Multiple head automated composite laminating machine for the fabrication of large barrel section components

a method for fabricating a section of an aircraft fuselage using a plurality of material delivery heads to apply composite materials on a mandrel surface of a mandrel having an axis, wherein the mandrel is rotatable relative to said plurality of material delivery heads, and wherein the mandrel surface substantially conforms to the section of the aircraft fuselage, the method comprising steps of:

• applying, via the material delivery heads, composite material along the mandrel surface during fabrication of the section of the aircraft fuselage;
• moving at least some of said material delivery heads relative to the mandrel surface during application of the composite material by the material delivery heads during fabrication of the section of the aircraft fuselage;
• and
• individually adjusting positions of at least some of said material delivery heads relative to the mandrel surface and the other material delivery heads during application of the composite material by the material delivery heads during fabrication of the section of the aircraft fuselage.

A device for fabricating a section of an aircraft fuselage via automated composite lamination on a mandrel surface, comprising:

• a mandrel comprising a rotational axis and the mandrel surface, wherein the mandrel surface substantially conforms to the section of the aircraft fuselage;
• a mechanical supporting structure moveable relative to the mandrel, wherein the mandrel is rotatable relative to said mechanical supporting structure;
• and
• a plurality of material delivery heads supported by said mechanical supporting structure, wherein said mechanical supporting structure provides for movement of said plurality of material delivery heads relative to the mandrel surface during fabrication of the section of the aircraft fuselage, and wherein each of said plurality of material delivery heads is:
• designed to apply composite material along the mandrel surface during fabrication of the section of the aircraft fuselage;
• and
• individually positionally adjustable relative to the mandrel surface and the other material delivery heads during application of the composite material by the material delivery heads during fabrication of the section of the aircraft fuselage.

A device for fabricating a section of an aircraft fuselage via automated composite lamination on a mandrel surface, comprising:

• a mandrel comprising a rotational axis and the mandrel surface, wherein the mandrel surface substantially conforms to the section of the aircraft fuselage;
• a mechanical supporting structure moveable relative to the mandrel, wherein the mandrel is rotatable relative to said mechanical supporting structure;
• and
• a plurality of material delivery heads supported by said mechanical supporting structure, wherein:
• said mechanical supporting structure provides for axial translation of said plurality of material delivery heads simultaneously relative to the mandrel surface during fabrication of the section of the aircraft fuselage, and wherein each of said plurality of material delivery heads is:
• designed to apply composite material along the mandrel surface during fabrication of the section of the aircraft fuselage;
• and
• individually positionally adjustable relative to the mandrel surface and the other material delivery heads during application of the composite material by the material delivery heads during fabrication of the section of the aircraft fuselage.

A device for fabricating a section of an aircraft fuselage via automated composite lamination on a mandrel surface, comprising:

• a mandrel comprising a rotational axis and the mandrel surface, wherein the mandrel surface substantially conforms to the section of the aircraft fuselage;
• a mechanical supporting structure moveable relative to the mandrel, wherein the mandrel is rotatable relative to said mechanical supporting structure;
• and
• a plurality of material delivery heads supported by said mechanical supporting structure and disposed surrounding the mandrel, wherein:
• said mechanical supporting structure provides for:
• axial translation of said plurality of material delivery heads simultaneously relative to the mandrel surface during fabrication of the section of the aircraft fuselage, and wherein each of said plurality of material delivery heads is:
• designed to apply composite material along the mandrel surface during fabrication of the section of the aircraft fuselage;
• and
• individually positionally adjustable relative to the mandrel surface, the mechanical supporting structure and the other material delivery heads during application of the composite material by the material delivery heads during fabrication of the section of the aircraft fuselage.

An aircraft part manufacturing device for fabricating a section of an aircraft fuselage via automated composite lamination on a mandrel surface, comprising:

• a mandrel comprising a rotational axis and the mandrel surface, wherein the mandrel surface substantially conforms to the section of the aircraft fuselage;
• a mechanical supporting structure moveable relative to the mandrel, wherein the mandrel is rotatable relative to said mechanical supporting structure;
• a plurality of material delivery heads supported by said mechanical supporting structure and disposed surrounding the mandrel, wherein said mechanical supporting structure provides for axial translation of said plurality of material delivery heads relative to the mandrel surface during fabrication of the section of the aircraft fuselage, and wherein each of said plurality of material delivery heads is:
• designed to apply composite material along the mandrel surface during fabrication of the section of the aircraft fuselage;
• individually positionally adjustable relative to the mandrel surface, the mechanical supporting structure and the other material delivery heads during application of the composite material by the material delivery heads during fabrication of the section of the aircraft fuselage;
• and
• an arm mechanism connecting said at least one material delivery head to said mechanical supporting structure, wherein:
• said arm mechanism provides motion of said at least one material delivery head independent of the other material delivery heads and relative to the mandrel surface in a direction normal to the mandrel surface;
• said arm mechanism provides rotation of said at least one material delivery head independent of the other material delivery heads and relative to the mandrel surface about an axis normal to the mandrel surface;
• said arm mechanism provides a circumferential position adjustment of said at least one material delivery head independent of the other material delivery heads and in a hoop direction relative to the mandrel surface;
• and
• said arm mechanism provides an axial position adjustment of said at least one material delivery head independent of the other material delivery heads and relative to the mandrel surface.

An aircraft part manufacturing device for fabricating a section of an aircraft fuselage via automated composite lamination on a mandrel surface, comprising:

• a mandrel comprising a rotational axis and the mandrel surface, wherein the mandrel surface substantially conforms to the section of the aircraft fuselage;
• means for supporting a plurality of material delivery heads, wherein the mandrel is moveable relative to said plurality of material delivery heads during fabrication of the section of the aircraft fuselage, and wherein each of said plurality of material delivery heads is designed to apply composite material along the mandrel surface during fabrication of the section of the aircraft fuselage;
• means for providing for movement of said plurality of material delivery heads relative to the mandrel surface during fabrication of the section of the aircraft fuselage;
• and
• means for providing an individual position adjustment relative to the mandrel surface for said plurality of material delivery heads during fabrication of the section of the aircraft fuselage, wherein each of said plurality of material delivery heads is:
• individually positionally adjustable relative to the mandrel surface and the other material delivery heads during application of the composite material by the material delivery heads during fabrication of the section of the aircraft fuselage.

A device for fabricating a section of a vehicle via automated composite lamination on a mandrel surface, comprising:

• a mandrel comprising a rotational axis and the mandrel surface, wherein the mandrel surface substantially conforms to the section of the vehicle;
• a mechanical supporting structure moveable relative to the mandrel, wherein the mandrel is rotatable relative to said mechanical supporting structure;
• and
• plurality of material delivery heads supported by said mechanical supporting structure, wherein said mechanical supporting structure provides for movement of said plurality of material delivery heads relative to the mandrel surface during fabrication of the section of the vehicle, and wherein each of said plurality of material delivery heads is:
• designed to apply composite material along the mandrel surface during fabrication of the section of the vehicle;
• and
• individually positionally adjustable relative to the mandrel surface and the other material delivery heads during fabrication of the section of the vehicle.