Method and apparatus for fabricating contoured laminate structures
First Claim
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1. A system for fabricating a plurality of distinct parts, comprising:
- a plurality of distinct lay-up tools respectively corresponding to the plurality of parts to be fabricated;
a plurality of forming modules configured to be combined together to define a plurality of distinct 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, wherein each of the forming modules includes a corresponding track in which a portion of a forming member is locally mounted; and
the forming member adapted for forming material over a particular lay-up tool from among the plurality of lay-up tools to form a particular part from among the plurality of parts, the forming member extending along the plurality of forming modules, the forming member being mounted on the corresponding tracks of the forming modules for movement over the particular lay-up tool along at least two axes, wherein the forming member is removably mounted in the tracks to allow interchangeability of a plurality of different forming members respectively having different shapes.
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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.
27 Citations
22 Claims
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1. A system for fabricating a plurality of distinct parts, comprising:
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a plurality of distinct lay-up tools respectively corresponding to the plurality of parts to be fabricated; a plurality of forming modules configured to be combined together to define a plurality of distinct 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, wherein each of the forming modules includes a corresponding track in which a portion of a forming member is locally mounted; and the forming member adapted for forming material over a particular lay-up tool from among the plurality of lay-up tools to form a particular part from among the plurality of parts, the forming member extending along the plurality of forming modules, the forming member being mounted on the corresponding tracks of the forming modules for movement over the particular lay-up tool along at least two axes, wherein the forming member is removably mounted in the tracks to allow interchangeability of a plurality of different forming members respectively having different shapes. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A method of fabricating a composite laminate structure, comprising:
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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, wherein each of the forming modules includes a track; linking the forming modules together to form a single former for forming an entire composite laminate structure; mounting a continuous forming member within the track on the forming modules, the continuous forming member defining a spline extending substantially an entire length of the former, the forming member being mounted on each of the forming modules for movement over the tool along at least two axes, wherein the forming member is removably mounted in the tracks to allow interchangeability of a plurality of forming members respectively having different shapes; and using the forming member to form and compact the composite plies on the tool. - View Dependent Claims (11)
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12. A system for fabricating a plurality of distinct parts, comprising:
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a plurality of distinct lay-up tools respectively corresponding to the plurality of parts to be fabricated; a flexible ply carrier adapted to hold at least one laminate ply thereon; a plurality of forming modules configured to be combined together to define a plurality of distinct formers respectively corresponding to the plurality of parts and the plurality of lay-up tools, wherein each of the forming modules includes a pair of spaced apart tracks adapted to releasably hold the ply carrier, each of the formers being adapted for laying down material on a particular lay-up tool from among the plurality of lay-up tools; a forming member adapted for forming laminate plies over a particular lay-up tool from among the plurality of lay-up tools to form a particular part from among the plurality of parts, the forming member extending along the plurality of forming modules, the forming member being mounted on the forming modules for movement over the particular lay-up tool along at least two axes; and a plurality of ply carrier control assemblies for holding the ply carrier in tension as of the forming member forms the at least one laminate ply over the particular lay-up tool. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20)
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21. A method of fabricating a composite laminate structure, comprising:
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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, wherein each of the forming modules includes a pair of spaced apart tracks, the tracks having a ply carrier held thereon; linking the forming modules together to form a single former for forming an entire composite laminate structure; mounting a continuous forming member within the track on the forming modules, the continuous forming member defining a spline extending substantially an entire length of the former, portions of the forming member being mounted on each of the forming modules for movement over the tool along at least two axes; holding the ply carrier in tension on the tracks while the forming member forms a laminate ply over the tool; and using the forming member to form and compact the laminate ply on the tool. - View Dependent Claims (22)
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Specification