Operator-assisted system and method for preparing a bladder for use in composite stringer manufacturing

A system for preparing a bladder for use in manufacturing a composite stringer, comprising:

• a sock application station having a sock cartridge configured to progressively apply a breather sock of breather material in tubular form onto a bladder as the bladder exits the sock cartridge to thereby result in a sock-bladder assembly;
• a cartridge replacement mechanism configured to remove and replace an empty sock cartridge at the sock application station with a loaded sock cartridge containing the breather sock;
• a film application station located downstream of the sock application station and configured to inflate a film from a flat shape into an open film tube prior to application over the sock-bladder assembly to thereby result in a film-sock-bladder assembly;
• and
• a composite ply application station located downstream of the film application station and having a wrap ply forming bed containing at least one forming bed opening, the wrap ply forming bed configured to receive one or more wrap plies of a wrap laminate for urging into the forming bed opening by the film-sock-bladder assembly to produce a ply-film-sock-bladder assembly.

A method of preparing a bladder for use in manufacturing a composite stringer, comprising:

• progressively applying, using a sock cartridge at a sock application station, a breather sock of breather material in tubular form onto the bladder as the bladder exits the sock cartridge to thereby result in a sock-bladder assembly;
• inflating, at a film application station located downstream of the sock application station, a film from a flat shape into an open film tube;
• moving the sock-bladder assembly into the film tube to thereby result in a film-sock-bladder assembly;
• receiving, at a composite ply application station located downstream of the film application station, one or more wrap plies to lay up a wrap laminate over a forming bed opening of a wrap ply forming bed;
• and
• urging, using the film-sock-bladder assembly, the wrap laminate into the forming bed opening to produce a ply-film-sock-bladder assembly.