# US 2014/0190625 A1 · Method and Apparatus for Fabricating Contoured Laminate Structures

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- Number: US 2014/0190625 A1
- Document ID: US20140190625A1
- Status: Published application
- Kind: A1
- Application number: 13/901,813
- Filed: 2013-05-24
- Published: 2014-07-10
- Earliest claimed: 2013-01-07
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: James N. Buttrick; Dennis Wayne Stewart; Andrew E. Modin; David Paul Banks; Edoardo Depase; Jesus Sanchez
- Web page: https://patentgrep.com/patent/US20140190625A1

## CPC

- B29C 70/38: Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)}
- B29C 69/00: Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore {(B29C48/001 takes precedence)}
- B29C 70/06: Fibrous reinforcements only
- B29C 70/541: {Positioning reinforcements in a mould, e.g. using clamping means for the reinforcement (positioning inserts in moulds B29C33/12; lay-up on a mould B29C70/30)}
- B29D 99/0003: {Producing profiled members, e.g. beams}
- B29K 2105/12: of short lengths, e.g. chopped filaments, staple fibres or bristles
- B29K 2307/04: Carbon
- B29L 2031/3082: {Fuselages}
- Y02T 50/40: Weight reduction
- Y10T 156/1002: with permanent bending or reshaping or surface deformation of self sustaining lamina
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## 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.

## Claims

### Claim 1

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.

### Claim 2 (depends on 1)

The system of claim 1, wherein:
the former modules are substantially identical, and
each of the plurality of unique formers is configured by coupling each of the substantially identical former modules to the corresponding unique lay-up tool.

### Claim 3 (depends on 1)

The system of claim 1, wherein the former modules are mounted on bases allowing the former modules to move in multiple directions.

### Claim 4 (depends on 1)

The system of claim 1, wherein former modules are rigidly linked together.

### Claim 5 (depends on 1)

The system of claim 1, wherein each of the former modules includes a forming head section adapted to form the material on a corresponding one of the lay-up tools.

### Claim 6 (depends on 5)

The system of claim 5, wherein each of the forming head sections includes compliance.

### Claim 7 (depends on 6)

The system of claim 6, wherein the compliance is removed when the former modules are coupled to the lay-up tool.

### Claim 8 (depends on 1)

The system of claim 1, wherein the part is a laminated structure.

### Claim 9 (depends on 1)

The system of claim 1, wherein the part is a carbon fiber reinforced plastic.

### Claim 10

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.

### Claim 11 (depends on 10)

The apparatus of claim 10, further comprising:
a forming member adapted for forming laminate plies over the tool, the forming member extending along a length of the fabrication modules, the forming member being mounted on each of the fabrication modules for movement over the tool along at least two axes.

### Claim 12 (depends on 11)

The apparatus of claim 11, wherein the forming member is continuous along the length of the fabrication modules.

### Claim 13 (depends on 11)

The apparatus of claim 11, wherein each of the fabrication modules includes a track in which a portion of the forming member is local mounted.

### Claim 14 (depends on 13)

The apparatus of claim 13, wherein the forming member is removably mounted in the tracks to allow interchangeability of a plurality of forming members respectively having different shapes.

### Claim 15 (depends on 11)

The apparatus of claim 11, wherein the forming member is adapted to sweep laminate plies over the tool, and includes compliance.

### Claim 16 (depends on 10)

The apparatus of claim 10, wherein each of the fabrication modules includes a clamp adapted for clamping a portion of a laminate ply against a portion of the tool.

### Claim 17 (depends on 11)

The apparatus of claim 11, wherein each of the fabrication modules includes a powered drive coupled with the forming member for sweeping the forming member over the laminate plies and compacting laminate plies on the tool.

### Claim 18 (depends on 11)

The apparatus of claim 11, further comprising:
a flexible ply carrier adapted to hold at least one laminate ply thereon, and
wherein each of the fabrication modules includes a pair of spaced apart tracks adapted to releasably hold the ply carrier, and a ply carrier control assembly for holding the ply carrier in tension as the forming member forms the ply over the tool.

### Claim 19 (depends on 18)

The apparatus of claim 18, wherein:
the forming member is engageable with the ply carrier to sweep the ply carrier along with the ply thereon over the tool, and
the ply carrier control assembly includes drives for adjusting a position of the ply carrier along two axes.

### Claim 20 (depends on 11)

The apparatus of claim 11, wherein each of the fabrication modules further includes:
a force sensor for sensing a level of force applied to the laminate plies by the forming member, and
a position sensor for sensing the position of the forming member.

