup mandrel;
- indexing the new layup mandrel to the lamination station;
- transporting the lamination station and the new layup mandrel in a counter process direction opposed to the process direction from the second location towards the first location;
- and
- laying up an additional laminate comprising layers of fiber-reinforced material on to the new layup mandrel via the lamination machine while the lamination station and the new layup mandrel are transported in the counter process direction.
8 more elements
A non-transitory computer readable medium embodying programmed instructions which, when executed by a processor, are operable for performing a method for forming a laminate, the method comprising:
- indexing a layup mandrel to a lamination station disposed at a first location;
- consolidating the laminate while the lamination station and the layup mandrel are transported in the process direction;
- transporting the lamination station and the layup mandrel in a process direction from the first location towards a second location;
- laying up the laminate having multiple layers of fiber-reinforced material onto the layup mandrel via a lamination machine by operating the lamination machine in the process direction to lay up a first layer, and operating the lamination machine is a second direction opposed to the process direction to lay up a second layer while the lamination station and the layup mandrel are transported in the process direction, wherein the lamination machine is disposed on a shuttle that is driven in the process direction, and wherein indexing the layup mandrel to the lamination station comprises indexing the layup mandrel to the shuttle via complementary indexing elements disposed at the layup mandrel and the shuttle;
- powering the lamination machine via a power supply disposed at the shuttle or via a powered rail along which the lamination station travels during the transporting;
- removing the layup mandrel and the laminate at the second location;
- returning the lamination station to the first location for laying up an additional laminate onto a new layup mandrel;
- indexing the new layup mandrel to the lamination station;
- transporting the lamination station and the new layup mandrel in a counter process direction opposed to the process direction from the second location towards the first location;
- and
- laying up the additional laminate having layers of fiber-reinforced material onto the new layup mandrel via the lamination machine while the lamination station and the new layup mandrel are transported in the counter process direction.
8 more elements
A lamination system for forming a laminate having multiple layers of fiber-reinforced material, the lamination system comprising:
- a layup mandrel having mandrel indexing elements;
- a lamination station comprising:
- a shuttle comprising shuttle indexing elements for engaging the mandrel indexing elements of the layup mandrel, wherein the shuttle indexing elements comprise cups, and the mandrel indexing elements comprise cones;
- a lamination machine attached to the shuttle, wherein the lamination machine is configured to lay up multiple layers of the laminate while being transported in a process direction, and wherein the shuttle includes at least one of a spare head and a spare spool for the lamination machine;
- a second shuttle comprising a second lamination machine, wherein the lamination machine and the second lamination machine are configured to lay up the laminate via coordinated action
- a drive system that transports the shuttle in the process direction while the lamination machine lays up the layers of the laminate onto the layup mandrel, wherein the shuttle includes a power supply and a gas supply that enable the lamination machine to operate while the drive system transports the shuttle, wherein the drive system comprises a chain drive that is coupled with the shuttle and a powered rail along which the drive system transports the shuttle and the shuttle includes an interface that couples with the powered rail;
- and
- a transfer machine that transports the layup mandrel from the lamination station to another lamination station after the laminate has been laid-up, wherein the transfer machine includes arms that insert into the layup mandrel.
5 more elements
Dependencies are inferred from the claim text.