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US 11,999,116 B2Granted
Composite forming apparatus, system and method
AssigneeThe Boeing Company
InventorsKurtis S. Willden, Brian G. Robins, Steven M. Shewchuk, Brice A. Johnson
Life of this patent
Estimating the term…
Abstract
A composite forming apparatus includes an end effector, a forming feature, and a non-contact heater. The forming feature is coupled to the end effector. The end effector moves the forming feature relative to a composite ply to form the composite ply over a forming tool or a prior formed composite ply. The non-contact heater heats to a portion of the composite ply before the portion of the composite ply is formed over the forming tool or the prior formed composite ply.
Claims25
A composite forming apparatus comprising:
- an end effector;
- a forming feature that is coupled to the end effector, wherein the end effector moves the forming feature relative to a composite ply to form the composite ply over a forming tool or a prior formed composite ply;
- a first arm;
- a first non-contact heating element that is coupled to the first arm, wherein the first arm positions the first non-contact heating element ahead of the forming feature along a forming direction, such that the first non-contact heating element indirectly heats a local portion of the composite ply from a first heating direction before the local portion of the composite ply is formed over the forming tool or the prior formed composite ply by the forming feature;
- a second arm;
- a second non-contact heating element that is coupled to the second arm, wherein the second arm positions the second non-contact heating element ahead of the forming feature along the forming direction, wherein the second non-contact heating element indirectly heats the local portion of the composite ply from a second heating direction, which is opposite the first heating direction, before the local portion of the composite ply is formed over the forming tool or the prior formed composite ply by the forming feature and
- a control unit configured to:
- control the first arm to position the first non-contact heating element ahead of the forming feature and move the first non-contact heating element along the forming direction relative to a first ply surface of the composite ply;
- and
- control the second arm to position the second non-contact heating element ahead of the forming feature and move the second non-contact heating element along the forming direction relative to a second ply surface of the composite ply, opposite the first ply surface the composite ply.
7 more elements
A composite forming system comprising:
- an end effector;
- a forming feature that is coupled to the end effector;
- a first arm that is coupled to the end effector;
- a first non-contact heating element that is coupled to the first arm;
- a ply support member;
- a second arm that is coupled to the ply support member;
- a second non-contact heating element that is coupled to the second arm;
- and
- a control unit in communication with the first arm and the second arm,
- wherein:
- the end effector selectively moves the forming feature relative to the composite ply and a forming tool to form a first portion of the composite ply over a portion of the forming tool or a prior formed composite ply and to compact the first portion of the composite ply against a forming surface of the forming tool or the prior formed composite ply;
- the ply support member selectively moves relative to the forming feature, the composite ply, and the forming tool to support a second portion of the composite ply downstream of the first portion of the composite ply;
- the control unit is configured to control the first arm to selectively position the first non-contact heating element ahead of the forming feature along a forming direction and independent of and relative to the forming feature and the first portion of the composite ply;
- the control unit is configured to control the first arm to move the first non-contact heating element along the forming direction to locally heat the first portion of the composite ply from a first heating direction via at least one of radiation and convection before the first portion of the composite ply is formed over the forming surface of the forming tool or the prior formed composite ply by the forming feature;
- the control unit is configured to control the second arm to selectively position the second non-contact heating element ahead of the forming feature along the forming direction and independent of and relative to the forming feature, the first portion of the composite ply, and the first non-contact heating element;
- and
- the control unit is configured to control the second arm to move the second non-contact heating element along the forming direction to locally heat the first portion of the composite ply from a second heating direction, opposite the first heating direction, via at least one of radiation and convection before the first portion of the composite ply is formed over the forming surface of the forming tool or the prior formed composite ply by the forming feature.
14 more elements
A method for fabricating a composite structure, the method comprising steps of:
- placing a composite ply over a forming tool or over a prior formed composite ply;
- selectively controlling a first arm using a controller to position a first non-contact heating element independent of and ahead of a forming feature of an end effector along a forming direction and relative to the composite ply;
- selectively controlling a second arm using the controller to position a second non-contact heating element independent of and ahead of the forming feature along the forming direction and relative to the composite ply;
- locally heating a portion of the composite ply from a first heating direction via at least one of radiation and convection using the first non-contact heating element;
- locally heating the portion of the composite ply from a second heating direction, opposite the first heating direction, via at least one of radiation and convection using the second non-contact heating element;
- positioning the forming feature in contact with the composite ply using the end effector;
- and
- forming the portion of the composite ply over the forming tool or the prior formed composite ply using the forming feature after heating the portion of the composite ply using the first non-contact heating element and the second non-contact heating element.
5 more elements
A method for forming a composite structure, the method comprising steps of:
- placing a composite ply over a forming tool or over a prior formed composite ply;
- selectively controlling a first arm using a controller to position a first non-contact heating element independent of and ahead of a forming feature of an end effector along a forming direction and relative to the composite ply;
- selectively controlling a second arm using the controller to position a second non-contact heating element independent of and ahead of the forming feature of the end effector along the forming direction and relative to the composite ply using an arm using a second arm;
- locally heating a portion of the composite ply from a first heating direction via at least one of radiation and convection using the first non-contact heating element;
- locally heating the portion of the composite ply from a second heating direction, opposite the first heating direction, via at least one of radiation and convection using the second non-contact heating element
- compressing the portion of the composite ply against a forming surface of the forming tool or the prior formed composite ply using the forming feature;
- and
- forming the portion of the composite ply over at least a portion of the forming surface of the forming tool or the prior formed composite ply using the forming feature after locally heating the portion of the composite ply using the first non-contact heating element and the second non-contact heating element,
- wherein the portion of the composite ply is heated by the first non-contact heating element and the second non-contact heating element directly ahead of forming by the forming feature.
6 more elements
Dependencies are inferred from the claim text.