### Claim 21 (depends on 10)

The apparatus of claim 10, wherein each of the fabrication modules includes a clamp for clamping the fabrication module to the tool.

### Claim 22 (depends on 10)

The apparatus of claim 10, further comprising:
linkage between the fabrication modules for rigidly coupling the fabrication modules together and for aligning the fabrication modules relative to the tool.

### Claim 23 (depends on 10)

The apparatus of claim 10, wherein the fabrication modules are substantially identical and interchangeable with each other.

### Claim 24 (depends on 10)

The apparatus of claim 10, further comprising a central controller for controlling and coordinating the operation of the fabrication modules to collectively fabricate the laminate structure.

### Claim 25

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.

### Claim 26 (depends on 25)

The method of claim 25, wherein arranging the fabrication modules includes:
moving each of the fabrication modules into proximity to the tool, and
rigidly linking the fabrication modules together.

### Claim 27 (depends on 25)

The method of claim 25, further comprising:
clamping each of the fabrication modules to the tool.

### Claim 28 (depends on 25)

The method of claim 25, wherein adapting the each of the fabrication modules includes learning, by each of the fabrication modules, the location of surfaces on the tool on which the part is to be fabricated.

### Claim 29 (depends on 28)

The method of claim 28, further comprising:
sweeping materials across the surfaces of the tool using a forming member, and
using the forming member to learn the location of the surfaces on the tool.

### Claim 30 (depends on 29)

The method of claim 29, wherein learning the location of the surfaces includes:
sensing a position of the forming member as the forming member sweeps materials across the surfaces of the tool, and
recording the sensed position of the forming member.

### Claim 31 (depends on 25)

The method of claim 25, wherein adapting each of the fabrication modules includes adjusting the elevation of the fabrication modules to a common waterline.

### Claim 32 (depends on 25)

The method of claim 25, further comprising:
forming a continuous spline along all of the fabrication modules.

### Claim 33 (depends on 32)

The method of claim 32, wherein forming the continuous spline includes mounting a continuous forming member along substantially the entire length of the fabrication modules.

### Claim 34 (depends on 25)

The method of claim 25, wherein:
each of the fabrication modules is a laminate ply former module for forming a local section of a ply, and
arranging the fabrication modules includes linking the fabrication modules together to form a single laminate ply former.

### Claim 35

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.

### Claim 36 (depends on 35)

The method of claim 35, further comprising:
placing the composite plies on a ply carrier, and
wherein using the forming member includes engaging and sweeping the ply carrier along with the plies over the tool.

### Claim 37

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.

### Claim 38 (depends on 37)

The forming module of claim 37, wherein the base is adapted to move over a supporting surface.

### Claim 39 (depends on 37)

The forming module of claim 37, further comprising a clamp for clamping the head section to the tool.

### Claim 40 (depends on 37)

The forming module of claim 37, wherein the head section includes an adaptive control for learning a profile of the tool.

### Claim 41 (depends on 37)

The forming module of claim 37, further comprising a nosepiece for engaging the ply carrier and forming the plies onto the tool, the nosepiece being mounted for movement on the head section along first and second axes.

### Claim 42 (depends on 41)

The forming module of claim 41, wherein the head section includes a load cell for sensing the magnitude of a force applied by the nosepiece to the ply carrier and the tool.

### Claim 43 (depends on 41)

The forming module of claim 41, wherein the base includes a powered slide assembly for moving the head section along a third axis substantially orthogonal to the first and second axes.

### Claim 44 (depends on 41)

The forming module of claim 41, wherein the head section includes at least one position sensor for sensing the position of the nosepiece.

### Claim 45 (depends on 41)

The forming module of claim 41, wherein the nosepiece has compliance allowing the nosepiece to conform to features of the tool.

### Claim 46 (depends on 37)

The forming module of claim 37, wherein the ply carrier control assembly includes a device for controlling tension on the flexible ply carrier.

### Claim 47 (depends on 37)

The forming module of claim 37, wherein the ply carrier control assembly is mounted on the head section.

### Claim 48 (depends on 37)

The forming module of claim 37, wherein the ply carrier control assembly includes an automatically controlled, motorized arm for supporting and displacing the ply carrier as the plies are being formed from the ply carrier onto the tool.

### Claim 49 (depends on 37)

The forming module of claim 37, wherein the head section includes a datum locator for locating a datum on the tool.