Method and Apparatus for Fabricating Contoured Laminate Structures
AssigneeThe Boeing Company
InventorsJames N. Buttrick, Dennis Wayne Stewart, Andrew E. Modin, David Paul Banks, Edoardo Depase, Jesus Sanchez
Life of this patent
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Abstract
A plurality of identical fabrication modules are linked together and configurable to fabricate any of a plurality of differing laminate structures in a family of structures having common features. Each of the fabrication modules is locally adapted to fabricate a section of the laminate structure on a corresponding tool. A controller controls and coordinates automated operation of the fabrication modules.
Claims49
A system for fabricating a plurality of unique parts, comprising:
- a plurality of unique lay-up tools respectively corresponding to the plurality of parts to be fabricated;
- and,
- a plurality of former modules configured to be combined together to define a plurality of unique formers respectively corresponding to the plurality of parts and the plurality of lay-up tools,
- each of the formers being adapted for laying down material on a corresponding one of the lay-up tools to form a corresponding one of the parts.
Apparatus for fabricating each of a plurality of differing laminate structures in a family of structures having common features, comprising:
- a plurality of separate fabrication modules each locally adapted to fabricate a section of the laminate structure on a corresponding tool, the fabrication modules being reconfigurable to fabricate each of the laminate structures in the family thereof;
- and
- a controller for controlling and coordinating automated operation of the fabrication modules.
A method of fabricating each of a plurality of differing parts in a family of parts having common features, wherein each of the parts is fabricated using a unique tool, comprising:
- arranging a plurality of separate, substantially identical fabrication modules to substantially match a tool on which one of the parts is to be fabricated;
- adapting each of the fabrication modules to a local section of the tool;
- and,
- controlling and coordinating operation of the fabrication modules to fabricate portions of the part over a corresponding section of the tool.
A method of fabricating a composite laminate structure, comprising:
- arranging a plurality of substantially identical forming modules to generally match a tool on which composite plies are to be formed to fabricate the laminate structure;
- linking the forming modules together to form a single former for forming an entire composite laminate structure;
- mounting a continuous forming member on the forming modules, the continuous forming member defining a spline extending substantially the entire length of the former;
- and
- using the forming member to form and compact the composite plies on the tool.
A forming module for forming a composite laminate part over a tool, comprising:
- a base;
- a ply carrier control assembly adapted for controlling the position of a flexible ply carrier on which composite resin plies are mounted;
- and
- a head section mounted on the base and adapted for automatically forming the composite resin plies from the ply carrier onto the tool.
Dependencies are inferred from the claim text.