Automated fabric layup system and method
AssigneeThe Boeing Company
InventorsW. Robert Nelson, Michael C Dowling, Mark K Stephen, Raymond L Royal, C. Tim Harbaugh
Life of this patent
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Abstract
To apply a resin impregnated fabric to a substrate, a device includes a surface having a layer of material and a first edge. The surface moves relative to the substrate and to conform to the substrate. The layer of material is compatible for use with the resin. The first edge is disposed at the front of the surface relative to the movement of the device to the fabric. The first edge is curved with a center portion of the first edge being relatively forward of a pair of side portions of the first edge.
Claims22
A method of fabricating a composite item from a prepreg comprising a resin coated or pre-impregnated course material placed on a layup form, the method comprising:
- determining a first location on the layup form to place the prepreg;
- determining a second location on the layup form to stop placing the prepreg;
- cutting the prepreg to generate a first edge that substantially conforms to the layup form at the first location in response to the first edge being different from the layup form at the first location;
- generating a vacuum to releasably secure the prepreg to a porous cylindrical anvil;
- removing the prepreg from the porous cylindrical anvil with a vacuum pickup device;
- tacking the first edge to the layup form at the first location;
- applying the prepreg long a natural path of the layup form between the first location and the second location, wherein the prepreg is urged outward from about a longitudinal centerline of the prepreg by movement of a curved surface relative to the prepreg;
- and
- cutting the prepreg material to generate a second edge that substantially conforms to the layup form at the second location in response to approaching the second location.
A method of placing plies to produce a composite item, comprising the steps of:
- drawing prepreg toward a vacuum cutting drum such that the prepreg is held on the vacuum cutting drum;
- performing an end cut on the prepreg when the prepreg is held on the vacuum cutting drum;
- transferring the prepreg from the vacuum cutting drum to a tool using a pressure shoe with a vacuum applied therein;
- and
- spreading the prepreg outwardly using a contact surface of the pressure shoe as the prepreg is applied to the tool.
A method of placing plies on a tool to produce a composite item from prepreg using an end effector, comprising the steps of:
- threading the prepreg through the end effector;
- drawing the prepreg toward a vacuum cutting drum of the end effector such that the prepreg is held on the vacuum cutting drum;
- cutting one of a leading edge and a profile in the prepreg at the start of a course using a cutting assembly;
- advancing the vacuum cutting drum until the leading edge is located relative to a pressure shoe of the end effector, the pressure shoe having a vacuum applied therein;
- transferring the prepreg from the vacuum cutting drum to the tool using the vacuum applied to the pressure shoe;
- dispensing the prepreg along a path across the tool;
- spreading the prepreg outwardly using a contact surface of the pressure shoe as the prepreg is applied to the tool;
- tacking the prepreg to the tool;
- applying a downward force to the pressure shoe to press the prepreg down upon the tool;
- and
- cutting an end of the prepreg when the prepreg has advanced to an end of the course.
Dependencies are inferred from the claim text.