Automated composite lay-up to an internal fuselage mandrel

A device for automated composite lay-up, comprising:

• a tool including a mandrel, wherein said mandrel has an interior mandrel surface that conforms to an outside mold line of a part;
• at least one circular ring rigidly attached to said tool wherein said circular ring surrounds said tool and said mandrel;
• at least one stiffener attached to said circular ring, said stiffener supporting said interior surface of said mandrel and providing additional rigidity of attachment of said circular ring to said tool;
• and
• a bearing that contacts said circular ring wherein said circular ring rotates supported by said bearing so that said tool and said mandrel rotate concentrically with said circular ring about an axis of rotation passing through the center of said circular ring.

A device for automated composite lay-up, comprising:

• a tool including a mandrel, a plurality of stiffeners, and a circular ring having a center, wherein:
• said mandrel has an interior mandrel surface that conforms to an outside mold line of a part;
• said circular ring surrounds said mandrel and is rigidly attached to said mandrel;
• and
• said plurality of stiffeners are each attached to said circular ring, said plurality of stiffeners support said interior mandrel surface and provide additional rigidity of attachment of said circular ring to said mandrel;
• and
• a bearing cradle including a plurality of bearings wherein:
• at least one bearing of said plurality of bearings contacts said circular ring;
• said bearing cradle supports the weight of said tool through said plurality of bearings;
• said circular ring rotates supported by said bearing so that said mandrel rotates concentrically with said circular ring about an axis of rotation passing through the center of said circular ring.

An aircraft part manufacturing device for automated composite lay up, comprising:

• a tool including a mandrel, a plurality of stiffeners, and a circular ring having a center, wherein:
• said mandrel has an interior mandrel surface that conforms to an outside mold line of a part;
• said circular ring surrounds said mandrel and is rigidly attached to said mandrel;
• said plurality of stiffeners are each attached to said circular ring, said plurality of stiffeners support said interior mandrel surface and provide additional rigidity of attachment of said circular ring to said mandrel;
• and
• a bearing cradle including a plurality of bearings wherein:
• at least one bearing of said plurality of bearings contacts said circular ring;
• said bearing cradle supports the weight of said tool through said plurality of bearings;
• said circular ring rotates supported by said bearing so that said mandrel rotates concentrically with said circular ring about an axis of rotation passing through the center of said circular ring;
• said bearing cradle is moveable;
• a material delivery head that delivers composite material directly to said outside mold line on said interior mandrel surface;
• a gantry beam that is cantilever supported, wherein:
• said gantry beam is moveable relative to said tool;
• and
• said gantry beam supports said material delivery head inside said interior mandrel surface of said mandrel;
• an arm mechanism, wherein:
• said material delivery head is connected to said arm mechanism;
• and
• said gantry beam supports said arm mechanism;
• a connecting mechanism connecting said arm mechanism to said gantry beam, wherein:
• said connecting mechanism supports said arm mechanism;
• said connecting mechanism provides axial motion of said arm mechanism relative to said interior mandrel surface;
• said arm mechanism provides motion of said material delivery head relative to said interior mandrel surface in a direction normal to said interior mandrel surface;
• said arm mechanism provides rotation of said material delivery head relative to said interior mandrel surface about an axis normal to said interior mandrel surface;
• and
• a creel, wherein:
• said connecting mechanism supports said creel;
• and
• said creel contains prepreg materials that are supplied to said material delivery head;
• and
• said creel contains control electronics for controlling said material delivery head.

An aircraft part manufacturing device for automated composite lay up, comprising:

• means for rotating a mandrel about an axis of rotation wherein said mandrel has an outside mold surface on the inside of said mandrel;
• stiffener means for supporting said outside mold surface of said mandrel and for providing rigidity of attachment of said rotating means to said mandrel;
• arm mechanism means for supporting a material delivery head above said outside mold surface;
• connecting mechanism means for supporting said arm mechanism means and supporting a creel means for containing a composite fiber material;
• and
• delivery head means for receiving said composite fiber material from said creel means and placing said composite fiber material inside said mandrel onto said outside mold surface.

A method for automated composite lay up on an interior mandrel surface of a tool having an axis of rotation and a circular ring concentric with the axis of rotation, comprising steps of:

• supporting said interior mandrel surface of said tool while providing rigidity of attachment of said circular ring to said tool;
• rotating a mandrel about the axis of rotation wherein said mandrel has an outside mold surface on the inside of said mandrel;
• supporting a material delivery head from an arm mechanism above said outside mold surface;
• supporting said arm mechanism and a creel on a connecting mechanism, said creel for supplying a composite fiber material, and said arm mechanism for providing relative motion between said material delivery head and said connecting mechanism;
• and
• placing said composite fiber material inside said mandrel onto said outside mold surface.